Lockout Tagout (LOTO) is a system that prevents the unexpected start-up of equipment or machinery during service or maintenance procedures. A successful lockout/tagout program safeguards workers from injury by blocking incoming energy and releasing stored energy, making it impossible for devices to turn on, run or move.
Lockout Tagout (LOTO) is a system that prevents the unexpected start-up of equipment or machinery during service or maintenance procedures. A successful lockout/tagout program safeguards workers from injury by blocking incoming energy and releasing stored energy, making it impossible for devices to turn on, run or move.
Training employees on detailed LOTO protocol is vital to protect everyone who works in an industrial environment. We created this comprehensive guide to lockout tagout systems to help you understand and implement an effective program that protects your employees from potentially dangerous equipment.
Lockout/Tagout refers to safety procedures that ensure dangerous machines do not experience unexpected energy bursts that cause injuries to workers during maintenance tasks. It requires the isolation of all energy sources to render equipment inoperable when service is necessary. A detailed, written plan protects employees from severe injuries or fatalities on-the-job.
Lockout/Tagout (LOTO) refers to the protocol for correctly shutting down equipment when repairs or maintenance are necessary. These procedures and systems protect employees from potential injuries or death by ensuring machines are inoperable and do not have any stored energy that may cause unintended start-ups.
Lockout devices lock machinery with a key or combination to block potential hazardous energy release, preventing unintentional start-ups.
Tagout systems alert workers and others in the area that they may not use or operate equipment until authorized personnel removes the warnings.
Any power source that poses a potential danger to workers is hazardous energy. Failure to effectively manage stored energy within machines can cause an unexpected discharge of power, leading to workers' injuries or fatalities. Some types of hazardous energy include:
• Electrical • Hydraulic • Pneumatic • Radiation • Mechanical • Thermal • Chemical
If not correctly discharged, hazardous energy can release suddenly, causing a power surge that turns on or moves equipment. An unexpected start-up during maintenance activities can result in severe or fatal injuries to people working on or near the machinery, including:
• Electrocutions • Burns • Fractures • Lacerations • Amputations • Crushing injuries • Paralysis
Lockout is the most reliable method to protect industrial workers from dangerous power sources. The use of a lockout device puts systems in a zero energy state, eliminating the potential hazards of stored energy. Authorized managers must identify all energy sources and discharge any dangerous remaining power to keep workers safe from perilous equipment or machines.
A manager is responsible for organizing and implementing all energy control procedures. The protocol identifies and details the steps involved for all related workers, machines and processes. A trained and authorized employee executes the protocol when equipment requires servicing. Industries must train all affected employees on the correct methods for maintaining safe working conditions.
A lockout/tagout procedure aims to protect employees from harm while performing service or maintenance tasks on machines. An effective plan ensures the release of stored energy that could unexpectedly start equipment while workers perform repairs.
The Occupational Safety and Health Administration regulates procedures and practices for disabling equipment to control hazardous energy release. Businesses need to follow all standards and procedures to prevent accidents that could cause significant harm to staff members.
OSHA requires the adoption and execution of systems and plans to disable equipment altogether while workers repair or service devices. This standard dictates safety procedures to isolate the machinery from all power sources, preventing the release of potentially hazardous energy.
OSHA standards dictate safety procedures to isolate the machinery from all power sources, preventing the release of potentially hazardous energy.
General Industry 29 CFR 1910.147: This section states that employers must establish a plan and employ systems that protect workers when repairing machinery. This standard involves attaching suitable energy-isolating lockout and tagout devices to equipment, preventing stored energy from discharging suddenly.
Construction 29 CFR 1926.417: This regulation states that workers must appropriately tag all deactivated controls during maintenance tasks to warn and inform others of the process.
Procedures for hazardous energy management must detail the following components:
• The scope of the process
• The purpose of the steps
• The personnel authorized to execute the procedures
• The required practices
• The methods used to ensure safety and compliance
• The devices needed to control the energy sources
Worker Obligations
Employers must train all employees on the necessary processes and tasks involved with LOTO safety procedures.
What do you do before starting service or maintenance activities?
Before anyone begins work on a lockout-out or tagged-out machine, an authorized employee must verify that the equipment's power sources are isolated correctly. They must also confirm there is no remaining stored energy within the system.
What do you do before removing lockout or tagout devices and re-energizing machines?
The OSHA standard requires the following:
• An authorized employee must inspect the machinery to ensure all components are operational and unimpaired.
• The same employee who attached the lockout and tagout devices removes them from the equipment.
• The employee informs workers that the lockout/tagout methods have been removed and asks them to clear the area.
When should you use lockout?
Workers must employ LOTO procedures under the following circumstances:
• The equipment requires repair, cleaning or service.
• Operators must work near the hazardous areas of the machinery.
• Someone must set up or install new equipment.
• A worker needs to replace a machine part.
• A supervisor must perform an equipment inspection.
How do you determine if an energy-isolating device can be locked out?
You can lock out equipment if it has a built-in locking mechanism, has a hasp to attach a lockout device, or can be locked without impairing or altering the energy control ability.
Can you use tagout devices instead of lockout tools?
As this method does not provide the safety of lockout, you should rarely use tagout by itself. Tags are warning systems and do not stop the energization of equipment. If an employer can prove that a tagout fully protects workers or there is no place to position a lockout device on the machine, you can use a tagout method without a lock.
What are the required standards for lockout/tagout devices?
Proper LOTO procedures as outlined by the OSHA standard for The Control of Hazardous Energy are as follows:
• Employers identify hazardous energy sources and devise detailed plans to keep workers safe.
• Employers ensure the proper execution of the required procedures.
• Managers need to train all employees on the importance, purpose and steps of the lockout/tagout program.
• Authorized personnel must review the safety protocol annually.
What if you need power to test or position equipment?
If testing the machinery requires energy, all employees must clear the area during the inspection. If workers must remain near the equipment to complete the test, employers must use alternate safety measures, such as:
• Plexiglas barriers • Cameras • Employee restraints • Two-hand control devices
Lockout/Tagout OSHA Compliance
In the United States, OSHA requires five elements for complete LOTO compliance:
LOTO program with detailed policies and systems
Training programs for all relevant employees and managers
Documentation of lockout/tagout procedures
Lockout/tagout devices to ensure safety
Annual review of LOTO program
Taking the essential steps to ensure safety in the workplace is crucial for businesses. Lockout/Tagout procedures are a vital part of a comprehensive protection plan. A detailed strategy trains employees on the proper steps for safely servicing equipment. It warns and notifies everyone affected of the work to be done and prevents potential worker injuries and deaths. Written policies are easy for managers and authorized employees to implement, keeping everyone on-site safe. The effort and time it takes to implement a complete program are well worth the long-term safety benefits.
Continue reading this blog in its entirety to learn more.
Previously Featured on Accuform NMC's blog.
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