Lockout Tagout (LOTO)

Date: 2025-11-24

Duration: [DURATION] minutes

Presenter: [PRESENTER NAME]

Location: [LOCATION]

Objective

To understand and apply the correct Lockout Tagout procedures to ensure worker safety during maintenance and servicing of equipment.

Introduction

Lockout Tagout (LOTO) is a critical safety procedure designed to protect workers from hazardous energy releases during the servicing and maintenance of machines and equipment. Failure to properly implement LOTO can lead to serious injuries or fatalities.

Key Points

• Importance of LOTO: LOTO procedures safeguard workers from hazardous energy releases. OSHA's standard 29 CFR 1910.147 outlines specific actions and procedures for controlling hazardous energy during servicing and maintenance. Proper LOTO practices can prevent nearly 10 percent of serious accidents in many industries. [6]
• Authorized vs. Affected Employees: It's important to differentiate between authorized and affected employees. Authorized employees are qualified to perform LOTO, while affected employees are those who work in the area where LOTO is performed but do not perform the LOTO themselves. All employees need to understand the purpose and use of energy control procedures. [6]
• Basic LOTO Steps: The basic LOTO steps include identifying energy sources, de-energizing and disabling equipment, applying lockout/tagout devices, and verifying a zero-energy state. It’s not always easy to identify every source of energy; machines or systems usually contain several forms of energy. [3] [3] [3] [3]
• Lockout vs Tagout: Lockout is the preferred method, involving physically locking energy-isolating devices. Tagout is used only when equipment cannot be locked out, and it requires additional safety measures to provide equivalent protection. Tags must have specific warnings like 'Do Not Start,' 'Do Not Open,' etc. [12] [12] [12]
• Periodic Inspections: Energy control procedures must be inspected at least annually to ensure they are effective and up-to-date. These inspections must be certified in writing. [15]
• Group Lockout/Tagout: Review site-specific group lockout procedures, emphasizing that they must be as protective as personal lockout devices. The authorized person in charge has specific responsibilities, including assessing, coordinating, and ascertaining the exposure status of each employee in the group. [1]
• Shift Changes: Review hazardous energy control procedures to be used during shift changes to ensure continuous LOTO protection. This ensures no gaps in safety when personnel change over. [1]
• Materials and Hardware: Ensure employees are provided with necessary LOTO equipment, such as accident prevention signs, tags, and padlocks. Tags must be readily secured to controls, non-reusable, attachable by hand, self-locking, and non-releasable with a minimum unlocking strength of at least 50 pounds. [1] [1]
• Repetitive Process Machines: If a repetitive process machine requires power to maintain indexing, and repairs, adjustments, testing, or setup cannot be done with the hazardous energy source disconnected, specific precautions must be taken. The operating station must be under the control of a qualified operator who is in constant communication with all participating workers. [1]
• Outside Servicing Personnel: Ensure that outside servicing personnel follow your LOTO procedures. This is crucial for maintaining consistent safety standards. [2]
• De-energization: De-energization is the process used to disconnect and isolate a system from a source of energy to prevent the release of that energy. By de-energizing the system, the risk that the system could inadvertently, accidentally, or unintentionally cause harm to a person through the release of hazardous energy is eliminated. [9]
• Responsibilities: Management, supervisors, and authorized individuals all have specific responsibilities in the LOTO program. Management is responsible for drafting, reviewing, and updating the program. Supervisors ensure proper use of equipment and that only trained employees perform LOTO. Authorized individuals follow the procedures. [8] [8] [8]
• Detailed Procedures: Each unique machine or equipment should have a detailed procedure or work instruction describing the steps to control hazardous energy. This includes specifying the machine, energy types, lockout devices, shutdown steps, and verification methods. [10]
• Lockout/Tagout Steps: General steps of a lockout/tag out procedure include preparing for shutdown, notifying all affected personnel, equipment shutdown, isolation of system (de-energization). [5] [5] [5] [5]
• Lockout/Tag Out Guidelines: When the system's energy sources are locked out, specific guidelines must be followed to make sure that the lock cannot be removed and the system cannot be inadvertently operated. These guidelines include: Each lock should only have one key (no master keys are allowed). All keys must be removed from locks and kept with the person who applied the lock. [7]
• Verify Isolation: Verify that the system is properly locked out before beginning any work. Verification can take place in several ways: The machine, equipment, or process controls (push buttons, switches, etc.) are engaged or activated, and the result is observed. No response means isolation is verified. Return controls to the safe position (off). [7]
• Removal of Lockout/Tag out devices: To remove locks and tags from a system that is now ready to be put back into service, the following general procedure can be used: Inspect the work area to make sure all tools and items have been removed. Confirm that all employees and persons are safely located away from hazardous areas. Verify that controls are in a neutral position. [4]
• Stored Energy: Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe. [13]
• Tag Placement: Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device. [13]
• Electrical Safety: De-energize electrical circuits before doing any type of work on them. Use lockout devices to prevent a circuit from becoming live. Clearly identify the disconnected power source and circuits. Use an AC voltage tester to verify that the electrical power is off. [11] [11] [11] [11]
• Blanking: Blanking is the process of inserting a metal disk into the space between two pipe flanges. The disk, or blank, is then bolted in place to prevent passage of liquids or gasses through the pipe. [14]
• Cord-and-plug-connected equipment: Cord-and-plug-connected equipment is not covered under the standard if it's unplugged, the plug is under the exclusive control of the operator, and electricity is the only form of hazardous energy. [15]

Hazard Identification

Identifying potential hazards is the first step in preventing accidents. In LOTO, hazards arise from the unexpected release of energy.

• Unexpected Startup or Release of Stored Energy: Electrocution, crushing injuries, loss of limbs, burns, and other serious injuries or death.
• Contact with hazardous energy sources (electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravity): Burns, electrocution, cuts, fractures, and other trauma.
• Failure to properly de-energize equipment: Exposure to live electrical circuits or moving parts, resulting in severe injury or death.

Control Measures

• Develop and Enforce an Energy Control Program: Establish written procedures, provide employee training, and conduct periodic inspections. [15]
• Use Individual Lockout Devices: Equip all machines that can be locked out with individual lockout devices. Ensure each authorized employee has their own lock and key. [15]
• Apply Tags When Lockout is Not Possible: If an energy-isolating device cannot be locked out, use tagout devices and implement additional safety measures to provide equivalent protection. [15]
• Verify Isolation: Before starting work, verify that isolation and de-energization have been accomplished. Use testing equipment to ensure capacitors are discharged and hazardous heat/pressure is relieved. [13]
• Control Stored Energy: Ensure all workers are trained on LOTO procedures, including the purpose and function of energy control programs, hazard recognition, and safe application/removal of energy control devices. [13]

Personal Protective Equipment (PPE) Requirements

• Safety Glasses: Always wear safety glasses to protect your eyes from debris or unexpected energy releases.
• Gloves: Use appropriate gloves (e.g., insulated gloves for electrical work) to protect against specific energy hazards.
• Appropriate Work Wear: Wear clothing appropriate for the task, avoiding loose items that could get caught in machinery.

Group Discussion

Discuss the following questions:

1. Who is authorized to perform LOTO?
2. Are there times when you are not sure whether to lock out or block out?
3. What particular problems have you encountered?
4. Do you have any suggestions for improvement?

Emergency Procedures

1. In case of an emergency, immediately stop work and ensure the equipment remains locked out.
2. Evacuate the area if there is an uncontrolled release of energy or hazardous materials.
3. Report the incident to the supervisor and follow established emergency response protocols.

Summary

Recap of main points:

• LOTO is essential for preventing injuries from hazardous energy.
• Follow all LOTO procedures and use appropriate PPE.
• Never remove someone else's lock or tag.
• If in doubt, ask your supervisor.

Report all hazards, near-misses, and incidents to your supervisor immediately.

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