Lockout/Tagout (LOTO) Procedures and Safety Guidelines

Date: 2025-10-16

Duration: [DURATION] minutes

Presenter: [PRESENTER NAME]

Location: [LOCATION]

Objective

To understand and apply Lockout/Tagout (LOTO) procedures to safely control hazardous energy during equipment maintenance and servicing.

Introduction

Lockout/Tagout (LOTO) procedures are essential for protecting workers from hazardous energy releases during the servicing and maintenance of machines and equipment. Failure to control hazardous energy accounts for nearly 10 percent of serious accidents in many industries. [1]

Hazard Identification

Identifying potential hazards associated with uncontrolled energy is the first step in preventing accidents during maintenance and servicing.

• Unexpected startup or release of stored energy: Serious injury or death to workers. [1]
• Electrocution: Severe burns, cardiac arrest, or death due to contact with electrical energy. [2]
• Crushing injuries: Fractures, amputations, or death due to moving parts of machinery. [2]
• Exposure to thermal energy: Burns from hot surfaces or fluids.
• Exposure to chemical energy: Chemical burns or poisoning from contact with hazardous substances.

Control Measures

• Develop hazardous energy control procedures.: Employers must develop step-by-step procedures for employees who clean, repair, service, set up, unjam, or adjust machinery or equipment. Separate procedures are required for each type of equipment. [2]
• De-energize and isolate power sources.: Electrical power must be de-energized at the circuit breaker, not just at the shut-off or emergency stop. Power-driven equipment and machines with lockable controls must be locked out or sealed in the "off" position. [2] [2]
• Apply lockout/tagout devices.: Use individual lockout devices for equipment that can be locked out. If an energy isolating device is not capable of being locked out, provide tagout devices instead of lockout devices only if the employer can demonstrate that the use of a tagout program provides full employee protection equivalent to a lockout program. [5] [5]
• Verify energy isolation.: Attempting to restart the equipment is one way to confirm isolation; however, testing equipment ensures that capacitors have been properly discharged, hazardous heat has dissipated, and excessive pressures have been relieved. [4]
• Train and authorize employees.: Only trained, authorized employees are allowed to conduct LOTO procedures. Training requirements depend on whether employees service equipment or just work near it while it is being serviced. [2] [3]
• Conduct periodic inspections.: Inspect energy-control procedures at least annually, and certify this in writing. [5]

Personal Protective Equipment (PPE) Requirements

• Safety Glasses: Wear safety glasses to protect eyes from debris or splashes during the lockout process and maintenance activities.
• Gloves: Use appropriate gloves (e.g., electrical, chemical-resistant) to protect hands from electrical hazards, chemicals, or sharp objects.
• Safety Shoes: Wear safety shoes to protect feet from falling objects or electrical hazards.

Real-World Example or Case Study

A worker was seriously injured when a machine unexpectedly started during maintenance because the LOTO procedures were not followed. The worker had not de-energized the machine properly, and another employee unknowingly re-energized it, resulting in severe crushing injuries.

Emergency Procedures

1. Ensure the equipment cannot be restarted.
2. Evacuate the area if necessary.
3. Report the incident to the supervisor immediately.

Questions and Answers

• Q: Who is authorized to perform LOTO?

A: Only trained and authorized employees are allowed to perform LOTO procedures. [2]

• Q: What should I do if I am unsure whether to lock out or tag out?

A: Always err on the side of caution and lock out the equipment. If you are unsure, ask your supervisor for guidance.

• Q: What do I do if I lost the key to my LOTO lock?

A: Notify your supervisor immediately. A specific procedure should be in place for removing the lock in such situations.

Summary

Recap of main points:

• LOTO procedures are critical for preventing injuries during equipment maintenance.
• Proper training and authorization are essential for performing LOTO.
• Always verify energy isolation before starting any work.
• Follow established LOTO procedures and use appropriate PPE.

Remember: Lockout/Tagout: Save Lives – Control Hazardous Energy!

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

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