*LOCKOUT / TAGOUT*

*LOCKOUT / TAGOUT*

LOCKOUT / TAGOUT

LOTO stands for lockout/Tagout. When done properly before equipment service or maintenance, lockout/Tagout procedures control hazardous energy and protect workers from harm.

In this article, we’ll look at the basics of lockout/Tagout and LOTO safety.

The Purpose of Lockout/Tagout and LOTO Safety

When machines or equipment are being prepared for service or maintenance, they often contain some form of “hazardous energy” that can cause harm to people in the area.

When we talk about hazardous energy, we mean any type of energy that can be released and might harm a person. This could include energy of the following types:

1. Chemical

2. Electrical

3. Hydraulic

4. Mechanical

5. Pneumatic

6. Thermal

7. Other sources of energy

Without the use of proper LOTO safety procedures, the serviced equipment can unexpectedly start up or otherwise release these forms of energy. This can lead to injuries and even death to the people working on the machine and even to others working in the area or living in the community.

Energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other sources in machines and equipment can be hazardous to workers. During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy can result in serious injury or death to workers.

Six Steps of LOTO Safety & Lockout/Tagout Procedures

A lockout/Tagout procedure should include the following six steps:

1. Preparation

2. Shutdown

3. Isolation

4. Lockout/Tagout

5. Stored energy check

6. Isolation verification

Let’s look at each of these steps of LOTO safety more closely in the sections below.

Step 1: Preparation:

The first step of locking and tagging out equipment for service and maintenance is to prepare.

During the preparation phase, the authorized employee must investigate and gain a complete understanding of all types of hazardous energy that might be controlled. In addition, it’s important to identify the specific hazards and of course means for controlling that energy.

Step 2: Shut Down:-

With planning complete, the actual process of powering down and locking out machines begins.

At this point, it’s time to shut down the machine or equipment that will be serviced or maintained.

Another important part of this step is to inform any employee affected by the shutdown, even if they won’t play a role in the service or maintenance.

Step 3: Isolation:

The next step of the lockout/Tagout procedure is to isolate the machine or equipment from any source of energy.

This may mean any number of things, such as turning off power at a breaker or shutting a valve.

Step 4: Lockout/Tagout:

With the machine or equipment isolated from its energy source the next step of lockout/tagout is to actually lock and tag out the machine. It’s fair to say that this entire six-step process takes its name from this step.

During this step, the authorized employee will attach lockout and/or tagout devices to each energy-isolating device. The point is to apply the lockout device on the energy-isolating device in a way so it says in the “safe” position and cannot be moved to the unsafe position except by the person performing the lockout.

Tagout refers to applying a tag on the device as well. This tag includes the name of the person who performed the lockout and additional information.

Step 5: Stored Energy Check

Even after the energy source has been disconnected, in step 3 of the lockout safety process, and the machine has been locked out, in step 4, that doesn’t entirely guarantee that there’s no hazardous energy still stored within the machine or that it’s safe to perform maintenance.

At this time, it’s important to look for any hazardous energy that’s been “stored” within the machine, or any “residual” energy. During this phase, any potentially hazardous stored or residual energy must be releived, disconnected, restrained, or made non-hazardous in some other way.

Step 6: Isolation Verification:

This last step is all about making sure.

Yes, you’ve shut down the machines, isolated them from their source of power, locked them out, and checked for hazardous stored energy. But now’s the time to double-check that you did it all right and it’s now safe to work on the machine or equipment.

At this point, an authorized employee verifies the machine has been properly isolated and de-energized.

What can/must an employer do to keep employees protected and safe from hazardous energy sources?

As an employer, you should:

1. Develop, document, implement, and enforce energy control procedures.

2. Have lockout/Tagout devices that are specifically intended for use with particular equipment and machinery.

3. Make sure those lockout/Tagout devices are effective, standardized, durable, and substantial.

4. Make sure lockout devices correctly identify individual users.

5. Use lockout devices on all equipment that can be locked out.

6. Allow employees to use Tagout devices instead of lockout devices only if the energy control program provides employee protection that’s equal to or better than the protection a lockout device would provide.

7. Develop a Tagout policy if machines and equipment can’t be locked out.

8. Develop a policy that allows only the employee who installed a lockout device to remove it.

9. Inspect your energy control procedures at least annually.

10. Provide effective lockout/Tagout training to your employees.

11. Ensure that all new or overhauled equipment can be locked out.

12. Comply with all other energy control provisions in OSHA standards when machines or equipment must be tested or repositioned, or when outside contractors work at the site, or in group lockout situations, or during shift and personnel changes.

Please note that some of the organizations like EPCL - Engro Polymer and Chemicals Limited, Port Qasim, Karachi addressing to LOTO term into LOTOTO - Lock Out Tag Out Try Out. So, that last TO is covering to step # 5 and step # 6 already.