How to manage Lockout/tagout

Getting Started

Before you can create a plan to protect workers you need to do an inventory to identify the hazardous energies in your machinery and equipment. Start by creating a list of machinery and equipment and document all the potential energy sources. We have provided a sample procedure that you can use to document your energy control requirements available under the Training & Resources tab. Lock out/tag out is not limited to only electrical equipment. Other common forms of energy are pressurized water, steam, heat, hydraulic equipment like forklifts, etc.

Energy sources can include:

• Electrical

• Mechanical (moving parts like springs or wheels)

• Hydraulic (pressurized liquid , usually oil)

• Pneumatic (pressurized gas, usually air or nitrogen)

• Chemicals and chemical reactions

• Thermal (usually steam)

• Gravity (usually suspended heavy objects)

It is common for machines to have more than one energy source. Just because you turned off the electrical power does not mean that it cannot move. Lockout/Tagout does not apply to work on cord and plug connected electric equipment when: (a) Unexpected energization or startup of the equipment is controlled by unplugging the equipment from the energy source; and (b) The plug is under the exclusive control of the employee performing the servicing or maintenance.

Basic LOTO Procedures

The terms “Lock Out” and “Tag Out” describe how you control the hazard. After turning off the power source, put a physical lock on the on/off switch, valve, etc. which prevents anyone from turning it on. Next, attach a warning tag that states, “do not operate” and says whom is responsible for the lock. Including contact information: name, title and number.

Written program

Creating a written energy control program will help you prevent injuries at your worksite. A written energy control plan describes how to LOTO all the different types of energy sources. Many pieces of equipment need to have multiple energy sources controlled; for example, an electrically powered machine may also have compressed air tanks and lines to operate pneumatic clamps.

Every program must include:

1. Specific LOTO procedures for all potential energy sources and equipment

2. Training requirements

3. Program re-evaluation

Businesses may have several different LOTO procedures because they have multiple types of equipment and energy sources. Some procedures may be standardized for similar equipment while others are specific to a machine.

Training

Train all employees working around equipment that may be locked/tagged out (affected employees) to an awareness level on the LOTO program and what the lockout/tagout gear means so employees do not attempt to restart equipment that is under maintenance. The maintenance employees performing LOTO (authorized employees) will need further training:

• Authorized Employees – employees who perform the LOTO procedure need additional training on the specific procedures and the energy sources at the business. In addition, they need to be able to recognize situations that need LOTO even when it is not listed.

Retraining whenever equipment changes, procedures change and if employees are not following the procedure.

All training must be documented.

Evaluations of LOTO

Review the LOTO program at least annually (Energy control procedures used less frequently than once a year, only need review before use). An authorized employee must conduct the periodic review. An authorized employee that does not use the energy control procedure under review. After the evaluation, make any needed updates to your program or procedures and retrain staff.

If the evaluation reveals problems with the LOTO program, then retrain all affected & authorized employees.For companies that work with large machinery, it's vital to control hazardous energy that machines can emit. 

What is lockout/tagout?

Lockout/Tagout (LOTO) refers to practices and procedures that safeguard employees from the unexpected energization or startup of machinery and equipment. Specifically, unexpected startup of machinery during service or maintenance can release energy that can be toxic or otherwise hazardous to the people working around them.

Following LOTO procedures is vital in maintaining a safe, properly functioning workplace, and helps ensure the health and safety of maintenance employees.

Why is lockout/tagout important?

Machines that operate through electrical, mechanical, hydraulic, pneumatic, chemical, and thermal methods often emit hazardous energy that can be a danger to those who work around or on them. Employees who service or maintain machines and equipment are at particular risk of exposure to this energy since performing service or maintenance on them often results in the release of stored energy. This can result in injury or even death to workers without the proper precautions.  

Controlling hazardous energy (lockout/tagout) is one of OSHA’s top 10 most frequently cited standards. It’s essential for companies that work with these machines to ensure they’re operating safely, with minimal risk to those who work on and around that equipment during servicing and maintenance tasks.

What are the steps of lockout/tagout?

Lockout/Tagout procedures are designed to ensure the safety of workers when they are working on or around equipment that has the potential to release stored energy. The process of Lockout/Tagout involves several important steps to ensure the safety of affected employees, and often are managed through a computerized maintenance management system (CMMS).

1. Prepare

Before starting any Lockout/Tagout procedures, it is essential to have a plan in place that includes identifying hazardous energy sources and determining which devices need to be locked out or tagged out. The preparation step should also include selecting appropriate lockout devices and tagout devices and ensuring that all employees involved in the process are appropriately notified that equipment will be shut down and trained in the Lockout/Tagout procedures.

2. Shut down

Once the preparation step is completed, the next step is to shut down the equipment or machinery to be serviced. This involves following the manufacturer's instructions or standard procedures to ensure a safe and efficient shutdown per normal operating procedures.

3. Isolate

After the equipment or machinery has been shut down, the energy source(s) must be isolated. This means disconnecting or isolating the energy source(s) from the equipment to prevent an accidental release of stored energy using an energy-isolating device, such as

• Valves

• Breakers

• Switches

• Blank flanges for piping systems

• Restraining devices

4. Lockout/tagout

Once the energy source has been isolated, apply the lockout or tagout devices. This involves physically locking and/or tagging out the energy source(s) using appropriate devices that prevent the equipment from being turned on or activated, keeping them in a “safe” position.

5. Check stored energy

After the energy source(s) have been isolated and locked or tagged out, it is essential to verify that there is no residual energy left in the equipment. This may involve releasing any residual pressure or discharging any stored capacitors. For example, closing a valve on pneumatic- or hydraulic-powered systems isolates the system from its primary energy source. Any air or liquid remaining in the system may be dangerous, so bleeding liquid or venting the air helps ensure there are no accidental exposures and injuries.

6. Verify

The final step of Lockout/Tagout procedures is to verify that the equipment is fully de-energized and that all Lockout/Tagout procedures have been properly implemented. This may involve visually inspecting the equipment, testing the controls or switches, and verifying that all affected employees are aware of the Lockout/Tagout procedures in place. This last step is crucial to ensuring employee safety, verifying that the machine or equipment is disconnected from its energy source before maintenance begins.

Lockout/Tagout procedures are essential for preventing workplace accidents and injuries caused by the unexpected release of stored energy. By following these Lockout/Tagout steps, employees can work safely on or around equipment or machinery that has the potential to release stored energy.

Simplifying lockout/tagout with your CMMS

Using a computerized maintenance management system (CMMS) can simplify and automate Lockout/Tagout procedures, making the LOTO process easier and safer. By reducing the manual efforts needed to provide the proper safety parameters for employees, a CMMS can reduce the potential for human error, and offer safeguards that will keep employees safe while working on equipment.

Storing critical LOTO information: A CMMS stores all of the critical information related to LOTO procedures in one centralized location. This includes information about energy isolation, isolation devices, and other important details. By having all of this information in one place, it becomes easier to ensure nothing is missed, and all steps are being taken to properly implement LOTO processes.

Including LOTO instructions on work orders: A CMMS has the capability to list LOTO instructions on work orders for specific pieces of equipment, ensuring employees are aware of the LOTO procedures that must be followed before working on that particular piece of equipment. By integrating LOTO procedures into work orders, employees can quickly and easily access the information, using it as a checklist to ensure compliance.

Providing compliance documentation: OSHA lockout/tagout regulations require that companies keep detailed records of LOTO procedures. A CMMS can provide documentation of those procedures, including the steps taken to isolate energy sources, apply LOTO devices, and verify that equipment is safe to work on. This documentation can be easily accessed and updated, ensuring companies remain compliant with OSHA regulations.

Automating LOTO processes: A CMMS can automate some of the LOTO processes, such as generating work orders and assigning tasks to employees. This can save time and reduce the risk of human error. For example, when a work order is generated, the CMMS can automatically include LOTO instructions for that particular piece of equipment.