SAF102-LECTURE 5: LOCKOUT TAGOUT (LOTO)

INTRODUCTION
Any workplace scenario involving equipment that could lead to the advertent release of
hazardous energy requires the use of lockout/tagout procedures.
In this context, “hazardous energy” includes not only the electricity but other forms of
energy such as pneumatic pressure, hydraulic pressure, and gas.
The purpose of LOTO procedures is both to prevent direct exposure to this energy, as
well as to prevent harm by any machinery or objects that could be moved by that energy
(e.g. a pneumatic press accidentally being activated)

The Occupational Safety and Health Administration (OSHA) has designed and
established stringent LOTO procedure guidelines; these guidelines were originally
drafted in 1982 and were put in place in 1989. These procedures provide employers
with a degree of flexibility based on the individual industries that they operate in.
They cover electric-powered equipment, which accounts for a significant percentage of
all injuries, and they also apply to equipment powered by alternative sources, such as
pneumatic and hydraulic equipment.

TERMINOLOGY
Lockout/tagout (LOTO) is a set of procedures that are used to ensure that equipment is
shut down, inoperable, and (where relevant) de-energized.
This allows maintenance and repair work on the system to be performed safely.

What is hazardous energy?

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.

What are harmful effects of hazardous energy?

Workers servicing or maintaining machines or equipment may be seriously injured or
killed if hazardous energy is not properly controlled.
Injuries resulting from the failure to control hazardous energy during maintenance
activities can be serious or fatal.
Injuries may include electrocution, burns, crushing, cutting, lacerating, amputating, or
fracturing body parts, and others.

LOCKOUT TAGOUT BASICS

The use of lockout/tagout procedures has traditionally been tracked via the use of
dedicated binder.
However, there is also dedicated LOTO software available that can perform the same
function.

IMPORTANCE OF LOCKOUT TAGOUT STANDARDS

The use of lockout/tagout procedures is considered a critical aspect of workplace in any
occupational setting in which workers come into direct contact with machinery or
workplace equipment. Accidents which can be prevented by LOTO procedures include:
 Electrical accidents
 Crushing
 Lacerations
 Fires and explosions
 Chemical exposure

Safety Tips
Lockout Tagout Safety Tips
Don’t neglect residual energy.
Always assume the machine is on, and capable of spontaneous operation prior to
cleaning or maintenance.
Locking out a switch or turning off the power does not guarantee safety.

LOCKOUT TAGOUT STANDARDS

Because of their critical safety importance. The use of LOTO or lockout tagout
procedures is legally required in every jurisdiction that has an advanced occupational
health and safety program.
In addition to legally prescribing the use of LOTO procedures, OSHA also places heavy
emphasis on the enforcement of those procedures. In the 2019-2020 fiscal year, LOTO-
related fines were the sixth-most frequent issued by OSHA, and their presence in
OSHA’s top-10 most-cited safety violations is an annual occurrence.
Lockout/Tagout
The following steps must be conducted prior to working on equipment
The Control of Hazardous Energy
1. Notify affected employees that machine or equipment will be shut down and
locked out
2. Shut down the machinery or equipment.
3. Isolate energy sources with energy isolation devices.
4. Lock out energy isolating devices with assigned locks
5. Release or restrain stored or residual energy.
6. Test machinery to make sure it can’t start up

What can be done to control hazardous energy?

This is particularly true when it comes to mandatory re-training and updating employees
on new equipment and protocols.
The cavalier assumption that people know what they are doing puts lives in danger.
There is also extensive anecdotal evidence indicating that even employees who have
worked for years at the same facility cut corners in an attempt to save time.
In addition to the above-mentioned procedures, OSHA also stipulates that all potentially
impacted employees must be adequately trained on LOTO protocols and procedures.
It is not enough to simply save OSHA-compliant procedures in place; instead, these
policies have to be put into practice on a daily basis.
This is something that is frequently overlooked or glossed over by the employers and
employees alike who do not want to devote time to things that seem like common sense.

An Employer’s Responsibility
The LOTO standard establishes the employer’s responsibility to protect workers from
hazardous energy.
Employers are also required to train each worker to ensure that they know, understand,
and are able to follow the applicable provisions of the hazardous energy control
procedures:
1. Workers must be trained in the purpose and function of the energy control
program and have the knowledge and skills required for the safe application,
usage and removal of the energy control devices.
2. All employees who work in an area where energy control procedure(s) are
utilized need to be instructed in the purpose and use of the energy control
 procedure(s), especially prohibition against attempting to restart or reenergize
machines or other equipment that are locked or tagged out.
3. All employees who are authorized to lockout machines or equipment and perform
the service and maintenance operations need to be trained in recognition of
applicable hazardous energy sources in the workplace, the type and magnitude
or energy found in the workplace, and the means and methods of isolating and/or
controlling the energy.
4. Specific procedures and limitations relating to tagout systems where they are
allowed.
5. Retraining of all employees to maintain proficiency or introduce new or changed
control methods.

LOCKOUT TAGOUT BASIC RULES

Develop a single, standardized LOTO program that all employees are trained to follow.
Make use of locks to prevent access to energized equipment. The use of tags is only
acceptable if the tagout procedures are strict enough that they provide equal protection
to what a lockout would provide.
Ensure that new and modified equipment can be locked out.
Provide a means of tracking every instance of lock/tag being applied to, or removed
from, a device. This includes tracking who placed the lock/tag as well as who removed
it.
Implement guidelines for who is allowed to place and remove locks/tags. In many cases,
a lock/tag may only be removed by the person who applied it.
Inspect LOTO procedures annually in order to assure that they are performing
acceptably.