Introduction to lock out/tag out

Lockout Tagout (LOTO) refers to the process of de-energizing and securing equipment, machinery, or processes to ensure that hazardous energy is not inadvertently reintroduced during maintenance or repair. The process involves shutting off electrical circuits, closing valves, neutralizing excessive temperatures, and securing moving parts, among other measures. Despite this straightforward definition, safety professionals believe that the scope of LOTO is much broader.

A Brief History of LOTO

Development of the standard

The OSHA standard for the control of hazardous energy (lockout/tagout), outlined in Title 29 Code of Federal Regulations (CFR) Part 1910.147, was developed by the United States Occupational Safety and Health Administration (OSHA) in 1982. It officially went into effect in 1989. Since its implementation, the LOTO standard has contributed significantly to workplace safety.

The impact of LOTO

• Lives saved: An estimated 50,000 injuries and 120 deaths are prevented each year.
• Cost reduction: decreased employee downtime and reduced insurance costs.
• Increased productivity: decreased equipment downtime.

OSHA provides a number of resources, including tips and fact sheets, to help workplaces comply with LOTO requirements.

Understanding Lock out/tag out

Although lock out/tag out are often used together, they refer to different processes.

lock out

Lockout involves physically isolating the energy source from the system using lockout devices such as padlocks, circuit breaker lockouts, or valve lockouts. This ensures that energy cannot be reintroduced while maintenance or repair work is being performed.

tag out

Tagout involves placing a tag on equipment, which provides information about ongoing maintenance. The tag typically includes:

• Danger or warning signs
• Instructions (e.g., “Do not operate”)
• Purpose of maintenance
• Timing statement
• Name/photo of authorized employee

While tagout alone does not prevent re-energization, combining it with lockout increases employee safety.

Lock out/tag out Program Components and Compliance

A comprehensive lock out/tag out (LOTO) program includes several elements to ensure OSHA compliance, including:

• Standards and procedures: creating, maintaining, and updating equipment lists and procedures.
• Workplace rules: complying with specific requirements, such as confined space entry.
• Best practices: Implementing periodic inspections and program standardization.

Inspection and Training

• Periodic inspection: Annual review of LOTO procedures.
• Standardization: Using lockout tagout software for consistency.
• Training: Annual (or more frequent) training for authorized personnel.
• Updating procedures: Keeping isolation points and lockout devices current.
• Contractor coordination: Ensuring contractors are informed and comply with LOTO procedures.

Group, Complex or Simultaneous Opration

Companies should maintain detailed logs and permits for complex operations, ensuring documentation and coordination.

Grouping Similar Machines

OSHA allows similar equipment to be grouped for ease of inspection, provided each machine has specific procedures.

Contractor Specific Requirement

Contractors should follow LOTO procedures and coordinate with host employers to ensure safety.

Lock out Device Management

Estimating Device Needs

Organizations should estimate lockout device needs based on equipment and high-hazard areas, monitoring and adjusting inventory as needed.

Training Requirements

Practical training with documentation is required, along with initial and periodic (e.g., annual) training to address any knowledge gaps or procedural changes.

Annual Audits and inspections

Requirements and Documentation

Annual inspections should be conducted by an authorized employee, reviewing each energy control procedure and employee responsibilities. Documentation should include details such as the equipment inspected, date, and names of employees involved.

Formality and Comprehensiveness

Audits should be thorough, employees should be observed and interviewed to ensure proper implementation of procedures, and group meetings should be held to reinforce responsibilities.

Conclusion

Lockout tagout is a critical safety procedure that goes far beyond simply locking out machinery. It involves extensive planning, regular training, thorough inspections, and coordination between employees and contractors. Proper implementation and adherence to LOTO standards not only increase safety but also improve productivity and reduce costs.

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