Accidents can happen any time on a job site – it’s important to take steps to prevent them from happening. Here’s an example: Before they started using Safety Mojo, one of our customers experienced a pretty serious issue. A subcontractor working on the project was installing a fire suppression system, when the worst scenario happened – the sprinklers burst under pressure, flooding the entire job site and ruining expensive power units and switchboards.
At the end of the day, what could have prevented this issue? Effective Lockout/Tagout procedures to reduce water pressure and shut down power.
What Is Lockout Tag Out?
Lockout/Tagout (LOTO) is a safety procedure used during the maintenance or servicing of machines and equipment. Its purpose is to make sure that machines are properly turned off and cannot be started again until the work is finished.
The Occupational Safety and Health Administration (OSHA) defines lockout/tagout in standard 29 CFR 1910.147. According to OSHA, LOTO procedures help prevent injuries caused by the unexpected energization, startup, or release of stored energy during servicing and maintenance.
Proper lockout/tagout procedures control these types of hazardous energy:
- Electrical: Power from electrical circuits and batteries
- Mechanical: Moving parts like gears, pulleys, and rotating equipment
- Hydraulic: Pressurized fluids in hydraulic systems
- Pneumatic: Compressed air or gas systems
- Chemical: Hazardous chemicals that could be released
- Thermal: Heat from hot surfaces or steam systems
OSHA reports following LOTO procedures prevents about 50,000 injuries and 120 fatalities each year in the United States. These numbers show lockout tagout is essential for protecting workers while they inspect and repair hazardous machinery.
Some risks of improper lock out tag out include unexpected equipment startup, stored energy release, and missing multiple energy sources on complex machines. If you fail to follow correct LOTO procedure, you’re looking at regulatory penalties from OSHA, which can be up to $16,550 per instance. Trust us, that number adds up fast.
Lockout Tagout Procedures For Controlling Hazardous Energy
An effective lockout tagout procedure follows several steps. Each piece of equipment requires a written procedure that describes how to safely isolate and control hazardous energy sources before maintenance or service. These procedures identify each energy source, outline the shutdown steps, and specify how to apply and remove lockout/tagout devices.
Lockout and tagout devices also both do different things. Standardized lockout devices physically prevent machinery from moving or being energized. These devices are designed to fit specific equipment and are easily identifiable. On the other hand, tagout devices provide a visible warning that equipment is out of service but do not physically prevent operation. Keep in mind even if you’ve tagged out, a negligent coworker could still try to start the equipment up. We’d recommend using both procedures together to provide total protection.
Documentation is also required for every lockout tagout procedure. This includes detailed records of the steps taken, the devices used, and who is responsible for each action. Communication protocols are part of every lockout tagout program to avoid confusion and maintain safety.
Written procedures for each piece of equipment include identification of all energy sources, step-by-step shutdown instructions, directions for isolating energy, instructions for applying lockout and tagout devices, steps for verifying isolation, and the sequence for removing devices after work completion.
Like we’ve said, following these steps help prevent serious injuries and keeps your crew in compliance with safety standards. Here’s how a typical LOTO procedure should go.
LOTO Steps
Following a consistent, step-by-step approach is necessary for lockout tagout safety. Each step in the lockout procedure addresses a specific hazard and helps maintain control of hazardous energy during maintenance or servicing.
1. Identify All Energy Sources
Start by reviewing the equipment to find all energy sources. These can include electrical currents, moving mechanical parts, hydraulic pressure, pressurized air (pneumatic), chemicals, or heat (thermal). Keep in mind a machine might use both electricity and hydraulics. In this case, both energy types should be documented in the procedure.
2. Shut Down Equipment
Begin the lockout process by shutting down the equipment using its normal controls. Follow the manufacturer’s guidelines and the site’s operating procedures. For example, turn off a machine using the off switch, then allow moving parts to stop completely before proceeding.
3. Isolate And Lock Out Each Source
Isolate each energy source by disconnecting or blocking it. For electrical energy, turn off the main circuit breaker. For hydraulic or pneumatic energy, close the valves and bleed off pressure. For mechanical energy, block moving parts with physical restraints.
4. Apply Tag Out Lock Out Devices
Place lockout devices and tagout devices on each energy isolation point. Each authorized employee working on the equipment should apply their own lock. Tags need to be attached to each lock to show who applied it and why.
Tag information should include:
- Name of the person: Who applied the lock and tag
- Date applied: When the lockout tagout was implemented
- Work description: Brief explanation of the maintenance being performed
- Contact information: How to reach the person if needed
5. Release Or Restrain Stored Energy
Check for sources of stored energy, like charged capacitors, compressed springs, raised machine parts, flywheels, hydraulic accumulators, or trapped air. Release or restrain this energy by draining, blocking, or discharging it using the correct method.
For example, bleed air from pneumatic lines, discharge electrical capacitors using grounding tools, or secure raised parts with blocks. Each type of stored energy is addressed based on its properties and potential hazards.
6. Verify Full Isolation
Test that all energy sources have been isolated. Attempt to start the equipment using its normal controls to confirm it does not operate. Use appropriate testing instruments to check for live energy, such as voltage testers for electricity.
Verification confirms that the equipment is safe to work on before maintenance begins and is a critical step in the lockout procedure. Once LOTO is applied, verified and documented, you can perform your inspection and maintenance.
Training Requirements and Employee Roles
OSHA recognizes three main groups for lockout tagout training: authorized employees, affected employees, and other employees. Each group has specific training requirements based on their roles and interactions with equipment. Let’s break them down.
Authorized employees apply and remove lockout/tagout devices. Their training covers recognizing hazardous energy sources, understanding energy types and magnitudes, and learning specific procedures for controlling energy. They receive initial training, annual retraining, and additional training when procedures or equipment change.
Affected employees operate equipment that is being serviced under LOTO procedures. Their training covers the purpose of energy control procedures and the importance of not restarting equipment while it’s locked or tagged out.
Other employees work in areas where lockout/tagout procedures are used but do not operate or service the equipment. Their training covers the basic purpose of LOTO and the meaning of lockout and tagout devices so they’re aware of what’s going on.
How To Conduct Routine Audits And Inspections
OSHA requires that every lockout tagout procedure is audited at least once per year. The purpose of these audits is to verify that procedures are being followed as written and remain adequate for the equipment and energy sources involved. If you’re using the same equipment every year, those procedures might not change drastically. But if something’s replaced or a procedure fails, then you’ll likely need to review everything.
Documentation of each inspection should include the date, the equipment or procedure reviewed, the names of employees involved, and the person conducting the inspection. Inspections need to be conducted by an authorized employee who is not regularly involved in the procedure being inspected. That way, the review can remain objective.
A lockout/tagout audit checklist includes:
- Procedure review: Checking written procedures for adequacy and accuracy
- Employee interviews: Assessing knowledge and compliance understanding
- Process observation: Watching the LOTO process as it happens
- Documentation review: Examining training records and implementation logs
- Corrective action planning: Identifying and addressing any gaps or issues
Using Technology And Data To Improve Lock Out Tag Out
Modern safety management platforms use technology to make lockout tagout programs more organized, consistent, and accurate. Digital procedure documentation stores all LOTO instructions electronically and updates them as equipment or regulations change.
Mobile access allows workers to view lockout tag out procedures from a phone or tablet while at the job site. This reduces the chance of using outdated instructions and helps everyone follow the same steps.
Electronic audit trails track who completed each step of a LOTO process and when it happened. Real-time compliance tracking monitors ongoing activities and shows immediately if a process is missed or completed out of order.
If possible, consider using a digital safety management platform like Safety Mojo to conduct your LOTO procedures and audits. Digital forms can help make sure every inspection goes according to plan, which means you get better data, and your crew can better engage in safety.
Ready to improve your on-site safety program? Book a demo with Safety Mojo to see how our digital safety management platform can help you implement these practices more efficiently: https://www.getmojo.ai/
Lockout Tagout FAQ
What happens if equipment has multiple energy sources during lockout tagout?
Each energy source is listed in the written procedure and locked out separately during maintenance. Safety Mojo records and tracks these sources for equipment with multiple energy types.
Can someone remove a lockout tagout device if the original worker is unavailable?
OSHA permits removal in specific situations following a detailed verification procedure outlined in written policies. Only management performs this removal after attempting to contact the employee who applied the device.
How does Safety Mojo help with lockout tagout compliance?
Safety Mojo stores all procedures in one digital location, tracks compliance activities, and provides data about how procedures are followed through electronic records and audit trails.
