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Showing posts with label Lockout Tagout (LOTO). Show all posts
Showing posts with label Lockout Tagout (LOTO). Show all posts

Toolbox Talk # 07 : LOCKOUT - TAGOUT

Toolbox Talk # 07

Lockout Tagout


Lockout - Tagout requirement needed to control hazardous energy while servicing or performing maintenance on machinery or other equipment.

Types of Hazardous Energy:
  • Electrical 
  • Mechanical 
  • Gravitational 
  • Thermal
  • Hydraulic 
  • Pneumatic 
  • Chemical
When are Lockout - Tagout Procedures Required:
  • Servicing/performing maintenance on energized equipment
  • Any form of work on equipment when safety guards or measures are bypassed
  • Any form of work which requires the individual to place any part of their body in the point of operation or designated danger zone 
When Are Lockout -Tagout Procedures Not Required:
  • Minor tool changes or adjustments (i.e. blade and bit changes, table saw adjustments)
  • Cord and plug controlled devices (i.e. portable power tools)
  • Routine, repetitive changes or adjustments that are integral to the use of the equipment; provided the work is performed using alternative measures that provide effective protection
Lockout - Tagout Definitions:
  • Affected Employee: An employee whose job requires them to operate or use a piece of equipment that is affected by the Lockout - Tagout or is working in the area where the maintenance/service is being performed
  • Authorized Employee: A trained employee who locks out or tags out equipment to perform maintenance/service.
  • Supervisor: The manager/supervisor of the Authorized Employee
  • Lockout: The placement of a lockout device on an energy isolating device that ensures the equipment controlled by that energy isolating device cannot be operated until the lock is removed.
  • Tagout: The placement of a tag on an energy isolating device notifying individuals of the work being performed. Harvard University policy never allows just a tag to be affixed to the energy isolating device, a lock and tag must be used anytime equipment needs to be de-energized and serviced

Stored or Residual Energy:
  • Examples of stored or residual energy: Capacitors, springs, elevated components,rotating flywheels, hydraulic systems, and air, gas, steam water pressure etc. 
  • Methods of Dissipating or Restraining: Grounding, repositioning, bleeding,blocking etc.
When Can Harvard Employees work on Energized Equipment:
Never– Employees are required to de-energize equipment in accordance with the organization Lockout - Tagout: Control of Hazardous Energy Standard

Saving Lives by lock out / Tag out

Saving Lives by lock out / Tag out

The rack out / de-energize standards is designed to prevent injuries and deaths by accidental start up of electrical equipment's during maintenance or servicing. It save lives. Yet unfortunate tragedies do still occur. Many of them could have been prevented if the rack-out / de-energize procedures were followed correctly. This safety topic provides a review of de-energizing procedure. Remember the standard can work only if it is used correctly every time.

De-energizing procedures

  • Obtain necessary permit to rack-out / de-energize
  • Verify correct tag no mentioned in the permit with field operator and the department working on the equipment.
  • Make sure the equipment is not running. If it is running, get it stopped by operators.
  • Isolate, put multi lock hasp and yellow padlock for electrical and keep the key in electrical department custody.
  • Other departments shall use their locks (for ex., green lock for operations, blue lock for mechanical dept. and black for others) and keep keys in their custody.
  • Proper tagging must be done clearly mentioning the purpose of rack-out / de-energize, time/date etc.etc.
  • Enter all activities in substation log book.
  • An attempt to start the equipment must be made to verify that the equipment cannot start during the maintenance activity.

Energizing procedures

  • A separate permit shall be obtained to energize the equipment.
  • Visually confirm that the activity on the equipment is complete and it is safe to energize.
  • Each dept. who placed a lock must remove it themselves before energizing.
  • Remove yellow lock (electrical shall be the last lock to be removed) and energize the equipment.
  • Enter the activity in the substation log book.

Procedures for performing rack-out / de-energize must be followed consistently. Don’t be tempted to take shortcuts for small jobs, even if the rack-out procedure takes longer than the job itself.

LOTO – Accidents Happen

LOTO – Accidents Happen

What if someone didn’t know that another person were working on a machine, or electrical outlet, and turned on the power?

Lockout/tagout/tryout is a safety procedure used to ensure that dangerous machines, equipment, or services are properly shut off and not able to be started up again before maintenance is completed.

I know about lockout/tagout, but why tryout? Workers have died (even recently) because they didn’t check the machine after performing the lockout/tagout procedure. The equipment’s potentially stored or residual energy can power the machine long enough to injure or kill anyone that may be working on it’s electrical, pneumatic, hydraulic, or tension components.

Employer have to get trained their employees to be trained in lockout/tagout/tryout procedures, and renew their training every three years. OHSAS standards require that employers establish energy controls procedures and a training program for employees. Employees must follow the established lockout/tagout procedure before performing maintenance.

What must workers do before they begin service or maintenance activities?

Before beginning service or maintenance, the following steps must be accomplished in sequence and according to the specific provisions of the employer’s energy-control procedure:
  • Prepare for shutdown;
  • Shut down the machine;
  • Disconnect or isolate the machine from the energy source's;
  • Apply the lockout or tagout device's to the energy-isolating device's;
  • Release, restrain, or render safe all potential hazardous stored or residual energy. If a possibility exists for re-accumulation of hazardous energy, regularly verify during service and maintenance that such energy has not re-accumulated to hazardous levels;
  • Verify the isolation and DE-energization of the machine.

LOTO - More Than A Lock

LOTO - More Than A Lock

Lockout/Tagout is more than just putting a yellow lock on the main electrical disconnect to a machine or part of a machine. 
Section 1:- 
There are Seven important steps you must do when putting Lockout/Tagout in place. "SEVEN STEPS FOR SHUTDOWN"
  • NOTIFY – Notify all affected employees that you are going to be conducting a lockout/tagout.
  • PREPARE – Before you begin, be sure you know all the types of energy involved, hazards presented by energy, and how to control the energy.
  • SHUTDOWN – Turn off machine or equipment.
  • ISOLATE - Isolate machine or equipment from its energy source(s). (For example, turn off main circuit breaker.)
  • LOCKOUT – apply your lock. Be sure that it holds the isolating device in the “off” or “safe” position.
  • RELEASE - Release stored energy. Relieve, disconnect, restrain, block, or otherwise ensure, that all energy sources – electrical, mechanical, hydraulic, compressed, etc. – are de-energized.
  • VERIFY – Try the on-off switch or other controls to be sure the machine won’t start. Return the switch to the “off” position.
Section 2 :- 
There are 3 very important steps you must do when removing a machine from a Lockout/Tagout state. "THREE STEPS FOR RESTART"

1. INSPECT – inspect the equipment to be sure that:
  • All tools and other materials are remove. 
  • Machine is fully reassembled 
  • Guards and other safety devices are reinstalled 
2. NOTIFY – Be sure that:
  • All employees are safely positioned. 
  • All affected employees are notified of the restart 
3. REMOVE – Remove lockout devices:
  • Remember that only the person who put the lock on may remove it. 
Section 3 :-  
Prior to servicing that requires Lockout/Tagout you must evaluate the potential energy that could be released while working in that area or on a specific device. There are several types of energy:
  • Electrical energy to operate the device. 
  • Pneumatic energy or commonly known as air that controls various devices.
  • Steam that heats various devices. 
  • Natural Gas that is used in compustion devices 
  • Water that may be used to cool devices 
  • Hydraulics that may be used to control devices
  • Gravity that may play a part in something lifted off the ground.
  • Thermal energy that may cause things to remain hot after the source has been turned off.
  • As OS&H states in their standard, the purpose of LOTO is to prevent the “unexpected" energization or start up of the machines or equipment, or release of stored energy could cause injury to employees.
Depending on the task you are performing you need to evaluate and isolate the systems and sources of energy that could cause injury

Section 4:-  
Various energy sources and devices have different methods for ensuring the energy is isolated.
  • For electrical cabinets, in most case it is just a matter of placing a lock on the built-in hasp to the disconnect. However, other energy sources may require the use of additional lockout devices to accomplish the task.
  • Devices available to lockout different types of valves and the like. For gate valves similar to your home’s outside water hose valve, there are covers that encase the entire handle to prevent anyone from turning it.
  • For ball valves that do not have a place for a lock, there are devices built that will hold it in the off position (either parallel or perpendicular to the pipe) and can be locked in place.
  • For larger valves for large gas pipes we have lockable bags where the handle can be removed after being shut off and placed inside the bag and locked in place.
  • For pneumatic (air) quick disconnect hoses there is a device we have that the male end of the coupling goes into and gets locked into this device with a padlock.
  • There are numerous devices available for very specific needs and applications. 
  • If you are in a situation where you are unsure how to lockout a specific energy source check with competent person for the availability of suitable LOTO.

Safety Tips: Control the Power of Your Lockout / Tagout Training

Safety Tips :
 Control the Power of Your Lockout / Tag out Training

Employees who service or maintain machinery and equipment need special training on lockout/tag out procedures.

The objective of the following safety tips is to evaluate authorized employees' understanding of hazardous energy sources and control of hazardous energy with lockout / Tag out.


  1. Discuss your workplace lockout / Tag out program and procedures. Bring lockout / Tag out devices that are used at your operation and review their uses.
  2. List the types of energy sources at your workplace. Identify the equipment at your workplace that needs to be locked out.
  3. Discuss an incident or near miss when equipment accidentally started. What was the root cause? What was changed to prevent reoccurrence?
  4. Choose a machine or piece of equipment subject to Lockout / Tagout. Identify all energy sources that have to be locked out/tagged out before anyone can service or repair the machine or equipment. Have an authorized employee demonstrate your company's specific shutdown and restart procedures.

    Note: Any recommendations or observations during the exercise, and discuss them with the appropriate personnel.


The following are examples of Lockout / Tagout and restart procedures.

The Lockout / Tagout procedures must include the following steps:
  1. Preparing for shutdown,
  2. Shutting down the machine(s) or equipment,
  3. Isolating the machine or equipment from the energy source(s),
  4. Supplying the Lockout or Tagout device(s) to the energy-isolating device(s),
  5. Safely releasing all potentially hazardous stored or residual energy, and
  6. Verifying the isolation of the machine(s) or equipment before the start of service or maintenance work.
In addition, before Lockout or Tagout devices are removed and energy is restored to the machines or equipment, certain steps must be taken to reenergize equipment after service is completed, including:
  1. Ensuring that machines or equipment components are operationally intact; and
  2. Notifying affected employees that Lockout / Tagout devices are removed from each energy-isolating device by the employee who applied the device.

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