Lockout Tagout Procedures: Controlling Hazardous Energy in 8 Steps

If a machine needs maintenance or servicing, company LOTO procedures apply. As these procedures already exist, it’s easy to reference them. Specifically, these procedures show:

• Energy type (electrical, mechanical, hydraulic, thermal, pneumatic, chemical)

• Energy magnitude (volts, temp, psi , etc.)

• Energy hazards

• Methods to control the energy

Lockout

• A lockout tagout device (e.g., breaker or ball valve lockout) holds the energy isolating device in a SAFE / OFF position.

• Safety padlocks (key or combination) then prevent the removal of the energy-isolating device to ensure energy cannot flow from its source to the machine.

• Assigned locks should be applied to each energy-isolation device.

Tagout

• Tagout refers to using a tagout device on an energy-isolating device.

• It should be securely fastened to the isolating device to indicate the energy-isolating device and equipment may not be operated until the tag is removed.

• Essentially, it warns others not to restore energy. The tag should include the name of the employee who applied it and why. That way, if anyone has questions as to why the equipment is locked out, they know who to ask.

Personal locks and tags should be used on:

• Line valves

• Circuit breakers / electrical disconnects

• Safety blocks on moveable parts

• Blank flanges on pipelines

Once energy-isolating devices are locked out, this step requires checking for stored energy. All residual energy must be depleted or drained from the equipment to ensure it’s in a controlled state. Examples include:

• Capacitors

• Springs

• Elevated machine members

• Rotating flywheels

• Hydraulic systems

• Air, gas, steam or water pressure

To verify that the equipment is disconnected from the energy source, you’ll need to test it.

• First, check that no personnel can be exposed to the threat of an energy hazard. Then, verify isolation by trying to operate it.

• This can include pushing an ON button or any other operating control, and visually checking gauges.

• Then, return the control / button to the OFF position after verifying isolation.

When the machine or equipment has been serviced or repaired, it’s time to get the work area and personnel ready for startup. Procedures must be followed in the correct order.

• Make sure that the machine or equipment is fully reassembled (guards and safety devices are reinstalled, access panels are closed).

• Then, check that tools have been cleared from the work area.

• Survey the work area, checking to see that all personnel are in a safe spot or removed from the area.

• Verify all controls are in neutral.

• Remove tags and lockout devices (by the same person who applied them).

• Inform affected personnel that the servicing or maintenance is finished and the equipment is ready for use.