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Lock out tag out

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Safe Work Procedure: Lock Out Tag Out (LOTO)

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This procedure covers the lockout and tagout (LOTO) of energy isolating devices to ensure that machines and equipment are isolated from energy sources before any maintenance or servicing activities are performed. It applies to all employees, contractors, and visitors involved in servicing and maintenance activities where the unexpected energization or release of stored energy could cause injury.

This procedure applies to all types of energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, and thermal energy. It should be used in conjunction with other safety procedures and standards, such as OSHA 29 CFR 1910.147.

2. Definitions

Lockout The placement of a lockout device on an energy isolating device to ensure that the device and the equipment being controlled cannot be operated until the lockout device is removed [1].

Tagout The placement of a tagout device on an energy isolating device to indicate that the device and the equipment being controlled may not be operated until the tagout device is removed [1].

Authorized Employee An employee who locks out or tags out machines or equipment to perform servicing or maintenance [2].

3. Responsibilities

3.1 Supervisors

  • Ensure all employees are trained in LOTO procedures.
  • Verify that LOTO procedures are followed correctly.
  • Conduct periodic inspections of LOTO procedures [3].

3.2 Workers

  • Follow all LOTO procedures as trained.
  • Use appropriate lockout and tagout devices.
  • Report any issues or deviations in LOTO procedures to supervisors.

3.3 Health and Safety Representative

  • Assist in the development and review of LOTO procedures.
  • Participate in incident investigations related to LOTO.

4. Potential Hazards and Risks

HazardRiskControl Measures
Unexpected energizationInjury or deathUse lockout devices to isolate energy sources [1].
Stored energyRelease causing injuryRelieve, disconnect, or restrain stored energy [4].
Inadequate communicationAccidental startupNotify all affected employees before and after LOTO [5].

5. Personal Protective Equipment (PPE)

Proper PPE must be worn at all times during LOTO procedures to protect against potential hazards.

  • Safety glasses - Protect eyes from flying debris.
  • Gloves - Protect hands from electrical and mechanical hazards.
  • Hard hats - Protect head from falling objects.
  • Hearing protection - Use in noisy environments.
  • Safety shoes - Protect feet from heavy objects.

Inspect PPE before use and replace any damaged items immediately.

6. Equipment and Tools

Use appropriate lockout and tagout devices to ensure energy isolation.

  • Locks - Secure energy isolating devices in the "off" position.
  • Tags - Indicate that equipment is not to be operated.
  • Lockout hasps - Allow multiple locks to be used on a single device.
  • Circuit breaker lockouts - Secure circuit breakers in the "off" position.
  • Valve lockouts - Secure valves in the closed position.

Inspect all equipment and tools before use to ensure they are in good condition.

7. Pre-Job Requirements

7.1 Training and Competency

All employees must receive training on LOTO procedures and demonstrate competency in their application [6].

7.2 Pre-Job Briefing

Conduct a pre-job briefing to review the LOTO procedure, identify energy sources, and discuss potential hazards.

7.3 Work Area Preparation

Ensure the work area is clear of non-essential items and that all employees are aware of the LOTO procedure being implemented.

8. Safe Work Procedure Steps

Step 1: Preparation for Shutdown

  • Identify all energy sources.
  • Notify affected employees of the LOTO procedure.
  • Prepare to shut down the equipment [6].

Step 2: Machine or Equipment Shutdown

  • Turn off the machine or equipment using established procedures.
  • Ensure an orderly shutdown to avoid additional hazards [5].

Step 3: Isolation of Energy Sources

  • Locate and operate all energy isolating devices to isolate the machine or equipment from energy sources [6].

Step 4: Application of Lockout/Tagout Devices

  • Affix lockout or tagout devices to each energy isolating device.
  • Ensure devices are clearly marked and identifiable [3].

Step 5: Release of Stored Energy

  • Relieve, disconnect, or restrain all stored energy sources [4].

Step 6: Verification of Isolation

  • Verify that the machine or equipment is isolated and de-energized before starting work [4].

9. Precautions and Safety Measures

  • Ensure all employees are trained and competent in LOTO procedures.
  • Use only approved lockout and tagout devices.
  • Communicate clearly with all affected employees.
  • Verify isolation before starting work.
  • Conduct periodic inspections of LOTO procedures.

10. Emergency Procedures

10.1 General Emergency Response

  • Evacuate the area if an unexpected energization occurs.
  • Report the incident to a supervisor immediately.

10.2 Specific Emergency Scenarios

  • Unexpected Energization - Evacuate and notify a supervisor.
  • Injury During LOTO - Provide first aid and call emergency services.

10.3 Emergency Contact Information

[List of emergency contacts and their phone numbers]

11. Incident Reporting and Investigation

Report all incidents, near-misses, and hazards to a supervisor immediately. An investigation will be conducted to determine the cause and prevent recurrence.

12. References and Related Documents

  • OSHA 29 CFR 1910.147 - The Control of Hazardous Energy (Lockout/Tagout)
  • [Reference 2]
  • [Reference 3]

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]

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6 source record(s)

Sources used for this answer

[1] Occupational Safety and Health Standards (OSHA 29 CFR 1910)

Page 115

Open source document

Source excerpt

## 29 CFR 1910 (OSHA) - (A) Work on cord and plug connected electric equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the servicing or maintenance. - (B) Hot tap operations involving transmission and distribution systems for substances such as gas, steam, water or petroleum products when they are performed on pressurized pipelines, provided that the employer demonstrates that ( 1 ) continuity of service is essential; ( 2 ) shutdown of the system is impractical; and ( 3 ) documented procedures are followed, and special equipment is used which will provide proven effective protection for employees. - (3) Purpose. (i) This section requires employers to establish a program and utilize procedures for affixing appropriate lockout devices or tagout devices to energy isolating devices, and to otherwise disable machines or equipment to prevent unexpected energization, start-up or release of stored energy in order to prevent injury to employees. - (ii) When other standards in this part require the use of lockout or tagout, they shall be used and supplemented by the procedural and training requirements of this section. ## (b) Definitions applicable to this section. - Affected employee. An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed. Authorized employee. A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee's duties include performing servicing or maintenance covered under this section. Capable of being locked out. A

[2] Occupational Safety and Health Standards (OSHA 29 CFR 1910)

Page 118

Open source document

Source excerpt

## 29 CFR 1910 (OSHA) - (ii) Lockout devices and tagout devices shall be singularly identified; shall be the only devices(s) used for controlling energy; shall not be used for other purposes; and shall meet the following requirements: - (A) Durable. ( 1 ) Lockout and tagout devices shall be capable of withstanding the environment to which they are exposed for the maximum period of time that exposure is expected. - ( 2 ) Tagout devices shall be constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate or the message on the tag to become illegible. - ( 3 ) Tags shall not deteriorate when used in corrosive environments such as areas where acid and alkali chemicals are handled and stored. - (B) Standardized. Lockout and tagout devices shall be standardized within the facility in at least one of the following criteria: Color; shape; or size; and additionally, in the case of tagout devices, print and format shall be standardized. - (C) Substantial -( ) 1 Lockout devices. Lockout devices shall be substantial enough to prevent removal without the use of excessive force or unusual techniques, such as with the use of bolt cutters or other metal cutting tools. - ( 2 ) Tagout devices. Tagout devices, including and their means of attachment, shall be substantial enough to prevent inadvertent or accidental removal. Tagout device attachment means shall be of a nonreusable type, attachable by hand, self-locking, and non-releasable with a minimum unlocking strength of no less than 50 pounds and having the general design and basic characteristics of being at least equivalent to a one-piece, all-environment-tolerant nylon cable tie. - (D) Identifiable. Lockout devices and tagout devices shall indicate the identity of the employee applying the device(s). - (iii) Tagout devices shall warn against hazardous conditions if the machine or equipment is energized and shall include a legend such as the following: Do Not Star

[3] Occupational Safety and Health Standards (OSHA 29 CFR 1910)

Page 121

Open source document

Source excerpt

## 29 CFR 1910 (OSHA) - (B) Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device. - (5) Stored energy. (i) Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe. - (ii) If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists. - (6) Verification of isolation. Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished. - (e) Release from lockout or tagout. Before lockout or tagout devices are removed and energy is restored to the machine or equipment, procedures shall be followed and actions taken by the authorized employee(s) to ensure the following: - (1) The machine or equipment. The work area shall be inspected to ensure that nonessential items have been removed and to ensure that machine or equipment components are operationally intact. - (2) Employees. (i) The work area shall be checked to ensure that all employees have been safely positioned or removed. - (ii) After lockout or tagout devices have been removed and before a machine or equipment is started, affected employees shall be notified that the lockout or tagout device(s) have been removed. - (3) Lockout or tagout devices removal. Each lockout or tagout device shall be removed from each energy isolating device by the employee who applied the device. Exception to paragraph (e)(3): When the authorized employee who applied the lockout or tagout device is

[4] Occupational Safety and Health Standards (OSHA 29 CFR 1910)

Page 116

Open source document

Source excerpt

## 29 CFR 1910 (OSHA) appurtenances. It is commonly used to replace or add sections of pipeline without the interruption of service for air, gas, water, steam, and petrochemical distribution systems. Lockout. The placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed. Lockout device. A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in a safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds. Normal production operations. The utilization of a machine or equipment to perform its intended production function. Servicing and/or maintenance. Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the employee may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy. Setting up. Any work performed to prepare a machine or equipment to perform its normal production operation. Tagout. The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. Tagout device. A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. - (c) General -(1) Energy control

[5] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1816

Open source document

Source excerpt

Division 2 AO 2-2017 Oregon Administrative Rules Oregon Occupational Safety and Health Division - (5) Notification. Affected employees must be notified by the employer or authorized employee of the application and removal of lockout or tagout devices. Notification must be given before the controls are applied and after they are removed from the machine or equipment. Note to paragraph (5): See also paragraph (7) of this rule, which requires that the second notification take place before the machine or equipment is reenergized. - (6) Lockout/tagout application. The established procedures for the application of energy control (the lockout or tagout procedures) must include the following elements and actions, and these procedures must be performed in the following sequence: - (a) Before an authorized or affected employee turns off a machine or equipment, the authorized employee must have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. - (b) The machine or equipment must be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be used to avoid any additional or increased hazards to employees as a result of the equipment stoppage. - (c) All energy isolating devices that are needed to control the energy to the machine or equipment must be physically located and operated in such a manner as to isolate the machine or equipment from energy sources. - (d) Lockout or tagout devices must be affixed to each energy isolating device by authorized employees. - (A) Lockout devices must be attached in a manner that will hold the energy isolating devices in a "safe" or "off" position. - (B) Tagout devices must be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the "safe" or "off" position is prohibited. - (i) Where tagout devices are used with energy isolating devic

[6] Occupational Safety and Health Standards (OSHA 29 CFR 1910)

Page 120

Open source document

Source excerpt

## 29 CFR 1910 (OSHA) - (A) Retraining shall be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures. - (B) Additional retraining shall also be conducted whenever a periodic inspection under paragraph (c)(6) of this section reveals, or whenever the employer has reason to believe, that there are deviations from or inadequacies in the employee's knowledge or use of the energy control procedures. - (C) The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary. - (iv) The employer shall certify that employee training has been accomplished and is being kept up to date. The certification shall contain each employee's name and dates of training. - (8) Energy isolation. Lockout or tagout shall be performed only bythe authorized employees who are performing the servicing or maintenance. - (9) Notification of employees. Affected employees shall be notified by the employer or authorized employee of the application and removal of lockout devices or tagout devices. Notification shall be given before the controls are applied, and after they are removed from the machine or equipment. - (d) Application of control. The established procedures for the application of energy control (the lockout or tagout procedures) shall cover the following elements and actions and shall be done in the following sequence: - (1) Preparation for shutdown. Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. - (2) Machine or equipment shutdown. The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipme

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