Lockout/Tagout Procedures: Essential Energy Control Safety
Lockout/Tagout (LOTO) procedures prevent the accidental energization of machinery and equipment during maintenance, repair, or cleaning activities. These life-saving procedures ensure that hazardous energy sources are properly controlled before work begins.
Why This Is Important
Failure to follow LOTO procedures is one of the leading causes of workplace fatalities and serious injuries. When equipment unexpectedly starts up or releases stored energy during maintenance, workers can be caught in moving parts, electrocuted, burned, or struck by pressurized materials.
LOTO violations often result from time pressure, inadequate training, or overconfidence from routine work. However, no maintenance task is routine enough to skip these crucial safety procedures. Every energized system poses potential fatal hazards until properly locked out.
Key Points to Remember
Types of Hazardous Energy
- Electrical: Live wires, charged capacitors, stored electrical energy
- Mechanical: Moving parts, rotating equipment, springs under tension
- Hydraulic: Pressurized fluids in cylinders and lines
- Pneumatic: Compressed air and gas systems
- Chemical: Stored chemical energy and reactions
- Thermal: Hot surfaces, steam, and heated materials
LOTO Requirements
- Authorized employees must receive comprehensive training
- Affected employees must understand when LOTO is used
- Other employees must know not to operate locked-out equipment
- Written procedures required for complex equipment
- Annual inspections of LOTO procedures mandatory
Best Practices & Safety Tips
Shut Down Equipment
Follow established shutdown procedures and ensure all moving parts have stopped before proceeding with lockout.
Apply Locks and Tags
Each worker applies their own personal lock and tag. Never share locks or work on equipment locked by others.
Verify Zero Energy
Test equipment to ensure all energy sources are isolated and no stored energy remains before starting work.
Remove Lockout Safely
Only the person who applied the lock can remove it. Ensure all workers are clear before re-energizing equipment.
Six-Step LOTO Procedure
- Preparation: Identify energy sources and shutdown procedures
- Shutdown: Turn off equipment using normal stopping procedures
- Isolation: Disconnect or isolate all energy sources
- Lockout/Tagout: Apply locks and tags to energy isolation devices
- Verification: Test that equipment cannot be started and energy is isolated
- Release: Remove locks only after work is complete and area is clear
Multiple Worker Procedures
- Each worker applies their own lock to a multiple lockout device
- Group lockout boxes used for complex procedures
- Shift changes require lock transfer procedures
- Clear communication essential for team safety
Discussion Questions
- What equipment in your work area requires LOTO procedures?
- How do you verify that all energy sources have been properly isolated?
- What should you do if you discover equipment that should be locked out but isn't?
- How do you handle LOTO procedures when multiple workers are involved in the same maintenance task?
- What are the consequences of bypassing or skipping LOTO procedures?
Action Items
- Review and update LOTO procedures for all equipment
- Ensure all affected workers receive proper LOTO training
- Conduct annual inspections of LOTO procedures and practices
- Verify adequate locks, tags, and lockout devices are available
Related Safety Topics
- Basic Electrical Safety - Electrical LOTO procedures and requirements
- Personal Protective Equipment - Additional protection during maintenance work
- Work Area Best Practices - Organizing safe maintenance work areas