INTRODUCTION TO
LOCKOUT/ TAGOUT
Protecting Lives & Machinery
Lockout Tagout (LOTO) is a crucial safety practice to ensure
the complete de-energization of equipment during
maintenance. This presentation explores LOTO’s role in
protecting employees from hazardous energy, with essential
tips for implementation and compliance.
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UNDERSTANDING OSHA STANDARD
1910.147: THE CONTROL OF
HAZARDOUS ENERGY
OSHA 1910.147 defines practices to prevent the
release of hazardous energy during servicing and
maintenance.
This standard ensures that machinery is isolated from
energy sources before maintenance begins.
Compliance with 1910.147 protects employees and
reduces workplace injuries.
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ELECTRICAL ENERGY DANGERS:
PREVENTING SHOCK AND INJURY
Electrical currents as low as 30 volts can carry a lethal charge. Prevent electrical injuries by using lockout
devices, ensuring de-energization, and following safety procedures.
Current
Reaction
1 MILLIAMP
Just a faint tingle.
5 MILLIAMPS
One 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.
6-25 MILLIAMPS (WOMEN)T
9-30 milliamps (men)
One who has no direct relationship to the LOTO program. But should be aware of its existence.
50-150 MILLIAMPS
Extremely painful shock, respiratory arrest (breathing stops), severe muscle contractions. Flexor muscles may cause holding on; extensor
muscles may cause intense pushing away. Death is possible.
1,000-4,300 MILLIAMPS
Ventricular fibrillation (heart pumping action not rhythmic) occurs. Muscles contract; nerve damage occurs. Death is likely.
10,000 MILLIAMPS
Cardiac arrest and severe burns occur. Death is probable.
15,000 MILLIAMPS
Lowest overcurrent at which a typical fuse or circuit breaker opens a circuit!
*EFFECTS ARE FOR VOLTAGES LESS THAN ABOUT 600 VOLTS. HIGHER VOLTAGES ALSO CAUSE SEVERE BURNS.
†Differences in muscle and fat content affect the severity of shock.
USE SAFE ELECTRICAL PRACTICES
Use non-conducting tools
Check circuits dead before working
Lock & Tag source breakers not switches
Ensure all control power is de-energized
Discharge all capacitors after Lockout
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MITIGATING MECHANICAL ENERGY
HAZARDS
Kinetic Hazards (Moving Parts): Machinery in motion poses
significant risks such as crushing, cutting, and entanglement.
Always de-energize and isolate moving parts before
servicing.
Stored Energy Hazards: Even after shutdown, energy can
remain in springs, elevated parts, or pressurized systems.
Properly release or block stored energy to prevent sudden
movement.
Common Mechanical Injuries: Workers can face injuries
such as amputations, fractures, or even fatalities if
mechanical energy isn’t properly controlled during
maintenance.
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PREVENTING CHEMICAL HAZARDS
THROUGH LOCKOUT/TAGOUT
Chemical energy hazards include reactions that can
cause fires, burns, or release harmful gases.
Chemicals must be safely contained, drained, or
vented before maintenance begins.
Before working with chemicals, ensure proper lockout
procedures are in place to prevent unintended
releases.
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THERMAL ENERGY: HOT AND COLD
HAZARDS IN THE WORKPLACE
Heat-Related Risks: Hot surfaces, equipment, or fluids
can cause severe burns. Workers must allow equipment to
cool before servicing.
Cold-Related Risks: Cold fluids and gases can cause
frostbite or skin damage. Handle with appropriate protective
gear.
Pressure Release Risks: Sudden release of compressed
gases or vapors can lead to rapid cooling, causing injury.
Ensure proper venting to avoid accidents.
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HYDRAULIC HAZARDS: THE DANGERS OF
PRESSURIZED FLUIDS
Pressure Hazards: Hydraulic systems store significant
energy that can cause equipment to move suddenly when
pressure is released, leading to crushing or other injuries.
Proper Depressurization: Always depressurize hydraulic
systems before servicing. This ensures any stored liquid
energy is safely released to avoid accidents.
Risks from Fluid Leaks: Leaking hydraulic fluids under high
pressure can penetrate skin, leading to severe injury. Inspect
equipment for any signs of leakage before maintenance.
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PNEUMATIC ENERGY: HANDLING
COMPRESSED GASES SAFELY
Compressed Gas Risks: Pneumatic systems store energy in
compressed gas that can rapidly expand if not properly
isolated, leading to severe injuries.
Uncontrolled Release: Sudden depressurization can cause
tools or equipment to move dangerously. Ensure all systems
are properly vented before starting work.
Temperature Extremes: The rapid expansion of compressed
gas can cause extreme cooling, leading to frostbite or
damage to equipment. Vent slowly into a proper container to
manage the risk.
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THE FIRST STEP TO SAFE LOCKOUT:
KNOW YOUR SYSTEMS
The first step in any LOTO procedure is to fully
understand the equipment and its energy sources.
Identify all isolation points and ensure that proper
lockout devices are available.
Follow documented procedures for each machine to
ensure comprehensive lockout compliance.
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WHO CAN LOCKOUT EQUIPMENT?
Only trained and authorized personnel are permitted to
perform lockout procedures.
Unauthorized employees must not attempt to lockout
or tamper with lockout devices.
Ensure that all authorized employees are properly
trained in LOTO procedures.
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EMPLOYEE TRAINING
Types of Employees
AUTHORIZED EMPLOYEES
AFFECTED EMPLOYEES
OTHER EMPLOYEES
Characteristics
One who locks out or tags out machines
or equipment in order to perform servicing
or maintenance
One 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.
One who has no direct relationship to the
LOTO program. But should be aware of
its existence.
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Type of Training
Shall receive training in:
1. The recognition of applicable hazardous energy sources,
2. The type and magnitude of the energy available in the workplace, and
3. The methods and means necessary for energy isolation and
control.1910.147(c)(7)(i)(A)
Shall be instructed in:
1. The purpose and use of the energy control procedure. 1910.147(c)(7)(i)(B)
Shall be instructed about:
1. The procedure, and about the prohibitior relating to attempts to restart or
reenergize machines or equipment which are locked out or tagged out.
1910.147(c)(7)(i)(C)
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ESSENTIAL LOCKOUT/TAGOUT
TOOLS AND EQUIPMENT
Ensure you have the proper lockout tagout equipment, including
LOTO locks, tags, hasps, and valve covers, along with a
documented LOTO procedure for each machine.
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WHAT’S A LOCK?
According to OSHA; a lock must be…
Provided by the employer.
Singularly identified; shall be the only devices(s) used for
controlling energy; shall not be used for other purposes.
Durable
Standardized; Color; shape; or size
Substantial; enough to prevent removal without the use of
excessive force
Identifiable; must indicate the identity of the employee
applying the device(s).
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WHAT’S A TAG?
According to OSHA; a tag must be…
Provided by the employer.
Singularly identified; shall be the only devices(s) used for
controlling energy; shall not be used for other purposes.
Durable; shall not deteriorate
Standardized by
Color
Shape
Size
Print and
Format
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BEST PRACTICES FOR USING
LOCKS AND TAGS
Only use locks and tags assigned to you to ensure
traceability and accountability.
Never use another worker’s lock or tag, as this
compromises safety.
Ensure locks and tags are properly applied and
removed only by authorized personnel.
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THE SIX ESSENTIAL STEPS OF
LOCKOUT/TAGOUT
Prepare for Shutdown
Shutdown Equipment
Isolate all energy sources
Place Locks & Tags
Release Stored Energy
Verify Equipment Isolation
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SAFELY RELEASING EQUIPMENT
FROM LOCKOUT/TAGOUT
Inspect Area and Equipment
Ensure all Machine Guards in place
Move tools away from equipment
Inform others of startup
Restore system connections
Remove Locks & Tags
Restore equipment to normal
Conduct normal startup
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WHO CAN REMOVE
LOCKS & TAGS?
Only the employee who placed the tag
or a supervisor, after obtaining
permission from the worker who placed
the tag.
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A PIECE OF EQUIPMENT ALREADY
HAS A LOCK AND TAG. DO I HAVE TO
PLACE MY OWN LOCKS & TAGS?
YE
S
Each person working on the equipment must
place their own locks and tags to ensure their
safety.
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LOCKOUT/TAGOUT: PROTECT
YOURSELF, PROTECT YOUR TEAM
Lockout Tagout procedures protect workers from
unexpected releases of hazardous energy.
Always follow proper procedures to ensure your
safety and the safety of your coworkers.
Implementing a strong LOTO program reduces the
risk of injury and promotes a culture of safety.
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Ensure compliance and protect your team today!
Contact us for comprehensive LOTO services, premium-quality lockout
tagout devices, and tailored LOTO solutions to meet your workplace safety
needs.
E-Square Alliance Pvt. Ltd.
512, New Delhi House, Barakhamba Road
New Delhi - 110001 (India)
www.safetylock.net
Email: sale@esquare.info
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Contact: +91 8750 333 102
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