Lock Out/Tag Out Training
2012
Lock-Out/Tag-Out
OSHA Definition
Lockout/Tagout (LOTO) refers to specific
practices and procedures to safeguard
employees from the unexpected energization
or startup of machinery and equipment, or the
release of hazardous energy during service or
maintenance activities.
Purpose
It shall be used to ensure that before any
service work is performed, equipment is :




Stopped
Isolated from all potentially hazardous energy
sources
Locked Out/Tagged Out
Under your control
LOTO applies to all powered equipment
with energy sources such as



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Electrical
Mechanical
Pneumatic
Hydraulic
The LOTO action may be extended to
include equipment upstream or
downstream of the work location.
OSHA stat- LOTO prevents an estimated
120 fatalities and 50,000 injuries each
year
Definitions
Affected employee- An employee who has
operational responsibilities for the equipment that
is being Locked Out/Tagged out.
Authorized employee- Employee(s) who
implement LOTO procedures on equipment and/or
perform any work on the Locked Out/Tagged Out
equipment.
Energy Source- Any source of energy, including,
but not limited to, electrical, mechanical,
hydraulic, pneumatic, chemical, thermal (>140
degrees F), gas, springs, elevated machine
members, gravity, water pressure, or steam.
Definitions, Cont’d
Group Lockout- When the desired maintenance
action requires multiple pieces of equipment to
be Locked Out/Tagged Out, production locks
will be applied to each respective energy
isolating device. The keys will be placed in the
lockbox. The production lock key is under the
direct control of the affected person or an
authorized person.
Lockout- The placement of a lock on an energy
isolating device in accordance with the LOTO
procedure, ensuring that the energy isolating
device and the equipment being controlled
cannot be operated until the lock is removed.
Definitions, Cont’d
Lockout Device- A device, such as a
lock, that utilizes a positive means to
hold an isolating device in the safe
position and prevent equipment from
becoming energized.
Definitions, Cont’d
LOTO/Line Break Permit- the
document that grants permission to
complete the work based on
successfully adhering to policies and
rules.
Multiple Locking Device- Used in
situations where more than one
employee is working on a piece of
equipment or in an area covered by
the lockout. A multiple locking device
allows a number of employees to
lockout the same piece of equipment
at the designated energy isolating
device.
No-Go Check- After the energy
isolating device has been locked out,
attempting to restart the locked out
equipment through normal controls.
Definitions,
Cont’d
Personal Lock- PURPLE COLOR: A lockout device applied by
either the authorized employee, who is in sole control of the key.
Personal locks are applied subsequent to the production locks.
Personal locks are uniquely identified by the owners name and can
only be removed by the owner of the lock.
Production Lock- BLACK/GREY COLOR: A lockout device applied
for the protection of equipment. The keys to each production lock
being used will be in the control of the authorized person or in a
lock box. Production locks can be removed by any affected or
authorized employee.
Tagout- The placement of a tagout device on an energy isolating
device in accordance with the LOTO procedure, indicating that the
equipment may not be operated until the tagout device is removed.
ALL PRODUCTION LOCKS MUST HAVE A TAG.
Tagout Device- A prominent warning device, such as a plastic
laminated tag, that can be securely fastened to an energy isolating
device. The tagout device must display the date it was attached
and the name of he person attaching the tag. It indicates that the
energy isolating device and the equipment being controlled may
not be operated until the tagout device is removed in accordance
with the LOTO procedures.
Lockout Essentials
Tagout
Device
Production
Lock
Hasp
Personal
Lock
Service and Maintenance Operations
If a service activity such as lubricating, cleaning, or unjamming
equipment takes place during production, the employee may be
subject to hazards that are not encountered during normal
production operations. Such operations are subject to the
LOTO procedures when:
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
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The employee must either remove or bypass machine
guards or other safety devices, resulting in exposure to
hazards at the point of operations.
The employee is required to place any part of his/her body
in contact with the point of operation of the equipment.
The employee is required to place any part of his/her body
into a danger zone associated with the operating cycle of
the equipment.
LOTO Procedure
Lockout/Tagout
The authorized employee will notify all affected employees of
the intentions to shutdown and lockout specific equipment.
A line break /LOTO permit will be used to list hazards and
control points if there are no SOP’s. The Permit should be
used as a guide in addition to job SOP’s.
The authorized employee will follow specific energy isolation
procedures to shutdown the equipment, isolate the equipment
from all energy sources, and dissipate or bleed off residual
energy. The authorized employee will affix a production lock
on all energy isolation devices.
Lockout of MCC Disconnect
What’s Wrong?
Manual Valves
Butterfly Valve
Tagout Only
Lockout/Tagout is strongly recommended over tagout alone. The
following tagout procedure is an alternative to the LOTO procedure that
is used only if the energy isolation device is not capable of being locked
out.
The tag shall be applied at the same location a lock would have been
applied. The tag requires the name of each authorized employee and the
date.
The tag will be attached to the energy isolating device with a nylon tywrap that is non-reusable and has a minimum strength of 50 pounds.
Tags shall warn against hazardous conditions if the equipment should be
energized. Employees must be aware that tags are warning devices and
do not provide a physical restraint of those devices. When a tag is
attached to an energy isolating device, it shall not be removed without
the authorization of the person responsible for it.
Group Lockout/Tagout
The authorized employee will notify all affected employees of the
intentions to the shutdown and lockout specific equipment.
The authorized employee shall lockout all energy isolation devices with
a production lock and place the keys in a lockbox. When all keys have
been collected in the lockbox, a production lock will be placed on it.
The authorized employee will then verify that all energy sources are
properly isolated by performing a No-Go Check. The equipment and
surrounding area must be cleared when performing the No-Go Check.
It is the responsibility of the authorized employee to verify that the NoGo Check has been performed.
Group Lockout/Tagout, Cont’d
All operating controls shall be returned to the neutral or off position
after the No-Go Check is completed.
A list of the equipment and corresponding energy isolating devices that
are involved in the group lockout will be attached to the lockbox.
All authorized employees will then attach their personal locks to the
lockbox in such a manner that the lockbox cannot be opened until all
personal locks are removed.
Group Lockout/Tagout, Cont’d
If any authorized employee completes their work or leaves the plant at
the end of their shift, they will remove their personal lock from the
lockbox.
When all work is completed and all personal locks are removed, the
affected employee may remove the production lock to open the
lockbox. The keys may now be removed and the completion of the
group lockout may proceed.
Completion of the group lockout is noted in the LOTO logbook.
Completion of Lockout/Tagout
Specific steps must be followed to remove LOTO equipment after the
work is completed. Specific energy isolation procedures will contain
step-by-step instructions for LOTO removal. These steps will include:
Visually ensuring that the area is clear of tools and materials, and that
the employees are safely away from the equipment.
Ensure that all energy dissipation devices are in the “off” or “safe”
position and controls are in manual phase.
Notify all authorized and affected employees of plans to re-energize the
equipment.
Remove all lockout and tagout devices and return equipment to
operation per normal operating procedures. Only the owners of
personal locks may remove them, however any affected or authorized
employee can remove a production lock.
Note completion in LOTO logbook and return production locks to the
LOTO station.
Non-Routine Lock Removal
If a personal lock or production LOTO lock is inadvertently left on an
energy isolation device and needs to be removed, the lock may only be
removed with the approval of the Technical Manager, EHS Specialist, or
their designee. Prior to removal, management staff must make all
reasonable efforts to notify the lock owner of it’s removal. If
notification cannot be made to the lock owner, it will be made
immediately upon their return to work. A written record will be
documented and retained for one year.
Non-Routine Lock Removal Form
The LOTO program is designed to
protect all employees: therefore,
heavy responsibility is placed on
every employee to follow this
program.