Lockout-Tagout (LOTO) refers to specific practices and procedures to protect employees from unexpected activations and start-ups by dangerous machines and equipment. The LOTO procedures also protect employees from the release of hazardous energy during service and maintenance activities (www.osha.gov).

Lockout (LO): Turning off and isolating energy sources
Tagout (TO): Marking and identifying locked energy sources
Tryout (TO): Testing the locked and identified energy source for reconnection.

• Limiting the number of industrial accidents
• Control of insurance and compensation fees
• Better use of machines: reduced downtime and increased productivity
• Strengthening employee capacity
• Optimize the reputation
• Comply with legislation and regulations

• Installation
• Adjustment
• Repair
• Maintenance
• Cleaning
• Testing
• Inspections
• Overhaul

If energy sources are not cut off, the equipment may accidentally restart. A wide range of energy sources must be cut off, such as:

• Electricity
• Hydraulic pressure
• Compressed air
• Gas
• Steam
• All types of liquids

The use of Lockout-Tagout as a procedure is not a legal obligation in Europe (unlike in the US). Lockout-Tagout, however, is a proven and widely used way of complying with laws and regulations.

The machinery directive also says something about the isolation (lockout), identification (tagout) and testing (tryout) of energy sources.

Appendix 1, Article 1.6.3 Shutting down the power sources

The machinery must be equipped with devices to isolate it from any of its power sources. These establishments must be clearly identifiable. They need to be able to be locked if reconnection could endanger persons. It must also be possible to lock these devices if the operator cannot check from all places, that he can reach, that the power source is still disconnected.

For machines that can be supplied with electrical energy via a plug connection, it is sufficient to pull out the plug, given that the operator can check from all places that he can reach that the plug is still unplugged.

After the power source has been cut off, it must be possible to dissipate the energy remaining or stored in the electrical circuits of the machinery without endangering persons.

This American standard says something about the use of Lockout-Tagout during service and maintenance of machines and equipment. The standard sets 4 crucial features for the use of LOTO resources

• The equipment must be identifiable.
• The equipment may only be used for controlling energy.
• The equipment may not be used for other purposes.
• The equipment must meet the following requirements; sustainable, standard, identifiable and substantial.
  

A LOTO procedure consists of:

• Corporate procedure
• Establishment procedure
• Machine-specific procedures or Task-driven procedures
• Link with the work permit system

Based on industry-leading practice, this can be deviated from to a certain extent

When carrying out Lockout-Tagout activities, the following 7 steps need to be followed:

1. Notify the employees involved in the lockout tagout activities.
2. Go through the procedure before starting the LOTO procedure
3. Switch off the machine as usual.
4. Isolate all energy sources to the machine.
5. Lock these energy sources in with a LOTO tool, a safety padlock and a tag.
6. Take stored and residual energy (venting, cooling, securing, block & bleed) into account.
7. Double-check if the machine really is insulated before starting the work.

Residual energy should always be taken into account when drawing up a LOTO procedure.

Residual energy can be stored in any energy source, for example electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gas, water, electricity, steam or gravity.

Energy can be stored in, for example:

• Mechanical parts that keep moving due to inertia.
• Mechanical parts that can move under gravity
• Capacitors, accumulators
• Liquids under pressure
• Springs
  

A procedure sheet contains at least the following points:

• Identification number
• Author
• Descriptions of the work equipment
• Required LOTO materials
• Approval and audit (data and responsible person)
• Positions of the isolation points
• Descriptions of the insulation points equipped with:

A. ID number

B. Type of energy sources

C. Tools (lockouts)

D. Location

E. Method

F. Control of residual energy

Group lockout is a method of lockout tagout that can significantly reduce the number of padlocks during larger Lockout Tagout operations.

With a group lockout, the person responsible for the group lockout locks all energy sources with 1 set of keyed-alike safety padlocks. The key to this set then goes into the group lockbox.

The group lockout manager then locks the lockbox with his personal safety padlock (preferably green), after which all those involved also place their personal padlock on the lockbox. When the work has been completed, each employee involved removes his personal lock, after which the group lockout manager can open the box with his personal padlock, get the key and unlock all the energy sources.

The LOTO procedure must be linked to other internal processes, to ensure that the lockout-tagout procedure is up-to-date and correct.

• Keep P&ID and electrical diagrams up to date.
• Make sure pipe markings are in place.
• Ensure all energy sources to be locked out are identified and marked.
• Make sure that adjustments to machines, new construction and/or alteration and assembly are implemented in the machine-specific procedure sheets (Management of Change).
• Provide a locked open register, for example, a sprinkler installation.
  

If only tagouts (e.g. safety tags) are used, employees should be trained in the following tag limitations:

• Tagout devices are necessary warning labels that are attached to the energy isolating devices, but they do not effectuate a physical locking as a lockout device can do
• If a tagout is attached to an energy isolation device, it may only be removed by the authorized employee responsible for it. This tagout device should never be bypassed, neglected, or by any other way ignored.
• Tagout devices should, in order to be effective, be clear and understandable to all authorized employees, affected employees and all other employees whose work (possibly) lies in the relevant area.
• The use of tagout devices could potentially lead to a false sense of security. Therefore this should always be seen as part of the total energy control program.
  

Where to start? In our opinion, the best approach is to define 6 essential elements of Lockout/Tagout safety and use them as a basis for continuous improvement.

A typical lockout programme includes the creation, maintenance and updating of machine-specific procedures, energy control points, equipment lists and hierarchies, training and planning. For optimal management, we split these tasks into 6 main elements.

1. Establish a Lockout-Tagout policy
2. Write machine-specific procedures
3. Identify energy isolation points
4. Training
5. Provide the right Lockout/Tagout tools
6. Sustainability

The first step towards a successful Lockout/Tagout is the development of a documented policy for the energy control of machines.

The written lockout document will be the framework for your lockout programme and will define and clarify that programme. It is important to take into account international standards, relevant legislation and sector regulations*, as well as company-specific requirements so that your employees understand the programme and can put it into practice.

A Lockout-Tagout programme is not a one-off solution but should be reviewed annually to remain relevant and effectively protect employees. A Lockout-Tagout programme should be established by all relevant levels of the company.

It is important that lockout procedures are formally documented and clearly identify the machines they refer to. They should outline the specific steps for shutting down, isolating, blocking and locking out machines to control hazardous energy. They should also include steps for the installation, inspection, removal and relocation of the Lockout-Tagout tools.

In addition to regulatory compliance, we recommend creating best practice procedures that include machine-specific photographs that clearly show the location of all energy control points. The procedures
are best communicated where they are relevant so that employees always have clear and visual instructions. Make sure your procedures are tailored to your employees for optimal understanding. For example, choose multilingual procedures if your employees speak different languages. 

Locate and identify all energy control points such as levers, switches, circuit breakers and plugs with permanent, standardised labels or tags. These points must be clearly identified. Also note that the labels and tags must be consistent with the machine-specific procedures.

Train your employees adequately, communicate processes clearly and carry out regular inspections to ensure your programme is working efficiently. During training, make clear why you are organising Lockout-Tagout, what it is exactly, what your Lockout-Tagout policy is and what your machine-specific procedures are. The training should be more intensive for employees who perform Lockout-Tagout, but we recommend communicating about Lockout-Tagout to all employees at a minimum. OSHA (USA) identifies three categories of employees:

AUTHORISED | Employees who lockout machinery and equipment for maintenance work.

CONNECTED | Employees who do not lockout machines or equipment themselves, but who use the machines on which maintenance work is being carried out.

The following table shows the number of hours worked in a given year, the number of hours worked in a given year, the number of hours worked in a given year, and the number of hours worked in a given year.

An important part of a robust Lockout programme is providing your employees with the right tools for their safety. There are many products on the market.

Choosing the best solution for your machines is key to the effectiveness of your Lockout-Tagout programme. It is important to document and use the tools that are best suited for each energy control point or lockout point.

Finally, we recommend that you continuously improve your Lockout-Tagout programme.

By continuously evaluating the programme, you create a safety culture that proactively addresses the challenge of safe interventions on machines. This allows your company to focus on maintaining a top-class Lockout-Tagout programme, rather than starting from scratch every year and only reacting when something goes wrong.

Make sure that Lockout-Tagout is permanently communicated on the work floor, for example with posters or banners.

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