Lock Out Tag Out Procedure Sample: Complete Guide

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Lock Out Tag Out (LOTO) procedures are critical for ensuring worker safety during maintenance or servicing of equipment, particularly when the equipment presents potential hazards from stored energy. A well-defined LOTO procedure helps prevent accidental equipment start-up or energy release, reducing the risk of injury.

 

Here’s a step-by-step guide for implementing an effective Lock Out Tag Out procedure.

 

 

Lock Out Tag Out Procedure Sample

 

Step 1: Preparation

  1. Identify the Equipment and Hazards
    Identify the machinery or equipment requiring lockout and assess any potential hazards associated with stored energy sources (such as electrical, mechanical, hydraulic, or pneumatic). Review the equipment’s operating instructions and locate energy isolation points.
  2. Notify Affected Employees
    Inform all employees in the work area that a lockout/tagout procedure is about to take place. Clearly communicate which equipment will be out of service and why.

 

Step 2: Shut Down Equipment

  1. Power Down Safely
    Power down the equipment following standard operating procedures. Ensure all controls are in the “off” position before proceeding.
  2. De-Energize and Relieve Stored Energy
    Once shut down, relieve any stored energy within the system. This could mean releasing hydraulic pressure, discharging electrical capacitors, or bleeding pneumatic lines. Ensuring complete energy release prevents accidental energy reactivation.

 

Step 3: Isolation of Energy Source

  1. Locate and Isolate Energy Controls
    Find the energy isolation devices (such as switches, breakers, or valves) and move them to the “off” or “closed” position.
  2. Verify Isolation
    Use a tester to confirm the equipment is fully de-energized. For electrical equipment, verify with a multimeter or other testing tools.

 

Step 4: Apply Lock and Tag Devices

  1. Attach Lockout Devices
    Attach lockout devices to each isolation point to ensure energy cannot be accidentally restored. Only authorized employees should be responsible for applying their lock.
  2. Attach Tagout Devices
    Add a tag to each lockout point to notify others that the equipment is under maintenance. Tags should clearly state who applied the lock and the reason for the lockout.
  3. Verify Each Lock is Secure
    After applying locks and tags, check each point to confirm security and visibility.

 

Step 5: Test for Isolation

  1. Double-Check Controls
    Return to the equipment’s controls and attempt to restart the machine to ensure it will not activate. This test verifies that the lockout is effective.
  2. Verify Complete Isolation
    Confirm all energy sources are isolated by checking all potential reactivation points.

 

Step 6: Perform Maintenance or Service

  1. Carry Out Work Safely
    Complete all necessary repairs or maintenance tasks. Follow safety protocols to avoid introducing additional hazards during this stage.
  2. Monitor LOTO Status
    Ensure the lockout/tagout system remains in place throughout the work. If additional employees or shifts are involved, transfer lockout responsibility according to workplace policies.

 

Step 7: Removal of Lockout/Tagout Devices

  1. Inspect and Remove Tools
    Inspect the equipment to ensure all tools and debris have been cleared. Confirm the equipment is ready for safe operation.
  2. Notify Affected Employees
    Inform all employees that the lockout/tagout procedure is complete and that equipment will soon be reactivated.
  3. Remove Lock and Tag Devices
    The same authorized employee who applied the lockout/tagout device should remove it. Each lock and tag should be removed individually, in reverse order of application.

 

Step 8: Restore Power and Test

  1. Re-Energize Equipment
    Reactivate the equipment following standard procedures. Check for proper functionality and observe the equipment for any potential issues.
  2. Conduct a Final Safety Check
    Once power is restored, perform a final inspection to verify that the equipment is operating safely.

 

Key Points for a Successful Lock Out Tag Out Procedure

  • Only Authorized Employees should conduct lockout/tagout procedures and device applications.
  • Documentation and Compliance: Regularly update LOTO procedures and ensure compliance with OSHA and company-specific safety guidelines.
  • Training and Reinforcement: Conduct regular LOTO training sessions to ensure all employees understand and adhere to the procedure.

 

Lock out tag out procedure sample Infographic

What is an Example of Lockout Tagout?

Lockout Tagout (LOTO) is a crucial safety procedure used in industrial and manufacturing settings to prevent accidental machine startup or energy release during maintenance or servicing. Below is an example of a lockout/tagout scenario that illustrates how the process is applied to a piece of machinery, specifically a large industrial conveyor belt.

 

Example of Lockout Tagout: Conveyor Belt Maintenance

 

Scenario:
A maintenance team needs to repair a large conveyor belt that moves materials across a factory floor. Due to the potential for sudden movement or release of stored energy, it’s essential to apply a LOTO procedure before beginning any work on the conveyor belt. Here’s how the team would carry out the lockout/tagout process.

 

Step-by-Step LOTO Procedure for the Conveyor Belt

 

Step 1: Preparation and Communication

  • Identify the Hazardous Energy Sources: In this case, the conveyor belt operates with electrical power and has a hydraulic system that provides movement. Both systems pose risks.
  • Notify Affected Employees: Inform all workers in the vicinity that the conveyor belt will be out of service due to maintenance. Communicate that the LOTO procedure is about to begin and that no one should attempt to activate the equipment.

 

Step 2: Shut Down the Conveyor Belt

  • Turn Off the Power: Follow the conveyor belt’s standard shutdown procedure to bring the belt to a complete stop.
  • Ensure the Belt is Stationary: Double-check that the conveyor belt has come to a complete stop and that no material is loaded.

 

Step 3: Isolate Energy Sources

  • Disconnect Electrical Power: Locate the main electrical power switch and move it to the “off” position. If there are secondary electrical power sources, turn those off as well.
  • Disable Hydraulic Systems: Locate and close any valves or switches controlling the hydraulic flow to prevent any unexpected movement.

 

Step 4: Apply Lockout and Tagout Devices

  • Lock Out Electrical Power: Attach a lockout device to the electrical power switch to prevent it from being turned back on. Only authorized personnel can place their unique lock on the device.
  • Tag Out the Lock: Attach a tag to the lock, clearly labeling it with the name of the person who applied the lock, the date, and a warning not to operate the equipment.
  • Hydraulic Lock Out: Place a lockout device on the hydraulic valves as well, and add a tag to alert others that the system is locked out.

 

Step 5: Test for Zero Energy

  • Attempt to Re-Energize the Belt: Return to the belt’s controls and try to turn it on. This “try-out” step confirms that the lockout devices are working and that the conveyor will not activate.
  • Confirm All Stored Energy is Released: Check that there is no remaining hydraulic pressure or stored energy within the system.

 

Step 6: Perform Maintenance or Repairs

  • With the conveyor belt effectively locked out, the maintenance team can begin work, knowing there is no risk of accidental startup.

 

Step 7: Remove Lockout and Tagout Devices

  • Clear the Area and Inspect Equipment: Before restoring power, the team ensures all tools and parts have been cleared from the area.
  • Inform Workers: Notify all employees that the lockout/tagout procedure is complete and that the equipment will soon be operational again.
  • Remove Locks and Tags: The authorized employee who placed each lockout device removes their own lock. All locks and tags are removed according to the established protocol.

 

Step 8: Restore Power and Conduct Final Tests

  • Turn on Power and Observe: Restore the conveyor belt’s electrical power and hydraulic systems. Observe the equipment to confirm it operates as expected and that the repair was successful.

 

Key Points to Remember

  1. Individual Responsibility: Only the individual who applied a lockout device can remove it, ensuring complete accountability.
  2. Effective Communication: Throughout the LOTO procedure, it’s vital to communicate with all affected employees, preventing misunderstandings.
  3. Testing for Zero Energy: Attempting to turn on the equipment as a final test step is essential for verifying that the LOTO procedure has worked.

 

Why LOTO Matters in This Scenario

This LOTO example illustrates how a clear lockout/tagout process protects maintenance workers from potential hazards. Without LOTO, there’s a high risk of injury from unexpected equipment activation. This example shows how critical lockout/tagout procedures are in eliminating risk and ensuring workplace safety.

 

Frequently Asked Questions

1. What are the three types of LOTO?

The three types of Lockout Tagout (LOTO) are electrical, mechanical, and hydraulic/pneumatic, each addressing energy control in different systems to ensure safety during maintenance.

 

2. What is the main purpose of Lockout Tagout?

The main purpose of Lockout Tagout (LOTO) is to prevent accidental energy release, ensuring worker safety during equipment maintenance or repair.

 

3. Who can remove a Lockout Tagout?

Only the authorized person who applied the Lockout Tagout can remove it, ensuring controlled and safe equipment reactivation.

Conclusion

The above Lock Out Tag Out procedure sample provides a structured guide for workplace safety, minimizing risks associated with machinery maintenance. Ensuring compliance with LOTO protocols helps maintain a safer work environment and reduces the chance of accidental injury.

 

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