Lockout/Tagout (LOTO): A Critical Safety Procedure for Hazardous Energy Control

Lockout/Tagout (LOTO): A Critical Safety Procedure for Hazardous Energy Control

Introduction to LoTo:

Workers use Lockout/Tagout (LOTO) in industrial and maintenance environments to properly shut off machines and equipment and prevent them from restarting before maintenance or repairs are complete.The aim is to protect employees from the dangers of hazardous energy, such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other forms of energy.

This article explains what LOTO is, why it matters, how to implement it, and what roles and responsibilities workers play in making it effective:

Reading Outcome:

• Understand what Lockout/Tagout is
• Learn why hazardous energy is dangerous
• Know how LOTO protects employees
• Familiarize with the step-by-step procedure
• Emphasize the importance of training, responsibility, and communication

What is Lockout/Tagout?

LOTO refers to specific practices and procedures to safeguard employees from the unexpected startup of machinery or the release of hazardous energy during servicing or maintenance.

When a piece of equipment is shut down, it must remain off while work is performed. This is especially critical in environments where multiple trades or technicians may be working simultaneously.

Key Facts:

• LOTO is part of a broader energy control program required by safety regulations.
• In addition, it combines physical locks and warning tags with clearly defined procedures.
• Qualified trainers must train employees in these procedures, and a qualified person outside the immediate workgroup must inspect the system annually.
  

Why Hazardous Energy is a Problem

Hazardous energy can be present in several hidden or unexpected forms, such as:

• Pressurized fluids in piping
• Electrical currents in capacitors
• Stored mechanical energy in springs or elevated components
• Gravity or thermal energy in heated surfaces

Example Scenarios:

• Someone may shut down a motor, but its connected piping can still hold pressure.
• A hydraulic arm can drop suddenly if its bracing fails or if pressure releases unexpectedly.
• Removing a pump without isolating upstream/downstream valves can result in dangerous fluid release.

Uncontrolled energy has led to numerous injuries and fatalities in the workplace, often due to overlooked sources or inadequate lockout procedures.

Who is an Authorized Person?

An Authorized Person is someone who:

• Has received training on the LOTO procedure
• Has a clear understanding of the equipment involved
• Is capable of properly identifying and isolating energy sources
• Is responsible for applying and removing locks and tags

This person plays a key role in ensuring that LOTO procedures are followed and that no hazardous energy remains in the system.

The Six Steps of Lockout/Tagout Procedure

Preparation

• Understand the types and magnitude of energy involved
• Identify all energy sources and methods to isolate them

Shutdown

• Notify all affected personnel
• Shut down the machine using normal procedures

Isolation

• Locate and operate all energy-isolating devices (e.g., valves, switches)

Lockout/Tagout

• Apply locks and tags to all energy-isolating devices
• Ensure locks hold devices in the safe position
• Tags should indicate “Do Not Operate”

Stored Energy Check

• Identify and release or restrain any stored energy (e.g., pressure, springs, gravity)

Verification

• An authorized employee must verify that all energy sources are isolated and safe before beginning work

Locks and Tags: Requirements

• Locks and tags must be durable and used exclusively for LOTO
• Must be standardized by color, shape, or size
• Each lock or tag must be identifiable to a specific employee
• For group work, a hasp system can be used, allowing multiple locks

Work Across Multiple Shifts

If work continues beyond one shift:

• The incoming worker must place their lock before the previous worker removes theirs
• This ensures continuous control and accountability

Important Aspects of an Effective LOTO Program

1. Personal Responsibility – Each worker’s lock protects their life
2. Clear Communication – Between all parties involved
3. System Understanding – Workers must fully understand the LOTO process
4. Responsibility to Others – Safeguard all those involved in and around the operation
5. Regular Training and Audits – Ensure ongoing competence and compliance

Contractor Compliance

External contractors working on-site must follow the host employer’s LOTO procedures. It is the responsibility of the site management to ensure proper orientation and monitoring of contractor compliance.

Restarting Equipment

Before restarting any equipment:

1. Inspect the work area to ensure all tools are removed
2. Ensure all workers are clear of danger zones
3. Notify affected employees
4. Remove only your own lock/tag
5. Restart equipment once all locks/tags are removed

Conclusion

LOTO is a life-saving process that ensures the safety of workers during maintenance and repair activities involving hazardous energy. Whether electrical, mechanical, hydraulic, or thermal, all energy must be controlled and confirmed safe before work begins. A culture of discipline, communication, and personal accountability is vital for the success of any lockout/tagout program.

Final Note

High-risk environments are often under pressure to return equipment to service quickly, especially during shutdowns. However, taking shortcuts with energy control procedures can be deadly. Always follow the LOTO process, every time.