Isolation, Lockout, and Use of Hold Tags

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Chapter : Lockout Tagout (LOTO)

Lockout/Tagout (LOTO) and Difference between LOTO or LOTOTO

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Chapter : Lockout Tagout (LOTO)

Lockout/Tagout (LOTO) and Its Importance for Safety  

Lockout/Tagout

When it comes to lockout procedures, a shortcut in the process can literally mean the difference between life and death. Long considered an important part of the safety program, lockout procedures protect not only the employees working on a piece of equipment, but also co-workers and contractors working onsite.

Lockout/Tagout (LOTO) is a safety procedure used to ensure that dangerous machines are properly shut Off and not started up again before the completion of maintenance or repair work.

Lockout refers to the specific steps taken to safeguard employees from unexpected startup of machinery and equipment or the release of hazardous energy during setup, service, or repair. To lock out equipment, a lock is placed on the energy source, control, or isolating device.

Importance of LOTO

• Prevents Accidents:LOTO prevents accidental machine startups, which can cause severe injuries or even fatalities.
• Protects Workers: Ensures that workers are safe from electrical, mechanical, and other energy hazards while performing maintenance tasks.

Usage of LOTO at Work

Lockout: Involves placing a lock on the energy-isolating device to ensure that the machine cannot be turned on. 

Tagout: Involves attaching a tag to the locked device, warning others not to turn on the machine.  

Steps for Effective LOTO

• Identify Energy Sources: Find all energy sources associated with the machinery.
• Shut Down Equipment: Turn off the machinery using the standard shutdown procedure.
• Isolate Energy Sources: Disconnect or isolate the energy sources to prevent the machine from restarting.
• Apply Locks and Tags: Place locks and tags on the energy-isolating devices.
• Verify Isolation: Ensure that the machine is properly isolated and cannot be restarted.
• Perform Maintenance: Carry out the maintenance or repair work.
• Remove Locks and Tags: Once work is completed, remove the locks and tags, and re-energize the machine.

Benefits Of LOTO:

• Reduces Injuries: Significantly lowers the risk of injuries from accidental machine startups.
• Enhances Workplace Safety: Creates a safer working environment for everyone.
• Increases Awareness: Educates workers about potential hazards and safe practices.
• Promotes Safety Culture: Encourages a culture of safety and responsibility in the workplace.

By following LOTO procedures, companies can protect their workers, comply with safety regulations, and create a safer working environment.

Difference between LOTO or LOTOTO 

Lock out Tag out (LOTO) and Lock out Tag out Try Out (LOTOTO) are both safety procedures used in workplaces to prevent accidents and injuries by ensuring that machinery and equipment are properly shut down and locked out before maintenance work is performed. While both procedures aim to enhance safety in the workplace, there are key differences between LOTO and LOTOTO that can impact the effectiveness of the safety measures.

LOTO is a safety procedure that involves shutting off the power supply to machinery and equipment, locking it with a padlock, and attaching a tag that warns others not to start or operate the equipment. This prevents accidental startup Of machines during maintenance work and helps ensure the safety Of workers. LOTO is widely used in many industries to protect workers from hazards such as electrocution, entanglement, and crushing injuries.

On the other hand. LOTOTO is a more stringent safety procedure that requires an additional step known as a "Try Out After equipment has been locked out and tagged out. a designated person must attempt to restart the machinery to verify that it is indeed isolated from the power source. This extra step adds another layer of protection by confirming that the equipment is safe to work on and reduces the risk of accidents caused by incomplete isolation.

While LOTO is effective in preventing accidents, LOTOTO provides an added level of assurance that the equipment is truly secure before maintenance work begins. By conducting a Try Out, maintenance workers can be confident that the machinery has been properly isolated and that there is no risk of unexpected energization. This helps to further reduce the likelihood of accidents and ensures the safety of workers in hazardous environments.

In conclusion, both LOTO and LOTOTO are important safety procedures that are designed to protect workers from accidents and injuries in the workplace. While LOTO is widely used and effective in many industries, LOTOTO offers an additional layer of protection by requiring a Try Out to verify the isolation of equipment. By implementing these safety procedures in the workplace, employers can create a safer work environment and prevent unnecessary harm to their employees.

Although specific lockout procedures vary by type of equipment used, below are basic guidelines

employees should be aware of:

• Inform all affected personnel of the planned lockout. A sudden loss of power could be dangerous if workers are not aware of the situation and are still working on the machinery.
• Identify all potential energy sources. A simple disconnect of the main power switch is not sufficient, as other types of energy may exist, such as hydraulic, electric, thermal, radioactive, pneumatic, gravity, and chemical energy. It is also important to drain, release, or block any stored energy.
• Correctly isolate energy isolating devices. To achieve proper equipment isolation, an energy isolating device – such as a circuit breaker, disconnect switch, or gate valve – must be found, tagged, and locked out in the closed position.
• Attach locks along with a warning tag indicating the date, purpose, and length of the lockout and who installed the lock. If there are several employees working on a job, each worker should attach his or her own lock to a multiple-locking device.
• Use uniquely keyed locks that come with only one key to ensure that employees cannot remove each other’s locks.
• After the lockout procedures have been performed, test the operation of the machinery to ensure that all energy sources have been secured.
• Return locked-out equipment to service only after all established start-up procedures have been followed. Special attention should be given to make sure all obstructions have been cleared, machine safeguards have been replaced, locks have been removed (in the correct order), and all workers have been notified and are free of the area.

LOTO : Control the Power - Instruction & Guidance

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Chapter : Lockout Tagout 

Control the Power - Instruction & Guidance 

Lockout - Tagout requirement needed to control hazardous energy while servicing or performing maintenance on machinery or other equipment.

Employees who service or maintain machinery and equipment need special training on lockout/tag out procedures.

The objective of the following safety tips is to evaluate authorized employees' understanding of hazardous energy sources and control of hazardous energy with lockout / Tag out.

Instructions:

1. Discuss your workplace lockout / Tag out program and procedures. Bring lockout / Tag out devices that are used at your operation and review their uses.
2. List the types of energy sources at your workplace. Identify the equipment at your workplace that needs to be locked out.
3. Discuss an incident or near miss when equipment accidentally started. What was the root cause? What was changed to prevent reoccurrence?
4. Choose a machine or piece of equipment subject to Lockout / Tagout. Identify all energy sources that have to be locked out/tagged out before anyone can service or repair the machine or equipment. Have an authorized employee demonstrate your company's specific shutdown and restart procedures.
   
   Note: Any recommendations or observations during the exercise, and discuss them with the appropriate personnel.

Guidance

The following are examples of Lockout / Tagout and restart procedures.

The Lockout / Tagout procedures must include the following steps:

1. Preparing for shutdown,
2. Shutting down the machine(s) or equipment,
3. Isolating the machine or equipment from the energy source(s),
4. Supplying the Lockout or Tagout device(s) to the energy-isolating device(s),
5. Safely releasing all potentially hazardous stored or residual energy, and
6. Verifying the isolation of the machine(s) or equipment before the start of service or maintenance work.

In addition, before Lockout or Tagout devices are removed and energy is restored to the machines or equipment, certain steps must be taken to reenergize equipment after service is completed, including:

1. Ensuring that machines or equipment components are operationally intact; and
2. Notifying affected employees that Lockout / Tagout devices are removed from each energy-isolating device by the employee who applied the device.

LOTO :- Life Saving Equipments

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Chapter : Lockout Tagout (LOTO)

Lockout Tagout-  Life Saving  Equipments 

The rack out / de-energize standards is designed to prevent injuries and deaths by accidental start up of electrical equipment's during maintenance or servicing. It save lives. Yet unfortunate tragedies do still occur. Many of them could have been prevented if the rack-out / de-energize procedures were followed correctly. This safety topic provides a review of de-energizing procedure. Remember the standard can work only if it is used correctly every time.

De-energizing procedures

• Obtain necessary permit to rack-out / de-energize
• Verify correct tag no mentioned in the permit with field operator and the department working on the equipment.
• Make sure the equipment is not running. If it is running, get it stopped by operators.
• Isolate, put multi lock hasp and yellow padlock for electrical and keep the key in electrical department custody.
• Other departments shall use their locks (for ex., green lock for operations, blue lock for mechanical dept. and black for others) and keep keys in their custody.
• Proper tagging must be done clearly mentioning the purpose of rack-out / de-energize, time/date etc.etc.
• Enter all activities in substation log book.
• An attempt to start the equipment must be made to verify that the equipment cannot start during the maintenance activity.

Energizing procedures

• A separate permit shall be obtained to energize the equipment.
• Visually confirm that the activity on the equipment is complete and it is safe to energize.
• Each dept. who placed a lock must remove it themselves before energizing.
• Remove yellow lock (electrical shall be the last lock to be removed) and energize the equipment.
• Enter the activity in the substation log book.

Procedures for performing rack-out / de-energize must be followed consistently. Don’t be tempted to take shortcuts for small jobs, even if the rack-out procedure takes longer than the job itself.

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Chapter : Lockout Tagout (LOTO)

LOTO – Accidents Happen

Lockout/tagout refers to practices used to protect you from unexpected energization or startup of machinery, or the release of hazardous energy during service or maintenance.

• Utilizing lockout/tag out procedures and best practices prevents many fatalities and injuries each year.
• Workers injured from exposure to hazardous energy are typically serious causing weeks of recovery time.

Hazards to watch for:

• Working on unfamiliar equipment and/or energy sources.
• Failure to identify all energy sources involved.
• Not utilizing proper LO/TO procedure or device.
• Failure to verify energy isolation.

Forms of Hazardous Energy:

• Kinetic (mechanical) energy in the moving parts of mechanical systems.
• Potential energy stored in pressure vessels, gas tanks, hydraulic or pneumatic systems, and springs.
• Electrical energy from generated electrical power, static sources, or electrical storage devices (such as batteries or capacitors)
• Thermal energy (high or low temperature) resulting from mechanical work, radiation, chemical reaction, or electrical resistance.

Safe procedures:

• De-energize equipment:
• Notify all “affected employees” that the equipment will be shut down.
• Shut down the equipment by normal stopping procedures.
• “Isolate” all the equipment’s energy sources.
• Apply the appropriate Lockout/tagout device, using assigned, individual locks.
• Release or restrain any stored energy by grounding, blocking or bleeding down.
• Assure that no one is exposed. Then try out the equipment to make sure it won’t operate.

Restore equipment to service:

• Clear the equipment or machinery of all tools and materials.
• Make sure all employees are clear and notified.
• Remove lockout /tagout devices.
• Re-energize machine or equipment carefully
• Notify employees that servicing is complete and equipment is ready for use.

Lockout/tagout/tryout

What if someone didn’t know that another person were working on a machine, or electrical outlet, and turned on the power?

Lockout/tagout/tryout is a safety procedure used to ensure that dangerous machines, equipment, or services are properly shut off and not able to be started up again before maintenance is completed.


I know about lockout/tagout, but why tryout? Workers have died (even recently) because they didn’t check the machine after performing the lockout/tagout procedure. The equipment’s potentially stored or residual energy can power the machine long enough to injure or kill anyone that may be working on it’s electrical, pneumatic, hydraulic, or tension components.

Employer have to get trained their employees to be trained in lockout/tagout/tryout procedures, and renew their training perodically. OSH standards require that employers establish energy controls procedures and a training program for employees. Employees must follow the established lockout/tagout procedure before performing maintenance.

What must workers do before they begin service or maintenance activities?

Before beginning service or maintenance, the following steps must be accomplished in sequence and according to the specific provisions of the employer’s energy-control procedure:

• Prepare for shutdown;
• Shut down the machine;
• Disconnect or isolate the machine from the energy source's;
• Apply the lockout or tagout device's to the energy-isolating device's;
• Release, restrain, or render safe all potential hazardous stored or residual energy. If a possibility exists for re-accumulation of hazardous energy, regularly verify during service and maintenance that such energy has not re-accumulated to hazardous levels;
• Verify the isolation and DE-energization of the machine.

Point To Remember:

Stay Safe—Lockout/tagout and try out! Your limbs or life may depend on it.

LOTO - More Than A Lock

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Chapter : Lockout Tagout (LOTO)

LOTO - More Than A Lock


Lockout/Tagout is more than just putting a yellow lock on the main electrical disconnect to a machine or part of a machine. 

 

Section 1:- 

 

There are Seven important steps you must do when putting Lockout/Tagout in place. "SEVEN STEPS FOR SHUTDOWN"

• NOTIFY – Notify all affected employees that you are going to be conducting a lockout/tagout.
• PREPARE – Before you begin, be sure you know all the types of energy involved, hazards presented by energy, and how to control the energy.
• SHUTDOWN – Turn off machine or equipment.
• ISOLATE - Isolate machine or equipment from its energy source(s). (For example, turn off main circuit breaker.)
• LOCKOUT – apply your lock. Be sure that it holds the isolating device in the “off” or “safe” position.
• RELEASE - Release stored energy. Relieve, disconnect, restrain, block, or otherwise ensure, that all energy sources – electrical, mechanical, hydraulic, compressed, etc. – are de-energized.
• VERIFY – Try the on-off switch or other controls to be sure the machine won’t start. Return the switch to the “off” position.

Section 2 :- 

 

There are 3 very important steps you must do when removing a machine from a Lockout/Tagout state. "THREE STEPS FOR RESTART"

1. INSPECT – inspect the equipment to be sure that:

• All tools and other materials are remove. 
• Machine is fully reassembled 
• Guards and other safety devices are reinstalled 

2. NOTIFY – Be sure that:

• All employees are safely positioned. 
• All affected employees are notified of the restart 

3. REMOVE – Remove lockout devices:

• Remember that only the person who put the lock on may remove it. 

Section 3 :-  

 
Prior to servicing that requires Lockout/Tagout you must evaluate the potential energy that could be released while working in that area or on a specific device. There are several types of energy:

• Electrical energy to operate the device. 
• Pneumatic energy or commonly known as air that controls various devices.
• Steam that heats various devices. 
• Natural Gas that is used in compustion devices 
• Water that may be used to cool devices 
• Hydraulics that may be used to control devices
• Gravity that may play a part in something lifted off the ground.
• Thermal energy that may cause things to remain hot after the source has been turned off.
• As OS&H states in their standard, the purpose of LOTO is to prevent the “unexpected" energization or start up of the machines or equipment, or release of stored energy could cause injury to employees.

Depending on the task you are performing you need to evaluate and isolate the systems and sources of energy that could cause injury

Section 4:-  

 

Various energy sources and devices have different methods for ensuring the energy is isolated.

• For electrical cabinets, in most case it is just a matter of placing a lock on the built-in hasp to the disconnect. However, other energy sources may require the use of additional lockout devices to accomplish the task.
• Devices available to lockout different types of valves and the like. For gate valves similar to your home’s outside water hose valve, there are covers that encase the entire handle to prevent anyone from turning it.
• For ball valves that do not have a place for a lock, there are devices built that will hold it in the off position (either parallel or perpendicular to the pipe) and can be locked in place.
• For larger valves for large gas pipes we have lockable bags where the handle can be removed after being shut off and placed inside the bag and locked in place.
• For pneumatic (air) quick disconnect hoses there is a device we have that the male end of the coupling goes into and gets locked into this device with a padlock.
• There are numerous devices available for very specific needs and applications. 
• If you are in a situation where you are unsure how to lockout a specific energy source check with competent person for the availability of suitable LOTO.
  

 

LOTO :- Lockout Tagout

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Chapter : Lockout Tagout (LOTO)