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If you work with machines or equipment that use or store energy, you may be exposed to the risk of hazardous energy release. This can happen when the machines or equipment are unexpectedly turned on or activated during maintenance or repair work. The consequences can be devastating, such as severe injuries, fatalities, property damage, or environmental harm.
To prevent such incidents, you must follow a safety procedure called LOTO, which stands for lockout tagout. Loto involves isolating and securing the energy sources of the machines or equipment before performing any service or maintenance work. It also prevents unauthorized or accidental start-up of the machines or equipment by applying locks and tags that indicate who is working on them and why.
LOTO is not only a good practice but also a legal requirement. The Occupational Safety and Health Administration (OSHA) has a standard for the control of hazardous energy (29 CFR 1910.147) that requires employers to establish and implement lockout/tagout programs for certain types of energy sources, such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or gravitational. OSHA estimates that complying with this standard can prevent an average of 120 fatalities and 50,000 injuries yearly.
In this blog post, we will explain the benefits of LOTO for workers and employers, the steps of lockout/tagout procedures, the types of locks and tags used, the roles and responsibilities of different employees involved, the common mistakes and challenges of implementing a lockout/tagout program, and the best practices and tips for effective management.
Benefits of LOTO for Workers and Employers
LOTO is a vital safety measure that protects workers from the hazards of unexpected startups or unauthorized energization or start-up of machines or equipment. By following the standardized procedures, workers can avoid injuries such as electric shocks, burns, cuts, crushes, falls, explosions, and fires. It also protects workers from exposure to hazardous substances or materials that may be released by the machines or equipment.
Employees also see benefits by reducing downtime, costs, and liability associated with hazardous energy incidents. By preventing accidents and injuries, LOTO can improve the productivity, efficiency, quality, and morale of workers. Effective implementation can also help employers comply with OSHA regulations and avoid penalties, fines, lawsuits, or reputational damage.
6 Steps of the Loto Procedure
The LOTO procedure consists of six basic steps that should be followed in sequence by authorized employees who are trained and qualified to perform service or maintenance work on machines or equipment. These steps are:
1. Prepare for shutdown:
The authorized employee should notify all affected employees (those who operate or use the machines or equipment) about the planned shutdown and the reason for it.
2. Identify and isolate energy sources:
The authorized employee should locate and isolate all the energy sources (such as electrical outlets, switches, valves, plugs, etc.) that supply power to the machines or equipment. Isolating any stored or residual energy (such as pressure, gravity, springs, capacitors, etc.) is also recommended.
3. Apply locks and tags:
Applying a lockout device (such as a padlock, hasp, cable lock, etc.) with a unique key or combination to each energy-isolating device to prevent it from being operated or moved should be followed by the authorized employee. The authorized employee should also attach a tagout device (such as a tag, label, sign, etc.) to each lockout device to provide the required information, such as the name of the authorized employee, the date and time of the LOTO, and the reasoning. The tagout device should also warn other employees not to operate or remove the lockout device or attempt to start the machines or equipment.
4. Verify zero energy state:
The authorized employee should verify that the machines or equipment are completely de-energized and isolated from all energy sources. It’s imperative for the individual to test the machines or equipment by trying to operate them using normal controls (such as switches, buttons, levers, etc.). Also, they should use appropriate testing instruments (such as voltmeters, and pressure gauges) to confirm that there is no residual or stored energy in the machines or equipment. During this stage, the authorized employee should ensure that all testing instruments are working properly and calibrated before and after use, and also ensure that no one is exposed to any hazards during the testing process.
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5. Perform maintenance or repair work
Now, the individual who is authorized can safely perform the service or maintenance activities on the machines or equipment. Of course, during this step, the employee should use the necessary tools, equipment, and personal protective equipment (PPE) for the work. The authorized employee should also follow the work instructions and procedures for the machines or equipment. The work area should not be left unattended or allow anyone else to access the machines or equipment during the work.
6. Remove locks and tags and restore normal operation
After completing the work, the authorized employee should inspect the machines or equipment and ensure that they are in safe and operable condition. Also, any tools, equipment, materials, or debris from the work area needs to be removed. Then, the authorized employee should notify all affected employees that the Lockout or tagout is about to be removed and that the machines or equipment are ready to be restarted. The authorized employee should then remove all locks and tags from the energy-isolating devices and restore them to their normal positions. Finally, the equipment needs to be re-energized and tested to ensure that they are working properly.
Types of Locks and Tags Used for Loto
Locks and tags are essential devices for LOTO that prevent unauthorized or accidental operation of energy-isolating devices and provide information and warnings. There are different types of lockout/tagout devices available for different types of energy sources and isolating devices. Some examples are:
Padlocks
These are portable locks that can be attached to hasps, chains, cables, or other devices to secure energy-isolating devices such as switches, valves, plugs, etc. Padlocks should have a unique key or combination that is only accessible to the authorized employee who applied them.
Hasps
These are metal devices that can be attached to energy-isolating devices such as switches, valves, plugs, etc. Hasps have one or more holes that can accommodate padlocks or other lockout devices. Hasps should be made of durable and non-conductive materials.
Cable Locks
These are flexible devices that can be wrapped around energy-isolating devices such as valves, pipes, levers, etc. Cable locks have a locking mechanism that can be secured with a padlock or other lockout device. Cable locks should be made of strong and non-conductive materials.
Valve Covers
These are devices that can be attached to valves or other energy-isolating devices that have handles or stems. Valve covers have a locking mechanism that can be secured with a padlock or other lockout device. Valve covers should be made of rigid and non-conductive materials and fit snugly over the valves or handles.
Circuit Breakers
These are devices that can be attached to an electrical circuit or other electrical energy-isolating devices. Circuit breakers have a locking mechanism that can be secured with a padlock or other lockout device. Circuit breakers should be made of non-conductive materials and prevent the circuit breakers from being switched on or off.
Warning Signs & Labels
These are devices that can be attached to lockout devices or energy-isolating devices to provide information and warning about the LOTO. Warning signs should be visible, legible, and durable. They should also include the name of the authorized employee, the date and time of the LOTO, and the reason for the LOTO.
Roles and Responsibilities of Employees Involved in LOTO
There are different roles and responsibilities for employees involved in LOTO, depending on their level of authority and involvement in the service or maintenance work. These roles are:
Authorized employees: These are employees who are trained and qualified to perform service or maintenance work on machines or equipment and to apply and remove LOTO devices. Authorized employees are responsible for following the LOTO procedures and ensuring their own safety and the safety of others during work.
Affected employees: These are employees who operate or use the machines or equipment that are subject to LOTO or who work in areas where LOTO is performed. Affected employees are responsible for complying with the LOTO procedures and not interfering with the LOTO devices or attempting to start the machines or equipment during work.
Other employees: These are employees who work in areas where LOTO is performed but are not directly involved in the service or maintenance work or in operating or using the machines or equipment. Other employees are responsible for being aware of the LOTO procedures and not interfering with the LOTO devices or attempting to start the machines or equipment during work.
Common Mistakes and Challenges of LOTO Implementation
Loto is a critical safety procedure that requires careful planning, execution, and monitoring. However, there are some common mistakes and challenges that can compromise the effectiveness and compliance of LOTO. Some examples are:
Lack of training: Employees who are not properly trained on the LOTO procedures and devices may not understand the hazards and risks involved in the service or maintenance work. They may also not know how to apply and remove the LOTO devices correctly and safely.
Lack of communication: Employees who are not informed or notified about the LOTO activities may not be aware of the status and location of the machines or equipment that are subject to LOTO. They may also not know who is authorized and responsible for the LOTO and the work.
Lack of coordination: Employees who are not coordinated or synchronized with each other during the LOTO activities may not follow the same sequence and timing of applying and removing the LOTO devices. They may also not verify or confirm the zero energy state of the machines or equipment before and after the work.
Lack of compliance: Employees who do not follow or adhere to the LOTO procedures and devices may not isolate and secure all the energy sources of the machines or equipment. They may also not apply and remove the LOTO devices properly and completely.
Lack of documentation: Employees who do not document or record the LOTO activities may not have a clear and accurate record of who, what, when, where, why, and how the LOTO was performed. They may also not have proof or evidence of compliance with the OSHA standard and other regulations.
Best Practices and Tips for Effective Loto Management
Loto is a vital safety procedure that requires continuous improvement and optimization. There are some best practices and tips that can help employers and employees manage LOTO effectively and efficiently. Some examples are:
- Conduct regular audits, inspections, reviews, and updates of LOTO policies and procedures to ensure they are current, relevant, and compliant with the OSHA standard and other regulations.
- Provide adequate training, education, and awareness to all employees involved in LOTO on the hazards, risks, procedures, devices, roles, responsibilities, and expectations of LOTO.
- Establish clear and consistent communication channels and methods among all employees involved in LOTO to ensure that they are informed, notified, coordinated, synchronized, verified, confirmed, and documented during the LOTO activities.
- Use appropriate and standardized LOTO devices that are durable, non-conductive, and identifiable for different types of energy sources and isolating devices.
- Implement a group LOTO system for complex or multiple machines or equipment that require more than one authorized employee to perform the service or maintenance work. A group LOTO system involves using a lock box or a multi-lock hasp to store and secure the keys or combinations of the individual LOTO devices applied by each authorized employee.
- Enforce a strict accountability and responsibility system for LOTO devices to ensure that only the authorized employee who applied the LOTO device can remove it and that no one else can access or tamper with it.
How Certainty Helps in LOTO Safety
Certainty provides you with various checklists that you can use to self-inspect or audit your current LOTO practices, such as:
- Facility Safety Inspection Checklist
- Jobsite Safety Inspection Checklist
- Warehouse Safety Inspection Checklist
- Behavioral Based Safety Observation Checklist
- Hot Work Permit Checklist
By using Certainty and its checklists, you can ensure that your LOTO program is up-to-date, relevant, and compliant with OSHA standards and other regulations. You can also identify areas of improvement and opportunities for enhancing your safety performance.
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