Lockout Tagout

1. An introduction to…
Lockout Tagout

2. Aim
Every year thousands of workers get killed or injured while performing repairs or
maintenance on industrial equipment or machinery. Many of these accidents are
caused by the uncontrolled release of energy. A good LOTO procedure can prevent
accidents and prevent unplanned damage to machinery.
Within this Toolbox Talk we cover:
• What is Lockout Tagout (LOTO)?
• Legislation
• Why you need a LOTO procedure
• Creating a LOTO program
• Awareness within your organisation
• Types of LOTO equipment
• Recommended staged LOTO process

3. UK Legislation
The Health and Safety at Work Act 1974, section 2 states:
• It shall be the duty of every employer to ensure so far as reasonably practical,
the health, safety and welfare at work of all employees.
The Provision and Use of Work Equipment Regulations 1998, Regulation 19 -
Isolation from Sources of Energy states:
• Every employer shall ensure, that where appropriate, work equipment is
provided with suitable means to isolate it from all its sources of energy.
• Every employer shall take appropriate measures to ensure that reconnection of
any energy source to work equipment does not expose any person using the
equipment to any risk to his health or safety”.

4. What is Lockout Tagout?
• Lockout Tagout is a system for isolating energy
sources.
• It prevents operation of machinery and
equipment whilst under repair, out of
commission or where it is only used for certain
groups or shifts.
• Using lockout devices prevents equipment from
being used accidently and unauthorised staff
from operating it.
• There should be clear company rules on what
isolation procedures are required, and in what
circumstances.
• In short, Lockout Tagout can prevent accidents
and prevent unplanned damage to machinery.

5. Definition of Lockout & Tagout
Lockout: Placing a locking device on an energy control device
to physically lock a system in safe mode. Equipment being
controlled should not be operated until the locking device has
been removed.
Tagout: The placement of a tag which indicates that the
energy isolating device and the equipment being controlled
must not be operated until the tag has been removed.

6. Why do you need a LOTO procedure?
• To ensure safe working while doing maintenance, cleaning or repairs
• To prevent injury, damage and errors being made
• A LOTO procedure also serves as a check sheet to help employees avoid
mistakes and reduce the risk of accidents and injuries
• Procedures speed up lockout activity, which in turn reduces downtime and
improves operational productivity
• Documented machine-specific energy control procedures are required by
OSHA
• It is a procedure which clearly communicates risk in the workplace

7. Creating an efficient Lockout Program
Follow the BEST GLOBAL PRACTICE plan for creating an efficient lockout program:
1. 4.3.2.

8. Awareness within your organisation
Keep in mind all the people in your facility, recognise three groups with different needs
of awareness degree:
Don’t forget about different circumstances such as shift
patterns, outside contractors and outsourced maintenance.

9. Energy Types
THREE main types of energy that LOTO is concerned with are:
• Mechanical - The movement of a piece of machinery (e.g. a printing press)
• Chemical - The flow of a substance or chemical in a pipe (e.g. steam/water)
• Electrical - The flow of electricity in an exposed installation

10. Types of LOTO Equipment
Conventional lock boxes and bags:
These can used to store safety critical equipment at site level with access only to
authorised persons – in remote locations this may include storage of the LOTO
equipment. Locking such equipment away minimises the risk of it being used by
unauthorised personnel who have not, perhaps, properly isolated the equipment.

11. Types of LOTO Equipment
Lockout devices:
These can actually isolate (or otherwise) the machine or feedstock. Examples include
electrical lock out, value lock outs, cable lock out and cylinder lock outs. They can be
designed for the specific machine concerned or be more generic, and specialist advice
needs to be taken in selection.
Gate Valve Lockout Pneumatic Lockout Electrical Lockout Kit

12. Types of LOTO Equipment
Padlocks, Hasps and Ties:
In addition to specific lock out devices, padlocks, hasps and ties can be used in a
number of LOTO scenarios, often with accompanying tags, but please note that there
are many different configurations and applications.
Lockout HaspSafety PadlockPadlock

13. Types of LOTO Equipment
Tags and Signs:
These provide information to employees and record key facts such as when the lock out
took place and by whom. These can be colour-coded especially where is there is more
one lock out authority, i.e. different staff doing their own maintenance regimes on the
machine concerned.

14. LOTO Process
 Prepare for shutdown
 Inform employees
 Turn off equipment
 Isolate energy sources
 Perform maintenance
 Test all circuits
 Test the equipment controls
 Lock off switches
A recommended staged LOTO process is as follows:

15. Conclusion
In almost every application involving machinery and large devices, LOTO needs be
considered. Sometimes it is the only solution to maintain compliance and promote
safe working.
As with many aspects of operational controls, safe systems of work should never be
assumed. Implementing LOTO procedures may highlight other areas of improvement
within the safety process.
Specialist advice will often be indicated to ensure that the most appropriate LOTO
devices are employed for the task in hand.