Injuries can happen when you’re dealing with energized equipment – even when you think it can’t hurt you.
Too many people have assumed they were safe because they powered down, turned off, or unplugged a piece of heavy machinery, only to get hurt by it regardless.
That’s because the equipment can store residual energy and release it unexpectedly.
You might think the mechanical press has been completely deactivated, but some leftover pneumatic energy can set it going. Residual oil in a hydraulic system can cause it to move even when it’s turned off. An unplugged machine’s parts might be set in motion while you’re servicing it.
And if your hand or any other part of your body is in the way when it does, the resulting injuries can be devastating.
Thankfully, there’s a system to prevent that. It’s called Lockout/Tagout (LOTO) and it does exactly what it says in the name:
- Step One: Lock the equipment so it can’t accidentally move or be activated by a release of energy
- Step Two: Tag the locked equipment so it doesn’t get unlocked by anyone other than the authorized personnel
But there’s actually more to it than just locking and tagging. To keep everyone safe while servicing, maintaining, or moving energized equipment, you’ll need a comprehensive Lockout/Tagout program.
In this article, we’ll look at what a thorough LOTO program should include – beyond a set of locks and tags.
5 Essential Elements of a Complete Lockout/Tagout Program
A Written Policy
Having the right locks and a rough idea of how to fill out the tags isn’t enough. You also need a comprehensive written policy to guide employees through every step of the LOTO procedure.
This will include clear details about:
- What equipment the lockout policy applies to
- What situations require the equipment to be locked
- Which locks are acceptable for locking out equipment
- Who is authorized to lock and tag the equipment
- Steps required to lockout the equipment (including notifying employees, de-energizing the equipment, and verifying that the lock is securely fastened)
- What information to include on the tag
- Who is authorized to unlock and re-energize the equipment
- When to inspect or replace lockout devices
A written policy that covers all the bases will ensure that there’s no confusing on the jobsite. Everyone will follow the same procedures and know which document to consult if there’s any uncertainty.
The Location of All Isolation Points
Every machine that falls under your LOTO program has a specific way that it should be locked. Some equipment might also have multiple places where locks can be affixed.
This is important information, because locking only one part of the machine might not isolate the energy to all of its components. This can result in situations where a worker thinks they have thoroughly locked the equipment, believes they are safe, but is still at risk of being harmed by some of its energized components.
It’s critical, then, to locate and clearly mark all energy control points, like plugs, switches, valves, and breakers.
Basically, anywhere an employee might have to apply a lock should be noted, marked, and included in your written Lockout/Tagout procedures.
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Machine-Specific Lockout Procedures
You can’t rely on a generic Lockout/Tagout procedure and apply it to all the equipment you have on site. Every machine is different and will require a unique lockout procedure.
Each of those unique procedures should be spelled out in your program. If your worksite has hydraulic presses, then you’ll need a rundown of how to de-energize and lock those presses. If there’s a large melting furnace, detail each step to locking it and ensuring it doesn’t heat up while being serviced.
You should also include details about the lockout devices themselves. An electric plug lock doesn’t work the same as a lockout hasp – and neither function the way a valve lock does. Don’t leave it to the employees to figure out how to use each of them – put it in writing.
Training on LOTO Procedures
Even a stellar written policy can’t make up for a lack of training. Your employees will need direct instruction, along with refreshers at regular intervals.
All employees who might work with energized equipment should be given training that covers all aspects of the Lockout/Tagout procedure. That includes workers who aren’t actually authorized to lockout the machinery but still use it, as well as employees who will be using the equipment very infrequently.
The training session should cover:
- The risks of maintaining, servicing, or moving equipment that hasn’t been properly locked
- The sources of hazardous energy on the on-site equipment
- When the Lockout/Tagout process is required
- Lockout procedures for all equipment
- Tagging procedures
- The LOTO chain of command (who is authorized to lock and unlock equipment)
In addition to providing instruction, you should also give employees some hands-on training. Supervising them while they de-energize and lockout equipment will give them a much better sense of how the procedure works and why it’s needed.
Continuous Improvement
Lockout/Tagout can seem like a straightforward process. Get the right locks and tags, apply them when needed, follow the procedure and everyone gets to stay safe.
But like every other aspect of your safety program, you should keep making sure it’s as effective as it can be.
Review your written LOTO policy at least once a year. Update it as soon as you get new equipment on site. Check for regulatory changes annually and modify your program accordingly.
In general, aim for continuous improvement. Even if your Lockout/Tagout procedures are good enough, it’s always worth asking if there’s any way to make them better.
Don’t Take Chances with Energized Equipment
This can seem like a whole lot of fuss compared to just slapping a lock on the equipment and getting on with it.
And yes, it is. But it’s also entirely warranted.
Lockout procedures are needed because of the severity of the injuries that can happen when a machine or piece of equipment unexpectedly releases energy. It’s important never to take chances with it – even a single incident is one too many.
Make sure you’ve got an airtight LOTO policy. Train your employees so they follow it to a tee. Then audit it regularly so it won’t fail you when you need it.
Ready to learn more? Check out our free webinar on Keeping Lockout/Tagout Top of Mind!
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