1. How to Effectively & Efficiently Control
LOCKOUT / TAGOUT
How to Effectively & Efficiently Control
Hazardous
Energy

2. Frequency Of LOTO Accidents
10% of all industrial accidents are LOTO-related
250,000 LOTO-related accidents each
year, resulting in approximately:
200 fatalities
60,000 injuries

3. Cost of LOTO Accidents Medical expenses, worker’s compensation
OSHA fines
Civil lawsuits
Low employee morale
Equipment damage, lost productivity
Higher insurance premiums

4. OSHA LOTO Regulations OSHA Standard 29 CFR 1910.147 Does not cover:
“Control of Hazardous Energy (Lockout/Tagout)”
Does not cover:
Work on electrical systems ( )
Electrical Power Generation ( )
Construction ( )
Oil / gas drilling and servicing
Agriculture
Maritime

5. LOTO Program Components
4 key components of a LOTO program:
Documented policies and procedures
Energy source ID
Employee training
Proper tools and devices

6. Energy Control Policy Purpose and scope of LOTO program
Equipment covered under the program
Who is authorized to perform LOTO
Enforcement policy
Group lockout procedures and shift transfers
Procedures for lock removal
Coordination with contractors

7. Lockout Procedures The KEY to a compliant, efficient lockout process
Inadequately documented procedures is one of the most frequently cited failures in LOTO violations
Additional benefits of good procedures:
Simplifies training
Helps prevent errors, enhancing safety
Speeds lockout, shortens downtime

8. Procedure Requirements
Separate procedure required for each piece of equipment to be locked out.
Multiple machines can be grouped under one procedure only if they have:
the same type and magnitude of hazardous energy
the same or similar means of controlling that energy
Documentation not needed for single-source equip.
Procedures must be audited at least once per year.

9. Procedure Contents Application of lockout Release of lockout
Notify & brief
Shutdown
De-energize
Apply LOTO devices
Release stored energy
Verify zero energy state
(Put warnings in place)
Release of lockout
Inspect machine / area
Confirm people are clear
Verify controls in neutral
Remove LOTO devices
Re-energize
Notify
Startup

10. Sample Lockout Procedure
Equipment identified at top
Provides clear step-by-step instructions
Uses color, pictograms to highlight energy sources
Use of photos ensures that workers can quickly find the correct control points, avoiding lost time and mistakes

11. Accessing Procedures Post at point of use Put in binders
Access online or attach to work orders

12. Energy Source Identification
Identify hazardous energy sources to
prevent mistakes, speed lockout activity.
Alternative Solutions:
Stock labels and tags
Do-it-yourself printing systems
Custom printed or engraved tags

13. LOTO Training Authorized employees Affected / other employees
Separate training must be provided for the following types of workers:
Authorized employees
Affected / other employees
Employers must keep a record of all training
Retraining for authorized & affected employees
Additional training required for tagout

14. Training & Awareness Aids
Training Videos
Training Booklets
Posters
Signs & Labels
Hard hat stickers

15. Lockout & Tagout Devices
Lockout and tagout devices must:
Be provided by employer
Be standardized and distinguishable from locks and tags used for other purposes.
Be used for LOTO purposes only
Be capable of withstanding the usage environment
Identify the person who applied the lock/tag

16. Exclusive Control
Each employee must have exclusive control of the locks they use. No worker should be able to open another another worker’s lock!

17. Brady Safety Padlocks The Ultimate Lockout Lock! Compact & lightweight
Non-corrosive
Non-conductive
Impact resistant
Tamper resistant

18. Tags Requirements For Tagout:
Tags can be used alone (as tagout devices) or in combination with locks (for ID purposes).
Requirements For Tagout:
Must be strong enough to prevent accidental or inadvertent removal.
Use non-reusable nylon cable tie or equiv. that withstands 50-lb pull test
Must include warnings and instructions (eg, Do Not Operate) understandable to all employees

19. Mechanical Lockout Devices
Gate Valves
Ball Valves
Air & Gas

20. Universal Valve Lockout
Gate valves
Ball valves
Butterfly valves

21. Electrical Lockout Devices
Circuit breakers
Fuses
Wall Switches
Plugs

22. EZ Panel Loc System

23. Cable Lockout Devices
Mini Cable
Lockout
All Purpose
Cable Lockout

24. Group Lockout

25. Lockout Storage & Transport

26. Visual Warnings