Lockout/Tagout (LOTO) procedures keep workers safe while they service machinery and equipment by preventing start up, a release of stored energy, or reenergization. In this article, we’ll take a closer look at OSHA’s LOTO standards, suggested steps for implementation, and additional resources that can provide support and guidance for effective LOTO practices and training.
Lockout/Tagout: An Overview
The OSHA LOTO standard can be found inTitle 29 Code of Federal Regulations (CFR) Part 1910.147, which addresses how “unexpected energization or start up of the machines or equipment, or release of stored energy” could injure workers during maintenance or service activities. The standard goes on to address how such “hazardous energy” should be controlled – including not just mechanical energy, but also electrical, pneumatic, thermal, hydraulic, chemical, and more.
In other words, it’s the employer’s duty to create energy control programs that protect workers from harm while servicing machinery or equipment. As OSHA’s Lockout/Tagout FactSheetstates, “This is generally done by affixing the appropriate lockout or tagout devices to energy-isolating devices and by de-energizing machines and equipment.”
In 1910.147(b), OSHA defines lockout and tagout, which will be quoted below. A lockout device, such as a blank flange or bolted slip blind, halts all operation and prevents reenergization until it is removed. In other words, it creates a state of…
“Lockout. The placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed.”
On the other hand, tagout devices “are essentially warning devices” and cannot physically halt the operations of a machine. For this reason, they may “evoke a false sense of security,” so it’s essential that workers are trained to understand the limits of tags and never ignore or bypass them.
“Tagout. The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.”
Lockout device
- Placed on an energy-isolating device under an established procedure
- Ensures the device and the equipment cannot be operated until it is removed
Tagout device
- Placed on an energy-isolating device under an established procedure
- Indicates the device and the equipment may not be operated until it is removed
- A warning device only: it cannot physically stop the machine
Implementing LOTO Program
OSHA has created many resources to guide employers and safety professionals through the process of creating LOTO programs. A general industry outline can be found in the LOTO standard mentioned above, while a full list of industry-specific standards can be read on OSHA’s website.
Other materials, such as case studies, example programs, and online training, will also be linked below. What follows is an abridged list of what OSHA’s LOTO FactSheet identifies as the “most critical requirements” of a LOTO program:
Develop an energy control program: Beyond reading the LOTO standard, OSHA recommends reading 29 CFR 1910.147 App A, intended as a guide to the “minimum requirements necessary” to develop an energy control program.
Employ lockout or tagout: For equipment that can’t be locked out, a tagout program that provides protection equal to a lockout program must be used. Only use lockout/tagout devices authorized for the particular equipment or machinery. Ensure only the worker who applied a lockout/tagout device can remove it.
Train workers: Workers must be trained to understand the implemented energy control program, their duties to maintain it, and OSHA’s lockout/tagout requirements – particularly concerning the prohibition against any attempt to reenergize a machine that has been locked or tagged out. An online training programis available.
Inspect energy control procedures: OSHA requires inspections of energy control procedures “at least annually” to identify and correct inadequacies and deviations.
Multi-employer workplaces: For workplaces with multiple employers, such as those that use outside contractors, all employers have a responsibility to share their LOTO programs with each other to ensure all parties understand the safety procedures in use.
Additional provisions: Comply with additional energy provisions in the standard concerning the testing and repositioning of machines, group lockout procedures, and shift or personnel changes.
