What Is a Lockout/Tagout System?

A Lockout/Tagout system is one of those workplace safety protocols that can be a lifesaver—literally. These systems are designed to protect workers from the hazards associated with the unexpected release of energy while they're working with machines and equipment. Whether you're managing a large industrial site or running a smaller manufacturing plant, understanding how lockout/tagout (LOTO) systems function can help keep employees safe and avoid costly accidents.

What is a Lockout/Tagout System?

In simple terms, a Lockout/Tagout system is a set of procedures used to ensure that dangerous machinery or equipment is properly shut off and cannot be turned on during maintenance or repair work. The system uses locks, tags, or both to prevent accidental operation. The purpose is to protect employees from coming into contact with hazardous energy sources, such as electrical, mechanical, hydraulic, or thermal energy.

The Lockout/Tagout system is built around the concept of controlling hazardous energy sources by physically locking them in a safe state. This gives workers the assurance that the machine they’re working on will not inadvertently start up while they're repairing or maintaining it. LOTO procedures also include clear labeling with tags to warn workers about the potential dangers of the equipment.

Why is Lockout/Tagout Important?

The importance of a Lockout/Tagout system cannot be overstated. OSHA reports that over 120 fatalities and thousands of injuries each year are related to the improper or lack of implementation of lockout/tagout procedures. Machinery and equipment can have unpredictable behaviors, and if proper precautions are not in place, workers can be exposed to serious risks, including electrocution, crushing, burns, or even death.

Here’s why you should consider adopting a Lockout/Tagout system if you haven't already:

• Protection Against Unexpected Energy Releases: Whether it’s an electrical short or a pressurized valve, hazardous energy can be dangerous. LOTO systems make sure that equipment is properly de-energized and securely locked before workers begin their tasks.
• Prevention of Accidental Machine Startups: Maintenance work on machines can sometimes inadvertently cause a machine to start up. Locking out the energy source or using a tag that signifies the equipment is under maintenance helps eliminate the chance of a worker becoming trapped or injured.
• Compliance with OSHA Standards: OSHA (Occupational Safety and Health Administration) requires employers to implement Lockout/Tagout procedures as part of their safety standards. These protocols are regulated by OSHA standard 1910.147, which outlines the practices and requirements for controlling hazardous energy.
• Employee Awareness and Safety: With clear communication about which machines are locked out and why, employees can feel more confident about their work environment. Workers understand the risks and the measures in place to protect them.

Key Components of a Lockout/Tagout System

The Lockout/Tagout system is more than just a set of locks and tags; it's a comprehensive approach to equipment safety. Below are the key components of an effective LOTO system:

• Energy Control Procedures: Every workplace that requires lockout/tagout procedures should have clearly written energy control procedures. These procedures should detail how to identify energy sources, how to isolate them, how to lock them, and how to test to make sure they’re not live before starting work. The written procedures ensure that employees follow the same steps each time to keep the system consistent.
• Lockout Devices: These are physical locks that are used to secure energy-isolating devices, such as valves, electrical switches, or circuit breakers, in the off position. Locks come in different sizes and shapes depending on the equipment, but they are designed to prevent anyone from accidentally re-energizing the system.
• Tagout Devices: Tags are used to provide clear warnings that the equipment is under maintenance or service. While tags alone don't physically prevent someone from turning the machine on, they serve as a visual warning. They should be used in conjunction with lockout devices to provide a clear communication system for workers.
• Personal Lock and Key: Each worker involved in maintenance should use their own lock and key. This prevents any one person from unlocking multiple locks, ensuring the machine remains in a safe state while multiple workers are involved.
• Training and Education: To make sure the Lockout/Tagout system is effective, training is key. Employees need to understand the procedures and when they should be followed. Additionally, they need to be able to identify hazardous energy sources and know how to apply lockout/tagout devices properly. Periodic refresher training ensures that everyone stays up to date with the system’s requirements.
• Periodic Inspections: Lockout/Tagout systems need to be inspected regularly to ensure they are functioning as intended. These inspections help identify any issues or weaknesses in the procedures, devices, or training. The goal is to catch problems early before they result in accidents.

Types of Energy That Lockout/Tagout Protects Against

Lockout/Tagout procedures are designed to control all potential hazardous energy sources. The most common types of hazardous energy include:

• Electrical Energy: This is perhaps the most common hazard in industrial settings. Proper lockout/tagout ensures that electrical circuits are de-energized and secured before maintenance begins.
• Mechanical Energy: Machines with moving parts pose a risk of injury if they are not properly locked out. This includes gears, wheels, and pulleys.
• Thermal Energy: Hot surfaces or components can cause serious burns or injuries. Locking out equipment that generates heat ensures workers aren’t exposed to hazardous temperatures.
• Hydraulic/Pneumatic Energy: Pressurized systems can cause dangerous fluid or gas releases. Locking out these systems prevents accidental pressurization during maintenance.
• Chemical Energy: Chemical processes or systems that contain hazardous substances should be locked out to prevent accidental exposure.
• Gravitational Energy: Heavy objects that could fall or move unexpectedly pose a risk to workers. Locking these systems out ensures safety during repairs.

Lockout/Tagout vs. Other Safety Systems

You may be wondering how Lockout/Tagout compares to other safety systems like machine guards or interlock systems. While each system has its place, LOTO is unique in its focus on controlling hazardous energy during service or maintenance work.

• Machine Guards: These are physical barriers designed to prevent workers from coming into contact with dangerous moving parts. While effective, machine guards are not enough on their own if workers need to access machinery for repairs.
• Interlock Systems: These safety devices are designed to prevent a machine from operating unless certain conditions are met, such as a door being closed or a safety bar being in place. However, interlocks can fail, and workers may still be exposed to hazards if proper LOTO procedures aren’t followed.

While machine guards and interlock systems are useful safety measures, Lockout/Tagout is essential for ensuring that hazardous energy sources are fully isolated and secured during maintenance. It’s a proactive approach to preventing injury or death.

Common Mistakes to Avoid in Lockout/Tagout Systems

A Lockout/Tagout system can be a powerful tool for keeping your workplace safe, but it’s only effective when properly implemented. Some common mistakes to avoid include:

• Skipping Lockout Procedures: Sometimes, workers may feel it’s quicker or easier to bypass lockout procedures, especially if they’re doing quick fixes or temporary work. This can lead to accidents. Always follow the lockout process.
• Using Incorrect Lockout Devices: Using the wrong lockout device, such as a generic padlock instead of a device that specifically fits the energy isolating switch, can compromise the safety system.
• Failing to Communicate: Lockout/Tagout requires communication between all involved workers. If a worker forgets to tag a piece of equipment or fails to notify others of a lockout, the system can fail. Ensure everyone knows when and why equipment is locked out.
• Not Training Employees: If workers don’t know how to apply lockout devices or understand the risks, the system won’t be effective. Proper training is key to ensuring that workers know what they’re doing.

How to Implement a Lockout/Tagout System in Your Workplace

To implement a Lockout/Tagout system, follow these steps:

1. Identify Hazardous Energy Sources: Conduct a thorough assessment of your workplace to identify all energy sources that need to be controlled. Consider electrical, mechanical, and chemical energy sources.
2. Establish Lockout/Tagout Procedures: Write clear procedures for each piece of equipment or energy source that needs to be locked out. These procedures should be easily accessible to all employees.
3. Provide the Necessary Equipment: Ensure you have the proper lockout devices, tags, and keys available. Every employee should have access to the tools they need to perform a lockout/tagout safely.
4. Train Employees: Train all employees on the lockout/tagout procedures. Regular refresher training is essential to ensure continued safety.
5. Inspect and Review: Regularly review your Lockout/Tagout system to ensure it’s functioning properly and make improvements if necessary.

Wrapping It Up

Implementing a Lockout/Tagout system in your workplace is one of the best ways to protect workers from hazardous energy sources. While it might seem like a hassle at first, the safety benefits far outweigh the costs. By providing workers with the right tools, training, and procedures, you’ll help create a safer work environment