An introduction to… Lockout Tagout

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

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”.

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.

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.

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

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

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.

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

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.

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 LockoutPneumatic LockoutElectrical Lockout Kit

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

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.

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:

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.