A Step-by-Step Guide to Apply and Remove Lockout Tagout Safety Procedures

In the wake of social, political, technical, and economic developments, the significance of workplace safety and health, particularly Lockout Tagout, has steadily and continually changed. Everybody has become aware of the tremendous dangers associated with industrial machinery. For this reason, most industrial machinery is built with safety features. Lockout tagout procedures are a crucial component of a successful hazardous energy control programme and are governed by OSHA CFR 1910.147 to maintain energy controls.

The Lockout Tagout regulation calls for the establishment and usage of methods and procedures to turn off equipment, separate it from its energy source(s), and stop the release of potentially harmful energy while maintenance and servicing tasks are being carried out. Following systematic procedures to release the Lockout Tagout devices from the machines is just as important as its application. It includes specific guidelines for creating a successful programme for the management of hazardous energy as well as basic performance requirements. Employers, however, have the freedom to develop lockout/tagout procedures that are appropriate for their specific facilities.

How to apply Lockout Tagout

Even the world's most comprehensive and in-depth written procedure won't be beneficial if the user can't comprehend it. To simplify, ensure uniformity in how equipment is labelled and processes are defined. Although OSHA prescribes minimum requirements for companies to establish Lockout Tagout procedures, every business can customise its own set of safety procedures using the following LOTO safety steps -

Preparation for shut-down

Preparation is the key before beginning any procedure, especially when it comes to safeguarding people’s lives. Before starting the maintenance procedure, the authorised employee needs to -

• Analyse the work environment and conduct a risk analysis
• Identify which precautionary measures need to be implemented
• Notify all nearby employees
• Ascertain if the repair work requires a Lockout

Turn-off Machines

All the machines and equipment being maintained need to be turned off. While turning off machines, the authorised employee needs to keep in mind that -

• Every machine has written shut-down steps
• All energy sources have been shut down
• Step-by-step established procedures are used to shut down machine
• Consult supervisors or the machine’s manual for guidance

Isolation

Energy isolation is a crucial part of the service system that enables activities to be conducted safely and without unexpected loss of control that might harm the surrounding environment of a facility, employees or piece of equipment. The authorised employee must -

• Locate all the hazardous energy sources
• Detect all energy isolating devices in a machine
• Ensure all possible energy sources have been isolated
• Follow proper procedures to isolate the machine

LOTO Application

Lockout Tagout devices like hasps, valve lockout, fuse lockout etc., along with padlocks and tags, need to be applied to energy isolating devices by -

• Ensuring that every energy isolating device has been locked out
• Applying the lockout device according to the energy isolating point
• Tags should identify the authorise employee applying the lock
• If multiple employees are working, each worker needs to apply an individual padlock

Release Store Energy

Often, machine or equipment retains energy in the form of stored electrical, mechanical, pneumatic, or potential energy. This needs to be dissipated -

• By using proper systematic steps
• After making sure the area is clear of employees
• Secure moving equipment
• Render machine to zero energy state

Verification

This step of verifying that all energy has been isolated is frequently overlooked or implemented incorrectly by the authorised employee.

• Make sure no employee is present in or near the machine
• Can be done through visual inspection, testing equipment or restarting by machine controls
• The procedure is deemed successful if the machine does not start again

How to remove LOTO

After the maintenance has been completed, the authorised employee needs to restore the machine so normal production operations can continue. But this can also be a dangerous task if implemented carelessly, so before restarting the machine, the authorised employee must –

• Make sure he has removed all the tools or scraps from the machine
• Check the work area and notify employees about the resumption of operations
• Remove the Lockout Tagout devices. The person who applied the padlock is the only one who should remove it.
• Re-energise the machine and restore the normal everyday operations of the machine

Conclusion

The foundation of a safety programme is the prediction, identification, evaluation, and management of dangers that may arise in or from the industry and endanger workers' health and well-being. Lockout Tagout specifications that are more unique to a particular site, location, or activity would need to be included in established procedures, worker safety guidelines, manuals, handbooks, or unique standards. No matter what position you hold within the company - whether you're a maintenance worker, a health and safety representative, or the president - it helps to be knowledgeable about these basic best practices for an efficient LOTO programme.

Mahesh Kumar, a dedicated safety expert with a decade in Occupational Health and Safety, conducts assessments, suggestions on lockout tagout, implements training, and develops compliance protocols across diverse industries.