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What is Lockout / Tagout

Lockout / Tagout prevents the unexpected startup of hazardous energy during maintenance or servicing of machinery by utilizing, tags, lockouts or a combination of both.

Fast Facts

OSHA estimates that 120 Fatalities and 50,000 injuries each year are prevented by LOTAG programs
An estimated 10% of all serious industrial accidents resulted from failure to control hazardous energy
- This equals 28,000 lost work days per year and 120 lives per year
Lockout / Tagout ranked #5 in OSHA’s Top 10 Violations for 2009

What is the difference between Lockout and Tagout?

Lockout device: Utilizes a positive means such as a lock to hold an energy-isolating device in the safe position and prevent the energizing of a machine or equipment.
Tagout device: A prominent warning device, such as a tag, which can be securely fastened to an energy-isolating device to indicate that the equipment being controlled may not be operated until the tagout device is removed.

How do I know when to use Lockout or Tagout?

When possible, lockout devices should be used. In the event that a lock cannot be applied, a tag should be adhered to the switch, alerting employees not to activate the machinery.

Characteristics of Lockout / Tagout devices
Sample lockout tagout

Durability: Capable of withstanding the environment to which they are exposed for the maximum period of time that exposure is expected.
Weather Resistance: Constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate or the message on the tag to become illegible.
Chemical Resistance: Tags shall not deteriorate when used in corrosive environments such as areas where acid and alkali chemicals are handled and stored.
Identifiable: Lockout devices and tagout devices shall indicate the identity of the employee applying the device(s).
Substantial: must be substantial enough to prevent removal without the use of excessive force or unusual techniques such as bolt cutters.

Tagout Device Requirements

Non-reusable type
** Lockout / Tagout devices must identify the employee who locked out the device and the date of lockout making each tag unique to each lockout event.
Attachable by hand.
Self-locking.
Non-releasable.
Have a minimum unlocking strength of no less than 50 pounds and having the general design and basic characteristics of being at least equivalent to a one-piece, all-environment-tolerant nylon cable tie.

Types of Hazardous Energy that may required Lockout / Tagout

Mechanical
Energy in moving machinery
Hydraulic
Energy of liquids under pressure
Pneumatic
Energy released by compressed gases
Chemical
Energy that can start fires or explosions, cause burns or generate harmful fumes
Electrical
Energy released from distribution systems, circuits and equipment
Thermal
Energy from hot or cold liquids, such as cryogenic solutions, hot equipment, or fluids

Basic Lockout / Tagout Procedure

Shut down equipment
1. Follow appropriate procedures for machinery to prevent accidents and injuries
Isolate all energy sources
Apply lockout devices
Release all energy
1. Block/brace parts that could move
2. Relieve pressure
3. Inspect the equipment to ensure all parts have stopped moving
Verify zero energy state
1. Test that equipment is locked by attempting to turn on equipment
Perform service/maintenance
Remove Lockout / Tagout Device
1. Remove all tools from work area
2. Take account of all employees, ensure they maintain a safe distance from the equipment
3. Lockout device must be removed by person who locked out equipment