Summit Lockout Tagout

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LOCKOUT
TAGOUT
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Introduction
Each year nearly 150 people die because
there was a failure to control energy in the
workplace. These deaths could be avoided
if workers would take the time to perform
proper LOCKOUT/TAGOUT procedures.
A lack of respect for the hazards of energy

could cost your life or that of your coworker.
Introduction
The purpose of LOCKOUT/TAGOUT (LO/TO)
procedures is to prevent injuries and deaths that
result from the accidental release of energy.
Everyone in the workplace needs to know about

LO/TO procedures, whether or not they are
responsible for the locks and tags.
What are locks?
• A lock is any sort of device that “locks out” any
electrical or other type of device.
• A lock is most often placed on machinery to
turn it off and prevent it from starting again.
• Locks prevent switches from being activated or
valves from being turned on.
• Locks are most often used when machinery
needs maintenance or repair.
What are tags?
• A tag is any sort of card, paper, or metal
marker that is tied to a lock.
• A tag usually indicates who placed the tag,
the date it was placed, names of workers
involved, the supervisor’s name, and the
equipment being worked on.
• Tags warn that machinery or equipment has
been de-energized so work can be safely
performed.
Accidents Can Be Prevented
Many employees are killed and injured each year
when they are working on machinery and power is
accidentally restored. If proper LO/TO procedures
are followed, these injuries could be prevented.
For example, a worker is instructed to clean an asphalt mixing

machine. While he is in the process of changing the paddles,
another worker bumps a switch and the mixer door closes,
hits the worker on the head, and kills him.
It could be you!
LOCKOUT/TAGOUT
Is Necessary
• Every industry relies on energy to power equipment
that manufactures goods.
• Energy comes in many forms. The most common

kinds of energy include electrical, chemical, thermal,
hydraulic, and mechanical.
• When machines or equipment need to be serviced or

maintained, this energy must be isolated so authorized
personnel can safely perform work.
The Goals of
LOCKOUT/TAGOUT
The goal of LOCKOUT/TAGOUT procedures is to
protect workers. Another goal is to prevent energy
from accidentally being released while machines and
equipment are being maintained and serviced.
Unlike small appliances or hand tools, industrial machinery
requires more than turning off a switch or unplugging a cord.
These machines get their power from multiple energy
sources that interact with each other. If all energy sources
are not isolated before service or maintenance is performed,
an accidental release of energy could occur and result in
injury.
LOCKOUT/TAGOUT
Procedures
LOCKOUT/TAGOUT procedures may only be
performed by authorized employees who have received
proper training.
Authorized employees are trained to recognize the

types of hazardous energy sources in the workplace and
know how to isolate and control that energy.
LOCKOUT/TAGOUT
Procedures
Seven Simple Steps

The process of LOCKOUT/TAGOUT is
most successful when seven simple steps
are followed in order:
LOCKOUT/TAGOUT
Procedures
Step One-Proper planning
Step Two-Notification to all personnel
Step Three-Shutdown of operating controls
Step Four-Isolation of all energy sources
Step Five-Lockout/Tagout of isolated devices
Step Six-Release of all stored or residual energy
Step Seven-Verification of isolation of energy
LOCKOUT/TAGOUT
Procedures
Step One: Proper Planning
Proper planning is key to the success

of any LO/TO procedure.
Authorized personnel must consult with written

procedures or the proper personnel to determine
the types and magnitude of energy involved,
the hazards of the energy that must be controlled,
and how to control the energy.
LOCKOUT/TAGOUT
Procedures
Proper planning helps authorized personnel answer
important questions about the system to be worked on.
•What equipment is needed besides locks?
•Are there any hazardous substances that need to be drained?
•Should protective equipment be worn?
•Could energy accumulate again while work is being performed?
•How many locks are needed for the job?
LOCKOUT/TAGOUT
Procedures
Step Two: Notify All Affected Personnel
All affected personnel must be notified.

If this step of LO/TO is not performed,
LO/TO procedures may not be effective.
It is important that affected personnel

understand the situation and do not
participate in or interfere with the process.
LOCKOUT/TAGOUT
Procedures
Step Three: Shutdown Of Operating Controls
Step three involves turning off the
machine at the operating controls.
Shutting down the machine at the

operating controls does not bring the
machine to a “zero energy state.”
Operation could still occur if there was

any stored energy left in the system, or
if the equipment has more than one energy source.
LOCKOUT/TAGOUT
Procedures
Step Four: Isolation Of All Energy Sources
After the shutdown of operating controls

is complete, all energy sources must be
isolated as close to the source as possible.
This means taking steps to make sure energy

has no way to reach the machine or equipment.
LOCKOUT/TAGOUT
Procedures
Many energy isolating devices are used,
depending on the type of energy to be isolated.
• Circuit breakers
• Disconnect switches
• Line valves
• Blocks
• Blanks or blinds
LOCKOUT/TAGOUT
Procedures
Step Five: Lockout/Tagout of Isolated Devices
As each energy source is isolated,

a lock must be applied to the
energy isolating device
by an authorized employee
to prevent it from being operated.
LOCKOUT/TAGOUT
Procedures
Step Five: Lockout/Tagout of Isolated Devices
As each energy source is isolated and locked,
a tag must be applied to the energy isolating
(lockout) device by an authorized employee.
Tags are important because they warn others not

to move energy isolating devices from the “off” position.
When tags are used, they must include the
name of the employee applying the tag.
LOCKOUT/TAGOUT
Procedures
Tags contain important information.
•The Date
•Names of the Workers Involved
•Supervisor’s Name
•Equipment Being Worked On
LOCKOUT/TAGOUT
Procedures
Never interfere with equipment or
machinery that is tagged.
If you find a tag lying on the floor,

contact your supervisor immediately.
LOCKOUT/TAGOUT
Procedures
Step Six: Release Of All Stored Or Residual Energy
After locks have been placed on the main isolating

devices, all downstream energy identified in the
planning stage must be released so the system
reaches a “zero energy state.”
LOCKOUT/TAGOUT
Procedures
Step Six: Release Of All Stored Or Residual Energy
Many methods exist for releasing residual energy.
Residual or “leftover” energy, if not released,
presents a safety hazard.
Energy may be released by opening drains,

relieving system pressure, blocking the system
from gravity, bleeding lines, leaving vent valves
open and/or cycling the system.
LOCKOUT/TAGOUT
Procedures
Step Seven: Verification Of Isolation Of Energy
The final step before maintenance or servicing can

be performed is the verification that all steps have
been followed and that all energy has been locked
out or dissipated.
This final check must be performed to release any

stored energy and to make sure you have isolated
the correct energy source.
Special Situations
Special situations may sometimes call for
different procedures to be followed than
those already mentioned.
No matter what the situation, it is important

that you respect the potential hazards of the
energy you work with.
Special Situations
Some Machines May Not Be Locked Out
In rare cases, a machine or equipment is not

able to be locked out due to its design.
Tags must be used in these cases.
Never interfere with a piece of equipment or a

machine that is tagged.
Special Situations
Lockout/Tagout Exceptions
Some repetitive, routine tasks may not require
lockout/tagout procedures if the proper
safeguards are used.
Sometimes tasks, such as unjamming,

lubricating, or cleaning, may be done if the
operator uses the proper tools and does not
bypass the machine guards.
Special Situations
Lockout/Tagout Exceptions
If a machine needs to be energized to test or
position it, locks or tags can be temporarily
removed from the energy isolating device.
The area should be cleared of all tools and

materials before locks and tags are removed.
After the procedure is completed, all systems must

be de-energized and locks and tags reapplied.
Special Situations
Lock Box
An alternative example to a group lockout
situation is the use of a lock box.
The lock box is most often used during
a shift change and works when all employees
put the keys to the locks of the isolating devices
in a box. This box is then locked with a
departmental lock by the person assigned to
oversee the lockout procedure.
Special Situations
Contractors
Outside contractors may have lockout/tagout
procedures that differ from your facility.
Before any work is done, both the employer and

contractor must coordinate their procedures.
A contractor’s procedures must be as safe as

those established at the facility.
Special Situations
Shift or Personnel Changes
A system being worked on must remain locked

out during a shift or personnel change.
The person leaving the job site should not

remove his/her lock until the arriving worker
has locked out with their own lock.
Equipment Startup And
Operation
When maintenance or servicing is complete,
steps must be taken to ensure the safety of
others before locks and tags are removed.
• Notify all employees before locks and tags are
removed.
• Clear away all tools and other items from the
machine or equipment and reattach guards.
• Follow procedure to remove locks and tags.
Your Role in Prevention
A study by the National Institute for Occupational
Safety and Health (NIOSH) found that 63%
of workers injured by the release of hazardous
energy were production workers that were NOT
authorized to perform LO/TO procedures
to maintain and service equipment.
Your Role in Prevention
LOCKOUT/TAGOUT SAFETY
BEGINS WITH YOU!
• Know your company’s LO/TO policies and procedures.
• Follow proper procedures at ALL times.
• Do not try to bypass locks and never interfere with locks or
tags unless you are authorized to do so.
• Know the machinery and type of energy it uses.
• Communicate any problems you find to proper authorized
personnel, including lost tags.
• NEVER reenergize a system if you are not authorized to do so.
Summit Training Source,
Inc.
Contact us at:
1-800-842-0466
or at
[email protected]

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www.safetyontheweb.

A lack of respect for the hazards of energy

Everyone in the workplace needs to know about

For example, a worker is instructed to clean an asphalt mixing

• Energy comes in many forms. The most common

• When machines or equipment need to be serviced or

Authorized employees are trained to recognize the

Seven Simple Steps

Proper planning is key to the success

Authorized personnel must consult with written

•Are there any hazardous substances that need to be drained?

•Should protective equipment be worn?

•Could energy accumulate again while work is being performed?

•How many locks are needed for the job?

All affected personnel must be notified.

It is important that affected personnel

Shutting down the machine at the

Operation could still occur if there was

After the shutdown of operating controls

This means taking steps to make sure energy

As each energy source is isolated,

Tags are important because they warn others not

If you find a tag lying on the floor,

After locks have been placed on the main isolating

Energy may be released by opening drains,

The final step before maintenance or servicing can

This final check must be performed to release any

No matter what the situation, it is important

In rare cases, a machine or equipment is not

Tags must be used in these cases.

Never interfere with a piece of equipment or a

Sometimes tasks, such as unjamming,

The area should be cleared of all tools and

After the procedure is completed, all systems must

Before any work is done, both the employer and

A contractor’s procedures must be as safe as

A system being worked on must remain locked

The person leaving the job site should not

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