LOCKOUT/TAGOUT (LOTO) PROCEDURE Company: [COMPANY NAME] Effective Date: [DATE] Review Date: [DATE] Procedure Number: LOTO-001 1. PURPOSE This procedure establishes the minimum requirements for lockout/tagout of energy isolating devices to prevent the unexpected energization or startup of machines and equipment during servicing and maintenance activities. 2. SCOPE This procedure applies to all employees who service or maintain machines and equipment where unexpected energization, startup, or release of stored energy could cause injury. This includes: • Electrical equipment • Mechanical equipment • Hydraulic systems • Pneumatic systems • Chemical process equipment • Steam systems 3. DEFINITIONS Affected Employee: An employee whose job requires operation or use of equipment on which servicing or maintenance is being performed under lockout/tagout. Authorized Employee: A person who locks out or tags out machines or equipment to perform servicing or maintenance. Energy Isolating Device: A mechanical device that physically prevents the transmission or release of energy (circuit breakers, disconnect switches, valves, etc.). Lockout: The placement of a lockout device on an energy isolating device to ensure it cannot be operated until the device is removed. Tagout: The placement of a tagout device on an energy isolating device to indicate it shall not be operated until removed. Servicing/Maintenance: Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining equipment. 4. RESPONSIBILITIES Employers: • Develop equipment-specific LOTO procedures • Provide adequate locks, tags, and devices • Train authorized and affected employees • Conduct periodic inspections • Ensure compliance with procedures Authorized Employees: • Follow LOTO procedures exactly • Apply personal locks and tags • Verify energy isolation • Remove only their own locks/tags • Notify affected employees Affected Employees: • Understand LOTO procedures • Do not operate locked/tagged equipment • Report LOTO violations • Follow restart procedures 5. ENERGY SOURCES ELECTRICAL ENERGY: • Main electrical panels • Motor control centers • Local disconnect switches • Circuit breakers • Fuses MECHANICAL ENERGY: • Rotating equipment • Springs under tension • Elevated components • Compressed gases HYDRAULIC ENERGY: • Pressurized hydraulic systems • Accumulators • Hydraulic cylinders PNEUMATIC ENERGY: • Compressed air systems • Pneumatic cylinders • Air receivers THERMAL ENERGY: • Steam systems • Hot surfaces • Heated fluids CHEMICAL ENERGY: • Process chemicals • Stored chemicals • Chemical reactions GRAVITATIONAL ENERGY: • Elevated loads • Counterweights • Suspended components 6. LOCKOUT/TAGOUT DEVICES LOCKOUT DEVICES: • Padlocks (keyed differently) • Hasps for multiple locks • Circuit breaker lockouts • Valve lockouts • Cable lockouts TAGOUT DEVICES: • Standardized tags • Warning labels • Do not operate tags • Danger tags DEVICE REQUIREMENTS: • Durable and standardized • Substantial enough to prevent removal • Identifiable to specific employee • Legible and understandable • Standardized color and format 7. GENERAL LOCKOUT/TAGOUT PROCEDURE STEP 1: PREPARATION • Identify all energy sources • Review equipment-specific procedure • Gather required LOTO devices • Notify affected employees • Plan the shutdown sequence STEP 2: SHUTDOWN • Follow normal shutdown procedures • Use established shutdown sequence • Ensure equipment is completely stopped • Do not force equipment to stop STEP 3: ISOLATION • Locate all energy isolating devices • Operate devices to isolate equipment • Ensure devices are in "safe" position • Block or secure movable parts STEP 4: LOCKOUT/TAGOUT APPLICATION • Apply lockout devices to energy isolating devices • Apply personal padlock and tag • Ensure each authorized employee applies own lock • Position locks to prevent operation • Complete tag information STEP 5: STORED ENERGY CONTROL • Relieve, disconnect, or restrain stored energy • Bleed hydraulic and pneumatic systems • Block elevated components • Discharge capacitors • Cool hot surfaces STEP 6: VERIFICATION • Attempt to start equipment using normal controls • Verify all energy sources are isolated • Test with appropriate instruments • Return controls to "off" position • Equipment is now safe for service 8. EQUIPMENT-SPECIFIC PROCEDURES [EQUIPMENT NAME]: [SPECIFIC PROCEDURE] Energy Sources: • [LIST ALL ENERGY SOURCES] Isolation Points: • [LIST ALL ISOLATION DEVICES AND LOCATIONS] Lockout Sequence: 1. [STEP-BY-STEP PROCEDURE] 2. [CONTINUE FOR ALL STEPS] Special Precautions: • [LIST ANY SPECIAL REQUIREMENTS] Verification Steps: • [SPECIFIC VERIFICATION PROCEDURES] 9. RESTORING EQUIPMENT TO SERVICE STEP 1: INSPECTION • Ensure work is complete • Remove tools and materials • Replace guards and safety devices • Check for proper component installation STEP 2: PERSONNEL ACCOUNTABILITY • Account for all personnel • Ensure all workers are clear • Verify safe positions • Communicate restart intentions STEP 3: REMOVE LOCKOUT/TAGOUT DEVICES • Remove only your own locks/tags • Remove in reverse order of application • Operate energy isolating devices to restore energy • Follow proper startup sequence STEP 4: NOTIFICATION • Notify affected employees • Announce equipment restart • Verify normal operation • Document completion 10. GROUP LOCKOUT PROCEDURES When multiple employees work on equipment: • Each employee applies individual lock • Use group lockout box if necessary • Designate primary authorized employee • Maintain individual accountability • Remove locks individually upon completion GROUP LOCKOUT BOX PROCEDURE: 1. Primary employee locks out energy sources 2. Places keys in group lockout box 3. Each worker applies lock to box 4. Workers remove own locks when finished 5. Primary employee removes energy isolation locks 11. SHIFT CHANGE PROCEDURES When lockout extends beyond shift: • Verify continuity of protection • Transfer lockout responsibility • Document transfer process • Ensure incoming employee understands situation • Maintain continuous protection TRANSFER STEPS: 1. Incoming employee applies locks 2. Outgoing employee removes locks 3. Document transfer in logbook 4. Verify energy isolation status 5. Brief incoming employee on work status 12. OUTSIDE CONTRACTORS Contractor Requirements: • Understand and comply with LOTO procedures • Use compatible lockout devices • Coordinate with facility personnel • Provide evidence of training • Follow facility-specific procedures Coordination Steps: • Pre-work meeting • Review energy sources • Establish communication methods • Verify contractor competency • Monitor compliance 13. TRAINING REQUIREMENTS AUTHORIZED EMPLOYEE TRAINING: • Recognition of hazardous energy sources • Type and magnitude of energy • Methods of energy isolation and control • Purpose and use of LOTO procedures • Prohibition against restarting equipment • Equipment-specific procedures AFFECTED EMPLOYEE TRAINING: • Purpose and use of LOTO procedures • Prohibition against removing locks/tags • Prohibition against restarting equipment • Recognition of lockout/tagout devices RETRAINING REQUIRED: • When procedures change • When new equipment is installed • When employee job assignments change • When periodic inspection reveals deficiencies 14. PERIODIC INSPECTION ANNUAL INSPECTION REQUIREMENTS: • Review of each LOTO procedure • Observation of authorized employees • Correction of deficiencies • Documentation of inspection • Update procedures as needed INSPECTION ELEMENTS: • Procedure adequacy • Employee knowledge • Proper device usage • Compliance with steps • Effectiveness of training DOCUMENTATION: • Date of inspection • Equipment inspected • Employees involved • Deficiencies identified • Corrective actions taken 15. TEMPORARY REMOVAL OF LOCKOUT DEVICES When temporary removal is necessary: • Follow specific temporary removal procedure • Clear equipment of personnel • Remove tools and materials • Restore guards and safety devices • Remove lockout devices • Energize and test equipment • De-energize and re-apply LOTO • Continue servicing activities 16. EMERGENCY REMOVAL OF LOCKS When authorized employee is unavailable: • Verify employee is not at facility • Make reasonable effort to contact employee • Ensure employee knowledge of removal • Follow emergency removal procedure • Document removal and reasons EMERGENCY REMOVAL PROCEDURE: 1. Supervisor authorization required 2. Verify work completion 3. Account for all personnel 4. Use bolt cutters or master key 5. Document removal 6. Inform employee upon return 17. RECORDKEEPING REQUIRED RECORDS: • Training documentation • Periodic inspection reports • Equipment-specific procedures • Incident reports • Emergency removal documentation RETENTION PERIOD: [SPECIFY YEARS] 18. VIOLATIONS AND ENFORCEMENT VIOLATION CONSEQUENCES: • Immediate work stoppage • Retraining requirement • Disciplinary action • Procedure review • Additional supervision REPORTING VIOLATIONS: • Immediate supervisor notification • Safety department involvement • Investigation of circumstances • Corrective action implementation • Documentation of incident 19. SPECIAL SITUATIONS TESTING OR POSITIONING: • Temporary removal may be necessary • Follow specific testing procedure • Minimize exposure time • Re-apply LOTO immediately after testing MINOR SERVICING: • Routine, repetitive adjustments • Alternative protection methods • Effective safeguards in place • No exposure to unexpected energization HOT TAP OPERATIONS: • Special procedures required • Demonstrated effective protection • Continuous supervision • Specialized equipment and training Approved by: _________________ Date: _______ [SAFETY MANAGER] Reviewed by: _________________ Date: _______ [MAINTENANCE MANAGER] Document Control: Version: 2.0 Next Review: [DATE] Distribution: Maintenance, Operations, Safety