How To Implement a Successful Lockout Tagout

What is Lockout Tagout?

Lockout Tagout safeguards against the unexpected release of energy.

Carrying out a successful Lockout Tagout programme will ensure the safety of all authorised employees involved and anyone else who may come into contact with the equipment. However, it is not just vital for health & safety, it is also important for protecting investments made in equipment.

The Programme

This robust programme will detail all the steps necessary to effectively isolate equipment from its power source.

Planning

Providing a well-written plan with details of each process required will reduce mistakes and ensure the process is carried out efficiently. The plan should outline responsibilities, training, isolation procedures, restoring equipment to normal operation, contractor control, the correct choice of Lockout Tagout products and permits to work etc…

Equipment Appraisal

Identify all equipment that will require isolation during maintenance, cleaning or repair activities as well as details of power and isolation points (e.g. switches, breakers etc). Work out the sequence in, which the source needs to be isolated, considering environmental factors such as confined spaces, adjacent activities and any equipment adaptions. Be sure to consider mechanical valves and/or LSS (Life Safety Systems) that are required to remain ON for safety purposes during these activities.

Equipment specific procedures

Use the information gathered in the last step to develop equipment specific procedures. This will also help define lockout product requirements following successful testing specific procedures should be posted alongside the equipment.

Training, procedure awareness & providing products

Ensure employees are aware of the procedure put in place and have the training to implement it. Authorised employees must be equipped with the relevant lockout products and tags.

Locking Off

Time to put that plan into action. Below are the recommended stages for isolating equipment, however detailed instructions should be provided in the audit, as these steps may be adapted to individual circumstances.

• Prepare to shut down
• Notify all affected employees that maintenance is required on a machine and that it will be shut down and locked out
• Turn Off Equipment Isolate the equipment from all energy sources
• Lock out the equipment and display the correct tag out
• Test Equipment controls and safety systems
• Test all circuits
• Perform repairs or maintenance required

Re-activating

It is just as important to follow the correct procedure to re-active the equipment once maintenance is complete. Below are general steps, but detailed instructions should be found in the audit.

• Check all work has been completed
• Check that system and all personnel are clear
• Re-install guards and remove blocks
• Remove all individual locks and devices
• Re-connect all energy sources
• Test the system
• Remove all relevant tags & signage
• Notify employees that the equipment is ready to use