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A lockout-tagout system ensures industrial equipment stays safe when it is not in operation.
So, should an engineer or maintenance staff attend to a piece of machinery, this system ensures the machine is completely shut off and that all potentially hazardous power sources are isolated.
Below, we discuss what lockout-tagout is, its steps, and the place lockout-tagout labels have in the process.
Lockout-Tagout Definition
Before explaining the procedure, it’s important to know what is meant by “lockout” and “tagout”.
Lockout/Tagout refers to the prevention of turning on a machine by employees or persons. This is done by a series of locks, as well as a procedure which completely shuts said machine down.
The lock, or tagout device, indicates that the equipment being controlled may not be operated until the device has been unlocked and removed.
The Lockout-Tagout Steps
Sometimes, an engineer has to perform maintenance on a machine they have never seen before. This can happen on any day at any time, so there is a possibility that nobody on-site can help said engineer negotiate the complex machine and keep them safe.
Lockout-tagout steps mean an engineer can follow a standardised, specific series of actions to stay safe. These steps are as follows:
- Draft equipment procedures – A detailed, step-by-step procedure should be in writing discussing the equipment’s location and its energy sources.
- Inform staff – Staff should be aware of where, when, and at what exact time maintenance will be occurring. Not only does this allow staff to stay in the loop, but it ensures that the equipment isn’t accidentally turned on at any point.
- Explain equipment shutdown – Explain the shutdown process in minute detail. This step is essential – it must not contain any generalisations and it must explain every part of the shutdown in a detailed fashion.
- Explain the disconnection of primary energy sources – Be as detailed as possible. Generalisations, once again, are not acceptable in this step. Explain how primary energy sources – electricity, steam, water, gas, compressed air, etc. – can be disconnected according to the procedure.
- Explain the disconnection of secondary energy sources – As above, explain how to disconnect secondary energy sources. Trapped heat, fumes or tension in springs all have an element of danger, so explain the process of releasing pressure and residual energy from the equipment’s system.
- Lockout/Tagout – Once the above steps are complete, double-check all of the above has been tended to and then lockout/tagout the equipment. There should be as many locks on the system as there are people working on it, so if there are four engineers performing maintenance, then four locks should be used. Only one key should be in circulation, too. Finally, apply an appropriate lockout/tagout tag.
- Verify the lockout – Verify that the system is locked out. There are several methods to do this, including engaging the machine's buttons to test the response, visual inspection of electrical connections, valves, etc. and direct testing of the equipment while checking temperature gauges, pressure gauges and circuitry by a qualified electrician.
- Perform maintenance – Once the maintenance has been completed, undo the locks and/or tagout tags. Ensure the work area has no tools or items left behind, confirm that all persons are away from hazardous areas, check whether controls are in a neutral position, remove devices and, finally, re-energise the equipment. As a final step, notify employees that maintenance has been completed.
What Does the Law Say?
According to the Provision of Work Equipment Regulations:
“Every employer shall ensure, that where appropriate, work equipment is provided with suitable means to isolate it from all its sources of energy.”
As for employers, the regulation states:
“every employer shall take appropriate measures to ensure that reconnection of any energy source to work equipment does not expose any person using the equipment to any risk to his health or safety.”
Get Your Lockout-Tagout Labels Here
Lockout-tagout requires the use of plastic lockout tags to convey information and ensure the above steps are followed.
All of our range complies with the latest regulations, so browse our lockout products today.
