The Ultimate In-depth Guide For Maximum Lockout-Tagout-Tryout (LOTOTO) Safety

What Is Lockout Tagout (LOTO)?

Lockout Tagout (LOTO) is a safety procedure used to ensure that machines are properly shut down and unable to restart before maintenance or repair work begins. It involves isolating energy sources and securing them to prevent accidental re-energization. This is crucial in preventing workplace injuries caused by the unexpected startup of machinery during service.

What is Lockout Tagout Tryout (Lototo)?

LOTOTO, or Lockout Tagout Tryout, is an extended version of the LOTO safety procedure that incorporates a “tryout” step to verify that machinery is entirely de-energized and safe to work on. While LOTO focuses on locking and tagging energy sources, LOTOTO goes a step further by testing for any residual or stored energy to eliminate risks of accidental startup.

Benefits of Lockout Tagout Tryout (Lototo) vs. Lockout Tagout (LOTO)

The tryout step in the modern LOTOTO procedure enhances LOTO safety by incorporating the tryout phase, ensuring that machinery is completely secure. It acts as an additional layer of safety which further minimizes risks associated with residual energy, making it a more comprehensive solution for energy isolation. The tryout phase is a very important addition to LOTO, and should be adopted by any industry that performs lockout tagout.

• Ensures complete de-energization

• Minimzes human error

• Improved safety

Why is Lockout Tagout Training Important?

In industries with heavy machinery and hazardous energy sources, effective workplace safety training becomes paramount. Lockout Tagout training is vital in preventing workplace injuries by ensuring that employees are competent in identifying hazards, using lockout devices, and following safety procedures. Comprehensive training reduces the risk of injury, instills confidence in safety protocols, and fosters a culture of safety across the organization.

• In 2023, control of hazardous energy (lockout/tagout) was the 6th most cited OSHA violation with 2539 violations.

• Lockout Tagout accidents have been cited in the top 10 of OSHA’s most cited violations for the last 30 years.

• Improper lockout tagout procedures can incur a maximum penalty of up to $16,131 per LOTO violation as of 2024, which has increased from $15,625

• In 2023, OSHA estimated that proper LOTO Compliance prevents 120 fatalities and 50,000 injuries each year.

What Is a Lockout Device?

A lockout device is a physical mechanism applied to machinery to lock energy-isolating devices in a safe, off position. Common types include padlocks, valve covers, and circuit breaker locks, all designed to prevent accidental access to energy sources during maintenance.

{caption}Lockout Device

{caption}Tagout Devices

What Is a Tagout Device?

A tagout device is a warning tag or label that is securely attached to an energy-isolating device. It serves as a visible indication that the equipment is under maintenance and must not be operated. While tagout devices do not provide the physical restraint of a lockout device, they communicate critical safety information, such as the name of the authorized person performing the procedure and the date of the lockout. In some cases, tagout devices are used in conjunction with lockout devices for added safety.

Who are considered ‘Affected Employees’ and ‘Authorized Employees’ in Lockout-Tagout?

• Affected Employees are those who operate or use the equipment or work in areas where a Lockout Tagout procedure will be performed. While they do not perform LOTO directly, they must be aware of ongoing safety measures. In a Lockout Tagout Scenario, this includes:

  • Any employees who work in or near the area where the equipment being repaired or having maintenance is.

  • Any employees who work in or near the area where the lockout tagout devices will be used. (i.e. Circuit breaker or other energy sources not close to the machine being serviced.)

• Authorized Employees are the employees who are trained and responsible for implementing the lockout tagout procedure. They understand how to identify energy sources, isolate them, and perform LOTOTO safely. The authorized employee is the only person who should have access to the keys for lockout devices.  In a Lockout Tagout Scenario, this includes:

  • The engineer who will be performing the lockout tagout procedure, and repair/maintenance.

  • If multiple engineers are servicing a machine together, both of them must have their own lockout/tagout devices on the equipment and be responsible for their own key.

  • Any engineer that is trained in lockout tagout procedure, and is required to take over the task if the initial engineer was unable to complete the repairing/maintenance service  for whatever reason. This engineer would need to discuss the issue with the initial engineer before they are given the keys.

What are the 8 Steps To Lockout Tagout Tryout (Lototo)?

All Lockout Tagout Tryout Steps

1. Preparation

2. Notification

3. Shutdown

4. Energy Isolation

5. Lockout and Tagout

6. Tryout

7. Servicing/Repair

8. Return to Service

1. Preparation

Prepare to shut down energy sources by identifying the types and levels of energy involved. Consider electricity, hydraulic, pneumatic, and other forms, noting their sources and control points, such as electrical supply lines or water pressure control valves. Review work orders, assess workflow issues, and equip the correct personal protective equipment (PPE) before beginning the procedure.

2. Notification

Inform all affected employees of the lockout tagout procedure. This includes any employees who work in or near the area where the equipment being repaired or having maintenance is, and any employees who work in or near the area where the Lockout Tagout devices will be used. (i.e. Circuit breaker or other energy sources not close to the machine being serviced.) Communicate the purpose, machinery involved, and potential hazards, advising them to avoid the area and refrain from operating the equipment until further notice. This can be done directly or via radio.

3. Shutdown

Turn off the machinery or equipment following standard shutdown procedures to avoid creating additional hazards. Use the local ON/OFF switches, such as buttons, levers, or dials, to safely power down each piece of machinery.

4. Isolation + Release Stored/Residual Energy

Isolate the machine from all external energy sources to ensure no power can reach it. For electrical energy, go to the circuit breaker connected to the machine and turn off the power supply, disconnect any external batteries or power connected to the machine needing servicing, and ensure hydraulic or pneumatic systems are depressurized. For fluid and gas systems, close and lock any relevant valves, adding chains if necessary. There are more in-depth details below these steps that go into how all the different types of energy should be isolated.

5. Lockout + Tagout

After isolating energy sources, apply lockout devices to secure the equipment and prevent it from being operated on. Directly after applying each lockout device, attach tags onto the lockout devices to communicate the locked-out status. Ensure each tag is clearly marked with relevant information, such as the name of the authorized employee performing the lockout. After locking each energy source, keep the keys with you as you are the only person authorized to use them.

6. Tryout (Verify Energy Isolation)

Conduct the tryout procedure by attempting to operate the equipment via normal controls. Confirm the equipment does not react or restart, indicating that all energy sources are indeed isolated and the machine is in a non-working state. This is a crucial step added into the procedure to ensure complete de-energization of the equipment and minimize the chances of human error. It may seem unnecessary, but it’s incredibly important to include this step as part of your lockout tagout process. As the saying goes, better safe then sorry.

7. Servicing/Repair

All 6 steps before this were needed in order to maximize safety for this step. With the safety precautions all ready and in place, you can safely perform the required maintenance or repairs as per the original work order. Follow all safety protocols and use designated tools and PPE to ensure safe servicing.

8. Return to Service

After completing the repair or maintenance service, the employees need to be able to use their equipment again!

The authorized employee needs to remove all lockout devices and tags separately from each location. Power the machinery back on and restore everything back to it’s original condition, after it’s safe and ready to be used again, notify supervisors and affected employees that the equipment is ready for regular use, ensuring all are aware of the machinery’s returned status so they can get back to working there.

Which Industries Use Lockout Tagout?

Industries that rely heavily on machinery and complex systems use lockout tagout to safeguard workers whenever these machines require repair, maintenance, an upgrade, or any other servicing. These industries include:

• Manufacturing

• Utilities and Energy

• Construction

• Automotive

• Chemical Processing

These industries deal with high-energy equipment that pose risks if started unexpectedly during maintenance.

{caption}Lockout tagout devices on a control panel

What are the Different Types of Energy Used in Lockout Tagout

Lockout Tagout (LOTO) procedures must account for the various types of energy sources that machinery or equipment may use. Each energy type presents unique risks and requires specific methods for safe isolation and control. Here’s a breakdown of common energy types, how LOTO procedures vary for each, and the specific hazards they present: How to Isolate Different Energy Types for LOTO

• Isolating Electrical Energy for LOTO

• Isolating Hydraulic Energy for LOTO

• Isolating Pneumatic Energy for LOTO

• Isolating Mechanical Energy for LOTO

• Isolating Thermal Energy for LOTO

• Isolating Chemical Energy for LOTO

• Isolating Gravitational Energy for LOTO

1. Electrical Energy

Electrical energy powers most machinery and can pose severe hazards due to shock, arc flash, or fire risks if not properly controlled.

LOTO Procedure: Locking out electrical energy often involves turning off circuit breakers, unplugging equipment, or disconnecting batteries. The lockout device might include a padlock on the circuit breaker or a plug lockout on the power cord to ensure no accidental reconnection.

Hazards:

• Electric shock, which can cause severe injury or fatality

• Arc flash, which can result in burns and explosions

• Fire risks from electrical faults or short circuits

2. Hydraulic Energy

Hydraulic systems use pressurized fluids (often oil) to power machinery, particularly in heavy equipment.

LOTO Procedure: To safely isolate hydraulic energy, employees must de-pressurize the system by draining the fluid lines or venting pressure. Hydraulic valves may be locked closed, and residual energy may require releasing fluid from cylinders or hoses to avoid accidental movement.

Hazards:

• Sudden release of high-pressure fluid causing injury

• Pinching or crushing injuries from uncontrolled movement of parts

• Oil spills or leakage, which can create slip hazards

3. Pneumatic Energy

Pneumatic energy involves compressed air or gas that powers equipment, such as tools or automated systems.

LOTO Procedure: LOTO procedures for pneumatic energy include shutting off the air supply, locking the valves in the closed position, and relieving any residual pressure from the lines. This step often involves bleeding out remaining air pressure to ensure the system is fully de-energized.

Hazards:

• Rapid release of compressed air, potentially causing eye or respiratory injury

• Whipping or moving parts due to uncontrolled release of air pressure

• Noise hazards from high-pressure air release

4. Mechanical Energy

Mechanical energy is stored within moving parts, springs, or suspended weights, and can cause injury if released unexpectedly.

LOTO Procedure: Mechanical energy can be controlled by physically restraining moving parts, securing or blocking gears, and using chain or rod locks to prevent stored mechanical energy from being released. This step is essential to avoid unintended movement of parts during maintenance.

Hazards:

• Crushing, pinching, or impact injuries from moving parts

• Sudden release of spring-loaded components

• Uncontrolled movement or rotation of gears, belts, or pulleys

5. Thermal Energy

Thermal energy refers to heat stored in equipment, fluids, or gases that could cause burns or other heat-related injuries.

LOTO Procedure: Thermal energy isolation often requires allowing equipment to cool down completely or using insulation and barriers. For systems with high temperatures, employees may need to monitor for residual heat and handle hot surfaces with care during the lockout procedure.

Hazards:

• Burns from contact with hot surfaces, steam, or fluids

• Fire risks if combustible materials are near hot equipment

• Thermal shock to equipment parts, which can cause cracking or explosion

6. Chemical Energy

Chemical energy is stored in reactive substances, often in processes involving flammable or toxic chemicals.

LOTO Procedure: Isolating chemical energy may involve draining tanks, closing valves, and locking out any sources that could introduce chemicals into a process. Venting or neutralizing chemicals may also be necessary to prevent any accidental reactions during maintenance.

Hazards:

• Exposure to toxic or corrosive chemicals, causing burns or respiratory injury

• Fire or explosion risk from flammable substances

• Chemical spills, which can create slip hazards or environmental contamination

7. Gravitational Energy

Gravitational energy is stored in elevated objects or equipment parts that could fall and cause injury if not secured.

LOTO Procedure: Securing gravitational energy often involves using blocks, restraints, or physical barriers to hold parts in place. Chains or mechanical locks can prevent equipment from shifting or falling due to gravity.

Hazards:

• Crushing injuries from falling or shifting equipment parts

• Impact injuries from uncontrolled descent of elevated components

• Structural damage from fallen equipment or parts

Lockout Tagout Training

There are many options for training employees in the lockout tagout procedure, traditional training methods often rely on manuals, videos, or classroom sessions. The problem with these traditional methods is they may not fully engage workers or accurately replicate the high-stress environments they might encounter on the job. As a result, proper LOTO Compliance is often ignored and there is a gap in effectively training workers to follow the correct steps for energy isolation, ensuring safety and compliance.

Training for such high-risk procedures can highly benefit from more engaging and interactive training, to defeat the highly common issue of complacency in these high-risk scenarios. SHIIFT created a highly effective Lockout Tagout Training tool to counter the difficulties companies consistently face in training for hazardous scenarios such as lockout tagout.

If you’d like the lockout tagout VR training, or a similar custom interactive training, whether using elearning, online web simulations, or virtual reality simulations, etc. or just a demo of our capabilities, get in touch by emailing hello@shiifttraining.com and our team can create something perfectly tailored to your needs.

Watch the video