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.
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:
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
