Lockout/Tagout (LOTO) procedures – they’re essential for protecting your workers from hazardous energy sources. By isolating energy sources and attaching a LOTO device to indicate that the equipment should not be used, you prevent accidental startup or the release of stored energy during maintenance.

What happens when procedures aren’t followed?

Here’s an example – the maintenance of a complex hydraulic press. In a rush to minimize downtime, the maintenance team bypasses key steps in the LOTO procedure. They overlook residual hydraulic pressure. As maintenance progresses, there is a release of stored hydraulic energy. The press begins ejecting heavy components, causing severe injuries to the team, damaging the machine irreparably, and causing structural damage, prompting an emergency shutdown and evacuation.

In a nutshell, failing to follow LOTO procedures results in a chain reaction of catastrophic events – from equipment destruction to life-altering injuries. But with these nine practical tips, and a helping hand from EHSQ software you can mitigate risks, significantly enhancing workplace safety.

#1. Inadequate training

Mistake: Failing to provide proper training compromises the safety of workers nearby, not just the individual working on the equipment.

Prevention: Thorough training programs are a must. Your workers should be well-versed in the procedures related to the equipment they handle. Extend awareness training to all, emphasizing the importance of following LOTO processes and refraining from tampering with tags or devices.

With Competence Management, you can track who’s following their training courses and ensure everyone’s knowledge and skills are up to date. No more head-scratching about who needs a refresher – our automated scheduling takes care of that.

#2. Incomplete documentation

Mistake: Inadequate, inaccurate, and poorly communicated documentation makes it difficult for workers to understand and follow LOTO procedures, leaving room for misunderstandings that can lead to accidents, injuries, or equipment damage.

Prevention: Develop clear, detailed, and up-to-date documentation for every step involved in the LOTO process, specifying the equipment involved, and providing clear instructions for execution.

Accessibility is key. A centralized digital EHSQ platform makes crucial documentation readily available to the relevant workers when they need it. Enforce consistent and reliable documentation practices through Document Control. Regularly review and update procedures to ensure documents are accurate, relevant to current operational processes, and include changes from technological upgrades or lessons learned from incidents.

#3. Failure to identify all energy sources

Mistake: Whether it’s an unintentional slip of the mind or a deliberate oversight, not shutting down and disconnecting machinery properly can lead to trouble. Just flipping a switch doesn’t equate to fully disconnecting the main power source.

And don’t forget, machines can have multiple energy sources, so it’s crucial to identify and shut down every potential source.

Prevention: Conduct comprehensive energy assessments to identify all hazards, including electrical, mechanical, hydraulic, pneumatic, chemical, and thermal sources. Leverage Piping and Instrumentation Diagrams (P&ID) for a clearer understanding of complex systems and more thorough identification and isolation of energy sources.

By making use of TenForce’s Lockout/Tagout module, you ensure that essential documents, such as P&IDs, are easily accessible to workers in the field and streamline the whole LOTO process. This centralized approach increases efficiency, minimizes the risk of oversight, and gives workers confidence to control energy sources.

#4. Inadequate lockout devices

Mistake: Using damaged lockout devices, those not specifically tailored to the machinery, or duplicates or master keys make it possible for others to disable the device without fully verifying if the equipment or area has been cleared for operations.

Prevention: Equip your workers with the correct lockout device for each piece of equipment. Opt for devices with simple messages, bold colors, or photo IDs for easy recognition. And schedule regular inspections to ensure that damaged devices are replaced.

For accountability, responsibility, and traceability purposes, it is essential for each technician to hold their own set of tagged lockout devices with a single key.

#5. Failure to drain residues and verify isolation

Mistake: Just cutting off the power supply doesn’t guarantee that machinery is safe for handling. Residual energy, such as excess pressure, residual heat, and toxic substances, all require careful drainage.

It’s essential to disconnect equipment from all power sources, secure movable parts in place, and empty residues before starting maintenance activities.  Neglecting this step could lead to unforeseen machine movements, unexpected energy releases, or accidental startups.

Prevention: Implement a thorough verification process to confirm that energy sources are truly isolated. With LOTO software you can complete standardized checklists and follow comprehensive workflows to ensure that no steps are overlooked.

You can include the following steps:

Functional Checks: Activate controls and observe. No response means successful isolation.

Visual Inspection: open electrical connections, lower suspended parts, check restricting devices, verify valve positioning, and confirm the presence of line blanking.

Testing Equipment: Test circuitry (certified electricians only), check pressure gauges to ensure the removal of hydraulic and pneumatic energy, and verify temperature gauges to ensure the discharge of thermal energy.

#6. Poor communication

Mistake: Poor communication between employees engaged in the LOTO process and those working in the vicinity of the isolated machinery.

Prevention: Make communication a priority. Stick to standard procedures for issuing and removing lockout tags and ensure everyone knows the status of machinery isolation.

By integrating LOTO processes with Shift Management, crucial information flows seamlessly to all workers during their shifts, minimizing the chances of misunderstandings or oversights.

#7. Ignoring Reviews

Mistake: Not regularly reviewing and updating LOTO procedures to account for changes in equipment, technology, or personnel.

Prevention: Schedule regular audits of LOTO procedures to ensure that they are being followed correctly and that all equipment is properly secured. With our Audits module, you can set up an automated audit schedule. It notifies trained personnel when audits are due and ensures that updates are communicated to the right team members.

#8. Inadequate follow-up

Mistake: Failing to follow up on completed LOTO procedures. Before unlocking and restarting machines for regular use, it’s crucial to check if tools are cleared, floors are safe, and all connections are restored.

Prevention: Incorporate a Pre-Startup Safety Review (PSSR) into your process to confirm that equipment is set for normal operation. With our Lockout/Tagout module, this is easily included in the automated workflow, ensuring a comprehensive check is completed before resuming operations.

#9. Not adapting to changes

Mistake: Overlooking the importance of updating LOTO procedures when there are changes in equipment or processes.

Prevention: Take a proactive approach by integrating LOTO procedures with our Management of Change module. When there’s a change in equipment, technology, or work processes, your procedures get an automatic update. This way, your team is always equipped with the latest safety measures.

Time to put it into action

Armed with these nine practical tips, you can build robust LOTO procedures that prioritize the safety of your workers.

Ready to put these tips into action? Book a demo with TenForce and we’ll show you how to incorporate LOTO into your operations, making safety an integral part of your workflow.

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