Lock Out Tag Out procedure

What is a LOTO procedure

Energy sources must be isolated whenever there is the potential for dangerous energy to be released whilst personnel are performing duties with machinery.

This may involve the development of an isolation or Lock Out Tag Out (LOTO) procedure for energy sources. A LOTO procedure is a set of predetermined steps that should be followed when workers are required to perform tasks such as maintenance, repair, installation, and cleaning of plant.

The LOTO procedure needs to be clearly defined, readily available and communicated to the personnel involved in these tasks and only authorised personnel, trained in the isolation procedures, should perform these duties.

LOTO procedures should be developed in consultation with relevant workers.

Steps to include in a LOTO procedure

The following simple steps could be included in a LOTO procedure:

1. Complete isolation plan which should include:
   • what machine
   • when it is to be isolated
   • who will conduct the work and isolate the machine
   • notification of people impacted by the shutdown.
2. Clear the machine of tools and people.
3. Place the machine to its rest position so that parts will not drop under gravity, for example using any chocks, locking pins, etc.
4. Apply the isolating device e.g., many power switches are now fitted with locks to stop them from being turned on.
5. Notify all affected personnel that work is about to commence.
6. Release any residual energy for example air or hydraulic pressure in lines.
7. Confirm the machine is completely de-energised by attempting to operate it.
8. Complete the work.
9. Clear the machine of tools and people and notify people the machine will be turned on.
10. Remove all locking devices by the personnel tasked with isolating the machine.
11. Re-energise the machine.

What training is required?

Only competent persons are authorised to perform Lock Out Tag Out. A system must be implemented to ensure persons have been trained and assessed as competent before they are issued with personal lockout devices to conduct any activities that require isolation and LOTO.

The system must include a method to verify the person’s understanding of the training which includes theory and practical assessments against defined criteria that demonstrates understanding and application of isolation and LOTO principles and practices.

PCBU’s must provide the necessary safety information and training to persons who are involved in installing, commissioning, testing, maintaining, or repairing plant, as well as decommissioning, dismantling, or disposing of plant.

Emergency instructions for an item of plant should be clearly displayed on or near it. Training programs should be practical and ‘hands on’ and consider the needs of workers. For example, literacy levels, work experience and specific skills required for safe use of the plant. Supervisors should take action to correct unsafe work practices associated with plant as soon as possible. Otherwise, workers may think unsafe work practices are acceptable.

Resources

If you are a small to medium business the below guidance materials and videos will help you develop a Lock Out Tag Out (LOTO) procedure.

• Plant, equipment and machinery energy isolation guide PDF, 10885.87 KB
• Handy checklist PDF, 66.7 KB
• Self-assessment checklist on machine safety PDF, 161.35 KB

SafeWork NSW YouTube videos

Simple Isolation - how to isolate machines before work commences

Complex Isolation - steps to undertaking complex plant isolation for machines with multiple isolation points and multiple workers