Lockout/Tagout Procedures: Step-by-Step Guide

Lockout/Tagout Procedures: Step-by-Step Guide

Lockout/tagout procedures protect workers by isolating hazardous energy before maintenance or servicing begins, preventing unexpected machine startups that cause severe injuries or fatalities. Imagine a workplace where servicing activities happen without fear of sudden energy release — that's the outcome a well-managed lockout tagout program delivers.

In May 2022, a worker suffered severe de-gloving injuries when his hand became trapped in a curtain-coating roller machine. Just a month later, another worker lost his life after being pulled into the drive shaft of a conveyor. These incidents highlight a critical aspect of workplace safety: robust lockout/tagout procedures.

What Is a Lockout/Tagout Procedure?

Lockout/tagout is a crucial safety procedure used across industrial processes. It ensures dangerous machines get shut off properly and can't restart until maintenance or repair work finishes. Lockout procedures safeguard personnel against sudden hazardous energy release, preventing potentially fatal injuries.

Key Terms and Definitions

• Energy Sources: Hazardous energy sources that must be isolated during maintenance or repair work. These include electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other forms of stored energy.
• Lockout Device: A physical lock placed on an energy isolation device to prevent operation.
• Tagout Device: A tag attached to an energy-isolating device warning personnel not to operate it.
• Energy Isolation Devices: Physical mechanisms preventing release of hazardous energy, such as circuit breakers, valves, or switches.

Step-by-Step Guide to Lockout/Tagout Procedures

To effectively implement lockout procedures, follow these eight critical LOTO steps below.

1. Identify Energy Sources, Lock, and Tag

First, understand and identify hazardous energy sources powering equipment. Sources typically fall into these categories:

• Electrical: Look for power sources such as outlets, generators, or batteries.
• Mechanical: Identify moving parts like gears, belts, and conveyor systems.
• Hydraulic and Pneumatic: Check fluid and air pressure systems, including lines and valves.
• Chemical: Know storage tanks, pipelines, and any areas where chemicals sit in use.
• Thermal: Heat-generating equipment such as furnaces and boilers falls under this category.

Conduct an audit for each piece of equipment to identify and document all potential hazardous energy sources. Use equipment manuals, schematics, and input from experienced staff so nothing gets overlooked.

2. Document Procedures

Once sources have been identified, create detailed, machine-specific lockout tagout procedures. Thorough documentation matters greatly here, so keep procedures readily available to all staff members. Essential elements of a standard energy control procedure include:

• Shutdown: Outline steps to turn off equipment safely.
• Isolation: Steps to isolate all hazardous energy sources, including locking and tagging them.
• Verification: A method for confirming energy sources have been completely de-energised before maintenance begins.

For broader documentation support, explore our Standard/Safe Operating Procedures (SOP) product guide alongside dedicated lockout resources.

3. Train Workers

Training requirements vary across industries, yet the underlying principle of ensuring worker safety through proper instruction remains universal.

Personnel directly responsible for executing lockout procedures need the knowledge and skills to isolate and de-energise equipment safely. Similarly, employees working near LOTO operations should understand the purpose of these measures to guarantee well-being and prevent unintended interference.

Comprehensive training programs should cover:

• Identifying and controlling hazardous energy sources
• Proper use of lockout devices, tags, and isolation devices
• Importance of following step-by-step processes
• Risks tied to failure of hazardous energy control procedures

Training must also address relevant Australian standards, including:

• AS/NZS 4836:2011 - Safe working on or near low-voltage electrical installations and equipment: provides safety guidelines for low-voltage electrical work, covering risk management, asbestos handling, underground work, cable cutting, test equipment use, and personal protective equipment (PPE).
• AS 4024.1603-2006 - Safety of machinery: outlines requirements for designing, constructing, and modifying machinery to protect against mechanical hazards, covering risk assessment, safety distances, interlocking guards, and control systems.

4. Apply Lockout/Tagout Devices

Once equipment shuts down and every energy source becomes isolated, lockout devices must be applied. These devices include:

• Padlocks: Secure energy isolation devices such as switches and valves.
• Tags: Attach to lockout devices, showing who applied them, application date and time, plus relevant safety warnings.
• Lockout hasps: Lock multiple isolation devices together.
• Valve lockouts: Secure valves in either closed or open position.
• Electrical lockouts: Prevent access to outlets and switches.
• Circuit breaker lockouts: Prevent circuits from switching on.

5. Verify Isolation

Before maintenance begins, machinery must be thoroughly checked to confirm every energy source sits fully isolated. A systematic approach validates effective isolation of hazardous thermal energy sources. Use the following verification methods:

• Risk Assessment Checklists
• Visual Inspections
• Electrical Testers
• Measurement Tools (such as pressure gauges or thermometers)

Our checklist resources support teams building an effective LOTO checklist tailored to specific machinery.

6. Perform Maintenance or Repair Work

Repair work can begin once equipment sits safely locked out and all energy sources are isolated and verified. Follow these safe work practices:

• Depending on equipment and work involved, workers may need protective gear such as gloves, goggles, or ear protection.
• Utilise the right tools for the task at hand.
• Ensure no hazards remain in the work area, such as chemicals or loose objects.
• Follow repair guidelines specified in the equipment manual.

7. Remove Lockout/Tagout Devices

Once maintenance finishes, the person who applied lockout devices must remove them. Before removal, confirm that:

• Equipment has been reassembled and stands ready for re-energising.
• All tools and maintenance gear have been cleared from the work area.
• No workers or contractors remain in harm's way.
• Guards and safety devices are correctly reinstalled.

Follow documented re-energisation procedures to restore power safely, then document removal and conduct a final check confirming equipment operates correctly.

8. Notify Affected Workers

Inform affected personnel once lockout/tagout devices have been removed and equipment returns to operation. This notification serves as a safety precaution, ensuring nobody inadvertently enters the area while repair work on dangerous machinery wraps up.

9. Review and Update Procedures

Lockout procedures should never sit as static documents; review them regularly so they stay current with equipment changes, new occupational safety regulations, or workplace incidents. Reviewing procedures after every maintenance shutdown also helps identify areas for improvement.

Why Are Lockout/Tagout Procedures Important?

As mentioned, lockout tagout procedures prove crucial for worker safety during maintenance activities. Here's why these procedures remain indispensable across Australian workplaces:

Preventing Injuries and Fatalities

Accidents caused by abrupt energy discharge can result in severe injuries like electrocution, electrical shock, amputation, burns, and crushing. Tragically, such incidents often lead to permanent disability or death.

Compliance with Regulations

In Australia, workplace safety falls under legislation such as the WHS Act and related Codes of Practice. The person conducting a business or undertaking (PCBU) bears responsibility for providing safe work practices, and lockout procedures form an essential part of that compliance obligation.

PCBU Responsibilities for Compliance

• Duty of Care: PCBUs must ensure worker and public health and safety, including effective lockout procedures.
• Provision of Information and Training: PCBUs must provide necessary information, training, and supervision.
• Duty to Consult: PCBUs must consult workers on safety matters.
• Responsibility to Others: PCBUs must protect customers, visitors, and the public from related risks.
• Incident Reporting: PCBUs must report serious incidents to regulators.
• Record Keeping: PCBUs must maintain records of training, procedures, and audits.
• Continual Improvement: PCBUs should improve their energy control program to enhance safety outcomes.

Explore our policies and procedures product guide for broader compliance documentation support.

Reducing Downtime and Costs

Accidents harm workers and disrupt normal production operations. Implementing effective lockout procedures minimises accident risk, reducing costs tied to medical expenses, compensation claims, and equipment repairs.

Protecting Equipment and Infrastructure

Improperly managed energy sources can damage machinery and infrastructure. Properly locked out equipment remains stationary and cannot accidentally re-energise, cutting down risk of damage and costly repairs.

Promoting a Culture of Safety

Implementing and enforcing lockout procedures fosters a genuine safety culture. When workers see occupational health prioritised, they're more inclined to follow protocols and actively support a secure work environment. Learn more through our guide on how to conduct a WHS audit to strengthen broader safety management systems.

What Industries Require a Lockout/Tagout Procedure?

Lockout/tagout procedures apply across various industries wherever machinery maintenance stays routine. Relevant sectors include, but aren't limited to:

• Manufacturing: This sector heavily relies on machinery for production processes.
• Construction: Sites often involve complex machinery requiring regular servicing.
• Automotive: LOTO procedures in vehicle manufacturing and repair isolate heavy machinery to protect personnel.
• Chemical Plants: Procedures safeguard workers from spills, explosions, and other hazardous energy releases.
• Utilities: Companies often use high-voltage equipment requiring lockout before maintenance activities occur.
• Mining: Sites typically feature large, complex equipment needing adequate lockout to prevent accidents.
• Transportation: Procedures prevent accidents during maintenance on trains, planes, and other transport equipment.

A Safe Workplace Is a Productive Workplace

Following the step-by-step lockout procedures outlined above helps keep workers safe while minimising accident risk. Complete these steps using proper tools and thorough documentation.

SafetyDocs by SafetyCulture offers a range of safety documentation, including lockout tagout procedures, to help build a safer work environment:

• Plant Lockout/Tag-out Plan
• Lock Out Tag Out - LOTO Safe Operating Procedure
• Machine Guarding Management Plan
• Plant Safety Management Plan

Investing in a robust lockout program isn't just about compliance — it's about protecting your most valuable asset: your workers. With SafetyDocs' expert guidance, you can build a safer workplace, reduce downtime, and avoid costly accidents.

Visit SafetyDocs today to learn more about our lockout resources and invest in a safer future for your business.

Our team of experts remains dedicated to providing accurate and informative content. Craig Cruickshank, senior HSEQ advisor at SafetyDocs by SafetyCulture, has reviewed this blog post to ensure the highest level of quality.

Learn more about Craig's work on LinkedIn for further industry insights.

Available for instant download and supplied in fully editable MS Word format for use in your business.

Please note that information above sits provided as a comment only and shouldn't be relied on as professional, legal or financial advice.