Introducing Lockout/Tagout

Preparation for shutting down machinery should take place in advance as far as is possible. However, this may not be the case if a machine suddenly fails, or emergency repairs are required. The planned shutdown should consider why the machinery needs to be taken offline, such as improving safety or reducing unplanned downtime. 

You can use a computerised maintenance management system (CMMS) to record the details, such as the technicians who will be doing the work, what the job involves, how long it will take, and who will need to access the machinery.

Employees must be informed that equipment is to be shut down and locked out before maintenance takes place. All workers who are affected need to be kept in the loop, either face to face in a meeting, or with a prominent notice in the location where the maintenance is due. 

It’s important that machinery is turned off by a technician who is authorised to do so and understands any hazards involved. There should be an established procedure for shutdown that minimises risk. 

Equipment should be isolated from the energy source. This can take place using devices such as circuit breakers, line valves, or blocks. There may be special valves or disconnects, safety blocks on moveable parts, or pipeline blank flanges which help to isolate equipment.

Stored energy (also known as residual or ‘potential’ energy) is energy that remains in a system or machinery even when it’s turned off. When stored energy is released in an uncontrolled way, individuals may be crushed or struck by objects, moving machinery, equipment, or other items.

Residual energy is therefore a big hazard. It can be stored in many forms, such as steam, gas or water pressure, or in springs, hydraulic systems, or capacitors. It’s crucial that all residual energy is drained from equipment as part of the lockout/tagout procedure.

Now lockout/tagout devices can be applied. A lockout device will lock the energy isolating device, such as a circuit breaker, in the ‘safe’ or ‘off’ position. Safety padlocks prevent the removal of the device and energy flowing into the machinery. 

Tagouts are visually prominent warning devices, Typically, a tag is securely fastened to an energy-isolating device to indicate that the machine may not be operated until the tag is removed. The lockout and tagout processes are performed at the same time. Placing a tag on a machine that is still capable of being locked out is incorrect, as is locking out a machine and not highlighting it with a tag.

Finally, it’s absolutely crucial that equipment is tested to check it is disconnected from the energy source. An engineer will determine no one is exposed to an energy hazard and then test the equipment by pushing an on-off button or switch to check it will not operate. Completing this step ensures machinery is ready to be serviced safely. 

There are numerous benefits to following lockout/tagout procedures. The number one advantage of lockout/tagout safety is a reduction in potential harm to employees. Everyone has the right to work in an environment that is risk-free. 

But there are other benefits, too. Carrying out maintenance work correctly and safely helps keep a plant productive and reduces unnecessary downtime. 

In addition, enabling lockout/tagout safety avoids penalties from regulators because safety procedures haven’t been correctly followed, resulting in injury – or worse. 

Check out the RS range of lockout/tagout kits here.