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An Introduction To Lockout Tagout

 Lockout Tagout Device

With Health and Safety being of upmost important when working with hazardous materials and machinery a proper Lockout Tagout procedure is vital in keeping employees safe.

Having a clear and simple Lockout Tagout procedure will help with the safe isolation of hazardous materials and machinery.

When maintenance is being undertaken, when repairs are being made or when cleaning any machinery or equipment a Lockout Tagout procedure must be in place. This is to make sure the stored energy has been safely dispelled and so that the machinery does not become active again which could result in serious harm or injury to the employee/s.

In this post we have highlighted the essentials for a successful Lockout Tagout procedure.

What is Lockout Tagout

Lockout Tagout when implemented and followed properly ensures that any machinery or equipment which is being worked on is completely shut off. It also makes sure that any stored energy has been safely isolated and that the machine or equipment cannot be accidentally restarted.

Lockout Tagout is implemented across many industries and across a variety of machinery and equipment throughout the world to comply with safety standards.

Different stages of Lockout

Lockout Tagout Procedures

The first stage of Lockout Tagout is to have a procedure manual produced so that employee’s can familiarise themselves with the procedures before working on/with the machinery or equipment.

Once this has been produced the workers should be made aware of it so that they know when a Lockout Tagout procedure is taking place so that they do not try to activate the equipment.

Only then should the equipment be shut down using the manufactures instructions, once the shut down is complete all the energy should be safely isolated.

The next stage is to implement the correct Lockout Tagout devices for the equipment which is shut down, this may include a lockout device such as the type manufactured by Pro-Lock, it may require additional padlocks and tags for information and/or security, it may require a hasp with several padlocks for multiple employees.

Once the correct Lockout Tagout devices have been applied all energy that is stored will be safely isolated and a final check for any remaining movement should be done.

Finally, when all the Lockout Tagout devices have been installed the machine should go through a test restart to make sure everything is locked off properly.

If the procedure has been followed correctly the machine would not start.

Once the machine has been shut back down safely, the work that was needed to be carried out can be done. Once all work has been completed, the Lockout Tagout devices can be safely removed and the machine restarted.

Essential Lockout and Tagout Devices

Green Pro-Lock Hex Head Lockout Device

As part of any Lockout Tagout procedure, there are a few essential pieces of equipment required to ensure safe isolation. These include the following:

Lockout Device: A key piece of equipment when working on valves and industrial equipment, a universal lockout device can be used on most valves and industrial equipment to lock them off. We have had a lot of success with our pro-locks being used across various industries and valves right across the world.

Xenoy Padlock Lockout Tagout

Padlock: Can be a very important part of Lockout Tagout, having the correct padlocks to place on your equipment is essential. By choosing the correct padlock be it Zenex, Brass, Non-conductive, or one of many other types specifically designed for Lockout Tagout would help to ensure a safe system of work.

Tags: Tags provide a visual method to help identify what is going on at that point. They can be used to help identify who applied the lock, this is helpful as it lets you know who the person is that can remove the lock during the Lockout Tagout procedure. Tags will also include information as to a name and date of isolation, what type of isolation it is and most often will have a clear warning sign-on for easy identification.


Security Seal Lockout Tagout

Security Seals: Security seals add another layer of security when attached to other Lockout Tagout devices. As most security seals are tamper-evident it stops anyone from tampering with the Lockout device unless they are authorised to do so. There are a variety of seals available for all types of situations not just for Lockout Tagout.

Lockout Hasps: Lockout Hasps are vital when operating a multi-person Lockout procedure, lockout hasps allow machinery or equipment to be isolated by more than one worker at a time. This means the machine or equipment cannot be re-started until each worker has removed their lock from the hasp.

Key Cabinets: Are essential when using multiple padlocks each with their own key, storing the keys within a cabinet will help with the organisation but will also ensure that only the authorised personnel can access them. The key cabinets can also be used to store the equipment/machine key to help prevent an accidental restart.

Lockout Key Station Lockout Tagout

Lock Out Stations: Are a great way to store all your Lockout Tagout equipment in one place. As Lockout Tagout equipment should not be used for any other procedures within the workplace, keeping them together and displaying them clearly will help to make sure they are not misplaced or misused.