Failure to control hazardous energy accounts for nearly 10 percent of the serious accidents in many industries. Proper lockout/tagout (LOTO) practices and procedures safeguard workers from hazardous energy releases.

What is hazardous energy?

Energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other sources in machines and equipment can be hazardous to employees. During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy can result in serious injury or death.

LOTO is a safety procedure which is used in industry settings to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or servicing work. The development of machine and process specific LOTO Procedures is the application of electrical and mechanical engineering to OSHA’s health and safety initiatives. Our experienced staff examine electrical and mechanical design documents and operating manuals, and work with facility personnel to develop machine and process specific LOTO procedures that identify all hazardous energy sources, then establish procedures for isolating, releasing, and verifying that the hazard has been removed prior to beginning service or maintenance work.

Our LOTO procedures are concise and use drawings or pictures of the equipment to provide visual identification of the various LOTO points and the sequence for successful control of Hazardous Energy.

Our procedures are produced in full color according to our customers’ preferred format and typically installed at central locations such as main control panels or operator workstations. Additionally, we apply custom labels or tags at each LOTO point. Our labels and tags are color coded to correspond to the master procedure and provide recognition of the hazardous energy type (electrical, mechanical, hydraulic, pneumatic, chemical, thermal). Additionally, our tags are developed from various materials (laminated, lamicoid, vinyl, aluminum, etc.) suitable for the manufacturing environment in which they are used.

PI provides turnkey LOTO procedure development and installation of placards and tags. Example LOTO Placards and Procedures are below and additional examples can be provided on request.