Lock-out Tag-out Try-out Isolation Guidance

Isolation is the process of disconnecting or blocking all energy sources for a specific piece of equipment and is an important part of the safety solution in any workplace where machinery is regularly in use. It allows operatives to work on repairing or maintaining equipment without the risk of injury caused by machinery being re-activated when it shouldn't.

To implement a LOTOTO isolation procedure, you need to start with a site audit to detail the specific steps needed to both isolate and re-activate equipment once repairs or maintenance have been completed.

Follow our 10-step process below, as best practice for safe isolation.

Develop an Implementation Plan to identify the processes required, energy sources used, potential hazards, and all control devices

• Identify all sources of energy and their isolation points
• Identify the LOTOTO equipment needed to complete a safe isolation
• Assign an authorised person to control the project
• Identify all the responsibilities of all people involved
• Ensure all people are competent with their duties
• Make sure all relevant permits are completed

Notify the people who are responsible for LOTO isolation, informing them of the timing of the work and how long the equipment may be unavailable

• Usual operators of the equipment
• Any other people who may be affected including visitors, contractors, or other operators in the immediate area
• Ensure vigilant observation is continued throughout the procedure
• Be very specific and clear as ambiguous language could lead to an incorrect or even dangerous action
• Inform the authorised person if you notice any faults, stored energy movements or inadequate isolations

In a safe manner, shut down all operating controls and turn off equipment

• The shutdown instructions should be detailed
• Spell out the exact actions to be taken and the correct sequence for those performing those actions
• Ensure that all machinery is properly de-energised. It's possible that there are sources of residual energy, such as trapped heat in a thermal system, fumes that may need to be vented, or even tension in a spring assembly
• Consider other hazards such as moving equipment that must be secured

Isolate all energy sources as defined in the prepare procedure

• Any energy sources should be isolated safe
• Controls must be used to de-energise equipment
• Emergency stop buttons and the "ON/OFF" controls should NOT be used as an isolation method
• Isolate any physical barriers that may pose a risk such as access doors, gates, conveyors

This is the physical lockout of all LOTOTO equipment.

• All people involved should have their own company issued personal padlock for the task. Consider any contractors involved - they should use company issued padlocks to guarantee unique key numbers
• Apply all relevant LOTOTO equipment to the correct isolation points as detailed in the plan
• After the LOTOTO equipment has been fitted, it is recommended that a hasp is used on all isolation points to allow for further padlocks to be added if they are required

LOTOTO tags should be applied in all cases where a lock is present.

• Tags are used to provide visual information and as deterrents not to use the equipment
• Tags provide extra information about the lockout operator, expected duration and contact details
• If appropriate LOTOTO equipment cannot be fitted safely, tags can be used to reinforce the safety message, but the risk must be managed by an alternative method

Ensure that any dissipated energy is safety relieved and cannot re-accumulate.

• Be cautious of hazards that may affect safety of their own accord such as loaded conveyors or ambient temperatures
• Adequate restraints should be employed if there is still a danger in the form of stored energy to prevent movement

This is the final test before any tasks can commence to ensure no one can get hurt.

• In a controlled safe manner, check all LOTO equipment is correctly fitted and effective
• All people should retreat and maintain at safe distance before try-out
• If equipment does not re-energise then the task is complete, the work permit can be signed off, and work can commence
• If equipment re-energises, stop the task immediately. Report and investigate in full

After the whole procedure has been completed and lockout tagout devices are attached and verified, work can now comment to perform maintenance or cleaning.

After work has been completed, re-energise/restart equipment by ensuring the correct procedure is followed as detailed in the equipment specification.

• Do not remove anyone else's lock, only your own lock and tag
• Inspect all tools, materials and LOTO equipment are removed, the machine is fully assembled, guards and other safety devices are reinstalled
• Notify all affected people that equipment is being restored
• Inform the authorised person of any issues. If re-start is unsuccessful then reapply the LOTO equipment and investigate
• Complete paperwork, permit and registers

View our extensive range of lockout tagout equipment.