Lockout Tagout Devices Explained

By R.W. Hurst, Editor

Lockout tagout devices are essential tools used to prevent the unexpected energization or startup of machinery and equipment during maintenance or repair activities. These devices help protect workers from hazardous energy and prevent accidents. A well-implemented lockout tagout program, which includes the use of lockout tagout procedures and loto devices, is crucial for ensuring workplace safety and compliance with safety standards.

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There are two main types of lockout tagout devices: lockout devices and tagout devices. Lockout devices, such as breaker lockout devices or plug lockout devices, physically isolate energy sources, preventing the equipment from being turned on. Tagout devices, on the other hand, provide a visible warning to workers that equipment should not be activated. Both types of devices are key components in any lockout tagout (LOTO) program.

Examples of lockout devices include circuit breaker lockout devices, which are designed to secure electrical circuits and prevent them from being energized during repairs. Valve lockouts, which prevent the operation of valves, and cable lockout devices, used to immobilize machinery with multiple energy sources, are also widely used in industrial settings. Tagout devices, such as warning tags, inform workers that maintenance or repair activities are in progress and caution them against operating the equipment.

When performing LOTO, it is essential to adhere to OSHA’s Control of Hazardous Energy standard (29 CFR 1910.147), which outlines the proper use of lockout tagout procedures. These guidelines ensure workers are protected from hazardous energy, whether electrical, mechanical, or hydraulic, while performing their duties.

Different Types of Lockout Tagout Devices

Several electrical lockout tagout devices are designed to address specific situations during maintenance or repair work. The right device for the job can depend on the type of machinery and the energy sources involved.

Lockout hasps: These devices allow multiple workers to lock out a single energy source by attaching their padlocks to the hasp. This ensures that equipment remains inoperable until every worker has completed their tasks.
Circuit breaker lockout devices: Used to secure electrical circuits, these devices prevent a circuit breaker from being turned on during maintenance. They fit over the circuit breaker switch and are secured with a padlock, protecting workers from electrical hazards.
Valve lockout devices: These devices immobilize valve handles to prevent the flow of hazardous energy through pipes. They are typically used in processes involving gas or liquid energy sources.
Plug lockout devices: These devices cover electrical plugs, preventing them from being connected to power sources during maintenance or repair activities.
Cable lockout devices: Designed for equipment with multiple energy sources, cable lockouts thread a steel or nylon cable through various components, effectively immobilizing them.
Warning tags: These highly visible tags provide critical safety warnings and information about the status of machinery or equipment undergoing maintenance. Tags should be attached securely to the lockout devices and contain detailed information about the procedure, including the names of authorized personnel.

Lockout Hasps

Lockout hasps are lockout devices that secure multiple workers from a single energy source. Commonly used in group lockout situations, they are placed over energy isolating devices such as circuit breakers or valves. Each worker involved in the repair places their lock on the hasp, ensuring that the energy source cannot be reactivated until every worker has removed their padlock.

Lockout hasps are typically made from durable materials like steel or aluminum and are essential for group lockout procedures where multiple workers are involved in maintenance or repair work.

Circuit Breaker Lockout Devices

Circuit breaker lockout devices are specialized tools used to prevent the energization of electrical circuits during repairs. These devices fit over circuit breakers, ensuring that the electrical circuits remain de-energized. Made from sturdy materials like plastic or metal, these lockout devices ensure that workers are safe from electrical hazards during the repair process.

To use a circuit breaker lockout device, it is first fitted over the circuit breaker switch and then secured with a padlock. The key is held by the worker performing the maintenance, ensuring only authorized personnel can re-energize the circuit.

Valve Lockout Devices

Valve lockout devices are designed to prevent the opening or closing of valves during maintenance work. These devices secure valve handles in place, ensuring that no fluid or gas can flow through the system until the work is completed. Like other lockout devices, valve lockouts are secured with a padlock to prevent unauthorized use.

Valve lockouts come in various designs and materials to fit different types of valves. The proper use of these devices is crucial for isolating hazardous energy during maintenance tasks involving pipelines or industrial systems.

Plug Lockout Devices

Plug lockout devices are used to secure electrical plugs, preventing equipment from being energized during maintenance. These devices are placed over the plug to physically block its connection to the power source. They are especially useful in situations where simply unplugging the equipment isn’t sufficient for ensuring safety.

These devices are typically made from durable materials and are locked with a padlock, ensuring that only authorized personnel can restore power to the equipment.

Cable Lockout Devices

Cable lockout devices offer a flexible solution for locking out multiple energy sources simultaneously. A steel or nylon cable is threaded through various components, such as electrical switches, valves, or disconnects, and then secured with a padlock. These devices are ideal for complex machinery where multiple energy sources need to be isolated.

Cable lockout tagout devices are versatile and can be customized for the specific equipment being serviced, ensuring that the machinery cannot be activated until the cable is removed.

Warning Tags

Warning tags play a critical role in any lockout tagout program by providing clear visual warnings to workers about ongoing maintenance or repair work. These tags are typically attached to lockout devices and include important information, such as the nature of the work being performed, the identity of authorized personnel, and the expected duration of the lockout.

Warning tags ensure that workers are aware of the status of the equipment and that no one inadvertently operates machinery undergoing maintenance.

By choosing the right lockout devices, such as breaker lockout devices or valve lockouts, and following lockout tagout procedures, companies can protect workers from hazardous energy during maintenance or repair tasks. Effective use of lockout tagout kits and adhering to OSHA standards ensure a safe work environment free from the dangers of unexpected energization.

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