What is lockout-tagout?
Lockout-Tagout or LOTO is a procedure in which safety locks, locks (lockouts) and safety tags (tag outs) are used to carry out safe and energy-free work on machines or processes.
This means all energy sources are isolated, locked and provided with a safety tag before the start of the work.
All lockout-tagout (LOTO) materials for safe maintenance of machines.
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Writing a lockout-tagout procedure
Drawing up and implementing a successful lockout tagout procedure can be a complex matter. To draw up a procedure as efficiently and safely as possible, an assessment of the current safety procedures (work permits), skills of the operators and an analysis of the installations, is required.
If a lockout-tagout procedure is drawn up or maintained incorrectly, this could lead to production loss, hazardous situations and even injury.
A proper lockout-tagout procedure complies with legislation and directives, but has also been implemented in all layers of the organisation and with all employees and is, as such, not merely a policy document.
Unique Safety Products can offer the following lockout-tagout programs that can take care of the whole or part of the problem:
- FUSACON B.V. (Functional Safety Consultants Nederland)
- Brady LINK 360 (VLOP services)
- Master Lock services
- Abus IMP lockout with system
Being a good employer requires you to enable your staff to work safely on machines and installations.
Lockout-tagout training days are a very efficient tool in order to correctly follow the LOTO procedure and detect any hazards.
In collaboration with Fusacon Safety Consultants we have developed a specialized training program which includes all aspects of Lockout-Tagout-Tryout.
Lockout Tagout (LOTO) on-site introduction training where our specialists deal with the use of lockout-tagout for safe and power isolated work on machinery and production lines.
The on-site Lockout-tagout (LOTO) specialist training covers both theory and practice. In addition to the basic knowledge, the implementation of an efficient LOTO procedure is also incorporated in this training.
The lockout-tagout audit service provides a clear and comprehensive analysis of your current lockout tagout systems and includes action points and recommendations based on an extensive checklist.
Padlocks for lockout-tagout
Safety padlocks are designed for Lock-Out, Tag-Out, Try-Out also known as LOTOTO applications and are used for locking energy sources.
By making use of colour codings (and optionally laser engravings), the function and the owner of the padlock can be identified.
Personal safety padlocks work in accordance with the principle: 1 employee = 1 padlock = 1 key (OSHA Standard 1910.147). If 1 employee needs multiple padlocks or group-lockout has been used, in general, keyed alike padlock sets are applied.
Safety padlocks have at least the following properties:
- Different colour codings (optionally with laser engraving)
- Fixed key when the shackle is open
- 1 padlock = 1 key
- Different key systems (master key, keyed alike, keyed different)
- Coded locks with (optionally) key registration
- Non conductive body/bracket
LifeGuard key registration
Safety padlocks are equipped with a safety cylinder that allows at least 40,000 unique key codes to be assigned.
Abus, Brady and Master Lock all offer the possibility of key registration on the end user to completely rule out the issue of duplicates.
Part of drawing up a LOTO procedure is registering the key plan. This specifies the following:
- The number of personal padlocks required.
- Number of employees with a set of equally coded padlocks
- Use/don’t use a master key system
- Number of generic coded sets for group lockouts
Safety Padlocks are colour coded to indicate the lock function. There is no official standardization for this, but there is industry-leading practice:
- Red: machine padlocks
- Blue: technical service
- Green: release of locks (machine supervisor)
- Yellow: external employees
1 key = 1 lock
Lockout-tagout procedures are often based on the regulations as recorded in OSHA 1910: 147.
This describes that lockout-tagout safety padlocks must be used and supplied according to the following principle:
1 employee = 1 padlock = 1 key, to minimize misuse as much as possible.
Safety padlocks locks are often provided with a permanent laser engraving to identify the lock and the key.
Engravings can be placed on the front, back, left side, right side and on the key. It is also possible to engrave a company logo.
Lockout hasps to put more padlocks on an isolation point
Lockout hasps are used when an isolation point needs to be locked with multiple personal safety padlocks.
Only when all padlocks have been removed from the lockout hasp it can be released so that the power source can be reactivated.
- Available in various materials such as nylon, stainless steel or aluminum
- Safety tags available with a lockout hasp function
- Different shackle diameters, for mounting on small electric padlock holes
Lock-out hasp with tag
Lockout hasps with a safety tag are available from both Brady and Master Lock and are available in 5 different colours and can both accommodate up to 6 padlocks.
Sizes and materials
Lock multipliers are available in many sizes and materials, such as nylon for electric applications or entirely INOX for the food industry.
Rewritable and erasable
Brady and Masterlock deliver a broad scala of rewritable and erasable safety tags for nearly every type of application.
These safety tags are writable with a permanent marker and can be wiped clean with alcohol wipes. These safety tags are also suitable for outdoor use.
For the food processing industry, we also supply “metal detectable” tags that can be detected if they end up in the production process.
Customized safety tags according to your wishes and specifications. Unique Safety Products designs and manufactures both reusable and one-off personalized safety tags for every industrial environment.
Provide the tags with your logo and optionally with sequential numbering.
Tags for isolation points
Isolation tags are used to mark the control points of the energy sources. The machine-specific lockout procedure refers to these isolation points and indicates in which order and with which locks the relevant energy source should be locked.
Isolation point tags exist for all types of energy sources and are numbered per energy type from 1 to 20.
Lockouts for electrical and mechanical dangers
Lockout-Tagout-Tryout locks are designed especially for the locking of energy sources during maintenance or cleaning activities.
These lock-outs are positioned on the isolation point of the energy source and subsequently locked with a safety padlock and marked with a safety tag.
The Lock-Out devices are available for the following energy sources:
Lockouts for valves
After the handwheel has been set to the lockable position (open or closed), it can be easily locked with a valve lockout, available in different sizes and colours.
It is also possible to use cable lock-outs to lock handwheel valves.
Electrical locking devices
Electrical locking devices are available for almost all types of circuit breakers. These lockouts are designed to, in combination with a safety padlock, secure the machine against being switched on again.
There are also, lock-outs are available for screw-type fuses, knife blade fuses (NH-fuses), plugs, push buttons and emergency stops.
Lockouts for ball valves
Ball valves come in a wide variety of shapes and sizes
Therefore, use universal ball valve lockouts or a cable lockout that is secured with a grip-tight to a fixed pipe nearby.
Pneumatic lockout devices
Airlines can easily be secured against connections with pneumatic coupling locks.
Universal lockouts fit on many different pipe couplings.
To prevent containment in confined spaces and manholes, covers are used that optionally can be locked with a safety padlock.
Universal cable lockouts
Cable locks are the ideal multi-functional solution for locking energy sources.
Use cable lock-outs for locking valves, ball valves and various circuit breakers
Lockouts for butterfly valves
With a universal insert, a butterfly valve can easily be locked in combination with a cable lockout and safety padlock.
The butterfly valve lock-out prevents the handle from being squeezed and the valve from being opened.
Blind flanges lockouts
When blind flanges are positioned during maintenance activities, the undesired removal of the blind flange can be prevented by placing blind flange lockouts, which can be locked with a safety padlock.
Blind flange locks are available in 3 different sizes.
Lockout stations organize LOTO materials
Lockout stations or padlock stations are used for the organised and clear storing of lockout-tagout materials.
By placing the lockout station near the relevant installation and providing it with the necessary materials to secure this installation, the LOTO procedure becomes clearer and safer.
- Available in different sizes
- Made from steel or impact-resistant plastic
- Permit to work station combines a group lock box with a padlock station for more functionality
- Lockout stations can be provided with storage bins for the storing of lockout materials
- Possibility to produce shadow boards in different sizes
Lockable lockout stations
For a well-organized storage space for your padlocks, tags and lock multipliers, Master Lock has launched 3 different lockable lockout stations.
- 1482B | 5 safety padlocks
- 1483B | 10 safety padlocks
- 1484B | 20 safety padlocks
Filled lockout stations
In addition to self-divisible empty stations, there are also pre-assembled lockout stations and lockout kits containing the most necessary materials for electrical and/or mechanical lockout.
ABUS Lockpoints are developed to easily create an organised storage station yourself, for all your lockout-tagout materials.
You can easily attach padlock rails, storage bins, group lock boxes and procedure sheet holders. You can personalise the lock point with your own logo.
Group lock boxen lock boxes for group lockouts
Group lock boxes are used during a group lockout. The principle of this is that an authorized employee isolates and locks all energy sources with a set of keyed-alike safety padlocks.
The key of this set then goes into the group lock box. After which every employee or contractor working on the installation places his or her safety padlock on the lock box.
Only when all safety padlocks are removed from the lockbox can the key be removed to unlock and reactivate the energy sources.
Work permit station
A work permit station is a group lock box equipped with a procedure sheet holder and a padlock carrier.
This makes that the station can be used as a starting point for more complex lockout tagout procedures.
Portable group locks can be taken to the installation where lockout tagout is performed.
When all energy sources are isolated by the person responsible for the group-lockout and he has placed his personal padlock, everyone performing work activities can place his padlock (and tag) on this box near the installation.
A complex lockout requires a large number of different energy sources to be isolated, a work permit is required and there are many employees involved.
The use of group locks in complex lockout reduces the number of safety padlocks required and helps to perform large maintenance jobs more safely and efficiently.
Schadow boards optimalise your LOTO procedure
Shadow boards help improve lockout tagout procedures and provide a visualization of the required materials and the work permit.
Shadow boards help operators find the necessary lockout materials for their operations. The coloured shade of the materials provides immediate insight into which materials are in use.
Shadow boards make LOTO procedures a lot more clear and efficient and they reduce the risk of accidents during cleaning and maintenance of industrial equipment and processes.
Poorly organized workplaces and work environments reduce employee productivity.
Shadow boards provide more overview, clarification of the available and required lockout materials and help you achieve your lean 5s objective.
Custom shadow board
Shadow boards are custom made and contain the materials you use during lockout tagout work. Shadow boards are printed on plastic and have a solid aluminium edge.
Indicate which materials you want to place on the board and we will take care of the design and implementation.
Connect to LOTO procedures
Have your lockout tagout procedures refer to the materials on the shadow board, so everyone can immediately see what work is being performed.
By placing a work permit display, the relevant permit is immediately visible to everyone.
Lockout kits pre-assembled sets for technicians
Lockout kits are pre-assembled sets with LOTO materials for installers, mechanics or technicians. The kits are equipped with a portable waist bag or tool case. We divide LOTO kits into kits for electrical and mechanical work.
For common lockout tagout activities, it is efficient to carry a lockout kit, so that simple LOTO’s can be carried out quickly and safely.
Electrical lockout kits
Vergrendelingssets voor elektrische gevaren zijn zo samengesteld dat de meest voorkomende elektrische installaties kunnen worden vergrendeld en gemarkeerd. Elektrische kits bevatten doorgaans geïsoleerde veiligheidssloten, veiligheidstags, automaatvergrendelingen en stekkervergrendelingen.
Mechanical lockout kits
Lockout sets to prevent mechanical dangers for technicians and the technical service department include as many universal locks for valves and ball valves as possible.
Usually, the set is also provided with a cable lock to lock non-standard valves to a fixed point or pipe.
Assemble your own kit
You can select the necessary materials for a set yourself or let our sales engineers advise you on how to put together the lockout kit that best suits the maintenance activities.
Lockout kits can also be marked per technician with name, position or company information.
Pipe markers to identify substances in pipes
Pipe markers are used to identify (hazardous) substances that run through pipes.
The use of pipe markings is documented in European Directive 92/95. The correct use of colours and symbols is also registered in this guideline.
For European uniformity, the NEN3050 specifies the use of different substance names and colours for pipe markers. To meet this requirement, our pipe markers are divided into the following categories:
- Flammable liquids
- Non vlammable liquids
- Fire fighting
Placing pipe markers
According to both National and European regulations, pipes must be marked at every connection point:
- Inputs of the valves
- Outputs of the valves
- Access points
CLP hazard pictograms
The CLP regulations (classification, labelling and packing) issued by the GHS (Globally Harmonized System) are mandatory as of December 1, 2010 and indicate whether and which hazard pictograms should be displayed per substance.
Different types of pipe markers
All standardized pipe markers are made from laminated polyester. Pipe markings are resistant to UV light, high and low temperatures and are provided with all legal inscriptions, colours and symbols.
Pipe markings are available in seven different standard sizes, on a roll and with or without a carrier.
Label printers print tags, labels and pipe markings
Brady has a wide range label printers for industrial applications such as identification, tags, labels, pipe markers and safety signs.
Brady’s industrial print solutions offer a multitude of options for labelling and marking within your organization. By using durable patented label materials and the supplied software, you can easily create custom labels that meet the guidelines. With the portable printers by Brady, you can print anywhere and everywhere. beacuse they are lightweight the portable printers are easy to carry and movable. The benchtop printers by Brady are excellent for printing big labels, and big quantities. These benchtop printers are perfect for eye-catching and easily recognisable visuals.
Brady has printers for: datacom, electrical identification, wire & cable marking, laboratories, general identification, hazardous materials, pipe markers, type & nameplates, safety pictograms & labels, lean/5S and inspection & repair.
examples of labels that can be printed with the Brady printers:
- Safety pictograms
- Pipeline coding
- Barcode labels
- General Signaling
- Safety tags
Printing pipe markers
Print your own pipe markings that comply with the CLP regulations. They are provided with the correct symbols, layout and colour scheme. Brady label materials are designed to withstand large temperature differences and humidity for years.
We help you select the right printing solution for your application, from handy portable printers for labelling to advanced multifunctional solutions for printing tags and pipe markers.
Patented print labels
Brady offers a suitable print label for every application. There is a choice in different materials, dimensions, coatings, carriers and colours. Brady has more than 30 patented innovations, making it the market leader in industrial label solutions. As of this moment Brady offers more than 50 different material types and more than 900 label designs.
Use the touchsceen in combination with the built-in keyboard, for easy designing of labels on the printer. Most Brady printers also have option to save designs. This way the same exact label can be printed again, and you do not need to design the label again.
Changing label rolls and print ribbons
Brady printers can recognise print ribbons and label rolls of Brady. As a result, the printers work swiftly. In less than 2 minutes, they can print on four different materials, without wasting material. The Brady printers have an automatic cutting blade, so no print materials are lost. The Brady printer recognises which print label is inside, and adjusts to the width of the label.
Brady has different print ribbons and labels with all kinds of properties. For example, there are print labels that are scratch, chemical and solvent resistant. There are also print ribbons that are diesel, solvent and friction resistant. In addition, all print ribbons are halogen-free and comply with RoHS 2011/65/EU and 2015/863.