Lockout-Tagout (LOTO)
What is Lockout-Tagout (LOTO)?
Lockout Tagout (LOTO) is a safety procedure in which energy sources of machines and industrial installations are isolated, locked out and tagged before maintenance, inspection or troubleshooting work is carried out.
Lockout Tagout uses safety padlocks (lockouts), lockout devices and safety tags (tagouts) to prevent machines or installations from being unexpectedly re-energized while employees are performing maintenance.
By physically locking out and clearly tagging energy sources, unintended machine start-up, the release of stored energy and hazardous situations during machine maintenance can be prevented.
In a correct LOTO procedure, all energy sources are first:
- shut down
- isolated
- locked out with a safety padlock
- tagged with a safety tag
This allows work on machines, installations and industrial processes to be carried out safely in a de-energized state.
| Lockout-Tagout solutions | Procedures | Training |
Lockout-Tagout solutions for safe energy isolation
Various Lockout-Tagout devices are required to safely perform maintenance on machines and installations. By correctly isolating, locking out and identifying energy sources, employees can work safely without the risk of unexpected start-up or the release of energy.
A complete LOTO system consists of multiple components, such as safety padlocks, lockout hasps, safety tags, energy isolation lockout devices, lockout stations and group lock boxes. Together, these devices ensure that energy sources are clearly isolated and that only authorized employees can release the installation.
This page provides an overview of the main Lockout-Tagout products and solutions for industrial applications.
Need support with Lockout-Tagout?
Our specialists can assist with LOTO procedures, product selection and implementation in the workplace.
Writing a lockout-tagout procedure
Developing and implementing an effective Lockout-Tagout procedure is essential for safely carrying out maintenance on machines and installations.
A good LOTO procedure starts with an assessment of energy sources, isolation points and work activities. Existing safety procedures, work permits and the experience of operators must also be taken into account.
If a Lockout-Tagout procedure is applied incorrectly or incompletely, this can lead to loss of production, hazardous situations and even serious injury.
An effective procedure complies with applicable guidelines and is implemented throughout all levels of the organisation. It is therefore more than just a document: it forms the basis for a safe working method during maintenance and troubleshooting.
Unique Safety Products can provide the following Lockout-Tagout programmes, enabling you to comply fully or partially with legislation and guidelines:
- FUSACON B.V. (Functional Safety Consultants Nederland)
- Brady LINK 360 (VLOP services)
- Master Lock services
- Abus IMP lockout with system
Lockout-Tagout training
Good employment practices require that employees can work safely on machines and installations and are familiar with Lockout-Tagout procedures.
To apply Lockout-Tagout procedures correctly and identify hazardous energy sources, LOTO training is an effective way to raise employee awareness of risks and safe working methods.
In cooperation with Fusacon Safety Consultants, Unique Safety Products has developed a practical training programme covering all aspects of Lockout-Tagout, from basic knowledge to implementing a safe LOTO procedure.
Lockout-Tagout
Introduction Training
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.
Lockout-Tagout
Specialist Training
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.
Lockout-Tagout
Consultancy
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.
Key plan
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
Coloured padlocks
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.
Engraving padlocks
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.
Lockout hasps are available in various versions, including:
- 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
Slotvermeerderaar met tag
Lockout hasps with safety tags are available from brands including Brady and Master Lock. They are available in several colours and accommodate up to six safety padlocks.
Materials and dimensions
Lockout hasps are available in various sizes and materials. Nylon versions are commonly used for electrical applications, while stainless steel versions are suitable for the food industry.
Safety Tags for Lockout-Tagout
A safety tag is attached together with a safety padlock to isolated energy sources to indicate that maintenance or repair work is being carried out.
The safety tag states who is carrying out the work, when the work is taking place and who is responsible for the lockout.
Safety tags also feature warning pictograms and clear instructional text.
Identification tags are permanently installed at isolation points. The numbers on these tags are then referenced on the LOTO procedure sheet.
Safety tags are available in various versions, including:
- Single-use tags or rewritable tags (Guardian Extreme)
- Metal-detectable tags for the food industry
- Tags with custom designs or sequential numbering
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.
Personalised tags
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.
Confined spaces
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 for Organising Lockout-Tagout Equipment
Lockout stations (also known as padlock stations) are used for the organised storage and management of Lockout-Tagout equipment such as safety padlocks, tags and lockout devices.
Lockout stations are often used as a central storage point for LOTO equipment within a factory or production site.
By installing lockout stations near machines or installations and equipping them with the appropriate lockout devices, LOTO procedures can be carried out more efficiently and safely.
Lockout stations are available with various options, including:
- Different sizes and configurations
- Steel or impact-resistant plastic enclosures
- Combination of padlock station and group lock box (permit-to-work station)
- Storage compartments for Lockout-Tagout equipment
- Custom shadow boards for visual organisation of LOTO equipment
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.
These stations often contain:
- Safety padlocks
- Safety tags
- Circuit breaker lockouts
- Cable lockouts
- Gate valve lockouts
Lockpoint
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 in group lockout situations where multiple employees are working on an installation at the same time. An authorised employee first isolates all energy sources and locks them out using a set of keyed-alike safety padlocks.
The key for these padlocks is then placed in the group lock box. Each employee or contractor performing work then attaches their personal safety padlock to the lock box.
Only when all personal padlocks have been removed can the lock box be opened and the key used to release the energy sources.
Group lock boxes are commonly used during major maintenance stops, shutdowns and installation work where multiple teams are working simultaneously.
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 lockboxes
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.
Complex lockout
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.
Shadow boards optimalise your LOTO procedure
Shadow boards help organise Lockout-Tagout equipment and make LOTO procedures clearer and more efficient.
Operators can immediately see which padlocks, tags and lockout devices are available and where they are located. The visual shadow outlines also make it easy to identify when an item is missing.
Shadow boards support clear LOTO procedures and reduce the risk of errors during maintenance, inspection and cleaning work on machines and installations.
Shadow boards are often installed near lockout stations or maintenance work areas to organise LOTO equipment centrally.
5S workstations
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 of Lockout-Tagout equipment for installers, technicians and technical service teams. The kits are supplied in a portable bag or tool case and contain the most commonly used lockout devices for maintenance work.
For many common Lockout-Tagout tasks, it is efficient to have a complete LOTO kit on hand so that energy sources can be isolated and locked out quickly and safely.
Lockout kits are commonly used by maintenance technicians, technical service teams and contractors who regularly work on machines and installations.
Electrical lockout kits
Electrical lockout kits contain lockout devices for electrical energy sources such as circuit breakers, switches and plugs.
The kits typically contain:
- insulated
- safety padlocks
- safety tags
- circuit breaker lockouts
- plug lockouts
- lockout hasps
These allow the most common electrical installations to be safely locked out during maintenance.
Mechanical lockout kits
Mechanical lockout kits are designed for locking out mechanical energy sources such as valves, ball valves and pneumatic couplings.
These kits often contain:
- universal
- valve lockouts
- cable lockouts
- safety padlocks
- tags and
- lockout hasps
These allow technicians to quickly and safely lock out multiple isolation points.
Assemble your own kit
Lockout kits can also be customised based on the installations within your organisation.
Our specialists can help you select the appropriate Lockout-Tagout equipment to ensure the kit matches your machines, energy sources and maintenance activities.
Kits can also be personalised with a name, job title or company identification.
Pipe markers to identify substances in pipes
Pipe markers are used to identify (hazardous) substances transported through pipes in industrial installations.
By clearly marking pipes with colour coding, substance names and hazard pictograms, it is immediately apparent which substances are flowing through a pipe.
Within Europe, guidelines have been established for pipe identification. EU Directive 92/58/EEC specifies the use of safety signs, while NEN 3050 describes colours, symbols and substance designations for pipe marking.
To comply with these guidelines, pipe markers are divided into various categories, such as:
- Acids
- Bases
- Air
- Flammable liquids
- Non-flammable liquids
- Fire-fighting lines
- Gases
- Steam
- Water
- Oxygen
Pipe markers are commonly used in chemical installations, the process industry and production environments.
Placing pipe markers
According to national and European guidelines, pipes must be marked at key points within an installation, such as:
- valve inlets
- valve outlets
- near equipment
- at passages through walls or floors
- at branches and connections
This allows personnel to quickly identify which substance is flowing through a pipe.
CLP hazard pictograms
The CLP Regulation (Classification, Labelling and Packaging) is based on the GHS (Globally Harmonized System) and specifies which hazard pictograms must be used for hazardous substances.
Since 2010, pipes carrying hazardous substances must display the appropriate CLP hazard pictograms.
Different types of pipe markers
Gestandaardiseerde leidingmerkers zijn gemaakt van gelamineerd polyester en zijn bestand tegen UV-straling, chemicaliën en extreme temperaturen.
De merkers zijn voorzien van alle wettelijk vereiste kleurcoderingen, stofnamen en gevarenpictogrammen.
Leidingmarkeringen zijn verkrijgbaar in verschillende standaardmaten en kunnen worden geleverd, op rol of als losse labels.
Label printers print tags, labels and pipe markings
Industrial label printers make it possible to print your own tags, labels, pipe markers and safety markings.
Brady offers a comprehensive range of label printers for industrial identification, including cable marking, pipe identification, safety labels and Lockout-Tagout tags.
The printers use durable label materials that are resistant to chemicals, UV light, moisture and extreme temperatures. This ensures that labels remain clearly legible even in industrial environments.
Both portable and benchtop printers allow labels to be easily designed and printed directly on site.
Label printers are widely used for Lockout-Tagout tags, pipe identification, cable marking and safety labels.
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.
Multifunctional printers
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.
Multitasking
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.
Durability
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.
Standards and Legislation for Lockout-Tagout
Standards and Guidelines for Lockout-Tagout
Lockout-Tagout (LOTO) procedures are used to safely isolate hazardous energy sources during maintenance, inspection and repair work on machines and installations. Various international standards and guidelines describe how energy isolation should be carried out and how unexpected machine start-up can be prevented.
The main standards and guidelines relating to Lockout-Tagout include:
Prevention of unexpected start-up
ISO 14118
The standard EN ISO 14118 – Safety of machinery – Prevention of unexpected start-up specifies measures to prevent machinery from starting unexpectedly during maintenance or cleaning.
The standard specifies, among other things, that:
- energy sources must be switched off and isolated
- isolation points must be lockable
- employees must be able to verify that the
- machine is de-energised
- procedures must be in place for safe maintenance
Lockout-Tagout systems with safety padlocks, tags and lockout devices help organisations comply with this standard.
Control of Hazardous Energy
OSHA 1910.147
The American OSHA standard 29 CFR 1910.147 specifies the requirements for controlling hazardous energy during maintenance and servicing activities.
This regulation forms the basis for many Lockout-Tagout programmes worldwide and specifies, among other things:
- development of LOTO procedures
- use of personal safety padlocks
- employee training
- periodic inspection of Lockout-Tagout procedures
An important principle of OSHA 1910.147 is:
1 employee = 1 padlock = 1 key
Work equipment
EU Directive 2009/104/EC
Within Europe, Directive 2009/104/EC concerning the use of work equipment sets requirements for working safely with machines and installations.
Employers are required to ensure that:
- machines can be safely switched off
- energy sources can be isolated
- maintenance work can be carried out safely
Lockout-Tagout procedures and lockout systems help organisations comply with these requirements.
Frequently Asked Questions about Lockout-Tagout (LOTO)
Lockout-Tagout (LOTO) is a safety procedure in which energy sources of machines and installations are switched off, isolated and locked out before maintenance or repair work is carried out. Safety padlocks (lockouts) and warning tags (tagouts) are used to prevent a machine from being unexpectedly restarted while employees are working on it.
Lockout-Tagout is applied when work is carried out on machines or installations where energy sources are present. This may include:
- maintenance work
- troubleshooting
- inspection or adjustment
- cleaning work
- work requiring safety guards to be temporarily removed
Isolating and locking out energy sources prevents the risk of unexpected start-up or release of energy.
Lockout and Tagout are often used together but have different functions.
Lockout means that an energy source is physically locked with a safety padlock or lockout device so that it cannot be activated.
Tagout means that a warning tag is attached to indicate that work is in progress and that the installation must not be switched on.
A clear Lockout-Tagout procedure ensures that employees know:
- which energy sources are present
- where the isolation points are located
- which lockout devices must be used
- in which order the steps must be carried out
This significantly reduces the risk of accidents during maintenance and troubleshooting.
Various products are used to safely implement Lockout-Tagout, including:
- safety padlocks
- lockout hasps
- safety tags
- valve and ball
- valve lockouts
- circuit breaker
- lockouts for electrical installations
- cable lockouts
- lockout stations and lockout kits
These devices ensure that energy sources can be safely isolated and locked out.
Unique Safety Products supplies Lockout-Tagout solutions from leading manufacturers such as ABUS, Brady and Master Lock.
We are one of the few suppliers in the Netherlands able to supply all three brands. This allows us to offer a suitable solution for every application, ranging from safety padlocks and lockout devices to complete LOTO systems.
Yes. An effective Lockout-Tagout programme consists not only of the correct products, but also of proper procedures and employee training.
During LOTO training, employees learn, among other things, how to:
- identify energy sources
- identify isolation points
- use lockout devices correctly
- carry out LOTO procedures safely
By combining training with clear procedures, an organisation can safely perform maintenance on machines and installations.
