LOTO Removal Form
This is the overview on the Abandoned Lock Removal process, an FAQ portion and includes the Abandoned Lock Removal Form.
Keeping workers safe and free of injury by controlling hazardous energy. Lock Out Tag Out (LOTO) allows employees to isolate hazardous energy to avoid an unexpected release of energy from equipment or systems during servicing and/or maintenance
It is important to get authorization and complete the necessary steps when removing someone else’s locks. Removing another person’s locks is not allowed for routine work. There are some situations where this is necessary and acceptable.
Scope: This procedure applies to all Facilities Planning & Management (FPM) employees who work on machines or equipment where the unexpected release of stored or operational energy could cause personal injury.
LOTO Forms & Quick Links:
Definitions
- Affected Person: A worker who operates or works near equipment currently being serviced under lockout/tagout.
- Authorized Employee: A trained worker authorized to apply and execute lockout/tagout procedures.
- Energy Isolating Device: A physical mechanical device (e.g., circuit breaker, disconnect switch, valve) that prevents the transmission or release of energy.
- Energy Source: Any hazardous energy type (electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or kinetic) capable of causing injury.
- Lockout Device: A positive lock mechanism that holds an energy-isolating device in a safe position to prevent energization.
- Personal Controlled Lock: A designated safety lock assigned specifically to an individual worker to secure LOTO devices during maintenance.
Roles & Responsibilities
Supervisors
- Identify equipment and energy sources requiring LOTO control procedures.
- Develop, maintain, and enforce LOTO policies and equipment-specific procedures.
- Maintain official LOTO documentation and ensure adequate hardware (locks, tags, hasps) is provided.
- Verify that only trained and authorized personnel perform lockout activities.
- Ensure all workers receive required LOTO safety training.
Employees (General & Affected)
- Strictly follow LOTO procedures, signs, and restrictions.
- Never attempt to bypass, restart, or operate locked or tagged equipment.
- Note: Failure to adhere to LOTO rules may lead to disciplinary action up to termination.
Authorized Persons
- Notify affected workers prior to starting service/maintenance and state the maintenance schedule.
- Properly apply, execute, test, and remove LOTO procedures.
Program Requirements & Guidelines
Training Requirements
- Authorized personnel must complete initial safety training and ongoing refreshers.
- Training covers isolating hazardous energy, proper application of devices, and verification.
- Mandatory retraining occurs whenever job assignments change, new hazards/equipment are introduced, or procedure failures are detected.
Lockout vs. Tagout
- Lockout: The primary safety method. Uses a physical lock to keep energy isolating devices open or off.
- Tagout: Used only when energy sources cannot accept a physical lock. Requires additional safety precautions (e.g., pulling fuses, blocking switches) to achieve equal protection.
Standard Exemptions
- Minor work on low-voltage systems (below 50 Volts) where electrical shock risks do not exist.
- Cord-and-plug electric equipment, provided the plug is kept under the exclusive control of the technician at all times.
Special Situations
- Multiple Workers (Group LOTO): Every technician working on the system must place their own personal lock on a multi-lock hasp or group lockout box.
- Abandoned / Leftover Locks: If an authorized worker leaves campus without removing their lock, only an authorized supervisor may remove the lock following strict validation and documented protocol.
LOTO Steps: Energy Isolation Protocol
Step 1: Prepare for Shut Down
- Understand the Equipment: Identify all energy sources, power feeds, valves, and switches.
- Notify Affected Staff: Communicate with all affected workers that equipment is being locked out and explain why.
Step 2: Shut Down Equipment
- Shut down the machine or equipment using normal operational stopping methods (e.g., push button, stop switch).
Step 3: Isolate Energy Source
- Operate switches, circuit breakers, valves, or disconnects so the equipment is fully isolated from all energy sources.
Step 4: Apply Lockout / Tagout Devices
- Apply personal lockout locks and tags directly to the energy-isolating devices.
- When necessary, apply lockout devices (e.g., gate valve covers, breaker lockouts) before attaching your lock/tag.
Step 5: Release Stored Energy
- Safely relieve, block, bleed, or ground any residual/stored energy (e.g., capacitors, air/steam pressure, hydraulic lines, heavy elevated components, flywheels).
Step 6: Verify Isolation (Zero Energy State)
- Verification of Isolation: Ensure all personnel are clear, then attempt to operate normal controls to verify isolation. Return controls to "OFF" or neutral afterward.
- Verification of Stored Energy: Check pressure gauges, sight glasses, or test equipment to ensure all residual energy is completely dissipated.
LOTO Steps: Return of Equipment to Service
Step 1: Inspect & Restore Area
- Check that maintenance work is complete and equipment is reassembled.
- Ensure all tools/materials are removed, safety guards are reinstalled, and all personnel are clear of the machinery.
Step 2: Inform Staff
- Notify all affected workers that lockout devices are about to be removed and the system re-energized.
Step 3: Remove Locks & Test
- Each personal lock and tag must be removed only by the authorized employee who originally applied it.
- Re-energize, test operations, and safely return the equipment to regular service.