Lockout Tagout Device
A lockout tagout device is a physical means used with an energy-isolating device to prevent energization (lockout device) or provide a warning not to operate (tagout device), in accordance with a written hazardous-energy control procedure. Lockout devices use a positive means like a lock to hold the isolating device in a safe position, while tagout devices are prominent warning devices securely fastened to indicate operation is prohibited until removal.
On a manufacturing shop floor, lockout tagout devices are applied to energy-isolating devices such as electrical disconnects, circuit breakers, valves, and control system isolating devices. The process involves shutting down equipment, isolating all energy sources, applying personal padlocks and mechanical hardware like hasps and valve covers, attaching standardized tags with worker identification and date, and verifying zero energy through try-start tests. This ensures maintenance, repair, or cleaning can be performed safely without unexpected energization, aligning with WorkSafeBC and OSHA requirements for written procedures and group lockout management.
- Locking or tagging control devices like push buttons or PLC inputs instead of energy-isolating devices, which does not physically prevent energization and is non-compliant with OSHA and WorkSafeBC standards.
- Using inadequate devices that lack durability, standardized identification, or are not dedicated solely to lockout, leading to tags falling off or locks being misused, increasing risk of inadvertent energization.
- Incomplete isolation by not locking out all energy sources, such as hydraulic accumulators, pneumatic lines, or secondary feeds, despite applying lockout to the main electrical disconnect, causing sudden movement from stored energy.
When is a tagout device alone acceptable in OSHA and Canadian practice?
Under OSHA, lockout is preferred; tagout alone is only acceptable if the employer demonstrates equivalent protection or the device cannot be locked out, with additional measures like removing handles. In Canadian practice (CSA Z460, WorkSafeBC), lockout is primary; tags are supplementary and not standalone for hazardous energy control, except in specific risk-assessed circumstances.
Are CSIDs considered valid points for applying lockout devices under WorkSafeBC?
Yes, if a control system isolating device (CSID) physically prevents activation of the control system, it can be part of a lockout procedure. However, CSID lockout typically supplements energy-isolating lockout and must be in the written procedure. Devices like HMIs or PLC software modes are not acceptable as primary lockout points.
What design features must a compliant lockout/tagout device have in a harsh manufacturing environment?
Per OSHA, devices must be durable (withstand chemicals, moisture, UV), standardized in color/shape/size, substantial (lockout devices resist removal; tagout attachments are non-reusable and require unusual force to remove), and identifiable with the authorized employee. Canadian CSA Z460 and WorkSafeBC align with individually keyed locks and standardized tags.