Lockout / Tagout Industrial Safety System

Eliminating the human factor during equipment repair and maintenance is one of the key tasks of industrial safety. The implementation of the Lockout/Tagout (LOTO) system becomes a natural stage in the development of a safety culture at manufacturing enterprises, ensuring personnel protection from unauthorized energy supply. The webinar details the practical experience of integrating lockout procedures at the Pirelli and Fels plants.

Visualization and Group Lockout on Extended Lines

The specifics of Pirelli's tire production involve long production lines (up to 40 meters), which complicates the control over energy isolation. Vladimir Alekseev demonstrates, using his enterprise as an example, how this problem is solved using a group lockout system. To separate areas of responsibility, lockout hasps and color differentiation are used: red locks are issued as personal ones, while yellow ones are used to lock out the energy sources themselves.

The keys to the yellow locks are placed in a group LOTO box, which is secured with the personal lock of the work supervisor. This ensures that no unit will be unlocked until the repair is completed by all participants. Additionally, visualized step-by-step instructions and isolation diagrams are placed on each piece of equipment, near the control panels. This approach allows technical personnel to always have a clear algorithm of actions in front of their eyes, reducing the likelihood of errors due to haste or forgetfulness.

Adapting LOTO to Current Electrical Safety Rules

The experience of the Fels enterprise (lime production) demonstrates how international lockout standards can organically complement Russian regulations. Andrey Staver analyzes a case where the initial idea of installing additional physical disconnectors on each device was rejected due to high costs and long lead times. Instead, the enterprise took the path of consolidated lockout of electrical devices directly in the switchboards.

To simplify the procedure, LOTO cards with photographs and precise indications of lockout installation locations were developed for each isolation point. The speaker emphasizes the importance of integrating LOTO with the internal permit-to-work system. The enterprise has implemented a three-stage control: the isolation is confirmed by the permit issuer, the admitting electrician, and the central panel operator. At the same time, the direct isolation of hazardous energy sources is always performed by a staff duty electrician, which eliminates confusion and increases system reliability.

Contractor Control and Overcoming Personnel Resistance

Both experts agree that allowing contractors to perform LOTO procedures requires strict regulation. Both enterprises have a rule: basic equipment lockout is carried out only by staff personnel. Contractors, having undergone training and testing, only attach their personal locks to the group box. This leaves full control over the safety of the work area in the hands of the enterprise.

The implementation of new procedures often faces personnel concerns about increased repair times. However, time studies conducted at the Fels plant showed that issuing a permit and installing lockout devices increase the total preparation time by only three minutes. Involving line personnel in the development of LOTO cards and joint training helped to overcome internal resistance and make the system a working tool rather than a formal requirement.

What you will learn from this webinar:

• How to organize group equipment lockout when multiple teams are working on extended lines?
• How to integrate LOTO procedures into the existing permit-to-work system without violating Russian HSE regulations?
• Why is developing visual LOTO cards with photographs more effective than text instructions?
• How to safely organize the work of contractors using individual and group locks?
• How to justify the need for LOTO implementation to technical personnel and overcome objections about lost working time?