LOTOTO vs LOTO - Which is Safer and Why?

Lockout Tagout (LOTO) and Lockout Tagout Tryout (LOTOTO), which is safer and why.  Both share the same overarching goal of preventing accidents related to hazardous energy sources, however, according to many, they differ significantly in their approaches and applications. Inevitable the question is always asked, which is safer and why?  The answer, is simpler than you think. - Firstly though

What is Lockout Tagout? 

Lockout Tagout, commonly abbreviated as LOTO, represents a widely recognized and practiced safety procedure. Its primary objective is to ensure the complete isolation of machinery or equipment undergoing maintenance or repair. The LOTO process typically involves the following key steps:

1. Identification: Workers and authorized personnel identify and catalog all the specific energy sources that need to be controlled or isolated during maintenance, servicing or start up/shut down activities. These energy sources can include electrical, mechanical, hydraulic, pneumatic, thermal, chemical, or gravitational sources. The goal is to create a comprehensive inventory of all potential hazards that could pose risks to workers and equipment during maintenance.  Example: Typically this is represented on a Lockout Tagout Form, with supplementary drawings, such as P&ID's used to identify the location of each energy source (Valve, Pump, Panel). Each item is assessed for the types of energy sources it uses, the potential isolation device which could be required, and the potential hazard associated.

2. Isolation: Once the energy sources are identified, the isolation phase begins. This is where physical lockout devices, such as lockout tagout padlocks, lockout hasps, or lockout valves, are used to physically isolate and secure each energy source. The purpose of isolation is to ensure that the energy cannot be unintentionally reactivated while maintenance or servicing work is underway. It is important to note, that proper procedures should be followed when applying the lockout device to the equipment. The system, should be powered down, or placed in an appropriate state ready for Lockout Tagout.  This typically means involving plant personnel, or engineers who are familiar with the equipment.  Example: Workers place a lockout tagout padlock on an electrical circuit breaker and secure it with a lockout hasp. This physically prevents the circuit from being switched on while maintenance is taking place.

3. Tagging: Tagging is a critical visual component of the LOTO procedure. After isolation, a highly visible and informative tag is attached to the locked-out equipment or energy isolation point. This tag provides essential information, including details about the maintenance work being conducted, the responsible personnel, and contact information. The tag serves as a clear warning to anyone who may come into contact with the equipment that it is temporarily out of service and should not be operated. It also provides a point of contact for each lockout.  Example: A lockout tag is attached to a motor control panel, indicating that maintenance is in progress, the date of lockout, and contact information for the authorized personnel.

4. Verification is the final and crucial step of the LOTO process. Before any maintenance work begins, it's essential to verify that all isolation and lockout measures are correctly in place. This verification step ensures that energy sources are effectively isolated, and there is no potential for accidental re-energization. Verification often involves a second set of eyes, where another qualified person cross-checks the isolation(s) and tags to confirm their accuracy. Example: An authorized employee conducts a final walkthrough, visually inspecting each locked-out energy source and confirming that isolation measures are correctly implemented. They also ensure that all tags are legible and up-to-date.

LOTOTO vs LOTO - The Safety Factor

Let's delve deeper into the comparison of LOTOTO and LOTO from a safety perspective. Lets summarise first:

1. LOTO (Lockout/Tagout): LOTO is a safety procedure that involves isolating and locking out all sources of hazardous energy to prevent accidental start-up during maintenance or repair work. The process includes shutting off power sources, locking them out, attaching tags to the locks and verifying the system is locked out.
2. LOTOTO (Lockout/Tagout/Tryout): LOTOTO a 'variation' of LOTO that involves  testing the equipment or machinery to ensure that all sources of hazardous energy have been effectively isolated. In this process, the person performing the maintenance or repair work must "try out" the equipment to ensure that it cannot be started up accidentally.

If you can't see a difference between these two processes you're not alone. Although LOTO-TO specifically calls for testing the integrity of isolations before undertaking a specific task, the process of LOTO intrinsically requires this.

Whether you state you follow LOTO or LOTOTO, you should always be testing the integrity of a lockout point before undergoing work.  Mistakes happen so easily. A robust safety program accounts for these mistakes, and provides safeguards to prevent this - identifying the isolations required, second pair of eyes verification, challenging the isolation. This ensures maximum safety to plant and workers. 

In summary, the main difference between LOTO and LOTOTO is that the latter calls out the last step of testing in its title.  Whether you opt for naming your site process LOTO or LOTOTO, remember that the key to success lies not only in the procedure but also in the quality of lockout devices. "The Lock Box" stands as your reliable partner, providing the essential tools for a safer workplace.