LOTO Lockout Devices | Safety Padlocks | Lockout Hasps

How the LOTO procedure works

1. Notify – workers are warned that the equipment will be shut down.
2. Identify all energy sources – main and backup supply, DC circuits of solar PV plants, generators, UPS, batteries, capacitors, as well as pneumatics, hydraulics and springs.
3. Isolate – the equipment is isolated from all energy sources by a power isolating device (disconnector, switch, valve).
4. Lock – each worker applies their own personal padlock to the lockout hasp. It is the power isolating device that is locked, not the control button or “STOP” – the control circuit does not isolate the equipment from the supply.
5. Tag – a tag with the worker's name, date and reason is attached, together with the prohibition sign "Do not switch on! Work in progress" („Nejungti! Įrenginiuose dirbama“).
6. Release stored energy – discharge capacitors, release pressure, lower raised parts, stop parts still rotating under inertia.
7. Verify – the absence of voltage is verified with a voltage detector whose operation is checked before and after the test. Mechanical equipment – by a test start to confirm that it does not start up.
8. Carry out the work.
9. Remove the padlocks – each worker removes only their own padlock after finishing their work. Another person's padlock may only be removed in accordance with the company's established procedure when its owner cannot be reached.

As long as at least one padlock remains on the hasp, the equipment must not be switched on.

Locked-out equipment does not yet mean that there is no voltage – the absence of voltage must be verified before touching.

Functions

• Protection against accidental switching-on – locked-out equipment cannot be switched on by a colleague, remotely or by accident.
• Personal responsibility – each worker has their own padlock and key, so nobody can open another person's padlock with their own key.
• Clear visibility – bright colours and tags immediately show that the equipment is locked out and who is working on it.
• Colour coding – colours help to distinguish workers, departments or contractors according to company rules.
• Reliable mechanism – some models have key retention, so the key cannot be removed until the padlock is locked and the padlock cannot be left open.

Applications

For the power engineer: Locking out switchboards, disconnectors, motor starting equipment and substation equipment during isolation. Clear control – the equipment is switched on only when everyone has finished their work.

For the safety engineer: Introducing and maintaining the LOTO procedure, issuing personal padlocks to workers, setting up a colour-coding system.

For the work supervisor: Coordinating several workers or crews on the same equipment. The lockout hasp shows who is still working.

For the electrician: A personal padlock that only they can remove – a guarantee that nobody will switch the voltage on while they are working.

How to choose

• Shackle diameter – must fit into the hole of the lockout device or lockout hasp.
• Shackle height – according to the space available around the lockout point.
• Key system – keyed different (KD) for each worker or keyed alike (KA) for a group.
• Number of padlock holes – 4 or 6 holes, depending on how many workers are working at the same time.
• Colour – according to the colour code established in the company.

Which LOTO device to choose

Red – danger   Green – safety   Yellow – information   ⚡ – electric shock hazard

LOTO check before starting work

Red – danger   Green – safety   Yellow – information   ⚡ – electric shock hazard

Advantages

• A simple and reliable way to prevent accidents caused by unexpected switching-on.
• Several workers can work safely on the same equipment.
• Bright colours and easily recognisable marking.
• Lightweight engineering plastic body with a strong steel shackle.
• Compact, lightweight and easy to carry.

Disadvantages

• LOTO padlocks are not intended to protect against theft – their purpose is occupational safety, not physical security of the site.
• Effective only when a LOTO procedure has been introduced in the company and is followed.
• Each worker needs a personal padlock and a responsibly kept key.
• The padlock shackle is made of steel and is electrically conductive – the padlock must only be hung on the lockout point of the isolating device, not near live parts.
• At a shift change, the lockout must be handed over according to the established procedure so that the equipment is not left unlocked even for a moment.

FAQ

Can a LOTO padlock be used as an ordinary padlock?
No. A LOTO padlock is intended for occupational safety only, as it shows that the equipment is locked out and that someone is working on it. When used for other purposes, it loses its meaning, and its plastic body does not protect against break-in.

How many LOTO padlocks are needed?
Every worker who works on equipment being isolated needs at least one personal padlock with a unique key. When one worker locks out several points, they need as many padlocks as there are points, or a group lock box is used.

What should be done if a worker has left and left their padlock on?
Another person's padlock may only be removed according to the company's established procedure: make sure the worker is not on site, try to contact them, obtain permission from the responsible manager, record the action and inform the worker on their return. Never cut off someone else's padlock on your own initiative.

Which padlock colour should I choose?
There is no single mandatory colour standard – colours are set by the company. Most often colours are assigned by department (e.g. electricians, mechanics, contractors) or by shift. The most important thing is that all workers know what each colour means.

LOTO lockout devices are an essential part of any occupational safety system wherever electrical, pneumatic, hydraulic or mechanical equipment is isolated. A safety padlock and a lockout hasp cost less than a single downtime, and their purpose is to ensure nobody switches the equipment on while someone is working on it.