Hazards and components of lockout/tagout procedures

Workers who engage in the servicing and maintenance of equipment face significant risks, including the potential for serious injuries or fatalities. This is primarily due to unexpected energization, unintended equipment startup or release of stored energy. To mitigate these risks, it is critical to implement effective control measures for hazardous energy, and one of the most effective methods is through lockout/tagout (LOTO) procedures.

These procedures are consistently ranked among the top ten most frequently violated standards set forth by the Occupational Safety and Health Administration (OSHA). Common violations related to lockout/tagout procedures include:

• Failure to identify energy sources
• Inadequate placards
• Unauthorized removal of locks and tags
• Irregular inspections
• Lack of employee training

Adhering to lockout/tagout protocols is not only a legal requirement but also a vital aspect of ensuring employee safety. Per OSHA regulations (29 CFR 1910.147), it is essential to establish a comprehensive lockout/tagout procedure tailored to each piece of equipment present in the workplace.

This program must outline the scope, purpose, authorization, rules and techniques the employer will use to control hazardous energy. Following lockout/tagout protocols is essential; compliance is estimated to prevent around 120 fatalities and 50,000 injuries annually, thus ensuring worker safety and promoting a safer workplace.

Components of a lockout/tagout program

Preparation and notification

An “authorized employee” (someone familiar with the equipment and capable of locking it out properly) should identify the hazards, energy sources (electrical, mechanical, hydraulic, etc.), energy magnitude and methods to control the energy of the equipment. Once it is determined that a shutdown must occur, authorized personnel should notify all employees who will be affected by the service.

Equipment shutdown

Once the hazards have been thoroughly identified, the first step is to safely shut down the equipment involved. This involves following the manufacturer’s shutdown procedures to ensure that the system is powered down correctly and safely.

Lockout/tagout devices

After shutting down equipment and isolating energy, apply a lockout/tagout device to prevent accidental startup. The lockout device keeps the energy-isolating device in a safe position, while the tagout device provides information on who is performing the task and the reason for the shutdown. Both devices serve as warnings to prevent energy restoration and equipment use.

Checking stored energy

Examine the area thoroughly to identify and locate any remaining sources of stored energy or hazardous energy that could pose a risk.

Isolation verification

Conduct an isolation verification test to ensure that the equipment is locked and ready for servicing. This test certifies that the equipment is powered off and all the energy sources have been disconnected and de-energized.

Equipment restoration

When servicing has been completed, it is time to safely return the equipment to service. Ensure that the work area is clear of tools and debris and all controls are neutral. The authorized employee should then remove the lockout/tagout device, and affected employees must be informed of the equipment's return to service.

Training

Employers must provide training for lockout/tagout procedures to ensure employees understand energy removal and usage. Authorized employees should receive additional training to recognize hazardous energy sources and the methods to control them. If new or updated energy control methods are introduced, OSHA requires re-training for all employees. Documentation of the training and employee certifications must be kept on file.

Sources:
OSHA regulations (29 CFR 1910.147)
https://www.osha.gov/control-hazardous-energy
https://www.osha.gov/etools/lockout-tagout/tutorial/printable-version
https://www.osha.gov/sites/default/files/publications/OSHAFS3529.pdf