Protection Against Unexpected Startup
Lockout/tagout (LOTO) procedures are critical for ensuring safety when working on electrical equipment.
These procedures prevent accidental energization of machinery, protecting workers from electrical shocks, burns, and other serious injuries. By isolating energy sources and securing them with locks and tags, LOTO minimizes risks associated with unexpected equipment startup or release of stored energy, creating a safe environment for maintenance and repair tasks.
General Industry: Lockout/tagout is required for general industry applications by OSHA Standard 1910.333(b)(2)(ii), Selection and Use of Work Practices .
Construction: For construction applications, the requirements are referenced in 29 CFR 1926.417, Lockout and Tagging of Circuits .
Here are the typical steps in a Lockout/Tagout (LOTO) procedure:
- Notify Employees: Inform all affected employees about the equipment shutdown and lockout/tagout process.
- Shut Down Equipment: Turn off the machinery or equipment using the normal operating controls.
- Isolate Energy Sources: Disconnect the machine from its energy sources (electricity, hydraulics, pneumatics, etc.).
- Apply Lockout/Tagout Devices: Attach lockout devices (locks) and/or tagout devices (warning tags) to energy isolation points to prevent reactivation.
- Release Stored Energy: Safely release any residual or stored energy, such as pressure in hydraulic lines or electrical capacitance.
- Verify Isolation: Test the equipment to ensure all energy sources are effectively isolated. This often involves attempting to start the machine using its controls.
- Perform Maintenance or Service: Complete the required work while ensuring the equipment remains secured.
- Remove Lockout/Tagout Devices: After completing the work, remove all devices and ensure that all tools and parts are cleared.
- Restore Power: Reconnect energy sources and restart the equipment, following proper procedures.
- Notify Employees: Inform affected employees that the maintenance is complete and the equipment is ready for use.
Maintenance of electrical equipment should be performed only by qualified electricians who have received training in safe lockout procedures. One individual lock and key should be issued to each maintenance worker authorized to lock out the equipment. Authorized employees who repair equipment must use unique individual locks. In most instances, only authorized workers are permitted to remove lockout devices.
A 29-year-old temporary worker at a food processing plant suffered critical injuries and a leg amputation after falling into an industrial blender while cleaning it during an overnight shift. OSHA found the company had failed to train workers on proper lockout procedures to prevent movement during cleaning and maintenance. As a result, OSHA cited the plant for multiple violations, amounting to $1.9 million in proposed penalties.
To prevent similar accidents, OSHA recommends that employers in the food manufacturing industry follow recognized safety standards, including proper training on lockout/tagout procedures and ensuring compliance with machine safety procedures.
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2-7. Which of the following procedures protects the electrician from accidental or unexpected equipment startup?
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