Practical tips to protect workers from hazardous energy and support OSHA compliance.
Table of Contents
- Introduction
- OSHA Context: Why Lockout/Tagout Matters
- Common Electrical Hazards in the Workplace
- Key Lockout/Tagout Safety Tips
- Checklist: Quick LOTO Safety Reminders
- Best Practices for Workers and Supervisors
- Quick Tips: Staying Safe Around Electrical Machinery
- FAQs: Lockout/Tagout Safety
- Conclusion
Working with machines and electrical systems can be dangerous. When equipment is not properly shut down, workers face serious risks from shock, burns, and unexpected startup. Many incidents are preventable. Lockout/Tagout (LOTO) controls hazardous energy so people can service and maintain equipment safely. The tips below help improve safety, support compliance, and reduce risk.
OSHA Context: Why Lockout/Tagout Matters
OSHA’s Control of Hazardous Energy standard, 29 CFR 1910.147, requires a written energy control program, machine-specific procedures, employee training, and periodic inspections. Electrical requirements in 29 CFR 1910 Subpart S support safe work around energized parts. A strong LOTO program prevents the unexpected release of electrical, mechanical, hydraulic, pneumatic, chemical, or thermal energy during service or maintenance.
Common Electrical Hazards in the Workplace
- Electric shock — Contact with live parts can cause burns, nerve damage, or cardiac arrest.
- Arc flash — Sudden energy release with extreme heat and blast pressure.
- Electrocution — Fatal exposure to electrical current.
- Stored energy — Capacitors, springs, pressurized lines, and gravity can still hold dangerous energy after shutdown.
Key Lockout/Tagout Safety Tips
Identify all energy sources before work. Include main power, control circuits, stored mechanical energy, and residual pressure.
Use dedicated locks and tags. Never use makeshift devices. Tags must be legible and durable.
Verify zero energy after isolation. Test for absence of voltage. Relieve or block stored and residual energy.
One person, one lock. Each authorized worker applies a personal lock and keeps the key.
Never remove another person’s lock or tag. Follow a formal removal process if someone is unavailable.
Keep written procedures for each machine. Make them accessible and clear.
Inspect regularly. Perform periodic inspections to confirm that employees follow procedures.
Checklist: Quick LOTO Safety Reminders
- Shut down the machine completely.
- Disconnect all power sources and isolate energy.
- Apply locks and tags properly to each point.
- Verify zero energy before starting work.
- Keep locks in place until the job is complete.
- Remove locks only when all workers are clear.
Best Practices for Workers and Supervisors
- Train employees to recognize hazards and perform LOTO correctly.
- Maintain a written energy control program that is current and machine-specific.
- Conduct periodic inspections to confirm compliance and correct gaps.
- Provide PPE such as insulated gloves, eye protection, and arc-rated clothing when required.
- Communicate clearly before re-energizing equipment and use a start-up checklist.
- Encourage reporting of unsafe conditions without retaliation.
Quick Tips: Staying Safe Around Electrical Machinery
- Keep hands and tools dry when near power.
- Use insulated tools approved for electrical work.
- Wear required PPE for the task and voltage level.
- Do not rush through shutdown steps or testing.
- Communicate with the team before restoring power.
FAQs: Lockout/Tagout Safety
Who is authorized to perform lockout/tagout?
Only trained and authorized employees can apply or remove locks and tags. Affected employees must be notified but are not permitted to perform LOTO.
What energy sources require lockout/tagout?
Electrical, mechanical, hydraulic, pneumatic, chemical, and thermal energy must be controlled. Consider gravity and stored energy in springs and capacitors.
How often should inspections be performed?
At least annually. Many sites check more often to strengthen compliance and correct issues quickly.
Conclusion
Lockout/Tagout protects people from hazardous energy. When workers follow the steps, verify zero energy, and communicate before start-up, injuries drop. Use these tips to improve safety, support compliance, and reduce risk on every job.