OSHA developed the lockout/tagout (LO/TO) standard (29 CFR 1910.147) precisely to prevent the terrible injuries—and deaths—caused by unexpected equipment start-up. The OSHA regulations require your company to develop a written lockout/tagout program, which must:

• Assign responsibilities for workplace energy control.
• Spell out the exact steps employees must use to shut down, isolate, block, and secure machines or equipment before beginning repairs or maintenance.
• Define the procedures for placing, removing, and testing the effectiveness of lockout/tagout devices.

In addition, you must:

• Provide locks, tags, and related equipment that meet OSHA standards.
• Inspect energy control procedures at least annually and correct problems.
• Train employees to understand and follow LO/TO procedures.

OSHA’s lockout standard also requires you to make sure employees isolate and render inoperative any and all energy sources. Depending on the equipment those sources might be:

• Electrical
• Pneumatic
• Hydraulic
• Mechanical
• Thermal
• Chemical
• Force of gravity

Failure to isolate all energy sources could—and often does—result in the injury or death of one or more employees.

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LO/TO Step by Step

To make sure you, OSHA, and your employees are all on the same page about lockout/tagout procedures, here are seven basic steps for safe LO/TO recommended by the Environmental Safety and Health Department at the University of California Santa Cruz:

1.  Think, plan, and check.

• If you are in charge, think through the entire procedure.
• Identify all parts of any systems that need to be shut down.
• Determine what switches, equipment, and workers will be involved.
• Carefully plan how equipment will be restarted when repairs or maintenance is completed.

  2.  Communicate.

  • Notify all those who need to know that a lockout/tagout procedure is taking place.
  • Identify all appropriate power sources, whether near or far from the jobsite.
  • Include electrical circuits, hydraulic and pneumatic systems, spring energy, and gravity systems.

  3.  Neutralize all appropriate power at the source.

  • Disconnect electricity.
  • Block movable parts.
  • Release or block spring energy.
  • Drain or bleed hydraulic and pneumatic lines.
  • Lower suspended parts to rest positions.

  4.  Lock out all power sources.

  • Use a lock designed only for this purpose.
  • Each worker should have a personal lock.

  5.  Tag out all power sources and machines.

  • Tag machine controls, pressure lines, starter switches, and suspended parts.
  • Tags should include your name, department, how to reach you, the date and time of tagging, and the reason for the lockout.

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  6.  Do a complete test.

  • Double-check all the steps above.
  • Do a personal check.
  • Push start buttons, test circuits, and operate valves to test the system.

  7.  Restart safely.

  • After work is completed, remove only your own locks and tags.
  • Make sure workers in the area are notified of restart and are at a safe distance from equipment.
  • Turn on the power.
  • Make sure equipment is running properly.

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