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Hazard Control

Lockout Tagout Safety

Essential guidance for controlling hazardous energy during servicing, maintenance, inspection and equipment intervention.

OSHA10 min readHigh Risk

Overview

Lockout Tagout protects workers from unexpected startup, energization or release of stored energy. Every hazardous energy source must be identified, isolated, locked, tagged, released and verified before work begins.

Main Hazards

  • • Unexpected equipment startup
  • • Electrical shock or arc flash
  • • Release of hydraulic or pneumatic pressure
  • • Movement caused by gravity
  • • Release of stored mechanical energy
  • • Thermal energy and hot surfaces
  • • Chemical or process product release
  • • Incorrect or incomplete isolation

Required PPE

  • ✓Safety helmet
  • ✓Safety glasses
  • ✓Task-specific gloves
  • ✓Safety footwear
  • ✓Arc-rated PPE where electrical risk exists
  • ✓Face protection where pressure release is possible

Essential Controls

  1. 1Identify every hazardous energy source before shutdown.
  2. 2Notify affected employees before applying lockout.
  3. 3Shut down equipment using the normal stopping procedure.
  4. 4Isolate electrical, mechanical, hydraulic, pneumatic, thermal, chemical and gravitational energy sources.
  5. 5Apply personal locks and identification tags to each isolation point.
  6. 6Release, block or restrain all stored and residual energy.
  7. 7Verify zero-energy condition using appropriate testing methods.
  8. 8Attempt a controlled start or try-out where safe and applicable.
  9. 9Use group lockout procedures when multiple workers are involved.
  10. 10Remove locks only under an approved and controlled removal procedure.

Common Mistakes

  • ×Locking only the main electrical switch
  • ×Failing to identify stored or residual energy
  • ×Using another worker's lock
  • ×Relying only on stop buttons or control circuits
  • ×Skipping zero-energy verification
  • ×Removing a lock without authorization
  • ×Using one lock for multiple workers
  • ×Starting work before all isolation points are secured

Pre-work Checklist

  • ✓The equipment and scope of work are clearly identified
  • ✓All hazardous energy sources have been listed
  • ✓Affected employees have been notified
  • ✓The equipment has been shut down normally
  • ✓All isolation points have been locked and tagged
  • ✓Stored energy has been released or restrained
  • ✓Zero-energy condition has been verified
  • ✓Group lockout controls are in place where required
  • ✓The work area is safe to enter
  • ✓Restart authorization responsibilities are understood

Unexpected Energy or Lock Removal

Stop work immediately if an unidentified energy source, pressure, movement or unsafe condition is discovered. Do not remove another person's lock unless the formal lock-removal procedure is authorized, documented and fully controlled.

OSHA References

OSHA 1910.147OSHA 1910.333OSHA 1926.417

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