Lockout/Tagout LOTO Procedures JSA – Job Safety Analysis
1. Introduction
Lockout/Tagout (LOTO) is a safety procedure used to ensure that machines and equipment are properly shut off and not able to be started up again before the completion of maintenance or servicing work. This process protects workers from the unexpected release of hazardous energy (electrical, mechanical, hydraulic, pneumatic, thermal, or chemical).
Failure to implement proper LOTO procedures has historically caused serious injuries and fatalities, making it one of OSHA’s most cited violations under 29 CFR 1910.147 – The Control of Hazardous Energy.
This JSA provides step-by-step guidance to ensure that all workers performing maintenance, servicing, or repair are protected from hazardous energy sources.
2. Purpose of This JSA
The objectives are to:
- Prevent accidental start-up of machines during servicing.
- Protect workers from hazardous energy release.
- Establish a standardized procedure for energy isolation.
- Ensure compliance with OSHA and international safety standards.
- Provide training and awareness to workers on LOTO practices.
3. Applicable Standards & References
- OSHA 29 CFR 1910.147 – The Control of Hazardous Energy (LOTO)
- OSHA 29 CFR 1910.333 – Selection and Use of Work Practices (Electrical)
- ANSI/ASSE Z244.1 – Control of Hazardous Energy
- NFPA 70E – Electrical Safety in the Workplace
- Company Energy Control Program (ECP)
4. Scope of Work
This JSA applies to all maintenance, servicing, cleaning, inspection, repair, and installation tasks where hazardous energy could cause harm. Examples include:
- Electrical panel maintenance.
- Machine servicing (presses, conveyors, pumps).
- Hydraulic/pneumatic system repairs.
- Pipeline isolation (steam, gas, chemicals).
- Equipment installation and commissioning.
5. Job Breakdown (Step-by-Step)
- Preparation for Shutdown – Identify all energy sources and affected workers.
- Notify Employees – Inform all personnel that lockout/tagout will be applied.
- Shutdown of Equipment – Follow standard procedures to turn off machinery.
- Isolation of Energy Sources – Apply isolation devices (switches, valves, breakers).
- Lockout/Tagout Application – Apply locks and tags to energy-isolating devices.
- Release of Stored Energy – Bleed, vent, or discharge residual energy.
- Verification of Isolation – Test to confirm zero energy state.
- Perform Work Safely – Conduct servicing, repair, or maintenance tasks.
- Release from Lockout/Tagout – Inspect area, remove tools, and remove locks/tags.
- Restart Equipment – Notify employees and restart machinery safely.
6. Hazard Identification
LOTO-related hazards include:
- Unexpected energization (electric shock, arc flash).
- Stored energy release (hydraulic/pneumatic pressure, gravity).
- Chemical hazards from pipelines and tanks.
- Mechanical hazards from moving machine parts.
- Failure to verify isolation before beginning work.
- Miscommunication between workers and supervisors.
7. Risk Assessment Table
| Task | Hazard | Consequence | Risk Level | Control Measures |
|---|---|---|---|---|
| Preparation for shutdown | Incomplete energy identification | Residual energy release | High | Review energy control plan |
| Isolation of sources | Wrong breaker/valve isolated | Electric shock, chemical spill | High | Label energy points, cross-check |
| Lockout application | Shared equipment | Unauthorized removal of lock | High | Use group lock box system |
| Stored energy release | Hydraulic/pneumatic pressure | Burns, injury | High | Bleed pressure lines, vent tanks |
| Verification | Failure to test | Machine starts unexpectedly | High | Test controls, use test equipment |
| Release from LOTO | Premature removal | Worker exposure | High | Supervisor verification before restart |
8. Control Measures
A. Engineering Controls
- Install energy isolation devices (lockable disconnect switches, lockable valves).
- Use group lockout boxes for multiple workers.
- Provide interlocks and emergency stop systems.
- Use bleeder valves and vents to safely discharge stored energy.
B. Administrative Controls
- Develop a written Energy Control Program (ECP).
- Train workers on LOTO procedures annually.
- Maintain a LOTO logbook for compliance.
- Conduct periodic inspections of LOTO practices.
- Assign Authorized, Affected, and Other Employee roles clearly.
C. PPE Requirements
- Hard hat.
- Safety boots.
- Insulated electrical gloves.
- Safety goggles/face shield.
- Flame-resistant clothing (arc flash rated).
- Hearing protection (for loud equipment).
9. Roles & Responsibilities
- Authorized Employees: Perform LOTO procedures and maintenance work.
- Affected Employees: Must not operate equipment under LOTO.
- Supervisors: Verify compliance and coordinate group lockouts.
- Safety Officer: Audit, train, and enforce LOTO procedures.
10. Emergency Preparedness
- Electrical Incidents: Use insulated rescue hooks and follow NFPA 70E protocols.
- Hydraulic/Pneumatic Incidents: Ensure pressure release valves are functional.
- Fire or Explosion: Fire extinguishers and emergency alarms in place.
- First Aid: Readily available for electric shock, burns, or chemical exposure.
- Emergency Communication: Ensure radios or alarms are accessible.
11. Best Practices for LOTO
- Always use personal locks with unique keys.
- Never share or duplicate keys.
- Attach durable tags with worker’s name, department, and contact info.
- Follow “One Lock, One Person, One Key” principle.
- Use multi-lock hasps when multiple workers are involved.
- Perform a try-start test after isolation to confirm zero energy.
- Remove all tools and reinstall guards before restarting.
12. Sample JSA Form – LOTO Procedures
Job Title: Lockout/Tagout Procedures
Location: ____________________
Date: ____________________
Supervisor: ____________________
| Task Step | Hazard | Control Measure | PPE Required | Responsible Person |
|---|---|---|---|---|
| Preparation | Residual energy not identified | Review ECP | Gloves, helmet | Authorized Worker |
| Isolation | Wrong breaker/valve | Label & verify | Gloves, goggles | Supervisor |
| Lockout | Lock not applied | Apply personal locks | Lockout device | Authorized Worker |
| Stored energy release | Hydraulic pressure | Bleed & vent | Gloves, FR clothing | Crew |
| Verification | Failure to test | Try-start test | Test equipment | Authorized Worker |
| Work execution | Accidental re-energization | Maintain lockout | PPE | Crew |
| Release | Premature restart | Supervisor check | Helmet, vest | Supervisor |
13. Conclusion
Lockout/Tagout is one of the most life-saving procedures in industrial safety. Proper implementation of LOTO prevents fatal electrical shocks, crushing injuries, chemical burns, and unexpected equipment movement.
By following this JSA, organizations can standardize energy control procedures, train workers effectively, and comply with OSHA standards, thereby reducing risks and ensuring a safe workplace.
✅ Final Safety Reminder:
“If it’s not locked out, it’s not safe – Always Lock, Tag, Test, and Verify.”
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