Outline the essential steps that constitute a comprehensive lockout/tagout (LOTO) procedure for de-energizing electrical equipment to ensure worker safety.

A comprehensive Lockout/Tagout (LOTO) procedure is crucial for preventing accidental energization of electrical equipment during maintenance or repair, thus ensuring worker safety. The procedure involves a series of detailed steps, each essential for creating a safe working environment. Here’s a breakdown of those steps:

1. Preparation for Lockout/Tagout: Before initiating any LOTO procedure, proper planning and preparation are necessary.
Identify the Equipment: Clearly identify the specific electrical equipment to be de-energized. For example, it could be a specific circuit breaker, a motor control center, or a panelboard. This identification must be precise to avoid accidental lockout of the wrong equipment, which can create unsafe conditions.
Understand the Energy Sources: Determine all sources of energy that power the equipment. This includes electrical power, but it may also include other hazardous forms of energy such as hydraulic, pneumatic, thermal, and mechanical energy. For instance, a motor may have electrical power and also mechanical energy stored in its rotating parts. All these sources must be identified and addressed to avoid any accidental energization.
Review Procedures: Review all relevant LOTO procedures, safety manuals, and schematics related to the equipment being de-energized. Workers should have a thorough understanding of the procedures and what to expect. A documented procedure for each piece of equipment can prevent confusion and ensures consistency in the process.
Notify Affected Personnel: Inform all affected employees and personnel that the equipment will be de-energized for maintenance or repair. This notification ensures that no one is caught by surprise and that no work is being performed while the equipment is being de-energized. A supervisor must communicate clearly to workers about the timeline and purpose of the lockout/tagout procedure.
Gather Necessary Equipment: Collect all required LOTO devices, including locks, tags, hasps, and other LOTO hardware. Insulated tools, test equipment and PPE such as gloves and safety glasses must also be obtained. Ensuring that all necessary items are on hand reduces the likelihood of delays or unsafe shortcuts.

2. Shutting Down the Equipment: After the preparatory steps, the next phase involves properly shutting down the equipment.
Normal Shutdown Procedure: Follow the normal shutdown procedure for the equipment by using the controls on the equipment itself. This step should not be skipped, as abrupt shutdowns can cause other issues.
Isolate the Energy Source(s): Identify and isolate all energy sources. This step involves opening the circuit breaker, turning off a disconnect, or closing a valve. Use insulated tools to de-energize equipment. For example, flip the breaker to the "off" position.
Verify Isolation: After isolating the equipment, verify that no energy remains present. Use a voltage tester to check that the equipment is indeed de-energized at all appropriate locations. Perform this check at each potential connection point to ensure complete isolation.
Dissipate Stored Energy: Release any stored energy that could be present in the system. This includes discharging capacitors, releasing pressure in hydraulic systems, or blocking potential mechanical motion. If capacitors are present they must be properly discharged. This will avoid an unexpected release of energy.

3. Application of Lockout/Tagout Devices: The core of the LOTO procedure is the secure application of locks and tags to ensure that equipment remains de-energized.
Apply Locks: Each authorized employee who will be performing work on the equipment must attach their personal lock to each energy isolation point. This prevents unauthorized access to the energy isolating device. For a circuit breaker, a lockout device is attached to the breaker to keep it open and each worker will place their lock on the lockout device.
Apply Tags: Place a tag on each lock indicating who applied the lock, why the equipment is de-energized, and when the lock was applied. The tag provides crucial information and an added layer of safety. The tag should provide clear warnings and the name and contact information of the person who applied the tag.
Verify Secure Lockout/Tagout: Ensure that all locks and tags have been properly applied and that the equipment is still in the de-energized state. Try to operate the controls to verify they remain de-energized and locked out. This secondary check ensures that the procedure was completed properly and is critical to avoiding an accidental energization.

4. Performing the Maintenance or Repair: With LOTO devices in place, work on the de-energized equipment can begin.
Complete Maintenance: Perform the planned maintenance or repair work. This is the reason for the LOTO procedure. Ensure that the worker is able to complete the task at hand safely and without pressure.
Follow Procedures: Work should be conducted according to safe practices and any relevant procedures. Proper technique is required to ensure a safe work environment.

5. Removal of Lockout/Tagout Devices: Once the maintenance or repair is completed, the LOTO devices must be removed in a controlled manner.
Verify Completion: Before removing any lock, the worker should verify that all work is complete, all tools and equipment have been removed from the area and it's safe to re-energize the equipment. A visual inspection is needed before removing LOTO devices.
Remove Locks and Tags: Each authorized employee who placed a lock on the equipment must personally remove their lock. Under no circumstance should anyone remove another person's lock. Each worker must physically remove their own lock after the work has been completed.
Notify Affected Personnel: Inform all affected personnel that the equipment is about to be re-energized. This prevents unauthorized access while the equipment is re-energized.

6. Re-energizing the Equipment: After removal of LOTO devices, the equipment can be safely re-energized.
Restore Energy: Gradually restore power to the equipment, carefully monitoring for any problems. All energy sources must be returned to their original state in a safe way.
Verify Proper Operation: Test the equipment to ensure that it is functioning as intended. Any abnormal readings, sounds or smells should be further investigated before proceeding.

7. Post-Procedure Review: After equipment is back online a final review of the process can highlight issues.
Review Procedure: Review the entire LOTO procedure to identify areas for improvement and ensure compliance. Continuous review and improvement of procedures ensure safety.
Document Changes: Any changes made to the procedure should be documented and communicated to all affected personnel. Updates ensure safety measures are current.

Following these essential steps for a comprehensive LOTO procedure ensures that workers are protected from the hazards of accidental energization during maintenance and repair of electrical equipment. Adhering to a thorough and documented procedure will help prevent workplace accidents and injuries.