What are the key components of a well-structured lockout/tagout procedure?

A well-structured Lockout/Tagout (LOTO) procedure consists of several key components designed to ensure that machinery and equipment are properly shut down and rendered inoperable before maintenance or servicing is performed. The first key component is a written LOTO program, which outlines the specific steps and requirements for controlling hazardous energy. This program should be specific to the equipment being serviced and include procedures for identifying and isolating all energy sources. The second component is energy source identification. All potential sources of energy, such as electrical, hydraulic, pneumatic, mechanical, and thermal, must be identified and documented. The third component is equipment shutdown and isolation. The equipment must be shut down using the normal operating procedures, and then all energy-isolating devices, such as circuit breakers, disconnect switches, and valves, must be activated to cut off the energy supply. The fourth component is lockout device application. Each energy-isolating device must be locked in the safe or 'off' position using a standardized lockout device, such as a padlock. The fifth component is tagout device application. A tagout device, typically a warning tag, must be attached to each lockout device to provide a clear warning that the equipment is out of service and should not be operated. The sixth component is stored energy verification. Any stored or residual energy, such as pressure in hydraulic lines or tension in springs, must be safely relieved or dissipated. The seventh component is isolation verification. The effectiveness of the lockout/tagout procedure must be verified by attempting to start the equipment or testing the circuits to ensure that they are de-energized. The final component is LOTO removal. Before restarting the equipment, all tools and materials must be removed, all workers must be safely positioned, and each worker must remove their personal lockout/tagout devices. For example, before replacing a hydraulic cylinder on an excavator, a well-structured LOTO procedure would involve shutting down the engine, relieving hydraulic pressure, locking out the hydraulic pump, tagging the controls, verifying the pressure is zero, and then performing the cylinder replacement.