Electrical Safety Training

OSHA Requirements for Work Involving Electrical Hazards (OSHA 29 CFR 1910.333)

Electrical safety training is a critical component of workplace safety, especially when working on or near energized electrical equipment. OSHA 29 CFR 1910.333 outlines specific safety-related work practices that must be included in any electrical safety training program.

The primary goal of these practices is to prevent electric shock and other injuries resulting from direct or indirect contact with energized electrical parts.

• Deenergizing Procedures:  OSHA mandates that workers must be trained to understand the importance of deenergizing live parts before starting any work, unless deenergizing introduces additional risks or is infeasible.  Our electrical safety training covers the correct procedures for deenergizing equipment, including when and how to do so safely.
• Lockout/Tagout (LOTO) Training:  Training includes a thorough understanding of the Lockout/Tagout (LOTO) procedures required by OSHA.  Workers are trained on how to effectively lockout and tag electrical circuits to prevent accidental re-energization during maintenance or repair tasks.  This includes verifying the deenergized state and understanding the importance of the LOTO process in electrical safety.
• Safe Work Practices Near Energized Parts:  OSHA emphasizes the need for training on specific work practices to be used when deenergizing is not feasible.  This includes maintaining safe distances, using insulated tools, and understanding the types of personal protective equipment (PPE) necessary for different voltage levels and work conditions.
• Qualified vs. Unqualified Personnel:  Our electrical safety training clearly differentiates between the tasks that qualified and unqualified workers can perform.  Qualified workers should receive training on the special precautionary techniques, PPE, and tools necessary for safely working on or near energized electrical parts.

NFPA 70E Requirements in Electrical Safety Training (Chapter 1, Article 130)

NFPA 70E provides a comprehensive framework for electrical safety training, focusing on the prevention of electrical hazards through safe work practices and risk assessments. Our electrical safety training incorporates the following key NFPA 70E requirements:

• Creating an Electrically Safe Work Condition (ESWC):  Our training emphasizes the importance of deenergizing equipment and creating an ESWC before any work begins.  This includes step-by-step training on disconnecting energy sources, verifying the absence of voltage, and using proper lockout/tagout procedures.
• Energized Electrical Work Permit:  When work on energized equipment is unavoidable, employees must be trained on the proper use of an Energized Electrical Work Permit.  This training covers the required elements of the permit, such as the justification for energized work, the description of work to be performed, and the specific safety measures that will be employed.
• Risk Assessments:  Our electrical safety training includes how to conduct electric shock and arc flash risk assessments.  These assessments are crucial for identifying potential hazards, estimating the likelihood of injury, and determining the necessary protective measures.  Our training provides practical examples of how to perform these assessments and apply the findings to real-world scenarios.
• Understanding Protection Boundaries:  NFPA 70E defines approach boundaries to protect workers from electrical hazards.  Training covers the concepts of Limited and Restricted Approach Boundaries and explain the specific PPE and work practices required when crossing these boundaries.
• Arc Flash Protection:  Arc flash risk assessments are a critical part of electrical safety training.  Employees must be trained on how to evaluate the potential for arc flash incidents and the importance of selecting the appropriate arc-rated PPE based on the level of risk.

Qualified Workers: Understanding Their Role and Requirements

Qualified workers are those who have received comprehensive training in electrical safety and possess the necessary knowledge and skills to perform tasks safely around electrical systems.   According to OSHA 29 CFR 1910.332 and NFPA 70E, these workers must be capable of recognizing and mitigating electrical hazards, and they are the only ones permitted to work within the Limited and Restricted Approach Boundaries of energized parts.

• Technical Competence:  Qualified workers must be proficient in identifying exposed live parts and understanding the nominal voltage of these parts.  They should be well-versed in the specific skills and techniques required to perform their tasks safely, including the use of electrical testing devices.  Any worker using such devices must be considered a qualified worker and possess both the technical and safety knowledge to operate them correctly.
• Approach Boundaries:  Qualified workers must understand the Limited Approach Boundary and Restricted Approach Boundary, which are critical safety zones around energized equipment.  The Limited Approach Boundary is the distance within which an unqualified person may not approach unless advised and continuously escorted by a qualified person.  The Restricted Approach Boundary is a zone closer to the exposed energized parts, where only qualified workers with appropriate training, PPE, and insulating tools may enter.
• Use of Insulated Tools and Testing Equipment: Training for qualified workers includes hands-on experience with insulated tools, voltage testers, and other specialized equipment.  They must also be adept at using PPE, such as rubber insulating gloves, arc-rated clothing, and face shields, to ensure their safety when working near or on energized parts.
• Refresher Training & Retraining: Qualified workers must be trained regularly to stay up to date with the latest safety standards, practices, and changes in their facility.  This includes regular audits and refresher training to ensure compliance with OSHA and NFPA 70E standards.  Annual Qualified Worker Audits must verify that the safety-related work practices are being followed correctly, and any non-compliance with these policies requires retraining on safety-related procedures.

Unqualified Workers: Safety Boundaries and Training

Unqualified workers are those who do not have the same level of training as qualified workers and are not permitted to work on or near exposed electrical parts.  However, they may still encounter electrical hazards in their work environment.  OSHA and NFPA 70E require that these workers receive appropriate training to recognize potential dangers and maintain safe distances from electrical equipment.

• Hazard Recognition: Unqualified workers should be trained to identify potential electrical hazards, such as exposed wires or damaged equipment, and understand the importance of reporting these hazards to qualified personnel.
• Energized Electrical Work Permit: They must be made aware of the Limited and Restricted Approach Boundaries, understanding that they are prohibited from crossing these boundaries unless continuously escorted by a qualified worker.  The training should emphasize that unqualified workers should never enter the Restricted Approach Boundary, as this area is reserved for trained and qualified personnel only.
• Risk Assessments: Even though unqualified workers are not allowed to perform tasks directly on electrical systems, they may need to work near such equipment.  Training should cover safe work practices, such as avoiding the use of conductive materials near electrical panels and understanding the risks associated with using tools or ladders around electrical installations.

Understanding the Shock Risk Assessment Process

A shock risk assessment must address several key questions and considerations:

• Justification for Energized Work: Determine if energized work is necessary.  If de-energizing the equipment presents a greater hazard or is infeasible, then energized work might be justified.  However, appropriate measures must be taken to minimize risks.
• Identifying Hazards: Assess the potential results of equipment failure and identify the degree of electric shock and arc flash hazards present.  This includes evaluating the condition of the equipment, the environment in which it operates, and any additional risks that may arise from the work being performed.
• Employee Exposure:  Consider whether employees will be exposed to electrical hazards during the task.  This includes determining if unqualified workers might inadvertently come into contact with live parts and ensuring that qualified workers are adequately protected.
• Protection Measures: Implement protective measures based on the hierarchy of risk control (HoRC).  This includes eliminating hazards where possible, substituting safer alternatives, implementing engineering controls, and using administrative controls and personal protective equipment (PPE) as a last resort.
• Boundary Considerations: Identify the Limited Approach Boundary and Restricted Approach Boundary.   These boundaries help determine how close workers can get to energized parts and the level of protection required.

Implementing the Shock Risk Assessment

The shock risk assessment process should follow these steps:

1. Determine the Voltage Levels: Identify the voltage of all conductors in the vicinity and the voltage rating of the tools to be used.  This will help in defining the necessary approach boundaries and selecting appropriate PPE.
2. Limited Approach Boundary: Unqualified persons must not cross this boundary unless they are continuously escorted by a qualified person.  This boundary helps protect unqualified workers from accidental contact with live parts.
3. Restricted Approach Boundary: Only qualified persons who are equipped with appropriate PPE and have the necessary training can cross this boundary.  This boundary is closer to the energized parts and presents a higher risk.
4. Assess the Severity and Likelihood of Electric Shock: Consider the current flow through the body, the path it takes, and the duration of exposure.  The severity of an electric shock injury depends on these factors, and the risk assessment should account for them to determine necessary protective measures.
5. Select Appropriate PPE: Based on the boundaries and voltage levels, select PPE that can protect workers from electric shock.  This may include rubber insulating gloves, voltage-rated tools, and insulated mats or blankets.
6. Document the Assessment: OSHA requires that employers document the risk assessment process.  This documentation must include the workplace evaluated, the person certifying the assessment, and the date(s) of the assessment.
7. Reevaluate as Necessary: Reassess the risks whenever there is a change in the electrical system, task, or work environment that could affect the assessment’s accuracy.  Regular reviews help maintain a high level of safety and compliance.

Understanding the Limited Approach Boundary

The Limited Approach Boundary represents the minimum distance an unqualified person must keep from exposed energized parts to prevent electrical shock.  This boundary is not merely a recommendation; it is a mandatory safety measure that must be rigorously enforced in environments where electrical hazards exist.

• Definition and Purpose:  The Limited Approach Boundary is the distance set to prevent unqualified individuals from inadvertently coming too close to energized electrical parts.  It serves as a protective measure, ensuring that those without adequate training are kept at a safe distance unless specific safety measures are in place.

• Who is Affected:  This boundary applies to all workers, but its significance is particularly emphasized for unqualified individuals—those who have not undergone the necessary electrical safety training.  Even qualified personnel must be mindful of this boundary, especially when supervising unqualified workers.

Determining the Limited Approach Boundary

The distance specified by the Limited Approach Boundary varies according to the voltage level of the exposed energized parts. NFPA 70E provides detailed tables that outline the necessary distances based on these voltage levels.

• Voltage and Distance: The required distance for the Limited Approach Boundary increases with the voltage. For instance, for systems operating at or below 5 kV, the boundary is set at 3 feet 6 inches. For higher voltage levels, such as 15 kV, the boundary extends to 5 feet, and for systems operating between 15 kV and 36 kV, the boundary is 6 feet.

• Importance of Accurate Measurement: Properly determining and marking this boundary is crucial for preventing accidental contact with energized parts. Workplaces typically mark these boundaries clearly using signs, tape, or physical barriers to ensure they are recognized and respected.

Requirements for Crossing the Limited Approach Boundary

Crossing the Limited Approach Boundary is subject to strict enforcement and requirements to ensure safety.

• Escorted Access:  Unqualified personnel are strictly prohibited from crossing the Limited Approach Boundary unless they have a justified reason and are under continuous supervision by a qualified person.  This ensures that the unqualified individual remains safe and does not approach the Restricted Approach Boundary or come into contact with any energized parts.

• Briefing & Awareness:  Before crossing the Limited Approach Boundary, unqualified workers must be briefed on the hazards they may encounter and the necessary safety protocols.  This includes a clear understanding of the location of energized parts and the risks associated with them.

Safety Practices for the Limited Approach Boundary

Maintaining safety around the Limited Approach Boundary involves a combination of effective training, clear signage, and diligent supervision.

• Use of Signage and Barriers:  Signs and physical barriers should be employed to mark the Limited Approach Boundary in areas where energized electrical parts are present.  These markers should clearly indicate the presence of electrical hazards and restrict unauthorized access.

• Supervision and Enforcement:  Employers and qualified supervisors are tasked with enforcing adherence to the Limited Approach Boundary.  Regular monitoring and audits should be conducted to verify that workers are observing the required safety measures.

• Emergency Procedures:  Workers must be trained in the appropriate emergency procedures if someone accidentally crosses the Limited Approach Boundary.  This includes immediate actions to de-energize the equipment if necessary and safely remove the individual from the hazardous area.

The Restricted Approach Boundary is the minimum distance at which a qualified person must take specific protective measures before approaching an exposed energized part.  Entry into this boundary without adequate protection is prohibited, as it represents a zone where the risk of electric shock is extremely high.

Understanding the Restricted Approach Boundary

Definition and Purpose:  The Restricted Approach Boundary is set to minimize the risk of direct contact with energized electrical parts.  The purpose of this boundary is to ensure that any work within this zone is conducted with appropriate protective equipment and techniques to prevent electric shock.

Who is Affected:  This boundary applies exclusively to qualified workers—those trained and authorized to work on or near exposed energized electrical parts. Unqualified individuals are strictly prohibited from entering this boundary.

Determining the Restricted Approach Boundary

The distance of the Restricted Approach Boundary varies depending on the voltage of the exposed energized parts, with specific requirements outlined by NFPA 70E:

• 50 volts to 150 volts: Avoid contact with exposed energized parts
• 150 volts to 750 volts: 1 foot
• 750 volts to 5 kV: 2 feet 1 inch
• 5 kV to 15 kV: 2 feet 2 inches
• 15 kV to 36 kV: 2 feet 7 inches

These distances indicate the minimum safe approach distance, within which specific protective measures must be taken.

Requirements for Crossing the Restricted Approach Boundary

Crossing the Restricted Approach Boundary is heavily regulated and can only occur under specific conditions:

Insulation or Guarding:  The qualified worker must be insulated or guarded from the energized parts.  This means wearing appropriate PPE, such as insulating gloves, sleeves, and other protective gear that are rated for the specific voltage.  Insulation or barriers must also be used to prevent direct contact with energized parts.

Insulation of Conductors:  The energized parts must be insulated from the worker and from any other conductive objects at different potentials.  This ensures that there is no direct path for current to flow that could result in an electric shock.

Use of Personal Protective Equipment (PPE):  Qualified workers must use appropriate PPE, such as voltage-rated gloves, insulated tools, and other equipment, when crossing the Restricted Approach Boundary.  This PPE is essential for protecting against the risk of electric shock.

Safety Practices for the Restricted Approach Boundary

Maintaining safety within the Restricted Approach Boundary requires strict adherence to established protocols:

1. Risk Assessment and Planning:
   A thorough risk assessment must be conducted before any work within this boundary begins.  This assessment should evaluate potential hazards, determine the necessary protective measures, and document the procedures that will be followed.
2. Supervision and Enforcement:
   Employers must ensure that only qualified workers with the necessary training and PPE are permitted to work within the Restricted Approach Boundary.  Regular audits and supervision are necessary to enforce compliance with safety standards.
3. Emergency Procedures:
   Workers should be trained to respond quickly in the event of an emergency, including knowing how to de-energize equipment and safely evacuate the area if necessary.

By understanding and adhering to the requirements of the Restricted Approach Boundary, workplaces can significantly reduce the risk of electric shock and other related hazards. This boundary is a critical component of electrical safety protocols and must be clearly communicated, enforced, and respected by all personnel working with or near energized electrical systems.

Shock PPE is essential for protecting workers from the risk of electric shock, which can occur when they come into contact with energized electrical conductors or circuit parts.  The severity of an electric shock injury can vary, but in many cases, it can lead to serious injury or even fatality.  Therefore, selecting the right PPE is critical to ensuring worker safety.

Types of Shock PPE

Shock PPE includes a variety of protective gear designed to prevent electrical current from passing through the worker’s body.  The main types of shock PPE include:

Insulating Gloves:  These gloves are specifically designed to protect against electrical shock.  They are made of rubber or other non-conductive materials and are tested for voltage ratings.  Insulating gloves must be paired with leather protectors to protect them from physical damage and arc flash.

Insulating Sleeves:  Worn in conjunction with insulating gloves, sleeves provide additional protection to the arms when working near exposed energized parts.

Voltage-Rated Insulated Tools:  Insulated tools are designed to protect workers from electric shock when working within the Restricted Approach Boundary.  These tools are rated for specific voltage levels and should be used in conjunction with other PPE.

Insulating Matting and Barriers:  These provide an additional layer of protection by preventing direct contact with the ground or other conductive surfaces, thereby reducing the risk of electric shock.

Selecting the Appropriate Shock PPE

Selecting the correct shock PPE involves several key steps to ensure that workers are adequately protected:

Determine the Voltage Level:  The first step in selecting shock PPE is to identify the voltage of the electrical equipment being worked on.  NFPA 70E and OSHA guidelines provide specific PPE requirements based on voltage levels.  For instance:

• 50 VAC to 150 VAC:  Avoid contact with energized parts.
• 150 VAC to 500 VAC:  Use Class 00 gloves.
• 500 VAC to 1 kVAC:  Use Class 0 gloves.
• 1 kV to 7.5 kVAC:  Use Class 1 gloves.
• 7.5 kVAC to 17 kVAC:  Use Class 2 gloves.
• 17 kVAC to 26.5 kVAC:  Use Class 3 gloves.
• 26.5 kVAC to 36 kVAC:  Use Class 4 gloves.

Conduct a Risk Assessment:  Before selecting PPE, a thorough risk assessment must be conducted to evaluate the potential for shock hazards.  This assessment should consider factors such as the working environment, the proximity of the worker to energized parts, and the specific tasks being performed.

Select PPE Based on Risk and Voltage:  Based on the voltage level and the risk assessment, select the appropriate class of insulating gloves, sleeves, and other PPE.  Ensure that the selected PPE is rated for the maximum voltage to which the worker may be exposed.

Check for Standards Compliance:  Ensure that all selected PPE meets the relevant standards, such as ASTM D120 for insulating gloves and ASTM F496 for in-service care of insulating gloves and sleeves.  PPE must be tested and certified for its intended use.

Inspection and Maintenance of Shock PPE

Regular inspection and maintenance of shock PPE are critical to ensuring its effectiveness:

Pre-Use Inspection:  Before each use, workers must inspect their PPE for any signs of damage, such as cuts, punctures, or wear.  Insulating gloves should be air-tested for leaks, and all PPE should be checked for cleanliness and integrity.

Periodic Testing:  PPE should undergo periodic electrical testing to ensure it can still provide adequate protection.  Insulating gloves, for example, should be tested every six months, while sleeves should be tested at least once a year.

Proper Storage:  PPE should be stored in a cool, dry place, away from direct sunlight and sources of ozone, which can degrade the materials.  Gloves should be stored in protective bags to prevent creasing and physical damage.

Training and Use of Shock PPE

Proper training in the use of shock PPE is essential for worker safety:

PPE Training:  Workers must be trained in the correct use, inspection, and maintenance of shock PPE.  This includes understanding the limitations of the PPE and knowing how to don and doff the equipment safely.

Emergency Procedures:  Workers should be familiar with emergency procedures in the event of PPE failure or an electric shock incident.  This includes knowing how to safely remove a worker from an energized circuit and how to administer first aid.

Before each use, shock PPE such as insulating gloves and sleeves must be thoroughly inspected to ensure they are in good condition.  This process is critical to identifying any defects that could compromise the protective capabilities of the equipment.

Inspection Procedures

Before each use, shock PPE such as insulating gloves and sleeves must be thoroughly inspected to verify they are in good condition.  This process is identifies defects that could compromise the protective capabilities of the equipment.

• Visual Inspection:  Carefully examine gloves and sleeves for any signs of physical damage, such as cuts, tears, punctures, or abrasions.  Look for areas of discoloration or wear that may indicate material degradation.

• Air Testing for Gloves:  Inflate insulating gloves by rolling them up from the cuff towards the fingers to create an air pocket.  Hold the gloves under light pressure to check for any leaks or weak spots. If the gloves fail the air test, they should be removed from service immediately.

• Check for Contaminants:  Ensure that the gloves and sleeves are free from contaminants such as oil, grease, or chemicals, which can degrade the material and reduce its insulating properties.

Proper Care Techniques

To maintain the integrity of shock PPE, it must be properly cared for and handled according to manufacturer guidelines and industry best practices.

• Cleaning:  Use only approved cleaning agents to clean gloves and sleeves.  Avoid using solvents or harsh chemicals that could damage the insulating material.  After cleaning, allow the PPE to air dry completely before storage.

• Handling:  Handle gloves and sleeves with care to avoid creating unnecessary stress on the material.  Avoid folding or crumpling the equipment, as this can cause cracks or other damage over time.

• Storage:  Store PPE in a cool, dry, and dark place away from direct sunlight, which can cause the material to degrade.  Insulating gloves and sleeves should be stored in a protective bag or container to prevent physical damage and contamination.

Regular Maintenance and Testing

Regular maintenance and testing of shock PPE are crucial to protection and compliance with safety standards.

• Electrical Testing:  Insulating gloves and sleeves must undergo periodic electrical testing to verify their insulating properties.  The frequency of testing depends on the usage and exposure conditions but should generally occur every six months for gloves used frequently.  Testing should be performed by a qualified laboratory.

• Replace When Necessary:  PPE that fails inspection or testing should be immediately removed from service and replaced.  Even minor defects can lead to serious injury, so it is crucial to err on the side of caution.

• Record Keeping:  Maintain detailed records of all inspections, tests, and maintenance activities.  This documentation is essential for tracking the condition of PPE and ensuring that it remains compliant with NFPA 70E and OSHA standards.

Training for Proper PPE Management

Workers must be trained on the importance of regular inspection, care, and maintenance of their shock PPE. This training should include:

• Inspection Techniques:  Teaching workers how to properly inspect their PPE before each use and recognize signs of wear or damage.
• Proper Cleaning and Storage:  Educating workers on the correct methods for cleaning and storing their equipment to prevent degradation.

• Understanding Testing Requirements:  Ensuring that workers are aware of the testing schedule for their PPE and the importance of complying with these requirements to maintain safety.

By following the requirements outlined in the Energized Electrical Work Permit, employers and workers can ensure that energized work is conducted safely and in compliance with all relevant safety standards. 

An Energized Electrical Work Permit is required under the following conditions:

When an Energized Electrical Work Permit is Required

• Work within the Restricted Approach Boundary:  If any work is to be performed within the restricted approach boundary, where the risk of electric shock or arc flash injury is significantly increased, a permit is mandatory.  The restricted approach boundary represents the minimum distance at which a qualified person must take specific protective measures before approaching an exposed energized part.

• Increased Likelihood of Arc Flash:  Even if conductors or circuit parts are not exposed, a permit is required if there is an increased likelihood of injury due to an arc flash hazard.  This includes situations where interaction with equipment could trigger an arc flash, necessitating careful risk assessment and control measures.

Exemptions from the Energized Electrical Work Permit

Certain tasks are exempt from the requirement for an Energized Electrical Work Permit, provided they are performed by a qualified person using appropriate safe work practices and personal protective equipment (PPE):

• Testing, Troubleshooting, and Voltage Measuring:  These tasks can be performed without a permit as long as they are conducted outside the restricted approach boundary and proper safety protocols are followed.

• Thermography, Ultrasounds, and Visual Inspections:  These tasks are also exempt, provided they are performed outside the restricted approach boundary.  These activities generally do not involve direct interaction with live parts but require careful observation and documentation.

• General Housekeeping and Miscellaneous Non-Electrical Tasks:  Accessing or exiting areas with energized electrical equipment for non-electrical tasks does not require a permit, as long as the restricted approach boundary is not crossed and no electrical work is performed.

Key Elements of an Energized Electrical Work Permit

The Energized Electrical Work Permit must include several critical elements to ensure that all potential hazards are addressed and that proper safety measures are in place:

• Circuit and Equipment Description:  A detailed description of the circuit and equipment involved, including their location, helps to identify the specific areas where the work will take place.

• Work Description:  Clearly outlining the work to be performed ensures that everyone involved understands the scope and nature of the task.

• Justification for Energized Work:  The permit must include a justification for why the work must be conducted in an energized state.  Typically, this is only permitted when de-energizing the equipment would introduce additional hazards or is infeasible due to the nature of the task.

• Safe Work Practices:  The permit should detail the specific safe work practices that will be employed to protect workers from electrical hazards during the job.

Shock and Arc Flash Risk Assessments

The permit must document the results of both shock and arc flash risk assessments, including:

• Voltage Levels and Boundaries:  Clearly define the voltage levels workers will be exposed to, along with the corresponding limited and restricted approach boundaries.

• Required PPE:  List all shock and arc flash PPE necessary to safely perform the task and protect against potential hazards.

• Incident Energy and Arc Flash Boundary:  Detail the available incident energy at the working distance or specify the Arc Flash PPE Category required, and the arc flash boundary.

Procedures for Restricting Access and Conducting Job Briefings

To maintain a safe work area, the permit must outline:

• Access Restrictions:  Methods employed to restrict the access of unqualified persons from the work area.

• Job Briefing Completion:  Evidence of a completed job briefing, including a discussion of any job-specific hazards, is required to ensure that all workers are fully aware of the risks and the measures in place to mitigate them.

Energized Work Approval

Signatures:  The permit must include the signatures of all electrically qualified persons involved in the work, along with the supervisor’s approval, to confirm that all safety protocols have been reviewed and that the work can proceed safely.

Lockout/Tagout (LOTO) procedures are a critical component of workplace safety, specifically designed to protect workers from electrical hazards during maintenance and servicing of machines and equipment.  These procedures are vital to maintaining an electrically safe work condition.

LOTO Program Requirements

1. Establishing a LOTO Program:  Each employer is required to establish, document, and implement a comprehensive Lockout/Tagout program that safeguards workers from exposure to electrical hazards. 

This program must:

• Be tailored to the experience and training of the workers.
• Meet all requirements outlined in Article 120 of NFPA 70E.
• Apply to all types of equipment, whether fixed, temporary, or portable.

2. Employer Responsibilities: 

Employers are responsible for:

• Providing all necessary LOTO equipment.
• Ensuring that employees receive LOTO training in accordance with NFPA 70E section 110.4(B).
• Conducting audits of the LOTO program annually to identify and correct deficiencies in the procedures, training, and execution.

3. Employee Involvement:  All employees who could be exposed to electrical energy must be involved in the LOTO procedure.  This involvement ensures that they understand the hazards and the steps required to isolate energy sources safely.

LOTO Equipment and Devices

1. Lockout Devices:  Lockout devices are physical locks that prevent the operation of disconnecting means. They must:

• Be identifiable as a LOTO device.
• Be attached securely to prevent accidental removal.
• Have no available spare keys.

2. Tagout Devices:  Tagout devices are used in conjunction with lockout devices to provide additional information and warnings. These devices must:

• Be clearly marked to prohibit unauthorized operation.
• Be durable enough to withstand environmental conditions and the duration of the tagout.

3. Grounding Devices:  When necessary, temporary protective grounding equipment must be applied to protect against electric shock hazards.  These devices must be capable of conducting the maximum fault current and be arranged to minimize exposure to electrical hazards.

General LOTO Process

The process for establishing and verifying an electrically safe work condition includes the following steps:

1. Notify Employees:  Inform all affected employees that LOTO procedures are being implemented.

2. Identify All Energy Sources:  Use all available information to identify and locate all sources of energy, including up-to-date diagrams and identification tags.

3. Machine or Equipment Shutdown:  Shut down the machine or equipment using the normal stopping procedure.

4. Isolation of Energy Sources:  Open the disconnecting devices for each energy source. Visually verify that all blades of the disconnecting devices are fully open, or that drawout-type circuit breakers are fully disconnected.

5. Verify Testing Device:  Ensure your testing device is working properly by testing it on a known live source.

6. Apply LOTO Devices:  Apply lockout and tagout devices according to the documented procedure. Ensure that these devices are securely attached and identifiable.

7. Release Stored Energy:  Release any stored energy from capacitors, springs, or other components. Ensure that all stored mechanical energy is relieved or blocked.

8. Test for Absence of Voltage:  Use a portable test instrument to test for the absence of voltage at each point of work. Verify the instrument’s operation before and after testing.

9. Re-Verify Testing Device:  Test the device again on a known live source to confirm its reliability.

10. Apply Safety Grounds (if necessary):  If induced voltages or stored electrical energy are present, ground all circuit conductors and parts before touching them.

11. Verify Isolation:  Ensure all disconnects have been opened and that the equipment is fully isolated from any energy sources.

12. Check Controls:  Operate all machine or equipment controls to ensure they cannot start the equipment.

13. Apply Lockout Device(s):  Install lockout devices to prevent accidental re-energization.

14. Relieve Stored Energy:  Ensure all stored energy is released or blocked.

15. Apply Safety Grounds:  Install temporary protective grounding equipment where necessary.

16. Return to Service:

• Inspect the Work Area: Ensure the work area is clean and safe.
• Verify Position of Controls:  Confirm that controls are in a neutral position.
• Notify Affected & Authorized Personnel:  Inform employees that the equipment will be re-energized.
• Remove LOTO Devices:  The person who applied the devices should remove them.
• Don the Appropriate PPE:  Wear the necessary PPE during re-energization.
• Re-energize Machine or Equipment:  Restore power to the machine or equipment.
• Check with Operator:  Verify proper operation of equipment.

Complex Lockout/Tagout Procedures

1. When Required:  Complex LOTO procedures are necessary when dealing with multiple energy sources, crews, crafts, locations, disconnecting means, or employers, or when the job spans multiple shifts.

2. Written Plan of Execution:  A written plan must be developed, identifying the person in charge of executing the LOTO procedure. This person is responsible for ensuring all steps are followed, and all employees are accounted for.

3. Group Lockout Devices:  In complex situations, group lockout devices such as lockboxes are used. Each authorized employee must apply a personal lock, and the person in charge must ensure the safety of all employees.

4. Coordination with Outside Contractors:  When outside contractors are involved, there must be a documented meeting to ensure proper coordination of LOTO procedures.

LOTO Training and Audits

1. Training Requirements:  All employees involved in or affected by LOTO procedures must be trained in:

• The LOTO procedures.
• Their responsibilities in executing these procedures.

2. Retraining:  Retraining must occur:

• When procedures are revised.
• At intervals not to exceed three years.
• When inspections indicate non-compliance.

3. Training Documentation:  Employers must document that each employee has received the necessary training. This documentation must include:

• Employee names.
• Dates of training.
• Contents of the training.

4. Auditing the LOTO Program:  The LOTO program must be audited annually by a qualified person. The audit must cover at least one LOTO in progress and should identify and correct any deficiencies in the procedures, training, and execution.