Workers can easily injure themselves when repairing, performing maintenance, or servicing HVAC equipment if stored energy is released or if the device accidentally gets turned on while being worked on.
Fans, belts and other moving components can snag body parts, resulting in serious injury. For this reason, a technician must physically lock out the equipment using the lockout-tagout (LOTO process) before beginning work to ensure no one can turn it back on until the job is complete.
The Occupational Safety and Health Administration requires all HVAC professionals to use these procedures when repairing or working on equipment. However, according to OSHA’s most recent data and statistics available, LOTO violations were the sixth most common citation in the 2020 fiscal year.
The LOTO procedure for heating and cooling equipment is the same as those used in other industries. These steps include:
- Prepare for shutdown by alerting staff and crew that the LOTO process is about to commence.
- Shut down the equipment by turning it off using the manufacturer’s guidelines.
- Remove the equipment from the local power source by either unplugging it or turning off the circuit breaker.
- Lockout or tagout the equipment using a LOTO device that prevents the equipment from turning on or being used during the repair process.
Technicians should release all residual energy from the machine by testing the movement of all gears and components. Some machines may continue running after they’ve been disconnected from the power source due to stored energy. This includes capacitors, which should be fully discharged to reduce the chance of a nasty shock. Before starting the repairs, ensure the machine has been properly disconnected and de-energized. Once the job is complete, remove the LOTO device.
It’s important to note that lockout and tagout can mean two different things in the field.
Lockout refers to locking out the equipment’s power supply, the “on” button, or circuit breaker before de-energizing the machine to eliminate all residual energy. This prevents the equipment from moving during the repair process.
Tagout refers to installing a tag on or around the machine’s power supply to alert workers of an equipment repair in progress, so they know not to turn it on. However, the equipment can still be powered up during this time. The tagout procedure relies on the team’s observational skills and proper training to ensure everyone knows what to do in this situation.
The person locking out the equipment is usually the person performing the repairs. This person typically uses a key to install the lock on the master switch or circuit breaker. They are usually the only person with the key, which they should wear on their person. However, in some cases, more than one person may have a key so multiple parties can carry out the LOTO process.
Throughout the seasons, many HVAC machines may need repairs. By following best practices for LOTO, technicians can protect themselves from injury. It’s the safest way to get the job done.
Rick Pedley is president and CEO of PK Safety. For more information, visit pksafety.com.
