While lockout/tagout (LOTO) is an OSHA-mandated safety practice, sometimes practicing it can be very dangerous because of unsafe conditions. These conditions may exist due to design errors, installation errors, maintenance errors, inadequate maintenance, and documentation problems.
Unless you know the facility is run in “tight ship” fashion, assume these issues exist until you verify otherwise. Some examples:
- Design errors: The designer “saved money” by omitting local disconnects on several loads, using the branch or feeder breaker for that purpose. This means opening under load.
- Installation errors. The disconnecting switch is installed such that you can't stand to the right side of it and operate it with your left hand.
- Maintenance errors. Cover bolts are missing.
- Inadequate maintenance. The condition of the equipment is unknown, due to a failure to perform the recommended maintenance at the recommended intervals. You must assume a worst-case scenario.
- Documentation problems. A facility either has controlled drawings or it has outdated drawings. The latter cannot be relied upon.