Lockout Tagout

By R.W. Hurst, Editor

Lockout Tagout (LOTO) plays a vital role in arc flash prevention and overall electrical safety in industrial and commercial environments. By controlling hazardous energy through the use of energy isolating devices and lockout devices, LOTO ensures that electrical systems remain de-energized during maintenance and repair tasks. This is especially critical in sectors like power generation, transmission, and distribution, where the risk of arc flash is high. When implemented correctly and carried out by authorized employees, LOTO aligns with key OSHA standards and protects workers from potential hazardous energy releases during servicing activities. Understanding LOTO's importance is essential to building a safe, compliant, and electrically secure workplace.

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What is Lockout Tagout?

Lockout Tagout is a safety procedure defined by OSHA that involves isolating energy sources and using lockout devices to prevent the unexpected startup of machines during maintenance.

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OSHA Lockout Tagout

To understand the foundation of all lockout tagout procedures, it’s essential to explore OSHA's role. Our OSHA Lockout Tagout page provides a high-level overview of the Occupational Safety and Health Administration’s approach to hazardous energy control, including why the standard was created and how it helps protect workers during equipment servicing.

OSHA Lockout Tagout Standard

The OSHA Lockout Tagout Standard, officially known as 29 CFR 1910.147, outlines the procedures and requirements for controlling hazardous energy during the servicing and maintenance of machines and equipment. This standard is essential in preventing injuries caused by the unexpected startup or release of stored energy. Our dedicated page explains how the regulation applies to electrical systems and what employers must do to comply with OSHA’s control of hazardous energy standard. To learn more, visit our page all about the OSHA Lockout Tagout Standard

OSHA Lockout Tagout Requirements

LOTO procedures are required by OSHA and CSA regulations to prevent serious injuries and fatalities. Without proper energy control, workers are at risk of electric shock, crushing injuries, burns, and more. Implementing a LOTO program is a regulatory requirement and a fundamental part of a strong safety culture. See our page on OSHA Lockout Tagout Requirements

OSHA Lockout Tagout Training

OSHA requires training for all employees involved in or around servicing operations involving hazardous energy. Under 29 CFR 1910.147(c)(7), authorized, affected, and other employees must understand their roles and the proper application of lockout tagout procedures. See our Lockout Tagout Training page for a detailed guide on training implementation and best practices. For a summary of regulatory requirements, visit OSHA Lockout Tagout Training.

Industrial and Commercial Machinery

Industrial and commercial machinery can store energy in more ways than just electricity. Compressed air, hydraulic pressure, mechanical movement, gravity, thermal energy, and even chemical reactions can all pose serious hazards if not properly controlled during servicing or maintenance. Understanding the full range of hazardous energy types is essential for any worker tasked with servicing equipment.

Before work begins, it's important to identify all energy sources connected to the system. Simply shutting off a power switch may not be enough. Some systems require pressure to be bled off, rotating parts to be blocked from movement, or batteries to be disconnected and discharged. Failure to address secondary energy sources is a common cause of injury.

This is why visual verification of energy isolation is just as critical as following procedures. It’s easy to miss a valve or a residual energy point in complex environments. Confirming zero energy through testing or observation ensures that workers are not exposed to unexpected motion or release.

When combined with a structured approach, these precautions help build a safety culture in which workers can confidently perform maintenance, knowing all risks have been minimized.

Core Components of a Lockout Tagout Program

An effective LOTO program includes:

Written procedures for each piece of equipment
An energy isolating device (locks, tags, hasps)
Employee training and retraining
Regular inspections and audits
Defined roles and responsibilities

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Lockout Tagout Procedures and Steps

Each LOTO event should follow a standardized process:

Prepare for shutdown
Notify affected employees
Shut down equipment
Isolate energy sources
Apply lockout/tagout devices
Verify isolation
Perform servicing
Remove devices and restore power

For more details, read our article on Lockout Tagout Procedure

Performing lockout tagout effectively requires strict adherence to OSHA-compliant procedural steps, including equipment shutdown, energy isolation, and verification. Learn how each of the 10 critical steps works in practice on our Lockout Tagout Steps page.

Types of Lockout Tagout Devices

Various LOTO devices are used to prevent physical energy release. These include:

Electrical lockouts
Valve lockouts
Plug lockouts
Circuit breaker lockouts
Tags and hasps

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Group Lockout Tagout

When multiple workers are servicing the same equipment, a group LOTO procedure must be used. This ensures each individual’s safety through the use of group lock boxes and personal locks. Learn more about group lockout tagout.

Lockout Tagout Training

Training is essential to ensure that employees understand the hazards and proper procedures. OSHA requires retraining under certain conditions, such as new equipment or procedural changes. Visit our page on Lockout Tagout Training.

Lockout tagout is more than just applying a lock—it’s a complete system designed to control energy and save lives. Whether you’re building a program, selecting devices, or training staff, understanding each part of the process is essential to compliance and safety.

Frequently Asked Lockout Tagout Questions

To help electrical professionals better understand the complexities of Lockout Tagout and ensure compliance with safety regulations, we've compiled answers to some of the most commonly asked questions. From training requirements to proper practices and the roles of different employees, these insights address real-world concerns about hazardous energy control in the workplace. You can explore them all on our dedicated page: