Lockout/Tagout (LOTO) failures cause approximately 120 fatalities and 50,000 injuries annually in the U.S. These incidents often occur during cleaning, repairing, or adjusting machinery when equipment unexpectedly energizes. In over 58% of fatal cases, LOTO procedures were not attempted, with common causes being failure to stop equipment, disconnect power, or release stored energy.
Key issue: Lockout/Tagout (LOTO) Hazards
- Electrical – (existing or old wiring feeds, panel boxes, receptacles, energized switchgear, equipment leads, panel boxes, etc.) ZERO energized work is allowed without specific documented approvals.
- Mechanical – (lifts, boom trucks, material handlers, elevated work platforms, shoring systems, etc.)
- Hydraulic – (lifts, boom trucks, material handlers, elevated work platforms, shoring systems, etc.)
- Pneumatic – (air-powered tools, shoring, compressed air cylinders, portable compressors, tires, etc.)
- Chemical – (pipe and supply lines, etc.)
- Thermal – (steam pipes, cryogenic system lines, energy sources, etc.)
- Gases – (natural gas, propane, methane, oxygen, nitrogen, etc.)
- Engulfment – (water, sewage, etc.)
- Hazardous Waste – (sewer plants, dormitory and housing projects, etc.)
- Gravitational – (suspended loads, material lifting equipment, etc.)
Policy
No work shall begin until energy isolation is verified.
This Lockout/Tagout (LOTO) Program establishes procedures for isolating energy sources to protect employees from the unexpected startup or release of hazardous energy during service or maintenance activities. It complies with OSHA [29 CFR 1926.417] – Lockout and Tagging of Circuits and [29 CFR 1910.147] – The Control of Hazardous Energy.
This program applies to all Quandel employees and subcontractors involved in the demolition, installation, service, maintenance, or repair of machinery, equipment, or systems that could release hazardous energy.
Control Measures
- Make sure that job role responsibilities are understood and documented.
- Notify affected employees.
- Shut down equipment properly.
- Isolate energy sources (open disconnects, valves, breakers, etc.).
- Apply lock(s) and tag(s).
- Release stored energy (bleed lines, discharge capacitors, block moving parts).
- Verify a zero-energy state using appropriate test equipment.
- Use a group lockbox for multiple workers.
Regulations
OSHA Standard 1910.147 Subpart J – Control of Hazardous Energy (Lockout/Tagout Program)
1910.147(c)(9) – Restoring Equipment to Service: When servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition, specific steps must be taken before restoring equipment to service.
OSHA Standard 1926 Subpart K
1926.416(a)(1): No employer shall permit an employee to work in such proximity to any part of an electric power circuit that the employee could contact the circuit in the course of work unless the employee is protected against electric shock by de-energizing and grounding the circuit or by guarding it effectively through insulation or other means.
1926.417(a): Controls that are to be deactivated during the course of work on energized or de-energized equipment or circuits shall be tagged. Equipment or circuits that are de-energized shall be rendered inoperative and shall have tags attached at all points where such equipment or circuits can be energized. Tags shall be placed to clearly identify the equipment or circuits being worked on.
1926.416(a)(3): Before work begins, the employer shall ascertain by inquiry, direct observation, or instrument testing whether any part of an energized electric power circuit, exposed or concealed, is located such that the performance of the work may bring any person, tool, or machine into physical or electrical contact with the circuit. The employer shall post and maintain proper warning signs where such a circuit exists and advise employees of the location of such lines, the hazards involved, and the protective measures to be taken.
What You Need to Know
Responsibilities
Authorized Employees
- Perform LOTO procedures.
- Apply and remove locks and tags.
- Verify a zero-energy state.
Affected Employees
- Work in areas where LOTO is being performed.
- Must not attempt to remove or bypass lockout devices.
Site Supervision
- Ensure LOTO procedures are followed.
- Maintain and distribute LOTO devices and documentation.
Lockout/Tagout Devices
- Only Quandel-approved locks and tags may be used.
- Each employee must use a personal lock and tag.
- Tags must be durable, legible, and include the employee’s name and contact information.
- Locks must be keyed individually; no shared keys are allowed.
General LOTO Procedure
- Notify affected employees.
- Shut down equipment properly.
- Isolate energy sources (open disconnects, valves, breakers, etc.).
- Apply lock(s) and tag(s).
- Release stored energy (bleed lines, discharge capacitors, block moving parts).
- Verify a zero-energy state using appropriate test equipment.
Restoring Equipment to Service
- Inspect the area and equipment to ensure it is clear.
- Ensure all tools and non-essential items are removed.
- Verify all employees are clear of danger zones.
- Remove locks and tags in reverse order of application.
- Notify affected employees.
- Restart equipment following normal procedures.
Important Do’s To Keep In Mind About Lockout/Tagout
- Do follow a strict six-step procedure: prepare, shut down, isolate, lock/tag, release stored energy, and verify.
- Do use your own personally assigned lock and key; no one else should have that key.
- Do verify that equipment is at a “zero-energy” state before starting work by attempting to start it.
- Do notify all affected employees before and after the LOTO procedure.
- Do ensure all stored energy (hydraulic, pneumatic, springs, etc.) is released or blocked.
- Do remove all tools and reinstall machine guards before removing locks.
- Do make sure tags are durable and clearly state who applied the lock.
- Do train all employees concerning their roles, responsibilities, and exposure.
Important Don’ts To Keep In Mind About Lockout/Tagout
- Don’t use someone else’s lock or share keys.
- Don’t leave your lock on at the end of your shift unless following specific company procedures.
- Don’t skip the verification step—never assume a machine is off simply because a button was pushed.
- Don’t bypass machine guards.
- Don’t remove another person’s lock.
- Don’t attempt to operate a machine that has a tag on it.
- Don’t ignore LOTO procedures for “quick fixes” or short-duration tasks.
Occupational Safety and Health Administration. “1910.147—The Control of Hazardous Energy (Lockout/Tagout).” OSHA, U.S. Department of Labor, https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.147. Accessed 11 June 2026.
Occupational Safety and Health Administration. “Control of Hazardous Energy (Lockout/Tagout) – Overview.” OSHA, U.S. Department of Labor, https://www.osha.gov/control-hazardous-energy. Accessed 11 June 2026.
Occupational Safety and Health Administration. “Control of Hazardous Energy (Lockout/Tagout) – Standards.” OSHA, U.S. Department of Labor, https://www.osha.gov/control-hazardous-energy/standards. Accessed 11 June 2026.
