How LOTO prevents electrical injuries and supports OSHA compliance.
Introduction
Working with electricity is dangerous. Every year in the United States, hundreds of workers die from electrocution and many more suffer burns and shocks. A major cause is unexpected machine startup or the release of stored energy.
The good news is that these events are preventable. OSHA’s Lockout/Tagout (LOTO) rules provide clear steps to control hazardous energy. This guide explains how LOTO prevents electrical injuries and how workers can use it to reduce risk and support compliance.
What Is Electrical Safety in the Workplace?
Electricity powers nearly every tool and machine used in industry. If it is not controlled, it can kill.
- How electricity harms: Shock occurs when current passes through the body. Even low current can cause burns, loss of muscle control, or cardiac arrest.
- Key terms: Conductors allow current to flow. Insulators resist current flow.
- Common hazards: Damaged cords, improper grounding, work on live circuits, and machines started unexpectedly.
OSHA 29 CFR 1910.333 requires de-energizing circuits before servicing and using safe work practices for electrical tasks.
Why Lockout/Tagout Is Critical for Worker Protection
During service or maintenance, stored energy can release or a machine can start without warning. If a worker is in contact with the equipment, the result can be deadly.
- Unexpected startup: Power can be reconnected or switches activated.
- Stored energy: Electrical systems, hydraulics, pneumatics, gravity, and springs may still hold energy.
OSHA’s 29 CFR 1910.147 requires energy control procedures. Locks and tags prevent anyone from starting a machine until it is safe.
Core Elements of a Lockout/Tagout Program
- Energy control program: Written steps to shut down, isolate, lock, and tag each machine.
- Authorized employees: Trained workers who apply locks and tags.
- Affected employees: Workers near the equipment who must understand LOTO.
- LOTO devices: Padlocks, tags, hasps, valve and breaker lockouts, lock boxes.
- Periodic inspections: Inspect and certify each LOTO procedure at least annually.
Step-by-Step: Lockout/Tagout Procedure
- Notify affected employees.
- Shut down the machine or equipment.
- Isolate all energy sources.
- Apply lockout and tagout devices.
- Release or block stored energy.
- Verify zero energy by testing controls.
- Perform the work.
- Remove locks and tags only when work is complete and the area is clear.
Important: Only the worker who applied a lock can remove it.
Top Mistakes Workers Make with LOTO
- Not verifying zero energy before starting work.
- Sharing locks or keys.
- Using tags alone without locks when locks are possible.
- Skipping regular procedure inspections.
- Relying on memory instead of written procedures.
Electrical Safety Quick Tips for Workers
Choose tools rated for the voltage.
Gloves, face shields, and arc-rated gear when required.
Tag and remove damaged cords or tools from service.
Follow the procedure every time.
FAQs: Lockout/Tagout and Electrical Safety
Who must perform lockout/tagout?
Only authorized employees who are trained and assigned by the employer may apply locks and tags.
Are tags alone enough to protect workers?
No. Tags are warnings. OSHA expects locks whenever possible to provide physical restraint.
How often are LOTO procedures inspected?
Each procedure must be inspected at least once per year. The inspection must be certified and documented.
Conclusion
Electrical hazards are deadly, but preventable. Lockout/Tagout procedures save lives by stopping accidental startup and energy release. Follow OSHA’s requirements, use the right devices, and never skip a step. Safer work starts with consistent LOTO.