Lockout/Tagout (LOTO) remains one of the most critical safety procedures in the electrical industry. Designed to protect workers from hazardous energy, LOTO saves lives when it’s done correctly. Unfortunately, OSHA consistently ranks LOTO violations among the Top 10 most-cited workplace safety issues, with thousands of citations and millions in penalties issued annually.
Even more troubling? Behind the statistics are real injuries and fatalities that could have been prevented with proper adherence to LOTO and live-dead-live testing. If you missed our deep dive on live-dead-live, you can read that here.
Let’s examine the five most common mistakes workers make when performing LOTO and how you can avoid them.
Too often, workers assume that once a breaker is thrown or a disconnect is pulled, the circuit is safe to work on. This assumption is deadly. Without proper verification, there’s no guarantee hazardous energy has truly been isolated.
How to avoid it: Always perform a live-dead-live test. This three-step method (testing on a known live source, verifying the de-energized circuit, and then retesting on a live source) ensures both your equipment and your procedure are reliable.
Not all multimeters or voltage testers are rated for the environment or the voltage present. Using the wrong tool not only jeopardizes accuracy but also creates new hazards.
How to avoid it: Use a properly rated CAT III/IV meter for the voltages in question. For medium-voltage applications, tools like the ChekVolt 3kV incorporate a 10:1 voltage divider, allowing you to safely use a standard 1000V multimeter to confirm the absence of voltage—no special equipment required.
Some electricians treat LOTO as “low risk” compared to energized work and skip personal protective equipment (PPE). But electrical hazards don’t disappear just because you think a circuit is dead.
How to avoid it: Follow NFPA 70E guidelines for PPE selection. Even during verification, wear insulated gloves, arc-rated clothing, and other gear required for your task-qualified role.
LOTO is not just about the individual; it’s about the team. Incomplete paperwork, missing tags, or failure to communicate can lead to accidental re-energization by another worker.
How to avoid it: Document every step. Use clear, durable tags. And when multiple workers are involved, implement a group LOTO procedure so every person applies and removes their own lock.
Even the best-written procedure is useless if workers don’t understand it. Inadequate training leads to shortcuts, missteps, and ultimately, accidents.
How to avoid it: Ensure all personnel are properly trained and qualified for LOTO and live-dead-live testing. OSHA and NFPA 70E require workers to demonstrate competence in recognizing hazards, using the right tools, and applying safe work practices.
Mistakes during LOTO are not small oversights; they can be fatal. Incorporating live-dead-live testing into your process provides the necessary safeguard against false assumptions and faulty equipment.
Modern tools, such as the ChekVolt, make it easier than ever to verify the absence of voltage while complying with NFPA 70E and OSHA requirements. With features like closed-door access and a 10:1 voltage divider for standard meter use on 3kV systems, among others, ChekVolt streamlines compliance and boosts confidence in every LOTO procedure.
⚡️ Take the next step in electrical safety. Request a ChekVolt sample today and discover how it can enhance your LOTO program with safer, faster, and more reliable live-dead-live testing.
Stay SAFE, and have a GREAT week!