Lockout/Tagout (LOTO) Procedure Checklist

What is a lockout/tagout checklist? A lockout/tagout (LOTO) checklist is a safety procedure form required by OSHA 1910.147 to control hazardous energy sources during equipment servicing and maintenance. LOTO prevents unexpected startup or release of stored energy that causes approximately 50,000 injuries and 120 deaths annually in the US. This checklist ensures proper isolation, lockout, tagout, and verification of zero energy state.

Industry: Construction / Manufacturing / Utilities
Frequency: Each maintenance/service activity
Estimated Time: 15-30 minutes (varies by equipment complexity)
Role: Authorized Employee / Maintenance Technician
Total Items: 46
Compliance: OSHA 1910.147 (Control of Hazardous Energy), OSHA 1910.333 (Electrical Safe Work), NFPA 70E (Electrical Safety), ANSI/ASSE Z244.1, HSE PUWER 1998 (UK)

Energy Source Identification

Identify ALL energy sources per OSHA 1910.147(c)(4). Equipment may have multiple energy types.

Electrical energy present?
Electrical voltage(s)
Hydraulic energy present?
Hydraulic pressure (PSI)
Pneumatic energy present?
Pneumatic pressure (PSI)
Mechanical/kinetic energy present?
Thermal energy present?
Chemical energy present?
Stored/residual energy identified?
...and 1 more items

Preparation for Shutdown

OSHA 1910.147(d)(1): Prepare for shutdown by understanding equipment and notifying affected employees.

Written LOTO procedure reviewed?
All affected employees notified?
Number of affected employees notified
All isolation points identified?
Number of isolation points
Adequate locks and tags available?
Required PPE identified and available?

Equipment Shutdown & Isolation

OSHA 1910.147(d)(2-3): Orderly shutdown and energy isolation.

Equipment shut down using normal procedures?
All operating controls in OFF/SAFE position?
Electrical disconnects opened/locked?
Process valves closed/locked?
Pneumatic supply isolated/vented?
Hydraulic supply isolated/depressurized?
Mechanical movement blocked/secured?
Line blanks/blinds installed (if required)?

Lockout/Tagout Device Application

OSHA 1910.147(d)(4): Apply locks and tags to each energy isolation device.

Personal lock(s) applied to ALL isolation points?
Tags applied identifying who locked out?
Group lockout box used (if applicable)?
Locks are substantial (not easily removed)?
Tags legible and securely attached?
Photo of lockout setup taken?

Stored/Residual Energy Release

OSHA 1910.147(d)(5): Release or restrain ALL stored energy before work begins.

Capacitors discharged/grounded?
Springs released or blocked?
All pressure relieved/vented?
Elevated loads lowered or blocked?
Rotating equipment at complete stop?
Hot/cold surfaces at safe temperature?
Process materials drained/purged?

Verification of Zero Energy State

OSHA 1910.147(d)(6): Verify equipment is at zero energy BEFORE starting work.

Tried starting equipment using normal controls?
Controls returned to OFF/SAFE after test?
Electrical - tested with meter (zero voltage)?
Meter verified on known live source before/after?
Pressure gauges reading zero?
No movement when controls activated?
Zero energy state verified - SAFE TO WORK?