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Lockout Tagout (LOTO) Training
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LOTO failures cause approximately 50,000 injuries and 120 deaths every year in U.S. workplaces. Get trained on the complete energy control procedure — 100% online, certificate on completion, accepted nationwide.

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  • 100% Online
  • Certificate on Completion
  • 45 Min — Authorized Employee
  • Awareness Level Also Available
  • 70% to Pass — Free Retakes
Whether you’re an individual needing certification to land a job or a business certifying your team, Aggie Safety makes OSHA compliance simple. Complete in under 1 hour, includes OSHA-required theory + certificate. Save more with bulk training discounts.
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Training Programs

Two LOTO Training Levels — Both Available Online with Certificate

OSHA 29 CFR 1910.147(c)(7) requires different training for different employee roles. Aggie Safety offers both levels online with immediate certificate on passing.
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Primary Course

Authorized Employee LOTO Training

For workers who perform servicing, maintenance, or repair on machines and equipment — and who personally apply lockout or tagout devices. This is the full LOTO procedure course covering all eight steps, all energy types, and all device types.

  • Complete 8-step lockout/tagout procedure (29 CFR 1910.147(d))
  • All energy types: electrical, hydraulic, pneumatic, gravity, steam, gas
  • LOTO device selection — locks, hasps, tags, valve lockouts, breaker lockouts
  • Stored and residual energy release — bleeding, blocking, discharging
  • Zero energy state verification before work begins
  • Restoring energy: safe sequence after work is complete
  • Machine-specific procedure requirements and written programs
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Awareness Level

Affected Employee / LOTO Awareness Training

For workers who operate equipment that may be locked or tagged out, or who work in areas where LOTO is being performed. Awareness training teaches workers to recognize LOTO devices and understand why they must never attempt to restart or re-energize locked-out equipment.

  • Purpose and scope of the LOTO standard (29 CFR 1910.147)
  • How to recognize lockout and tagout devices in the field
  • Why locked-out equipment must never be restarted or re-energized
  • What to do when you see a LOTO device on equipment you operate
  • Consequences of bypassing or removing another employee's LOTO device
  • Who to contact when LOTO-related questions arise at your worksite
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Program Support

Written LOTO Program & Machine-Specific Procedures

OSHA requires every employer with covered equipment to have a written energy control program and machine-specific LOTO procedures for each piece of equipment. Aggie Safety provides program development support as an add-on to training — so your team is not just trained, but your written documentation is audit-ready.

  • Written energy control program development (29 CFR 1910.147(c)(1))
  • Machine-specific LOTO procedure documentation for each piece of equipment
  • Energy Source Identification Sheets — electrical, hydraulic, pneumatic, gravity
  • Periodic inspection requirements — annual review of energy control procedures
  • Training records and retraining documentation
  • Contact (713) 613-2830 to discuss program development
  • Why LOTO consistently ranks in OSHA's Top 10: OSHA 29 CFR 1910.147 has appeared in the federal agency's top-cited standards every year for more than a decade. The three most common LOTO citation categories are: no written energy control program, inadequate machine-specific procedures, and missing or insufficient training documentation. All three are directly addressed by Aggie Safety's training and program support services.
Regulatory Basis

What OSHA Requires for Lockout/Tagout Compliance

29 CFR 1910.147 establishes comprehensive requirements for the control of hazardous energy. Compliance requires three elements that must work together: a written program, machine-specific procedures, and documented training.

Regulatory Framework — 29 CFR 1910.147, Control of Hazardous Energy

29 CFR 1910.147(c)(1) — Written Energy Control Program: Every employer must establish, document, and utilize energy control procedures covering the scope, purpose, and rules of the LOTO program. The written program must address the use of lockout vs. tagout, employee compliance requirements, and the means for enforcing procedures — including removal of unauthorized devices. This written program is the first document an OSHA inspector requests during a LOTO inspection.

 

29 CFR 1910.147(c)(4) — Energy Control Procedures (Machine-Specific): Employers must develop, document, and use energy control procedures for each machine or piece of equipment where unexpected energization or startup could cause injury. Each machine-specific procedure must identify the types and magnitudes of energy, the location of energy isolation points, the specific LOTO devices required, and the sequence of steps to achieve and verify zero energy state.

 

29 CFR 1910.147(c)(6) — Periodic Inspection: Energy control procedures must be reviewed at least annually by an authorized employee other than the one using the procedure. The inspection must be certified in writing with the date, equipment inspected, names of employees included, and the name of the inspector.

 

29 CFR 1910.147(c)(7) — Training and Retraining: Authorized employees must be trained in recognition of applicable hazardous energy sources, the type and magnitude of the energy present, and the methods and means necessary for energy isolation and control. Affected employees must be trained in the purpose and use of LOTO procedures. Retraining is required when a change in machines or processes presents a new hazard, or when a periodic inspection reveals deficiencies in employee knowledge.

 

29 CFR 1910.147(d) — Sequence of Lockout/Tagout Procedure: The standard prescribes an eight-step sequence for energy control: notify, identify, shut down, isolate, apply devices, release stored energy, verify zero state, and restore energy. Deviation from the sequence — particularly skipping stored energy release or verification — is the most common cause of LOTO-related injuries and fatalities.

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Core Procedure

The 8-Step OSHA Lockout/Tagout Procedure — Covered in Full

29 CFR 1910.147(d) defines the sequence that authorized employees must follow. The Aggie Safety course walks through each step with practical examples for all energy types — not just electrical.

Prepare for Shutdown
The authorized employee in charge reviews the Energy Source Information Sheet to identify all stored energy sources powering the machine — electrical, hydraulic, pneumatic, gravity, steam, gas. All employees affected by the pending lockout are notified before the shutdown begins.
Notify Affected Employees
All employees who operate or work near the equipment being locked out must be informed of the pending LOTO. This ensures no one attempts to start or use the machine during servicing and prevents confusion when LOTO devices are found on equipment.
Identify All Energy Isolation Points
Using the machine-specific energy control procedure, the authorized employee identifies and locates every isolation point — disconnect switches, breaker panels, valve locations, plug outlets, hydraulic reservoirs. Complex machines may have multiple energy sources requiring multiple devices.
Shut Down the Equipment
The equipment is shut down using the normal stopping procedure. This step prevents unexpected releases when energy is subsequently isolated. The authorized employee follows the manufacturer's recommended shutdown sequence for complex machinery.
Isolate All Energy Sources
All energy isolation devices identified in Step 3 are engaged — circuit breakers opened, disconnect switches thrown, valves closed, plugs removed. Each isolation point must be addressed; a machine with both electrical power and pneumatic supply requires isolation of both.
Apply Lockout/Tagout Devices
Each authorized employee working on the machine installs their own personal lock on the hasp at each isolation point. The key must remain under that employee's exclusive custody — no duplicate keys permitted. A LOTO warning tag listing the reason, date, and contact information is attached at each lock.
Release or Restrain Stored Energy
Residual and stored energy must be eliminated before work begins. This includes: bleeding or venting pneumatic and hydraulic lines to zero pressure, blocking or restraining machine parts that could move due to gravity, discharging capacitors, allowing steam lines to cool, and closing ball valves on gas lines with valve lockout devices installed.
Verify Zero Energy State
Before work begins, the authorized employee verifies that isolation is complete. This means attempting to start the machine using normal operating controls to confirm it cannot energize. For electrical circuits, a voltmeter confirms zero voltage. For hydraulic and pneumatic systems, gauges confirm zero pressure. Only after verification is confirmed may work begin.
Restoring Energy — the Reverse Sequence: When work is complete, the authorized employee must follow the reversal sequence before restoring power: inspect the machine for tools or objects left in or on it; remove all locks and LOTO devices (each employee removes their own lock); clear non-essential personnel; and restore energy only after all employees have approved. The authorized employee tests the equipment to verify all operating systems are functioning correctly before returning it to service.

Hazardous Energy Sources

All Eight Energy Types Covered — Electrical Is Not the Only Hazard

The most common LOTO mistake is isolating electrical power and overlooking other stored energy sources. The Aggie Safety course covers all energy types defined under 29 CFR 1910.147, with machine-specific isolation methods for each.

Electrical
Most common energy type. Isolation methods: circuit breaker lockout, electrical cutoff lockout, plug lockout, bag lockout. Each isolation point requires its own LOTO hasp and personal lock.
Hydraulic Pressure
Stored hydraulic pressure can cause sudden machine movement even after electrical power is removed. Must be bled to zero using the hydraulic reservoir's drain procedure before isolation is complete.
Air Pressure (Pneumatic)
Pneumatic lines retain pressure after the compressor is isolated. Air must be vented from the reservoir and all lines. Ball valve lockout devices or LOTO hasps are applied after venting.
Gravity
Machine parts, rams, or components that can fall or move under gravity when hydraulic or mechanical support is removed must be physically blocked, pinned, or restrained before work proceeds.
Steam
Steam valves must be isolated with valve lockout devices. Lines must be allowed to cool and condensate must drain before work begins. Ball valve lockout devices or cable lockout devices are used at steam isolation points.
Compressed Gas
Gas cylinders and compressed gas supply lines require valve lockout devices. After isolation, residual pressure must be vented. Ball valve lockout or cable lockout devices are applied at the isolation valve.
Water Pressure
Water pressure systems are isolated using clamshell valve lockout devices, ball valve lockouts, or cable lockout devices at the supply valve. Systems must be bled to zero pressure before work begins.
Natural Gas
Natural gas supply lines are isolated at the gas valve using a valve lockout device. The line must be purged of gas before hot work or maintenance involving ignition sources can proceed.
LOTO Device Reference — Devices Covered in This Course

LOTO Hasp: Multi-lock hasp that allows multiple employees to apply their own personal lock to a single isolation point. Required when more than one authorized employee is working on the same machine. Each employee applies and removes only their own lock.

Breaker Lockout Device: Clamp-style device that fits over a circuit breaker in the tripped or open position and accepts one or more padlocks. Prevents the breaker from being reset while LOTO is active.

Plug Lockout / Bag Lockout: For corded equipment with plug-in power — a plug lockout or bag lockout device encases the plug and prevents reconnection during servicing.

Ball Valve Lockout Device: Clamp-style device that fits over a ball valve handle and accepts a padlock, preventing the valve from being opened or closed while LOTO is in effect.

Cable Lockout Device: A flexible cable with a locking loop — used for valves, gas cylinders, and other isolation points where a standard lockout device does not fit. Highly versatile across all energy types.

LOTO Warning Tag: Required in addition to the lockout device. Must list the reason for the lockout, the date it was applied, and contact information for the authorized employee who applied it.

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The Process

How LOTO Certification Works

Three straightforward steps. Aggie Safety delivers Step 1 fully online.

Enroll & Complete Online Training
  • Purchase the course — instant access, no scheduling required
  • ~45-minute video instruction for Authorized Employee level
  • ~20-minute video for Awareness/Affected Employee level
  • Self-paced: pause, rewind, and review as many times as needed
  • Covers all requirements of 29 CFR 1910.147(c)(7)
Pass the Quiz & Download Certificate
  • Pass the quiz at 70% or higher
  • Unlimited retakes at no additional cost
  • Certificate of Completion available for immediate download
  • Print on the spot to show your employer or job site supervisor
  • Documentation satisfies OSHA's written training record requirement
Machine-Specific Training with Your Employer
  • OSHA requires training on each specific machine or equipment type
  • Your employer provides machine-specific procedures for each piece of equipment
  • Authorized employees practice the LOTO procedure on the actual equipment
  • Together, this satisfies the full requirements of 29 CFR 1910.147(c)(7)

Course Content

What the Authorized Employee LOTO Training Covers

Built on 25 years of LOTO training experience. Video instruction covers all topics required under 29 CFR 1910.147(c)(7), followed by a graded quiz with immediate certificate on passing.

Introduction to Hazardous Energy Control
Why LOTO exists, what hazardous energy is, the scope of 29 CFR 1910.147, and the industries and equipment types the standard covers. The difference between lockout and tagout — and when tagout alone is permitted.
Employee Roles Under LOTO
Authorized employee vs. affected employee vs. other employee — definitions, training requirements, and responsibilities for each. Who may apply a LOTO device and who is prohibited from removing another worker's lock.
Energy Source Identification
How to identify all types of hazardous energy on a machine: electrical (plug, breaker, disconnect), hydraulic, pneumatic, gravity, steam, compressed gas, water pressure, and natural gas. Using the Energy Source Information Sheet.
LOTO Devices — Selection and Use
How to verify zero energy state before work begins: attempting to start the equipment using normal controls, using a voltmeter for electrical confirmation, checking pressure gauges for pneumatic and hydraulic systems. Why verification is not optional.
The 8-Step Lockout Procedure
Full walkthrough of the OSHA-required shutdown sequence for machines with one and multiple energy sources. Notification, identification, shutdown, isolation, device application, stored energy release, zero energy verification.
Stored and Residual Energy — The Most Dangerous Step
How to eliminate stored energy after isolation: bleeding hydraulic and pneumatic lines to zero, blocking gravity-driven parts, discharging capacitors, cooling steam lines, purging gas lines. Why skipping this step causes most LOTO fatalities.
Zero Energy State Verification
How to verify zero energy state before work begins: attempting to start the equipment using normal controls, using a voltmeter for electrical confirmation, checking pressure gauges for pneumatic and hydraulic systems. Why verification is not optional.
Restoring Energy Safely
The reverse sequence after work is complete: machine inspection for tools or objects left inside, notifying and clearing all personnel, each employee removing their own lock, restoring energy, and testing equipment before returning it to service.
Written Program and Machine-Specific Procedures
What a written energy control program must contain under 29 CFR 1910.147(c)(1). How machine-specific LOTO procedures are developed. What happens when a machine has more than one energy source — and why generic procedures are not sufficient.
Periodic Inspections and Retraining
The annual periodic inspection requirement under 29 CFR 1910.147(c)(6): who must conduct it, what it must cover, and how it must be documented. Conditions that trigger mandatory retraining for authorized and affected employees.
Common LOTO Violations
The specific violations OSHA inspectors cite most often: no written program, generic procedures instead of machine-specific procedures, LOTO applied only to electrical without addressing other energy sources, and no training documentation.
Graded Quiz + Certificate
Pass at 70% or higher. Unlimited free retakes. Certificate of Completion available for immediate download. Authorized Employee course duration: approximately 45 minutes.
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OSHA Compliance

Most Common LOTO Violations — Addressed in This Course

Violation OSHA Standard Max Fine (2025) What This Training Covers
No written energy control program documenting the scope, purpose, and rules of the LOTO program 29 CFR 1910.147(c)(1) $16,550 Written program requirements covered in Chapter 9; program development support available at (713) 613-2830
Generic energy control procedure used instead of machine-specific procedure for each piece of equipment 29 CFR 1910.147(c)(4) $16,550 Machine-specific procedure requirements, Energy Source Information Sheet format, and what must be documented for each machine
No annual periodic inspection of energy control procedures — or inspection not documented in writing 29 CFR 1910.147(c)(6) $16,550 Periodic inspection requirements: who must conduct it, what it must cover, and required certification documentation
No training documentation — employer cannot demonstrate that authorized or affected employees received LOTO training 29 CFR 1910.147(c)(7)(iv) $16,550 Certificate provides documentation of formal instruction; employers receive sign-in sheet template
LOTO applied only to electrical energy; hydraulic, pneumatic, gravity, or other stored energy not isolated or released 29 CFR 1910.147(d)(5)(i) $16,550 All eight energy types covered in full; stored energy release procedures covered in Chapter 6
Worker performs servicing or maintenance on equipment without applying a personal lock — relies on supervisor's lock or "someone else" will lock it out 29 CFR 1910.147(c)(4)(i) Up to $165,514 (willful) Personal lock requirement — one employee, one lock, one key in that employee's exclusive custody
Tagout used without justification that equipment cannot be locked out — no written documentation of equivalent protection measures 29 CFR 1910.147(c)(3) $16,550 Lockout vs. tagout distinction, when tagout alone is permitted, and required additional safeguards when tagout must be used
Stored energy (pneumatic, hydraulic, gravity) not released or restrained before work begins — zero energy verification skipped 29 CFR 1910.147(d)(5)(ii) Up to $165,514 (willful) Zero energy state verification — the critical step most often skipped; Chapter 7 covers verification methods for all energy types
Authorized employee removes another employee's lock, or lock is removed without the applying employee's presence and consent 29 CFR 1910.147(e)(3) Up to $165,514 (willful) Lock removal authority — only the applying employee may remove their own lock; emergency removal procedure and documentation requirements
2025 OSHA maximum penalties: $16,550 per serious violation; $165,514 per willful or repeat violation. LOTO willful violations are among the most frequently elevated to the willful category because OSHA views energy control as a life-safety standard.

Benefits

Benefits of LOTO Training with Aggie Safety

Built on 25 years of LOTO training experience. Video instruction covers all topics required under 29 CFR 1910.147(c)(7), followed by a graded quiz with immediate certificate on passing.

Prevent Fatalities
LOTO failures kill approximately 120 workers per year. Trained authorized employees who follow the eight-step procedure and verify zero energy state before work begins are the most direct defense against these deaths.
Documented Compliance
Certificate provides written proof of training completion required under 29 CFR 1910.147(c)(7)(iv). When OSHA inspects, training documentation is the first item they request in a LOTO inspection.
~45 Minutes
Video instruction plus quiz. Complete in a single session from any device. No travel, no scheduling, no minimum group size. Instant access after purchase for both Authorized Employee and Awareness levels.
Reduce Fine Exposure
LOTO generated 2,554 violations in FY 2024. Documented training is the most direct way to demonstrate compliance — and the strongest factor in penalty reduction at informal conference when a citation is issued.
Free Retakes
Failed the quiz? Retake at no additional cost, as many times as needed. Review the course material between attempts. Your certificate issues the moment you pass.
Nationwide Acceptance
Training covers 29 CFR 1910.147 — the federal OSHA General Industry standard that applies in all 50 states and U.S. territories without a State Plan, and is adopted by reference in all OSHA State Plans.
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Your Certificate

What You Receive After Passing

  • Downloadable Certificate of Completion — available instantly after passing
  • Documents formal instruction under 29 CFR 1910.147(c)(7)
  • Print immediately to show your employer or maintenance supervisor
  • Accepted in manufacturing, construction, oil & gas, food processing, and all general industry sectors nationwide

When is LOTO retraining required? 29 CFR 1910.147(c)(7)(iii) requires retraining when: (1) a change in machines, equipment, or processes presents a new or different hazard not previously covered; (2) a change in energy control procedures occurs; or (3) a periodic inspection reveals deficiencies in the employee's knowledge or use of energy control procedures. There is no fixed annual renewal interval mandated by the standard — retraining is triggered by change or deficiency. Many employers adopt an annual cycle as a best practice.

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Who Needs This Training

Industries Where LOTO Training Is Required

29 CFR 1910.147 covers general industry — any workplace where servicing or maintenance of machines and equipment takes place and where unexpected energization could cause injury. The following industries are most frequently cited.

Industry Common LOTO Hazards Most Frequent LOTO Citations
Manufacturing & Assembly Electrical + hydraulic on presses, conveyors, CNC machines, injection molding equipment, robotic cells No machine-specific procedures; stored energy (hydraulic/gravity) not addressed; no annual periodic inspection
Oil & Gas Production & Refining Electrical + pneumatic + steam + gravity on pumps, compressors, heat exchangers, rotating equipment, pressure vessels Generic procedures instead of equipment-specific; steam and pneumatic energy sources not addressed in LOTO program
Food Processing Electrical + pneumatic + gravity + water pressure on conveyors, mixers, slicers, packaging lines, refrigeration equipment Electrical isolated but pneumatic and gravity energy not addressed; no written program; no retraining after machine changes
Chemical & Petrochemical Electrical + hydraulic + steam + compressed gas + natural gas on reactors, distillation columns, pumps, heat exchangers Tagout used without justification; stored energy release not documented; no machine-specific procedures for PSM-covered equipment
Construction Electrical + pneumatic on power tools, concrete equipment, HVAC, electrical panels during renovation No written program for construction employers; employees performing electrical maintenance without LOTO devices
Warehousing & Distribution Electrical on conveyors, sorters, dock equipment, hydraulic dock levelers, HVAC systems No authorized employee training for maintenance staff; dock leveler hydraulic energy not addressed in LOTO procedures
Utilities & Facilities Maintenance Electrical + pneumatic + water pressure + natural gas across building systems, HVAC, boilers, electrical switchgear Multi-energy source equipment addressed as electrical-only; no coordination procedure for group LOTO with multiple authorized employees
2025 OSHA maximum penalties: $16,550 per serious violation; $165,514 per willful or repeat violation. LOTO willful violations are among the most frequently elevated to the willful category because OSHA views energy control as a life-safety standard.
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Why Aggie Safety

Why Employers and Workers Choose Aggie
Safety for LOTO Training

25 Years of LOTO Training Experience
Course content built from 25 years of training maintenance workers, technicians, and engineers on energy control procedures — across oil and gas, manufacturing, food processing, and chemical facilities. Not a generic textbook course.

All Eight Energy Types — Not Just Electrical
Most online LOTO courses focus on electrical energy and treat other sources as an afterthought. Aggie Safety's course gives equal coverage to hydraulic, pneumatic, gravity, steam, compressed gas, water pressure, and natural gas — because workers die from those sources too.
Stored Energy — The Most Dangerous Step
Releasing stored and residual energy is the step most often skipped — and the step most responsible for LOTO fatalities. Aggie Safety dedicates a full section to this step because workers who are electrocuted after applying locks almost always skipped stored energy release.
Backed by Full OSHA Compliance Consultants
Aggie Safety's training is backed by the team that conducts OSHA inspection representation, citation defense, and facility LOTO program audits. Sumit Anand, PE — our CTO with 20+ years in process safety — has seen every category of LOTO violation from both sides of an inspection. Visit our About Us page for full credentials.
Written Program Support Available
Training alone does not satisfy 29 CFR 1910.147. You also need a written energy control program and machine-specific procedures. Aggie Safety can develop both — so your team is trained and your documentation is audit-ready when the inspector arrives. Call (713) 613-2830.
5-Day Money-Back Guarantee
If you purchased within 5 days, have not completed the course, and have not yet generated your certificate, you're eligible for a full refund. Contact info@lonestar-losscontrol.com with your order details.

Frequently Asked questions

Answers to the most common questions about OSHA compliance, safety training, and working with Aggie Safety.
Who is required to have LOTO training under 29 CFR 1910.147?
29 CFR 1910.147(c)(7) requires training for three groups of employees. Authorized employees — those who perform the servicing or maintenance and who apply lockout or tagout devices — must receive full LOTO procedure training covering energy recognition, isolation methods, device application, stored energy release, and zero energy verification. Affected employees — those who operate or use machines being locked or tagged out, or who work in areas where LOTO is performed — must receive awareness training on the purpose of LOTO and the prohibition against restarting locked-out equipment. Other employees who work in areas where LOTO is used must be instructed not to remove lockout or tagout devices and not to attempt to restart locked-out equipment.
What is the difference between lockout and tagout?
Lockout means applying a physical lockout device — a lock — to an energy isolation point to keep it in the de-energized position and prevent re-energization. Tagout means applying a warning tag in lieu of a lock when an energy isolation device cannot accept a lock. Lockout is preferred and required wherever the energy isolation device can accept a lock. Tagout alone provides less protection than lockout because a tag can be removed or ignored. When tagout is used without a lock, the employer must implement additional protection measures — removing and blocking control circuit components, opening additional disconnecting means, removing valve handles — to provide a level of protection equivalent to lockout. Most modern equipment has isolation points that accept LOTO hasps and padlocks; tagout-only programs are appropriate only for specific, documented cases where lockout is physically impossible.
What must a machine-specific LOTO procedure contain?
29 CFR 1910.147(c)(4)(ii) requires that machine-specific energy control procedures include: the scope, purpose, and authorization rules for the procedure; the specific steps to shut down, isolate, block, and secure machines or equipment; the steps to release stored or residual energy; the steps to verify isolation before work begins; and the steps for returning the equipment to service. Each procedure must identify the types and magnitudes of energy, the methods and means to control the energy, and the specific LOTO devices to be used. Generic procedures that say "de-energize the machine" without identifying the specific isolation points and devices are not compliant — and are one of the most common LOTO citation categories. Aggie Safety can develop machine-specific procedures for your facility; call (713) 613-2830.
Can one lock on a disconnect switch protect all workers on a machine?
No. Under 29 CFR 1910.147(f)(3), when a group of workers is performing servicing or maintenance on the same machine, each individual authorized employee must apply their own personal lock to the energy isolation point using a LOTO hasp. A hasp is a device that holds multiple locks simultaneously — all employees insert their locks, and the hasp cannot be removed until every employee has removed their lock. No supervisor's lock, no master lock, and no single lock can substitute for each employee's personal lock. The key for each personal lock must remain under the exclusive custody of the employee who applied it — no duplicate keys permitted. This personal lock requirement is what prevents one worker from removing another's lock and restoring power while coworkers are still inside the machine.
What is stored energy and why is it the most dangerous step in LOTO?
Stored energy is energy that remains in a machine after the primary energy source has been isolated — energy that has been accumulated, trapped, or held in the machine and that can be released unexpectedly if not addressed. Examples include: hydraulic pressure in cylinders or accumulators that remains even after the hydraulic pump is shut off; pneumatic pressure in air lines or reservoirs that remains after the compressor is isolated; gravity energy in machine components (presses, rams, gates, suspended loads) that can fall or move when support is removed; electrical energy stored in capacitors that remains after power is disconnected; steam pressure that remains in a line after the steam valve is closed; and spring tension in spring-loaded components. Stored energy causes the majority of LOTO fatalities because workers who correctly apply locks at the isolation point fail to release stored energy before reaching into the machine — and are then struck by unexpected movement, electrical discharge, or pressure release. 29 CFR 1910.147(d)(5) requires that all stored energy be released, restrained, or otherwise rendered safe before work begins.
How often must LOTO procedures be inspected under OSHA?
29 CFR 1910.147(c)(6) requires that each energy control procedure be reviewed at least annually to ensure it is being properly implemented and remains adequate. The annual periodic inspection must be performed by an authorized employee other than the one who normally uses the procedure — meaning the employee performing the inspection cannot be the same person whose procedure is being reviewed. The inspection must be certified in writing with the machine or equipment name, the date of inspection, the names of the employees included in the inspection, and the name of the inspector. The periodic inspection also serves as a retraining opportunity: if the inspection reveals deficiencies in the employee's understanding or use of the energy control procedure, retraining is required before the employee continues to perform LOTO.
Can an authorized employee remove another employee's lockout device?
No — under normal circumstances, only the employee who applied a lockout device may remove it. This is one of the most fundamental rules of LOTO. 29 CFR 1910.147(e)(3) addresses the one exception: if the authorized employee who applied the lock is unavailable and the device cannot be removed by that employee, the employer may remove it only under a documented procedure that includes verification the employee is not in the facility, reasonable efforts to contact the employee, and notification to the employee before they return to work. The emergency removal procedure must be documented in the written energy control program. Supervisors who remove employees' locks without following this procedure — even to restart production — expose the facility to willful OSHA citations with penalties up to $165,514 per violation and potentially to criminal liability if an injury results.
Does LOTO training need to be conducted in Spanish?
OSHA requires that training be conducted in a manner that employees can understand — which means in the language they speak. For workplaces with Spanish-speaking authorized or affected employees, LOTO training in Spanish is required. Aggie Safety offers LOTO training in Spanish and English. Our Houston-based team is bilingual in English and Spanish, and our training materials are available in both languages. If your workforce includes Spanish-speaking maintenance or production workers, contact us at (713) 613-2830 to discuss Spanish-language LOTO training and documentation options.
Is this LOTO course approved by OSHA?
OSHA does not formally approve or endorse specific training courses or providers. What OSHA evaluates is whether the training content meets the requirements of 29 CFR 1910.147(c)(7) — the training must ensure that authorized employees can recognize hazardous energy, understand the type and magnitude of energy present, and demonstrate the methods and means for energy isolation and control. Aggie Safety's course is designed to meet and exceed these content requirements. Compliance is determined by content, documented delivery, and the employee's demonstrated ability to apply procedures — not by any external course approval process. The certificate documents that the formal instruction component of training was completed; machine-specific hands-on training by the employer on actual equipment completes the requirement.
Do you offer bulk pricing for certifying a maintenance team?
Yes. Aggie Safety offers bulk training pricing for businesses certifying multiple workers at once — particularly useful for maintenance departments, industrial contractors, and facilities with large authorized employee populations. We also offer on-site LOTO training for facilities that prefer instructor-led training in addition to or instead of the online course — particularly valuable for companies that need to combine the formal instruction component with machine-specific hands-on training in the same session. Call (713) 613-2830 or use the "Certify My Team" button to discuss group pricing and on-site training options.

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