Cord-and-Plug Lockout/Tagout (LOTO) Exception

Energy Control
English (Canada)

The Problem

Lockout/Tagout (LOTO) procedures are designed to protect workers from hazardous energy during maintenance or servicing of equipment. However, an exception applies to cord-and-plug connected equipment. Misunderstanding this exception can result in serious injury or even death—especially when residual energy isn’t fully neutralized or when the plug is not under exclusive control. Today, we’ll clarify the conditions under which this exception applies and how to ensure safety on site.

Identify the Hazards

  • Residual Energy: Equipment such as compressors or machinery with capacitors may retain energy after being unplugged. Electrical energy stored in capacitors or backup systems can still pose a risk.
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  • Loss of Plug Control: If the plug is not under the direct control of the person doing the work, it could be accidentally reconnected.
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  • Multiple Workers Involved: If several people are servicing the equipment, and communication fails, re-energizing the equipment too early can lead to serious harm.

Safety Practices and Preventative Measures

1. Ensure Complete De-Energisation

  • Unplugging must eliminate all hazardous energy sources.
  • Example: Compressors may still hold pressure in tanks or lines, or electrical equipment may retain charge in capacitors.
  • Always test to confirm residual energy has been released before starting work.

2. Maintain Exclusive Control of the Plug

  • The plug must remain:
    • Within arm’s reach.
    • In the worker’s direct line of sight.
    • Under their exclusive control at all times.
  • If more than one person is working on the equipment, this exception does not apply. Each worker must apply their own lock.

3. Default to Lockout If Unsure

  • If you’re uncertain about energy release or control of the plug, always use a full lockout procedure.
  • When in doubt—lock it out.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

On one site, a worker servicing a machine relied on the cord-and-plug exception. Unbeknownst to them, capacitors within the unit still held charge. While the machine was unplugged, they suffered a serious electric shock due to residual energy. This incident could have been avoided by verifying full de-energisation before commencing work.

Employee Responsibilities

  • Confirm all energy (including stored energy) is discharged before beginning work.
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  • Keep plugs under exclusive personal control during servicing.
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  • If plug control is not possible, apply full lockout/tagout.
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  • Report unclear or unsafe procedures to your supervisor.

    • Employer Responsibilities

    • Train workers on when the cord-and-plug exception applies and how to use it safely.
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    • Provide access to appropriate testing tools and personal lockout equipment.
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    • Encourage safe decisions and promote a “when in doubt, lock it out” culture.

    Discussion & Questions

    • “What challenges have you encountered when applying the cord-and-plug exception?”
    • “Has anyone had to switch from cord control to full lockout? What prompted the decision?”

    Commitment/Action Plan

    Let’s commit to using the cord-and-plug exception only when all conditions are clearly met. Take the time to verify that all energy has been fully neutralized and that the plug is always within your control.

    Wrap-Up

    The cord-and-plug exception can simplify low-risk work, but safety must never be compromised. If in doubt, lock it out. Understanding the conditions and applying safe practices will protect you and your team. Thank you for making safety your priority.

    Standards Overview

    Under CCOHS guidance and Canadian workplace safety regulations, employers must ensure control of hazardous energy during servicing and maintenance. Cord-and-plug exceptions are only valid when:

    • The equipment is fully de-energized by unplugging, and
    • The plug remains under the exclusive control of the person performing the task.

    Disclaimer

    “The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.

    It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.

    Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.

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    Last Updated:
    July 10, 2025