Episode 2 - Lockout-Tagout Application Steps

🔧 The Key LOTO Application Steps

1. Prepare for Shutdown

• Identify all energy sources (electrical, mechanical, hydraulic, pneumatic, thermal, chemical).

• Review equipment procedures and understand the hazards before touching anything.

2. Notify Affected Employees

• Communicate clearly with operators and nearby workers.

• Explain what will be locked out, why, and for how long.

3. Shut Down the Equipment

• Follow the manufacturer’s or site‑specific shutdown sequence.

• Ensure all motion stops before proceeding.

4. Isolate the Energy Sources

• Open disconnects, close valves, block mechanical parts, bleed pressure, or secure moving components.

• The goal: zero energy flow.

5. Apply Locks and Tags

• Each authorized employee applies their personal lock.

• Tags explain who applied the lock and why.

• Dr. Ayers emphasizes: One worker = one lock = one key.

6. Release or Restrain Stored Energy

• Drain capacitors, bleed hydraulic lines, block gravity hazards, release tension, or vent pressure.

• Stored energy is often the most overlooked hazard.

7. Verify Zero Energy State

• Try‑start the equipment to confirm it cannot operate.

• This is the most critical step — and the one most often skipped.

 

🔄 Removal Steps (When Work Is Complete)

• Inspect the area and ensure tools are removed.

• Confirm all employees are clear.

• Remove locks only by the person who applied them.

• Restore energy in a controlled, communicated manner.

 

💡 Leadership Takeaways

• LOTO is not just a compliance requirement — it’s a life‑saving discipline.

• Supervisors must model consistency: no shortcuts, no exceptions.

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