Figure 1 - The 10 Most Common Lockout/Tagout Violations.

 

 

What is Lockout/Tagout?​

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Lockout/Tagout refers to the process of controlling hazardous energy during servicing or maintenance. A lock provides physical restraint to prevent activation, while a tag communicates who placed the lock and why.

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​Types of Hazardous Energy

 

LOTO protects against multiple forms of energy, including:

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• Electrical (primary and stored)

• Mechanical (springs, moving parts)

• Hydraulic & Pneumatic

• Thermal (hot surfaces, steam)

• Chemical

• Gravity & Potential Energy

• Capacitors & Induction

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The Six Fundamental Steps of LOTO

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1. Prepare for Shutdown – Identify all energy sources and required isolations.

2. Shut Down Equipment – Turn equipment off using normal stopping procedures.

3. Isolate Energy Sources – Open disconnects, close valves, block mechanical motion, etc.

4. Apply Lock and Tag – Each authorized worker applies their personal lock and identification tag.

5. Release or Restrain Stored Energy – Bleed off pressure, block moving parts, discharge capacitors.

6. Verify Zero-Energy State – Test equipment using appropriately rated test instruments before work begins.

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​Key LOTO Rules

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• Only authorized workers may apply or remove locks.

• One lock per worker—no group locks without proper procedures.

• Never operate, remove, or bypass another worker’s lock.

• Tags alone do NOT provide physical protection unless used where locks cannot be applied.

• Always re-test for energy after breaks, shift changes, or system disturbances.

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Common LOTO Mistakes

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• Failure to identify secondary or hidden energy sources.

• Not verifying zero-energy state after lockout.

• Inadequate communication during shift or crew changes.

• Removing locks prematurely.

• Assuming equipment is safe because it is “off”.

• Not locking valves or mechanical isolations properly.

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LOTO for Electrical Systems

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• Always test-before-touch using a properly rated meter.

• Use NFPA 70E-compliant procedures.

• Remember: opening a disconnect does NOT remove stored energy.

• Verify each phase, including neutral and grounded conductors.

• For high-voltage systems, apply grounds using proper sequence.

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Restoring Equipment to Service

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• Inspect the work area and remove tools.

• Ensure all guards and covers are reinstalled.

• Notify workers of lock removal.

• Remove locks in reverse order of application.

• Re-energize equipment following proper startup sequence.

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Emergency Response

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• Do not energize equipment in an emergency without confirming the safety of all personnel.

• For electrical shock: call 911, begin CPR/AED if trained.

• For stored-energy release injuries: maintain spinal precautions and stop bleeding.

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​Discussion Questions

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• Have all energy sources been identified for today’s task?

• Do we have the correct locks, tags, and devices on hand?

• Who is the authorized worker responsible for LOTO today?

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RATTLIR Takeaway

 

LOTO saves lives by preventing unexpected energization. Precision, discipline, and verification ensure we strike before it bites – every time hazardous energy is involved.