Lockout tagout (LOTO) energy isolation procedure

What’s inside

1. 1

   Prepare the job and identify every energy source

   Follow your site’s written energy-control procedure for this equipment. List every energy source (electrical, pneumatic, hydraulic, mechanical, thermal, chemical, gravity) and locate each isolation point before touching anything.

   Inspection15 min

   Tools: Energy-control procedure, equipment drawings

   Risks: A missed energy source is the most common cause of lockout accidents.

2. 2

   Notify affected people

   Tell the operators and everyone working in the area that the equipment will be shut down and locked out, why, and for how long.

   Action5 min
3. 3

   Shut the equipment down normally

   Stop the equipment with its normal operating controls and stopping sequence, not by opening the isolator under load.

   Action5 min
4. 4

   Isolate every energy source

   Open the disconnects, close the valves and disconnect or block each source identified in step 1. A push-button, selector switch or emergency stop is a control device, never an isolation.

   Action15 min

   Tools: List of isolation points, arc-rated PPE

   Risks: Arc flash when operating electrical disconnects; wear the PPE required for that switchgear.

5. 5

   Apply personal locks and tags

   Each person working on the equipment fits their own lock and tag on every isolation point, or on a group lockbox. The tag shows the name, date and reason.

   Action10 min

   Tools: Personal padlocks, danger tags, hasps, breaker and valve lockout devices, group lockbox

6. 6

   Release or restrain stored energy

   Bleed residual pressure, discharge capacitors, release or block springs, lower or block raised parts, let flywheels stop and hot or cold parts reach a safe temperature. Fit blocks or pins wherever energy could build up again.

   Action15 min

   Tools: Bleed valves, mechanical blocks and pins, discharge tool

   Risks: Pressure, springs, gravity and heat can still injure after isolation. Recheck any source that can build up again during the job.

7. 7

   Verify zero energy

   With everyone clear, try to start the equipment with its normal controls: nothing must move. Test for absence of voltage with a test instrument proven on a known live source before and after, check that gauges read zero, then return the controls to off.

   Verification10 min

   Tools: Voltage tester, proving unit, pressure gauges

   Risks: Treat every conductor as live until it has been tested dead.

8. 8

   Carry out the maintenance work

   Do the planned work with all locks in place. At a shift change, transfer locks as your procedure requires so that the equipment is never left unprotected.

   Action60 min
9. 9

   Check the area and refit guards

   Remove tools, materials and blocks, refit every guard and safety device, and confirm the equipment is complete and ready to run.

   Inspection10 min
10. 10

    Account for everyone and remove the locks

    Make sure everyone is clear of the danger zone. Each lock and tag is removed only by the person who applied it; any other removal follows your site’s exceptional removal procedure.

    Action5 min

    Risks: Never remove another person’s lock.

11. 11

    Notify and re-energise

    Tell the affected people that the equipment is about to restart, restore the energy sources in a safe order and confirm normal operation.

    Verification10 min

    Risks: Unexpected movement on restart; keep people out of the danger zone.

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