Lockout Tagout is a critical safety procedure used to prevent injuries caused by the unexpected release of energy during equipment repair, maintenance, or inspection. Public works crews regularly service vehicles, pumps, conveyors, compactors, gates, and electrical panels. Without proper control of hazardous energy, workers can be crushed, shocked, burned, or caught in moving parts. This guide teaches the essential steps for isolating and securing equipment before work begins.
By the end of this training, workers should be able to:
• Identify types of hazardous energy.
• Recognize when lockout tagout is required.
• Understand the difference between locking out and tagging out.
• Follow the basic steps of a LOTO procedure.
• Use locks, tags, and hasps correctly.
• Verify that energy has been fully isolated before starting work.
• Example lockout padlocks
• Lockout hasps
• Tagout tags and zip ties
• Example energy isolation devices
• Printed copy of agency LOTO procedures
• Equipment or mock panel for demonstration
• PPE as required by task (gloves, safety glasses, hard hat)
"Good morning everyone. Today we are going to review how to control hazardous energy using lockout tagout. Before anyone works on equipment, we must make sure it cannot start up by accident. This includes electrical, mechanical, hydraulic, and other forms of energy. We will walk through the steps of isolating equipment, locking and tagging it out, and verifying that it is safe to begin work. These procedures protect us from injuries that can happen in an instant."
• Unexpected start up of equipment
• Stored hydraulic or pneumatic energy releasing suddenly
• Electrical shock or arc flash
• Gravity or mechanical movement of parts
• Hot surfaces or steam lines retaining heat
• Multiple workers servicing the same equipment without group lockout
Determine if lockout tagout is required. If equipment could move, energize, or release stored energy during service, LOTO must be applied.
Identify all energy sources. These may include electrical, hydraulic, pneumatic, mechanical, chemical, thermal, or gravitational.
Notify affected employees that the equipment will be shut down and locked out.
Shut down equipment following the manufacturer's instructions or your agency's standard procedure.
Isolate the energy sources by opening disconnects, closing valves, bleeding lines, blocking movement, or securing mechanical parts.
Apply locks to each energy isolation point. Only the worker performing the task places and removes their personal lock.
Apply a tag that clearly identifies the person who locked out the equipment and the reason for the lockout. Tags do not replace locks and are used together unless your agency has a tagout only exception.
Release or block stored energy. Bleed air pressure, release hydraulic pressure, discharge capacitors, secure elevated parts, or wait for hot surfaces to cool.
Verify isolation by testing the controls. Attempt a start using the normal operating switch to ensure the equipment will not run.
Perform the maintenance or repair.
When work is complete, ensure all guards are reinstalled, tools removed, and employees are clear. Remove locks only by the person who applied them. Restore energy slowly and check for abnormal conditions.
• Show various energy isolation points such as a disconnect switch, valve, or breaker.
• Demonstrate how to apply a lock, hasp, and tag.
• Walk the crew through a mock LOTO scenario using a piece of shop equipment.
• Demonstrate verification by testing the controls after isolation.
• Show the proper removal sequence once work is complete.
• Have crew members identify energy sources on a selected piece of equipment.
• Let workers practice applying locks and tags to a demonstration panel or valve.
• Ask the group to walk through a sample scenario and decide the steps required for safe lockout.
• Provide several equipment photos and ask crews to identify isolation points.
• What types of energy are present on equipment you service regularly?
• Why is verification important even after placing a lock?
• What should you do if someone else’s lock is still on a piece of equipment?
• When is group lockout required?
• Can a supervisor remove a worker’s lock without permission?
Insert your agency’s complete LOTO program, authorized employee list, written procedures for specific machines, tag requirements, group lockout rules, and reporting requirements.
• Safety glasses
• Work gloves for handling equipment
• Hard hat in areas where overhead hazards may exist
• Steel toe boots
• Arc rated clothing if required by electrical tasks (according to agency policy)
• Lockout tagout prevents unexpected energization.
• Identify all energy sources before starting work.
• Apply personal locks and tags to each isolation point.
• Release or block stored energy.
• Verify isolation before beginning the task.
• Only the person who applied the lock removes it.
Which of the following is a type of hazardous energy?
a. Mechanical
b. Electrical
c. Hydraulic
d. All of the above
True or False: A tag alone is always enough to prevent equipment from starting.
What is the purpose of verifying isolation before beginning work?
(Short answer)
Who is allowed to remove your personal lock from equipment?
a. You
b. Any supervisor
c. Anyone working nearby
Name one example of stored energy that must be released or blocked before beginning work.
(Short answer)
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