Episode 2 - Lockout-Tagout Application Steps

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

Review equipment procedures and understand the hazards before touching anything.

Communicate clearly with operators and nearby workers.

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

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

Ensure all motion stops before proceeding.

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

The goal: zero energy flow.

Each authorized employee applies their personal lock.

Tags explain who applied the lock and why.

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

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

Stored energy is often the most overlooked hazard.

Try‑start the equipment to confirm it cannot operate.

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

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.

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

Supervisors must model consistency: no shortcuts, no exceptions.