🔐⚡ Lockout Tagout (LOTO) – Control Energy, Save Lives

Every year, many workers get seriously hurt because machines start suddenly while they are cleaning or repairing them.

The main reason? Stored energy was not properly controlled.

That’s why we have a life-saving procedure called Lockout Tagout (LOTO).
It’s simple — turn it off, lock it out, and tag it before you touch it. 🔒

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🧠 What Is LOTO?

Lockout Tagout (LOTO) is a safety system used to make sure machines are completely shut down and cannot start during maintenance or repair work.

It involves two main actions:
1️⃣ Lockout – Physically locking the switch or valve with a padlock.
2️⃣ Tagout – Placing a warning tag that says “DO NOT OPERATE.”

Together, they protect workers from unexpected machine start-ups or energy release. ⚡

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⚙️ Types of Energy That Need Control

LOTO is not just about electricity!
It applies to all forms of hazardous energy, like:  

• 🔋 Electrical (motors, panels)

• 🔥 Thermal (steam, hot oil)

• 💨 Pneumatic (compressed air)

• 💧 Hydraulic (pressure lines)

• ⚙️ Mechanical (springs, moving parts)

• 🧊 Chemical (stored gases or liquids)

Each one can cause serious injuries if not properly isolated.

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🧰 Step-by-Step LOTO Procedure

1️⃣ Prepare for Shutdown

Identify all energy sources.
Inform everyone nearby that maintenance work is about to start.

2️⃣ Turn Off Equipment

Switch off the machine using the normal stop button or lever.

3️⃣ Isolate the Energy

Disconnect the power — unplug, close valves, or trip circuit breakers.

4️⃣ Apply Lock & Tag

• Use your personal padlock on the switch or valve.

• Attach a tag with your name, department, and contact number.

5️⃣ Release Stored Energy

Bleed pressure lines, discharge capacitors, or lower any raised parts.

6️⃣ Verify Zero Energy

Try to start the machine — it should not start.
This confirms all energy is isolated. ✅

7️⃣ Perform the Work

Now it’s safe to repair, clean, or inspect the machine.

8️⃣ Remove Lockout

After work is done, remove the lock and tag only by the person who applied it.

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⚠️ Common LOTO Mistakes

🚫 Sharing one lock for multiple workers
🚫 Removing someone else’s lock
🚫 Not checking for stored energy
🚫 Forgetting to inform nearby workers
🚫 Starting work without testing isolation

Each of these shortcuts can lead to a life-changing accident.

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🧍‍♂️ Real-Life Example

At a chemical plant, a technician was cleaning a pump.
Another operator, not aware of the maintenance, turned ON the motor.
The shaft rotated suddenly and injured the technician’s arm.

After the incident, the company introduced a strict LOTO policy —
Now, every maintenance starts only after all locks and tags are applied.

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💡 Safety Tip of the Day

“Never trust a switch — lock it, tag it, and test it before you touch it.” 🔐⚙️

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✅ LOTO Do’s and Don’ts

✅ Do’s	❌ Don’ts
Use your own lock and tag	Share locks with others
Verify zero energy before work	Assume power is off
Keep keys with yourself	Leave locks open
Inform team before and after	Remove someone else’s lock

 

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