LOT/General/TBT-LOT-017
LOTO Procedures and Permit Process
Lock Out Tag Out › General › LOTO Procedures and Permit Process
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LOTO Procedures and Permit Process
The lock out tag out procedure follows a strict sequence that must be completed fully before any maintenance, repair, or inspection work on machinery or systems. The steps are: prepare, shut down, isolate, lock and tag, verify dead, and release stored energy. Each step is critical and skipping any one of them has caused fatal incidents. On construction sites, LOTO is typically managed through the permit to work system, with the isolation details recorded on the permit for every person working on the system.
Key Hazards
Re-energisation of equipment while maintenance workers are inside or adjacent
Stored energy in hydraulic, pneumatic, or spring systems releasing unexpectedly
Multiple energy sources on complex plant not all identified and isolated
Locks removed prematurely before all workers have completed their tasks
Control Measures
- Follow the six-step LOTO sequence: prepare, shut down, isolate, lock and tag, verify, release stored energy.
- Identify every energy source feeding the equipment including electrical, hydraulic, pneumatic, and gravity.
- Shut down the equipment using the normal operating controls before proceeding to isolation.
- Isolate at every identified isolation point and apply your personal lock and tag to each one.
- Verify the equipment is de-energised by attempting to restart or testing with appropriate instruments.
- Release all stored energy including bleeding hydraulic lines and blocking raised components.
- Ensure each person working on the system applies their own personal lock — never share locks.
- Record all isolation details on the permit to work including isolation points and lock numbers.
- Remove your lock only when you have personally confirmed the work is complete and the area is clear.
Remember
- The six-step LOTO sequence must be followed in full every time without shortcuts or omissions.
- Every energy source must be identified — complex plant may have multiple electrical and mechanical feeds.
- Each worker must apply their own personal lock because your lock protects only you.
- Stored energy in hydraulic accumulators, springs, and raised loads must be safely released after isolation.
- Verify the system is dead after locking out — never assume isolation is successful without testing.
- Your lock stays on until you personally confirm your work is complete and the area is safe.
Applicable Legislation: PUWER 1998 · Electricity at Work Regulations 1989 · Health and Safety at Work etc. Act 1974 · Management of Health and Safety at Work Regulations 1999
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