How to Create Equipment Specific Lockout/Tagout Procedures

Identify hazardous energy sources—electrical, mechanical, thermal, pneumatic, chemical, hydraulic, steam—and other stored or residual energies. Emphasize a hands-on equipment survey to locate power sources before maintenance.

Identify and isolate hazardous energy sources, apply lockout/tagout, and reattach guards to protect point of operation during maintenance of belt and pulley systems, bypass systems, hydraulics, power, and air systems.

Learn to use durable, standardized locks and tags for lockout/tagout, plan for weather and delays, and apply a color-coded system (red for maintenance, blue for contractors) with clear tags.

Explore devices and hardware for lockout tagout, including hasp and cable loop systems, hand valves with clamshells, brake and steering wheel lockouts, and energy isolation for gas cylinders.

Master the six-step lockout/tagout procedure—prepare for shutdown, inform others and secure tools, shut down equipment, isolate power, apply lockout/tagout, bleed stored energy, and verify isolation.

Learn to perform lockout/tagout steps 1–3 by notifying personnel, gathering tools, shutting down equipment, and isolating hazardous energy across chemical, hydraulic, and other forms.

Apply steps four to six of the LOTO process, lockout devices to all energy inputs, bleed stored energy from hydraulic, compressed air, and springs, then verify and restart.

Explore the equipment specific lockout/tagout template, including admin details, equipment name and location, maintenance procedures, surveys, energy sources, isolation testing, and the use of dropdowns and photos.

Explore three separate examples using the lockout/tagout template for a conveyor system, focusing on one energy source, electrical power, and isolation testing to ensure zero energy before maintenance.

Demonstrates a carbon dioxide system lockout/tagout procedure, applying electrical power isolation per NFPA 70, dissipating energy, and bleeding trapped CO2 before maintenance.

Demonstrate equipment-specific lockout/tagout for a spin coater with electrical, nitrogen gas, a solvent based cleaner, air, and vacuum, covering isolation and energy control steps.

Coordinate with outside contractors to assign lockout/tagout tasks, clarify roles, and manage outages during controlled shutdowns. Align with service agreements, permits, and color-coded lock and tag status for equipment.

Remove locks and tags, replace guards, remove tools, and inspect machine to ensure it is back in working order. Notify employees and survey the equipment to confirm 100 percent readiness.

Verify the authorized employee is not at the facility, attempt contact, cut off the lock with bolt cutters, restore service, and notify the employee on return.

Identify and isolate hazardous energy using tags and protective hardware, follow the lockout/tagout template, and work through three examples increasing in difficulty with five energy inputs, concluding with removal steps.

Dr. Ayres concludes by outlining how to create equipment-specific lockout/tagout procedures and invites learners to explore more courses.

Dr. David Ayres presents the references behind creating equipment specific lockout/tagout procedures and invites contact for presentation photos and resources.