Lockout & Tagout (LOTO) – Hazardous Energy Control System

The Lockout & Tagout (LOTO) – Hazardous Energy Control System training is a specialized onsite certification programme designed to prevent injuries caused by unexpected energization, start-up, or release of stored energy during maintenance and servicing activities.

This programme is aligned with Indian statutory requirements and OSHA 29 CFR 1910.147, widely adopted as an industry benchmark in India. The training combines regulatory knowledge, step-by-step procedures, and mandatory hands-on practical demonstrations on real equipment.

Standards & Regulatory Framework

Indian & International Standards

As India does not yet have a dedicated IS Standard exclusively for LOTO, organizations follow a combination of Indian laws and international best practices:

Factories Act, 1948 – Machinery safety & isolation provisions
BOCW Act & Rules – Construction and maintenance safety
Relevant IS Codes related to:
- Electrical safety
- Machine guarding
- Valves & pressure systems
OSHA 29 CFR 1910.147 – Control of Hazardous Energy (LOTO)
Indian Government circulars on energy isolation and shutdown procedures
(India Code references)

Technical Guidance Sources

IIT Roorkee – LOTO hazard identification & isolation guidance
National Productivity Council (NPC) – LOTO training and audit guidelines

Course Objectives

Participants completing this training will be able to:

Identify all types of hazardous energy sources
Understand energy isolation and zero-energy state concepts
Apply step-by-step LOTO procedures correctly
Use locks, tags, hasps, chains, and lockout devices safely
Verify isolation before starting maintenance work
Understand statutory responsibilities under Indian laws
Develop equipment-specific LOTO procedures
Perform supervision, auditing, and periodic inspections

Introduction to LOTO

Definition of Lockout
Definition of Tagout
Purpose of LOTO – preventing injury from unexpected energization
Types of hazardous energy:
– Electrical
– Mechanical
– Hydraulic
– Pneumatic
– Chemical
– Thermal
– Gravitational
(All covered under OSHA scope and Indian safety practice)

Hazardous Energy Overview

Using IIT Roorkee and OSHA references:

Stored energy hazards:
- Springs
- Pressure systems
- Capacitors
- Rotating parts
Common accident examples:
- Conveyor release
- Steam line valve opening
- Electrical shock
- High-pressure fluid leaks

LOTO Legal Requirements in India

Factories Act, 1948

Mandatory isolation before maintenance
Prevention of accidental start-up
Equivalent controls when guards are removed

BOCW Act & Central Rules

Safe maintenance practices
Locking and isolation prior to repairs
Contractor compliance requirements

OSHA 1910.147 (Benchmark Standard)

Written energy control programme
Authorized vs affected employees
Periodic inspections and audits
Device specification requirements

India Code – Government Circulars

Mandatory shutdown and isolation procedures

Types of LOTO Devices

Based on IIT Roorkee guidance and industry standards:

Lockout padlocks
Hasps / multiple lock devices
Electrical breaker lockouts
Valve lockouts (gate, ball, plug)
Pneumatic and hydraulic lockouts
Cable lockouts
Tagout tags (warning devices)

LOTO Authorization Levels

Authorized Employees: Perform lockout and tagout
Affected Employees: Work in LOTO-controlled areas
Supervisors: Verify, audit, and approve LOTO
Contractors: Must comply with site LOTO programme

(NPC-aligned guidance)

Step-by-Step LOTO Procedure (Core Module)

Derived from OSHA and IIT Roorkee standards:

Prepare for shutdown – identify energy sources
Notify affected employees
Shut down machinery safely
Isolate energy sources (breakers, valves, disconnects)
Apply locks and tags
Release or restrain stored energy
Verify zero-energy state (try-start test)
Perform maintenance work
Remove tools and restore equipment
Remove locks and tags (authorized personnel only)
Notify stakeholders before restart

Equipment-Specific LOTO Procedures

Training includes development and implementation of LOTO procedures for:

Electrical panels
Motors and pumps
Valves and pipelines
Compressors
HVAC systems
Conveyors
Boilers and steam lines
High-pressure hydraulic systems

Group LOTO & Complex LOTO

Multi-team maintenance scenarios
Group lockout boxes
Control key procedures
Shift change LOTO practices
Supervisor sign-off and verification

(As per OSHA multi-person lockout rules)

Tagout Requirements

When physical lockout is not possible
Tag specifications:
- Non-reusable
- Durable
- Securely attached
Risks of tag-only systems
Required compensatory safety measures

Verification & Zero-Energy Testing

Try-start method
Pressure gauge checks
Voltage tester usage
Valve position verification

LOTO for Non-Routine Tasks

Commissioning
Cleaning operations
Troubleshooting
Breakdown maintenance
Testing and re-energization sequences

(NPC training module)

LOTO Programme Requirements

Aligned with OSHA and Indian regulatory guidance:

Written LOTO programme
Equipment inventory
Authorized personnel list
Device inventory
Isolation point identification and marking
Annual audits and competency evaluation

Emergency Situations

Lost key procedures
Emergency lock removal (with supervisor authorization)
Incident response protocols
Hazard analysis for abnormal conditions

Practical Demonstration (Mandatory Onsite)

Lock application on real equipment
Verification of isolation
Group lock box demonstration
Releasing stored energy:
- Electrical
- Hydraulic
- Pneumatic

Assessment & Certification

Theoretical Assessment

25–30 MCQs
Standards, roles, procedures, and device selection

Practical Assessment

Perform complete LOTO cycle
Identify correct isolation points
Demonstrate verification procedures
Maintain LOTO logbook

Certification

Issued by ITESCS
Validity: 2 Years

Deliverables Provided During Training

LOTO Standard Operating Procedure (SOP)
Equipment-specific LOTO templates
LOTO Permit format
LOTO audit checklist
LOTO device catalogue

January 30, 2026

January 30, 2026

January 30, 2026

January 30, 2026

January 30, 2026