LTCT Procedure Lock, Tag, Clear & Try

[Audio] Hello everyone, and welcome to our online Lock, Tag, Clear and Try (LTCT), or LOTO, training session. We are excited to have you join us today as we explore essential safety procedures that protect you and your colleagues in the workplace. Today, we will focus on understanding the importance of LTCT procedures and how they help prevent accidents during maintenance activities. Thank you for being here, and let's get started on our journey to enhance workplace safety together!.

[Audio] "Let's begin by understanding the objective of the LTCT program. This procedure is designed with one main goal: to prevent the accidental or unauthorized activation of machinery or equipment during activities like maintenance, repairs, servicing, installations, or construction. Why is this so important? Because unexpected start-up of equipment — or the release of stored energy — can result in serious injuries, or even fatalities. This program is all about protecting the safety of workers by ensuring that equipment stays properly isolated throughout the job. To make this effective, training is a must. All employees who are involved in any aspect of LTCT must receive proper training — so they not only understand the steps, but also the reasons behind each one. And finally, refresher training isn't just a one-time thing. It's required annually, or whenever there's a change in procedure, to make sure that safety practices stay current and consistent for everyone involved.".

[Audio] "Now, let's talk about legal compliance — because following the LTCT procedure isn't just about safety; it's also the law. Under the WSH (General Provisions) Regulations S134/2006 R16-Q, 'lock-out procedures' are legally defined as a required set of steps. These procedures must ensure that all energy sources to relevant equipment — whether it's machinery, electrical installations, or any other plant — are properly isolated, disconnected, or discharged. The goal is to prevent any part of that equipment from being inadvertently activated or energized. We also refer to SS 571:2011, which is the Code of Practice for Energy Lockout and Tag-out. According to this standard, it's the responsibility of the occupier — that is, the company or organization — to develop, document, and implement a clear and effective lockout/tagout policy. And this isn't just a recommendation — it's enforceable by law. Under WSH Regulation R45, any person who fails to comply with these regulations, and who has a duty to do so, is committing an offence. The penalties are serious — a fine of up to $20,000, up to 2 years of imprisonment, or both. So, following LTCT isn't optional. It's a critical responsibility — both for safety and for staying compliant with the law.".

[Audio] "In this section, we'll go over the five different types of locks used in the Lock, Tag, Clear and Try procedure. Each lock type has a specific purpose, color coding, and is used by designated personnel. Understanding the difference is essential to applying the procedure correctly and avoiding confusion in the field. First, we have the Personal Lock – red in color. This is used by every individual who is directly performing the work. The personal lock is placed on the Key Control Box before work begins. Importantly, these locks are individually keyed, and only the person using the lock holds the key. That means no one else can remove it — ensuring personal control over safety. Second, the Work Group Lock – green. This lock is applied by Work Group Leaders, such as those from Mechanical Maintenance, E&I Maintenance, or Contractors. It provides a layer of group-level control and accountability for team-based tasks. Third, we have the Facility Owner Lock – blue. This lock is applied by the Facility Owner — for example, personnel from Production, TPU Production, Warehousing, or Lab departments. It confirms that the facility itself acknowledges and is aware of the lockout process taking place. Fourth, there's the Equipment Lock – yellow. This is applied directly on isolating devices — like valves or breakers — by the Lockout Leader or someone delegated by the Facility Owner. This lock physically ensures energy isolation at the equipment level. And finally, the Administrative Lock – black. This is also applied on isolating devices, but specifically for equipment that is either not in use, or for situations where a permanent lock is needed to keep something in an open or closed position. This is managed by the Lockout Leader or their delegate. Each of these locks serves a distinct role in the LTCT process. Using the correct lock, with the correct procedure, helps keep everyone safe and ensures full accountability throughout the job.".

[Audio] "Before we move on, let's quickly go through some common terms that you'll often hear during Lockout/Tagout procedures. Understanding these will help you follow the steps correctly and communicate clearly during operations. First, we have the control circuit. This is the part of a machine's electrical system that sends signals to direct the machine's operations — but it doesn't carry the main power current. Think of it like the 'messenger' — it tells the machine what to do, but doesn't actually power it. Next is the control device. This is what we use to start, stop, or change the state of a system. Examples include push buttons, emergency stops, selector switches, and other devices found in the control circuit. These are the points of manual or automatic input. Then we have the Electrical Plug Lockout Device. This is a rectangular box used specifically to lock out three-pin electrical plugs. It prevents anyone from plugging the device back into a power source while it's being serviced. Now, the term energized means that a piece of equipment is still connected to an energy source, or contains stored energy — whether it's electrical, mechanical, thermal, or hydraulic. If something is energized, it is not safe to work on. An Energy-Isolating Device is used to physically block or prevent the release of that energy. These devices include: Manual circuit breakers Disconnect switches. Switches that isolate all poles of a circuit Isolation valves. Slip plates, blanks, physical disconnections, And mechanical blocks.".

[Audio] "This slide covers a list of common terms used in the Lock, Tag, Clear and Try process. These definitions are important for everyone involved to fully understand the equipment, documentation, and potential hazards in the work environment. Let's start with control circuit. This refers to the part of a system that carries electrical signals to operate controllers. It doesn't carry the main power — just the instructions. A control device is something that changes the state of the equipment. This includes push buttons, emergency stops, selector switches, and other similar devices. An Electrical Plug Lockout Device is a rectangular box used to lock a three-pin plug, preventing it from being connected to a power source while maintenance is ongoing. The term energized means that the equipment is still connected to a power source or has stored energy inside — whether that's electrical, mechanical, or otherwise. An Energy-Isolating Device physically prevents the release or flow of energy. Examples include manual circuit breakers, disconnect switches, isolation valves, slip plates, and mechanical blocks. Now, moving to equipment classifications: Office Equipment refers to items that are powered by a three-pin connector and are not easily movable, such as those found in a maintenance office or lab. In contrast, Portable Equipment includes items that can be easily transported, like label printers or laminating machines. Plant Equipment covers all major process and service systems — pumps, compressors, refrigeration systems, HVAC, plumbing, lighting, instrumentation, and circuit breakers. These are generally fixed installations in the production or plant area. Next, let's look at key documentation: P&IDs, or Piping and Instrumentation Diagrams, are detailed drawings attached to the Lockout List or Blind/Physical Disconnect List. These diagrams help identify the lockout points, disconnect locations, and first break points clearly and visually. The Blind/Physical Disconnect List itself is a reference showing exact locations where blinds are inserted or lines are physically disconnected — often necessary for hot work or vessel entry. Lastly, two very important safety terms: Hazardous energy includes any form of energy — electrical, mechanical, hydraulic, pneumatic, chemical, or thermal — that could cause injury or damage if not controlled. Electrical hazards specifically refer to energized conductors or components that pose a risk of shock, arc flash, or other injury..

[Audio] "Let's take a moment to go over some key terms that are essential for understanding our lockout/tagout procedures and the types of hazards we manage. First, we have Mechanical Hazards—these are present when equipment can unexpectedly start up or release stored energy. This is a serious risk during tasks like maintenance or adjustment, where sudden movement can cause injury or damage. Next are Process Hazards, which involve the unexpected release of gases, liquids, or solids. These hazards typically occur during tasks such as fabrication or maintenance of pipelines and equipment, and can be just as dangerous. Now, when it comes to controlling these hazards, we rely on tools like the Key Control Box. This box securely holds the keys to equipment locks. Remember: once a lock is applied, the key must stay in the control box until it's safe to remove it. Locking refers to placing a lockout device on a point of isolation to prevent re-energization. Every system or piece of equipment will have a Lockout Point, which is the exact spot where energy is isolated. We also maintain a Lockout List, which documents all these points and why they've been locked out. This list is stored centrally for easy access and recordkeeping. Finally, everything is housed in the Lockout Station—a designated location that holds Key Control Boxes, Lockout Lists, and Disconnect Lists. It's important to note that the Lockout List or Blind/Physical Disconnect List must always stay next to the Key Control Box it corresponds with. Understanding and following these definitions ensures everyone stays safe while working with or around hazardous energy.".

[Audio] "Now let's talk about the roles and responsibilities of the Facility Owner during lockout/tagout procedures. The Facility Owner holds a critical role in ensuring safety. First and foremost, they are responsible for isolating all energy sources. This means they must lock, tag, clear, and then try—which includes physically verifying that the equipment is de-energized and cannot be started. They must also designate locations for Key Control Boxes and identify a Lockout Leader who will manage the lockout process at the site level. The Facility Owner is expected to take the P&ID—or piping and instrumentation diagram—into account, identify all isolation points, and prepare the lockout list. This list will guide the lockout process and should be prepared by referencing the correct procedures. Another key responsibility is ensuring that all energy sources are properly isolated and that every party involved has applied their locks and tags. Once everything is in place, the Facility Owner must perform the 'Try' step—this is to verify that the equipment truly cannot start up after isolation. A special point of caution: The Facility Owner must be especially alert to any interlocks or overrides that might make equipment appear to be shut down. They need to confirm that the equipment is truly locked out—not just temporarily disabled due to an interlock. Additionally, the Facility Owner takes ownership of the Key Control Box. Any boxes not in use must be returned to and stored in their designated area. Finally, before any equipment can be re-commissioned, the Facility Owner must ensure that all work is complete and all locks and tags have been removed. They also have the authority—and the responsibility—to stop work immediately if it is not being performed safely or correctly..

[Audio] "Now let's look at the responsibilities of the Work Group Leader in the lockout/tagout process. The Work Group Leader plays a vital coordination role between the maintenance team and the Facility Owner. One of their primary responsibilities is to keep the Facility Owner informed about the status of the work at all times. Before any work begins, they must apply their own lock and tags in accordance with the Lockout Procedure and ensure that authorization has been received from the Facility Owner. If there is any uncertainty, they are expected to clarify the lockout status directly with the Facility Owner. They also have the responsibility to verify that the Facility Owner has completed the lockout steps—including proper isolation, lockout, tagging, clearing, and the 'Try' step—before beginning work. The Work Group Leader must verify and sign off on the Lockout List, acknowledging that everything is in order. Once the Facility Owner completes the Lockout/Tagout/Clear/Try (LTCT) process and hands over the equipment, the Work Group Leader takes over ownership of the Key Control Box. At that point, they may move the Key Control Box to the work area for easier access—but it remains under their care. They must keep the Key Control Box clean and dry, especially during wet weather, to ensure it remains in good condition. At the end of the workday—or once the job is completed—the Key Control Box must be returned to its designated storage area. In short, the Work Group Leader ensures proper coordination, communication, and care throughout the lockout process to maintain a safe and controlled work environment.".

[Audio] "Let's now cover the responsibilities of the Contractor Supervisor when involved in lockout/tagout procedures. The Contractor Supervisor must first ensure that all work is carried out under proper authorization, which includes obtaining and complying with a valid Permit to Work (PTW). They are required to apply their lock and tags according to the Lockout Procedure, just like any other party involved in the work. Importantly, these locks and tags must also be placed on the Key Control Box, which secures the equipment lock keys during the job. Another key responsibility is ensuring their workers are fully protected. This includes clearly understanding the scope of the job and confirming that all necessary safety measures are in place before work begins. If at any point there is uncertainty about the lockout status, the Contractor Supervisor must check directly with the Facility Owner before allowing any work to proceed..

[Audio] "Another important role in the lockout/tagout program is that of an authorized employee who is not directly involved in the current lockout procedure being inspected. This individual is responsible for conducting periodic audits to ensure ongoing compliance and safety. During the audit, this authorized employee must conduct an interview with each authorized employee and affected person who participated in the lockout procedure. The purpose of the interview is to verify that everyone understands and is following their responsibilities under the procedure. To ensure accountability and compliance, the site must document the audit by certifying several key elements: The identity of the machine or equipment where the lockout procedure was applied, The date the audit was conducted, The names of all authorized employees and affected persons involved in the audit, and The name of the authorized employee who performed the audit. This periodic auditing process is not just a formality—it helps confirm that procedures are understood, followed, and effective, and it identifies any gaps in training or practice before they lead to an incident.".

[Audio] "Finally, let's talk about the responsibilities shared by all personnel involved in the Lock, Tag, Clear, and Try—or LTCT—procedure. Every individual working under this procedure is required to apply their personal lock and tag in accordance with the Lockout Procedure. It is critical that each person fully understands and adheres to the process—this isn't optional; it's essential for safety. Before leaving the plant or when the work is complete, each person must remove their personal lock and tag from the Key Control Box. Leaving your lock behind creates confusion and delays, and more importantly, it could result in unsafe conditions. Personnel must also keep appropriate supervision informed of their work status. Regular communication ensures alignment and avoids unnecessary risks. If there's ever uncertainty about the lockout, the right course of action is to check directly with the Facility Owner—never assume. It's also the responsibility of each worker to renew any tags that become illegible. A faded or damaged tag is as good as no tag at all when it comes to safety. Additionally, workers must ensure that each active Lock Box has a valid Lockout List attached. If a lock box is in use and doesn't have one, this must be reported to the Facility Owner immediately. This is a critical compliance step. When it comes to shift handovers, incoming employees must personally verify that all equipment is effectively de-energized and isolated. You cannot rely on the actions of others—especially those who have already left the site. Each employee must take ownership for their own safety and confirm conditions before starting work. And lastly, once the lockout is complete, ensure that the completed Lockout List is properly filed in its designated location for recordkeeping and future audits..

[Audio] "In certain situations, there may be a need to test a motor while it's uncoupled, which requires temporarily energizing the equipment. This is a controlled and high-risk activity, so strict steps must be followed. First, the Facility Owner must ensure that, prior to uncoupling, the personnel responsible for removing the coupling or belts from the rotating equipment have locked out the Key Control Box. This includes applying their Work Group Lock, Personal Lock, and tags. Once that lockout is in place, all other work associated with the lockout must be suspended. Then, the Work Group and all associated personnel must remove their locks and tags from the Key Control Box, clearing the way for controlled re-energization. Next, the guard over the coupling or belt area must be properly installed and tagged—this is a critical safety step to protect against accidental contact with rotating parts. The area around the equipment to be energized must then be clearly barricaded to prevent unauthorized access during the test. It is also essential to tag the local start/stop switch in the 'OFF' position to reduce the risk of unintentional activation. Before racking in the circuit breaker, the Facility Owner must clear all personnel from the area and confirm it is safe to proceed. Finally, after completing the test or procedure, the Lockout List and Blind/Physical Disconnect List must be updated to reflect any changes in system status or configuration..

[Audio] "Sometimes, there may be a situation where a personal lock or tag needs to be removed, but the individual who applied it is not present on the plant. In such cases, there's a very specific procedure that must be followed to maintain safety and accountability. First and foremost, every attempt must be made to contact the person who placed the lock or tag. Only when all attempts to reach them have failed can the removal process begin. At that point, the authorized personnel must: Understand the reason the lock or tag was applied, Review the status of the job that was being worked on, Physically inspect the equipment, and Ensure it is completely safe to remove the lock or tag based on this information. Only after verifying all of the above, the authorized person may proceed to remove the personal lock and/or tag. It's also important that efforts are made to inform the individual whose lock or tag was removed, as soon as they return to the plant. This ensures clear communication and helps maintain the integrity of the lockout/tagout system. Remember, removing someone else's lock or tag is never taken lightly. It is always treated as an exceptional situation with multiple safeguards in place.".

[Audio] "In some situations, a single LTCT box may not have enough locks to perform a complete system lockout. In such cases, we implement what's called a Master and Slave Lockout procedure, where multiple LTCT boxes are used together to isolate all necessary lockout points. The Facility Owner is responsible for assessing the lockout requirements. They will: Assign LTCT boxes to individual systems based on the number of isolation points and available locks, and Designate one box as the Master and the other(s) as Slave(s). Once the setup is determined, the lockout is carried out according to standard Lockout Procedures. When the lockout is complete: The keys from both the Master and Slave LTCT boxes remain inside their respective boxes. It's important to remember: Do not transfer keys from the Slave box into the Master box. A lock from the Master LTCT box is then used to secure the Slave LTCT box—this is done without using a multiple locking device. Finally, the Master LTCT box is locked following the standard procedure. And just as important, the Lockout List must clearly state which box is the Master and which is the Slave. This documentation helps ensure everyone involved understands the lockout configuration. This method ensures a scalable, secure approach to lockouts when a single box isn't sufficient—and maintains control and traceability across the entire system.".

[Audio] "Here, is an example of Master and Slave physical example.".

[Audio] "Even with office equipment, Lock, Tag, Clear, and Try (LTCT) procedures are essential to ensure safety during maintenance or servicing. Here's how it should be done: First, turn off the energy source at the switch socket outlet. Then, remove the 3-pin plug from the outlet to fully disconnect the equipment from power. Next, apply an electrical plug lockout device to the 3-pin plug or connector, and secure it with a lock and tag. After that, both parties must apply their locks: The Facility Owner applies a Facility Lock along with a "DANGER – DO NOT OPERATE" tag. The Vendor or Contractor then applies their Personal Lock with the same "DANGER – DO NOT OPERATE" tag. Once all locks and tags are in place, the "TRY" step is performed—this involves pressing the "Start" or "Operate" button to confirm that the machine cannot power on. This is a critical verification step to ensure proper isolation. Only after successfully completing the TRY step can the work or job begin. And finally, once the job is complete, all locks and tags must be removed from the lockout device, restoring the equipment to normal operation. This simple but essential procedure protects everyone involved, even in low-voltage or seemingly low-risk environments like offices.".

[Audio] "Let's now take a moment to understand the Lockout List, which is a critical part of the Lock, Tag, Clear, and Try (LTCT) process. The Lockout List is a formal document that: Identifies all the lockout points on a machine, system, or equipment, States the reason for each lockout, and Details the specific isolation method required for each energy source involved. This list ensures that no energy source is missed and that every point of potential hazard is accounted for and properly controlled. It serves as both a checklist for those performing the lockout and a record for future reference or audit purposes. The Lockout List must: Be accurately prepared before the lockout begins, Be kept next to the corresponding Key Control Box, and Be signed by the Facility Owner and all involved personnel to confirm that they have reviewed and understand the lockout points. If multiple LTCT boxes are used—for example, in a Master and Slave configuration—the Lockout List must clearly indicate which box corresponds to which part of the system. Once the lockout is complete and the work is done, the completed Lockout List is filed in a centralized location for documentation and compliance. In short, the Lockout List is your roadmap for safe energy isolation—and a critical safeguard to ensure nothing is missed during lockout procedures.".

[Audio] "Next, let's discuss the Blind or Physical Disconnect List, another essential document in our lockout/tagout procedures. The Blind or Physical Disconnect List is used when physical barriers or blinds are installed to prevent the accidental flow of energy or materials through pipes, ducts, or equipment. This list: Identifies all locations where blinds or physical disconnects have been installed, Specifies the type of blind or disconnect used, and Provides details on the status and condition of these physical isolation points. The purpose of this list is to ensure that everyone involved in the lockout is aware of these physical barriers, which serve as a secondary and highly reliable means of isolation beyond just locks and tags. Like the Lockout List, the Blind/Physical Disconnect List must: Be prepared and updated whenever blinds or disconnects are installed or removed, Be kept alongside the related Key Control Box during the lockout process, and Be signed off by responsible personnel to confirm the barriers are in place and intact. By maintaining this list, we enhance safety by ensuring that physical isolation measures are clearly documented, verified, and communicated—minimizing the risk of accidental energy release or material flow. In summary, the Blind/Physical Disconnect List is a vital tool for documenting physical isolation points and ensuring a higher level of protection during maintenance and servicing activities.".

[Audio] "To conclude our training on the Lock, Tag, Clear, and Try procedure, let's review the key points. Lockout/Tagout is critical to protect personnel and equipment from unexpected energization or release of hazardous energy during maintenance and servicing. Lock – Apply locks to isolate all energy sources, using Key Control Boxes where necessary. Tag – Attach clear, durable tags to communicate the lockout status and identify responsible personnel. Clear – Ensure all personnel are clear of the equipment and the area is safe before attempting to re-energize. Try – Attempt to start or operate the equipment to verify isolation has been successful and energy sources are effectively controlled. Each role—from Facility Owner to Contractor Supervisor and all involved personnel—has specific responsibilities to ensure the process is followed correctly. Proper use of Lockout Lists and Blind/Physical Disconnect Lists ensures no energy source is overlooked and that physical isolation points are documented and verified. Remember, communication and documentation are vital—keep all records accurate, accessible, and up to date. Finally, always stop work immediately if you believe safety is compromised. Following the LTCT procedure thoroughly protects everyone and prevents costly incidents. Thank you for your attention and commitment to safety.".