Lockout/Tagout Training, Requirements and Benefits

Every year, over 3 million workers in the United States are exposed to hazardous energy sources while working with machinery and equipment. Such energy sources, whether electrical, mechanical, or hydraulic, pose a significant danger to workers unless properly controlled. LOTO training ensures that all hazardous energy is adequately isolated before maintenance or repair work begins, saving the lives of workers from the accident that could go worse.

In this blog, we will be discussing what LOTO training is, why it's so important, and OSHA's specific requirements for compliance. We also outline the procedures key to lockout/tagout, how you may become certified as a worker, and how a solidly trained workforce will pay off. All of these are very important aspects in the creation of a safe workplace and to the prevention of costly accidents or violation fines. So, let's get started.

What Is Lockout/Tagout Training?

Lockout/Tagout, or LOTO, is the completion of a safety process that removes the chances of possible accidents since workers are servicing or repairing the equipment. LOTO trains employees on how to properly lock off and isolate energy sources, like electricity, hydraulics, or mechanical power, before beginning any form of maintenance work. A lock is used to prevent the energy source from turning on, while tags are attached to warn other people that the equipment is being serviced. This is because, as OSHA determines, the major portion of work-related injuries by electrical shocks and other kinds of mechanical injuries and fatalities arises from improper control of hazardous energy.

Training on LOTO further trains workers to ensure they verify that all the energy has been isolated fully before any work starts. The procedure is called energy verification, which goes a long way in determining whether or not the equipment is safe and ready for work. Reports issued by OSHA indicate that among the most frequent causes of injuries in industries involving complex machineries is improper isolation of energy source. Thus, LOTO training reduces those risks and also makes the workplace safer since it ensures that workers know how to safely lock, tag, and verify equipment.

OSHA LOTO Training Requirements

OSHA sets clear guidelines on LOTO training to help workers in safety from the inherent hazards of hazardous energy. In standard 29 CFR 1910.147 set by OSHA, "any employee who works with or near a machine or equipment which may release hazardous energy during servicing or when reshutting a machine or equipment must receive training on lockout/tagout". The employees who install, service, maintain and repair equipment are trained on LOTO besides those employees whose work may be affected by the energy isolation process.

Several major areas must be included in the training: workers must learn to identify sources of energy, learn how to control them, and what procedures are implemented for lockout/tag out of equipment. OSHA also requires employees to be trained on the recognition of potential hazards and to know what to do in case there is an unexpected energy release. The training should also be given when hiring starts and when changes occur in the workplace, for instance when introducing new equipment or procedures.

In addition, OSHA requires that LOTO training be refreshed after three years to ensure that employees keep abreast of changes in procedure and legislation. For example, if the duties of a worker change or if the worker is exposed to new types of machinery, he or she should be updated with such information. Employees properly trained on LOTO procedures will continue operating with safety in the workplace while adhering to federal regulations.

Key Elements Of LOTO Procedures

The procedure under LOTO entails some key steps in the proper isolation of hazardous energy as well as preventing machinery or equipment to accidentally come online during a maintenance. 

• First, it is to identify all energy sources. These energies include electrical, mechanical, hydraulic, pneumatic, as well as thermal sources that might cause harm during the time for maintenance. Workers have to be trained to recognize types of energy sources that are connected to the equipment and be aware of the way to isolate each one of them.

• Then, the energy sources must be isolated. This is usually done through deenergization of the equipment and disconnection of any energy source that could present a potential hazard. 

• Once this is done, then the use of lockout devices such as padlocks is used to lock out the energy-isolating devices. 

• The function of the lock is to prevent accidental actuation of the equipment because of the physical locking mechanism during the maintenance process. It should be accompanied by lockout with the tagout equipment; the tag affixes to show that the equipment is under service and should not be operated.

  
  

Once locked and tagged on the equipment, the workers are asked to check the isolation of energy. That is, checking whether all the energy is cut off within the equipment effectively so that there could not be an untimely release of energy. Only after such verification can the worker start maintenance tasks. However, maintenance of proper communication with all personnel involved throughout this process is necessary to ensure everyone's knowledge about the status in energy isolation and keeping the work area safe. 

Common LOTO Mistakes and Avoiding Them

While employees undertake proper training in LOTO, they commit numerous common mistakes while following the lockout/tagout process. These can lead to accidents. Knowing the mistakes and preventing them are an essential aspect of a safe workplace. Here are some common errors and practical solutions to ensure that LOTO procedures are performed accurately:

• Missing Verification Procedure

The most crucial thing in the LOTO procedure is to verify all the energy sources. Sometimes, employees believe that after locking a device, it becomes safe to work on. However, not checking if the energy is cut off increases accident possibilities. Always test to ensure it is de-energized before beginning any maintenance work.

• Inadequate Application of Tags

Tags must never be considered an alternative for lockout devices. Though tags are a notification that equipment has been serviced, they do not lock out the equipment. To keep you and others safe, lockout devices and tags must be used together always. Never use tags as a means of isolation of energy alone.

• Not Locking Out All Sources of Energy

Turning off the primary power supply is not enough. Many workers neglect to isolate and lock out energy sources related to, for instance, pneumatic or hydraulic systems, because their shutdown does not appear to be obvious. Identify all energy sources that may be linked with the equipment and lock them out. A proper check on every possible source of energy is necessary in order to fully isolate.

• Failure to Inform Operators and Others Affected

While doing maintenance or lockout/tagout, every exposed employee is to be informed so that they do not inadvertently attempt to use the equipment. Everyone within the area is to be made aware of the work being performed, the status of the energy isolation, and who did the work.

• Removal of Locks End

Removal of the lock should only be made by the worker who applied the device. Letting someone else remove the lock leads to incorrect re-energization of equipment before the work has been completed. When the worker who had applied the lock is not available, removal procedures of the lock should be taken under strict observation for safety purposes. 

How LOTO Procedures Apply Across Different Industries

Benefits of Regular LOTO Training

How To Get LOTO Trained and Certified

While all recognize that working around machinery and sources of energy exposes everyone to a risk, LOTO training has become that best safety tool that has been used to prevent major accidents. According to OSHA, nearly 10% of all workplace injuries come from the improper control of hazardous energy. Certification in LOTO ensures that your employees understand how to isolate energy sources safely when maintaining their equipment. 

To help you cut the complexity, here's step by step how to get trained and certified in LOTO procedures:.

Step 1: Choose an Authorized Training Provider

Choose a qualified training provider. It may be an internal program, an online course, or a third-party safety organization. The training provider should be recognized by OSHA or reputable safety bodies such as the National Safety Council (NSC) or the American Society of Safety Professionals (ASSP).

Step 2: Complete the LOTO Training

Employees should then undertake the LOTO training course, which will be both theoretical teaching and practical exercises. The programme will also be focused on providing training in sources of energy, use of lockout/tagout devices, as well as verification techniques of isolation. The training may take various durations depending on the nature of the workplace.

Step 3: Demonstrate Knowledge and Skills

After a competent training, the employees are required to perform so as to prove that they can indeed apply what they have acquired. This might be in the form of written tests or practical assessment where they are obliged to prove that they can safely implement LOTO procedures in real-life situations.

Step 4: Get Certification

After the workers have passed the tests, each worker will be given a LOTO training certificate. Then, this will act as proof that an employee has completed the needed training and is consequently qualified to follow proper lockout/tagout procedures.

Step 5: Re-Certification

In order to retain the certification, employees must attend refresher courses every three years. Moreover, whenever there is a change in equipment, procedures, or job responsibility, re-certification is mandatory so that employees remain updated about the new developments concerning safety practices.

Message From The LearnTastic Team

LearnTastic understands that effective LOTO training will be reported to prevent as many as 50,000 injuries a year if the employees are trained to handle hazardous energy. Certifications will ensure the safety of your team and give you the peace of mind knowing that your team is in compliance with OSHA regulations. 

We have a variety of Lockout Tagout courses and modules to help meet different requirements. Take a look at our offerings, and decide which would better suit your safety training needs. Safety first; let's choose the right kind of training for today.

References/Citations:

1. PFW Annual Training: Lockout/Tagout Training: https://www.pfw.edu/offices/rem/safety-training/doc/Lockout%20Tagout%20Training.pdf 

2. National Agricultural Safety Database (NASD) – Research Publications-11, Lockout/Tagout: https://nasdonline.org/1632/d001514/research-publications-11-lockout-tagout.html 

Loss Control Services: Protect Workers From Hazardous Energy During Servicing and Maintenance: https://www.mylosscontrolservices.com/Images/CMO-0933AO%20Lockout%20Tagout_tcm148-21067.pdf