Lockout Tagout for Authorized Employees Training

**Lockout/Tagout (LOTO) for Authorized Employees Training** is designed for workers who are directly involved in implementing the lockout/tagout procedures during maintenance, repair, or servicing of equipment. These employees, known as "authorized employees," are responsible for isolating hazardous energy sources, locking out or tagging out equipment, and ensuring that proper safety measures are in place before workers perform their tasks.

This training ensures that authorized employees are thoroughly familiar with the procedures necessary to prevent the accidental release of hazardous energy and to protect themselves and their coworkers from potential injuries or fatalities. Authorized employees are the key personnel responsible for carrying out the LOTO process.

### **Key Components of Lockout/Tagout for Authorized Employees Training**

#### 1. **Introduction to Lockout/Tagout (LOTO)**
- **Definition**:
- **Lockout**: The placement of a lock on an energy-isolating device (such as a valve, switch, or circuit breaker) to prevent the release of hazardous energy during maintenance or servicing.
- **Tagout**: The placement of a tag on the energy-isolating device indicating that it should not be operated until the tag is removed, signaling that maintenance is being performed.
- **Purpose**: The primary purpose of lockout/tagout is to protect workers from unexpected equipment startups, the release of stored energy, and other potentially hazardous conditions while equipment is being serviced or maintained.

#### 2. **Understanding the Hazards**
- **Types of Hazardous Energy**:
- **Electrical Energy**: Shock, electrocution, burns, or arc flashes.
- **Mechanical Energy**: Moving parts that can cause crushing, amputation, or entanglement.
- **Hydraulic/Pneumatic Energy**: Pressurized fluids or gases that can cause injection injuries, burns, or explosions.
- **Thermal Energy**: Hot surfaces or materials that can cause burns.
- **Chemical Energy**: Spills, leaks, or chemical burns from hazardous substances.
- **Consequences of Inadequate Lockout/Tagout**:
- Accidental equipment start-up, leading to injuries.
- Exposure to hazardous materials.
- Unexpected release of stored energy.

#### 3. **Roles and Responsibilities of Authorized Employees**
- **Before the Lockout/Tagout Process**:
- **Plan the Lockout**: Assess the equipment or machine to be serviced and identify all energy sources. This includes electrical circuits, hydraulic systems, and any stored energy.
- **Obtain Permission**: Ensure that work is authorized and that appropriate permits (such as a permit-to-work) are in place.
- **Notify Affected Employees**: Inform all affected employees that equipment will be locked/tagged out, and describe the work being performed.

- **During the Lockout/Tagout Process**:
- **Isolate Energy Sources**: Identify and isolate all energy sources before placing locks or tags.
- **Lockout/Tagout Devices**: Apply lockout devices to energy-isolating devices and ensure they are secured. Use tags to indicate that the equipment is out of service.
- **De-energize Equipment**: Ensure that equipment is completely de-energized by confirming it is not in operation, and check for any residual or stored energy.
- **Verify Zero Energy State**: Test and verify that the equipment cannot be started or energized before beginning any maintenance work. This includes checking valves, switches, and circuits to confirm that they are in the off position.

- **During Maintenance or Service Work**:
- **Conduct Work Safely**: Perform the necessary tasks while maintaining a high level of safety, ensuring that no equipment is re-energized until the work is complete.

- **When Work Is Complete**:
- **Removal of Lockout/Tagout Devices**: Only the authorized employee who applied the lock or tag should remove it. In cases where the employee is unavailable, proper procedures for lockout/tagout device removal should be followed.
- **Test Equipment Before Returning to Service**: Once lockout/tagout devices are removed, verify that the equipment is safe and operational before it is returned to service.
- **Notify Affected Employees**: Inform affected employees that the equipment is safe to use and that the lockout/tagout procedure has been completed.

#### 4. **Steps in the Lockout/Tagout Procedure**
- **Preparation**: Review equipment or system manuals to understand all energy sources. Identify and understand the types of energy (electrical, hydraulic, mechanical, etc.).
- **Shutdown**: Shut down the equipment according to the manufacturer’s guidelines.
- **Isolation**: Isolate all energy sources connected to the equipment (e.g., turning off power, shutting off gas, disconnecting fluids).
- **Lockout/Tagout**: Place locks and tags on the energy-isolating devices to prevent accidental re-energizing of the equipment.
- **Release Stored Energy**: Safely release any residual energy that may still be present in the equipment.
- **Verification**: Test and verify that all energy has been isolated and that the equipment cannot be activated.
- **Performing Maintenance or Service**: Only after ensuring the equipment is de-energized and locked/tagged out can maintenance or repair work proceed.
- **Restoration**: After work is completed, remove lockout/tagout devices and verify that the equipment is operational before restarting.

#### 5. **Tools and Equipment for Lockout/Tagout**
- **Lockout Devices**: Locks, hasps, and lock boxes used to secure energy-isolating devices.
- **Tagout Devices**: Warning tags placed on energy-isolating devices to signal that the equipment is not to be operated.
- **Key Considerations**:
- Locks must be durable and resistant to tampering.
- Tags should be clearly visible and contain the name of the authorized employee and the reason for the lockout/tagout.
- **Lockout/Tagout Kits**: Complete kits should be available to authorized employees, including various lockout devices, tags, and necessary tools.

#### 6. **Special Lockout/Tagout Considerations**
- **Group Lockout**: When multiple workers are involved in servicing a piece of equipment, group lockout procedures are used, where a primary lock is applied, and each worker applies their own lock to ensure that no one can accidentally re-energize the equipment.
- **Energy Control Procedures**: Develop clear, written procedures for controlling hazardous energy, specifying how and when to lock out/tag out, and who is responsible for each step.
- **Testing and Inspection**: Ensure that employees are trained to test energy isolation and verify that the system is properly de-energized before starting work.
- **Return to Service**: Ensure that after completing maintenance, the equipment is checked for safety and ready to be returned to service.

#### 7. **Challenges and Troubleshooting**
- **Miscommunication**: Ensure clear communication between authorized employees and affected workers to prevent misunderstanding about the status of lockout/tagout procedures.
- **Tampering or Bypassing**: Reinforce the importance of not tampering with or bypassing lockout/tagout procedures. Establish disciplinary actions for violations.
- **Unexpected Energy Sources**: Authorized employees should be trained to identify and handle unexpected or hidden energy sources that may not be initially apparent.

#### 8. **Emergency Situations**
- **In Case of Injury**: If an injury occurs while working with lockout/tagout devices, the procedure must stop immediately, and emergency medical assistance should be summoned.
- **Accidental Release of Energy**: In the event that energy is inadvertently released during work, authorized employees must know how to react quickly to control the situation and minimize harm.

#### 9. **Documentation and Record-Keeping**
- **LOTO Procedures**: Keep clear records of lockout/tagout procedures, including employee training, audits, and any deviations from standard procedures.
- **Training Records**: Maintain records of training completion for all authorized employees to ensure compliance with OSHA regulations.

### **10. Conclusion**
Lockout/tagout is a critical safety procedure for protecting workers during maintenance, repair, and servicing of equipment. Authorized employees must be thoroughly trained in the LOTO process to ensure that equipment is properly isolated and that all energy sources are controlled to prevent accidental release. This training is essential to prevent workplace accidents, injuries, and fatalities, ensuring that workers can carry out their tasks safely and in compliance with regulatory requirements.