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Lockout/Tagout. Worker Training of Electrical Hazards Including Arc Flash SH-16614-07

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Worker Training of Electrical Hazards Including Arc Flash SH-16614-07

This material was produced under grant number SH-16614-07 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

  • Introduction
  • Application
  • LO/TO Program
  • Lockouts Types
  • Training
  • Contractors
  • Estimated to prevent
    • Approximately 120 fatalities per year
    • 28,000 serious injuries
    • 32,000 minor injuries
  • Lockout/Tagout is a horizontal standard which means all industries must comply.
  • LO/TO accidents are severe
    • Average lost work days for failure to LO/TO is 24 days per injury
    • 7% of all fatalities are related to failure to LO/TO
  • Purpose of the Control of Hazardous Energy Program:
    • If a risk exists to any person on unexpected start up, all protective measures are taken to isolate all sources of hazardous energy.

Application of Lockout/Tagout is required:

  • when servicing and/or maintaining machines or equipment,
  • if it is necessary to remove a guard or bypass safety device or interlock,
  • if employee has the potential to be exposed to material being processed or machine cycle.

The Lockout/Tagout standard does not apply to:

  • Cord and Plug Electrical Equipment
    • plug under exclusive control of employee performing servicing or maintenance
  • Hot Tap operations..transmission and distribution systems..water,gas, stream or petroleum products
    • continuity of service essential
    • shutdown of system is impractical
    • documented procedures are followed
lo to program
LO/TO Program
  • Responsibility of the program is assigned to a responsible person.
    • lock acquisition
    • safe work procedures
    • training coordination
    • contractor coordination
    • assist supervisors in implementation and enforcement of disciplinary actions for non-compliance
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LO/TO Program
  • Conduct periodic inspections
  • Document changes in control program as result of inspections
  • Assist in development of specific procedures
  • Maintain program availability for employees and interested persons
lo to program2
LO/TO Program
  • Any employee who may be involved in the operation, installation, service or maintenance of any machine or equipment that has potential for release of hazardous energy is authorized to Lockout/Tagout if he or she is trained.
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LO/TO Program

Authorized Employee

  • Person who locks out or tags out machine
  • Appendix of the LO/TO Program contains a list of Authorized Employees
lo to program4
LO/TO Program


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LO/TO Program
  • Affected employees are those employees whose job requires them to operate machine or process on which maintenance or service is being performed.
    • Need to be notified on shutdown and start up.
  • Individual Lockout:
    • Shut down, control off, lockout
    • Stored energy dissipated, isolated
    • Operate controls for operation, verify OFF
    • Work may proceed
    • If shift changes, individual LO/TO repeated by next shift
  • Individual restoration to service:
    • Replace all guards and safety devices
    • Notify all personnel/affected employees
    • Vents and bleeders closed, blinds removed, blocks and tags removed
    • Each employee removes his or her lock
  • Group Lockout:
    • Same as individual lockout except
      • Operations personnel will place keys in lock box…and fill out “Isolation List for Group Lockout”
      • Operations turns equipment over to Maintenance Department
      • Maintenance will place their personal lock and complete work
      • update “Isolation List”
  • Group restoration to service:
    • Maintenance - replaces all guards and safety devices
    • Maintenance - notifies all Personnel/Affected Employees
    • Vents and bleeders closed, blinds removed, blocks and tags removed
    • Maintenance and Operations - each employee removes his or her lock
  • Long Term Safety Lockout:
    • Extended period of time… discontinued ...not longer part of operation
    • Long term locks available for use by the responsible person

Additional Training for Authorized Persons

  • When implementation is required.
  • Recognition of hazardous energies.
  • Returning equipment to service.
  • If questions on application specific actions to be taken.

Additional training required if . . .

  • new equipment is introduced
  • changes in LO/TO equipment
  • periodic audit identifies need
  • Exchange of LO/TO procedures
  • Agreement of procedures before work begins
  • Discipline of contractor and/or contractor employee(s) for failure to LO/TO