Many employers do not realize that it is required to develop a “Specific” Energy Control Procedure for each piece of equipment that exposes employees to hazardous energy while cleaning, servicing, maintaining, adjusting, unjamming, or setting up.

Cal OSHA’s regulatory references are CCR Title 8 Sections:

3314. Cleaning, Repairing, Servicing and Adjusting Prime Movers, Machinery and Equipment
3340. Accident Prevention Signs
3341. Accident Prevention Tags

Fed OSHA’s regulatory reference is 29 CFR 1910.147

OSTS provides training sessions that will ensure that all facets of the Lockout Tagout Blockout Standard requirements are clearly understood.

General Program Development

OSTS can develop your general Lockout Tagout Blockout policy as required by OSHA.   This is the general document and does not include development of machine-specific Energy Control Procedures (ECPs).  The general program will include an ECP form to enable your employees to develop ECPs on your own.

Energy Control Procedure Development Class

A select group of your employees, typically maintenance personnel, can participate in this course where they will learn how to develop Energy Control Procedures.  This class includes classroom lecture, classroom tabletop exercises, and actual hands-on exercises where students will develop procedures for your machines and come back to the classroom to critique and correct.

Authorized Level training

This training will assist the students in understanding the potential for exposure and their liability and responsibility as it relates to the company’s Lockout Tagout Program. If equipment-specific ECPs do not exist, students may want to participate in the ECP development course prior to participating in an Authorized Level course.  Individuals who participate in this training will be given a comprehensive overview of the Regulatory Standard, your written policies and procedures and how energized machines and equipment affect their daily activities. Key points that will be covered in this course include:

The control of hazardous energy must be done according to a six-step procedure:

  • Preparation for shutdown
  • Equipment shutdown
  • Equipment isolation
  • Application of lockout tagout devices
  • Control of stored energy
  • Equipment-isolation verification

Before removing the lock:

  • Make sure equipment is safe
  • Conduct a head count
  • Notify all affected personnel that lockout is being removed

Special situations to be aware of:

  • Outside contractors
  • Temporarily reactivating equipment
  • Servicing that lasts more than one shift
  • Removal of lockout by personnel who did not apply it

Participants will receive materials/handouts needed to assist in subject retention. The session for “Authorized” individuals can last many hours when specific energy controls procedures are being discussed and explained.

Affected Level Training

This class is designed to provide an awareness level of information to those employees who will not be involved in the Lockout Tagout processes and procedures.  This is required training to ensure that Affected Level employees do not attempt to bypass any locked out and tagged out equipment.

The Lockout Tagout Standard requires the following issues to be addressed:

  1. Conduct an Evaluation of potential energy sources your employees may be exposed
  2. Develop a formal Written Policy
  3. Assign “Authorized” Personnel
  4. Develop Energy Control Procedures per piece of equipment
  5. Acquire necessary locks, tags, and locking devices*
  6. Conduct Training for Employees – “Authorized” and “Affected”
  7. Establish Procedures To Maintain The Program

* To be acquired from a safety equipment supplier

All training is performed in accordance with Federal OSHA, applicable State-chartered OSHA, and other State Regulations and local Ordinances.
 

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