Electrical Lockout/Tagout Training

Lesson 1 • Scope of Lockout/Tagout Programmes

Defines which tasks and equipment require lockout/tagout controls. Learners distinguish covered servicing activities from normal production operations.

Lesson 2 • Roles and Responsibilities on the Job

Identifies authorised, affected, and other employees in an energy control programme. Clarifies accountability at each role to prevent unauthorised re-energisation.

Lesson 3 • Regulatory Framework for Energy Control

Introduces the regulatory basis for lockout/tagout programmes without citing specific codes. Learners understand employer and worker obligations under energy control standards.

Lesson 1 • Stored Mechanical and Hydraulic Energy

Addresses springs, gravity loads, and pressurised hydraulic systems adjacent to electrical work. Learners recognise when mechanical energy must be controlled alongside electrical isolation.

Lesson 2 • Thermal and Chemical Energy Hazards

Identifies heat stored in conductors, capacitors, and chemical processes near electrical systems. Learners apply cool-down and neutralisation steps before work begins.

Lesson 3 • Electrical Energy Sources and Forms

Covers AC and DC circuits, capacitors, and battery systems as energy sources. Learners map energy entry points on common industrial equipment.

Lesson 1 • Lockout Devices and Their Applications

Covers padlocks, hasps, circuit breaker lockouts, and valve lockouts. Learners select the correct device for each isolation point type.

Lesson 2 • Device Inspection and Maintenance

Establishes criteria for inspecting lockout hardware before each use. Learners remove defective devices from service and document replacements.

Lesson 3 • Specialised Isolation Hardware

Introduces blanking flanges, electrical plug covers, and pneumatic line caps for complex systems. Learners identify specialty devices needed for non-standard isolation points.

Lesson 1 • Stored Energy Release and Verification

Covers bleeding, blocking, grounding, and restraining residual energy after isolation. Learners verify zero energy state using appropriate test instruments.

Lesson 2 • Preparation and Hazard Assessment

Covers pre-job review of energy sources, equipment drawings, and written procedures. Learners gather all required hardware and notify affected employees before starting.

Lesson 3 • Applying Lockout and Tagout Devices

Demonstrates correct placement of locks and tags on each isolation point. Learners apply personal locks and complete tag information before proceeding.

Lesson 4 • Equipment Shutdown and Isolation

Teaches proper shutdown sequencing and operation of energy-isolating devices. Learners distinguish between energy-isolating devices and energy-control devices.

Lesson 1 • Notifying Affected Employees Before Restart

Establishes communication requirements before re-energising equipment. Learners notify all affected employees and confirm the area is clear before applying power.

Lesson 2 • Pre-Release Inspection and Cleanup

Covers inspection of the work area for tools, materials, and personnel before lock removal. Learners verify that all work is complete and the equipment is ready for service.

Lesson 3 • Re-Energisation and System Verification

Covers the controlled application of energy and functional testing after restart. Learners confirm normal equipment operation and report any anomalies immediately.

Lesson 1 • Group Lockout Procedures and Hasps

Explains how multiple workers each apply personal locks to a shared hasp. Learners assign a group coordinator and track individual lock accountability.

Lesson 2 • Temporary Removal of Lockout Devices

Defines the limited conditions under which a lock may be temporarily removed for testing. Learners re-establish full lockout protection immediately after the test is complete.

Lesson 3 • Shift-Change and Contractor Handoffs

Addresses continuity of protection when workers change shifts or contractors enter the work area. Learners apply transfer procedures that maintain uninterrupted lockout protection.

Lesson 4 • Emergency and Abandoned Lock Removal

Establishes the authorised procedure for removing a lock when the worker is unavailable. Learners follow management-authorised steps and document the emergency removal.

Lesson 1 • Corrective Action and Programme Improvement

Covers root cause analysis of audit deficiencies and tracking corrective actions to closure. Learners update procedures and training based on audit outcomes.

Lesson 2 • Conducting the Annual Programme Audit

Teaches the structured inspection of energy control procedures and worker performance. Learners conduct field observations and document findings against audit criteria.

Lesson 3 • Elements of a Machine-Specific Procedure

Covers required content for written energy control procedures, including equipment ID and step-by-step isolation instructions. Learners draft a complete procedure for a sample machine.

Lesson 1 • Retraining Triggers and Frequency

Identifies events that require retraining, including procedure changes, incidents, and audit failures. Learners apply a decision framework to determine when retraining is mandatory.

Lesson 2 • Programme Documentation and Recordkeeping

Establishes documentation standards for training records, audits, and procedure libraries. Learners organise records to support regulatory inspections and internal reviews.

Lesson 3 • Continuous Improvement and Programme Metrics

Introduces key performance indicators for measuring lockout/tagout programme effectiveness. Learners use incident rates, audit scores, and near-miss data to drive programme improvements.

Lesson 4 • Competency Assessment Methods

Covers written tests, practical demonstrations, and field observations as competency tools. Learners design assessments that verify real-world lockout skill, not just knowledge recall.