5.1 Preparation for Lockout/Tagout

Make a survey to locate and identify all isolating devices to be certain which switch(es), valve (es), or other energy isolating devices apply to the equipment to be locked or tagged out. More than one energy source (electrical, mechanical, stored energy, or others) may be involved.

5.2 Sequence of Lockout or Tagout System Procedure

  • Notify affected employees that a lockout or tagout system is going to be utilized and the reason therefore. The authorized employee shall know the type and magnitude of energy that the machine or equipment utilizes and shall understand the hazards thereof.
  • If the machine or equipment is operating, shut it down by the normal stopping procedure (depress stop button, open toggle switch, etc.).
  • Operate the switch, valve, or other energy isolating device(s) so that the equipment is isolated from its energy source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc.
  • Lockout/Tagout the energy isolating devices with assigned individual lock(s) or tag(s).
  • After ensuring that no personnel are exposed, and as a check on having disconnected the energy sources, operate the push button or other normal operating controls to make certain the equipment will not operate. CAUTION: Return operating control(s) to neutral or off position after the test.
  • The equipment is now locked out or tagged out.

5.3 Restoring Machines or Equipment to Normal Operations

  • After the servicing and/or maintenance are complete and equipment is ready for normal production operations, check the area around the machines or equipment to ensure that on one is exposed.
  • After all tools have been removed from the machine or equipment, guards have been reinstalled and employees are in the clear, remove all lockout or tagout devices. Operate the energy isolating devices to restore energy to the machine or equipment.

5.4 Procedures Involving More Than One Person

  • In the preceding steps, if more than one individual is required to lockout or tagout equipment, each shall place his/her own personal lockout/tagout device on the energy isolating device(s). When an energy-isolating device cannot accept multiple locks or tags, a multiple lockout or tagout device (hasp) may be used. If lockout is used, a single lock may be used to lockout the machine or equipment with the key being placed in a lockout box or cabinet which allows the use of multiple locks to secure it. Each employee will then use his/her own lock to secure the box or cabinet. As each person no longer needs to maintain his or her lockout protection, that person will remove his/her lock from the box or cabinet.

5.5 Maintenance Requiring Undisrupted Energy Supply

  • Where maintenance, repairing, cleaning, servicing, adjusting, or setting up operations cannot be accomplished with the prime mover or energy source disconnected, such operations may only be performed under the following conditions:

The operating station (e.g. external control panel) where the machine may be activated must at all times be under the control of a qualified operator.

All participants must be in clear view of the operator or in positive communication with each other.

All participants must be beyond the reach of machine elements, which may move rapidly and present a hazard.

Where machine configuration or size requires that the operator leave the control station to install tools, and where there are machine elements which may move rapidly, if activated, such elements must be separately locked out.

During repair procedures where mechanical components are being adjusted or replaced, the machine shall be de-energized or disconnected from its power source