Lockout/Tagout Eight-Step Process

Reprinted from GRAIN JOURNAL May/June 2019 Issue

This article is based on a webinar by the Grain Handling Safety Coalition as part of the Stand-Up for Safety Week, March 25-29, 2019. The presenter was Douglas Clark, EHS leader-North America, Cargill Animal Nutrition, Wayzata, MN (612-840-1611). The webinar can be viewed for free at www.grainnet.com/LOTO.

1. Prepare for shutdown. Identify all energy sources, and notify all affected personnel that lockout/tagout procedures are being implemented prior to servicing equipment, bypassing or removing guards, entering a grain bin, or performing other operations.

2. Shut down machine. Written procedures must be followed and executed when equipment is turned off or shut down.

3. Isolate energy sources. Disconnect or isolate all energy sources to release stored or residual energy.

Examples of stored energy include a mechanical device under pressure, battery back-ups, springs, capacitors, flywheels, gravity-elevated hydraulic systems, air, gas, and others.

Stored, hazardous energy can be released by grounding, repositioning, bleeding, venting, and blocking.

4. Lockout/tagout. Locks must be installed on energy sources, and tags should be attached to locks and/or the machine. There should be one lock and tag per person, per machine with their name and the function to be performed.

5. Try it out. Attempt to start the machine to verify if it has been locked out properly.

6. Begin and complete work. After maintenance or service work has been completed, tools must be removed, and the area should be cleaned. Account for the tools and parts, and make sure the equipment is intact.

If the work is finished in one shift, then tools can be removed and affected workers can be notified that the machine is going to be turned back on. If there’s a wait for parts, or if the work is going to be held over for another shift, then the next shift’s workers must put their locks and tags on it. If it is locked out, waiting for parts, maintain your lock on it. Then, write on that tag that this machine is locked out pending the arrival of parts.

7. Notify others of startup. Once work has been completed, notify affected personnel that energy is being restored and the machine is being restarted. Ensure others are at a safe distance when startup occurs.

8. Release lockout/tagout. Only the person who attached the locks and tags should remove them. After the lock has been released and removed, start the equipment and verify that it is operating appropriately.

- Jerry Perkins, contributing writer