21 Mar Lockout/Blockout Safety

Lockout/Blockout Safety

Lockout/blockout safety protects workers from the unexpected startup, movement, or release of hazardous energy from machinery and equipment during cleaning, servicing, adjustment, maintenance, or repair. Before beginning work, identify every energy source and make sure the equipment cannot move, operate, or release stored energy while anyone is exposed to a danger zone.

When Lockout/Blockout Is Needed

Lockout/blockout procedures may be required whenever an employee must:

• Service, maintain, clean, adjust, or repair machinery or equipment.
• Remove or bypass a guard or other safety device.
• Place any part of the body into an area where hazardous movement could occur.
• Work around equipment that could move because of gravity or stored energy.
• Perform work where unexpected startup or energization could cause injury.

Never assume that shutting off the normal operating controls makes equipment safe.

Identify and Control Hazardous Energy

Before beginning work, inspect the equipment and surrounding area and identify all hazardous energy sources. These may include:

• Electrical energy.
• Mechanical energy.
• Hydraulic or pneumatic pressure.
• Chemical or thermal energy.
• Gravity and elevated components.
• Springs, capacitors, accumulators, or other stored energy.

All hazardous energy must be isolated and stored energy must be released, restrained, blocked, or otherwise controlled before work begins.

Lockout and Blockout

Lockout physically prevents an energy-isolating device from being operated. Each authorized employee must follow the established equipment-specific lockout procedure and apply their personal lock and required tag.

Blockout is used to physically prevent equipment or components from moving. Blocking may be necessary for raised blades, buckets, booms, presses, suspended components, or other equipment that could move, fall, rotate, or shift because of gravity or stored mechanical energy.

Never rely solely on hydraulic or pneumatic pressure to support elevated equipment. Use appropriate blocking, cribbing, pins, stands, or other manufacturer-approved means of securing the equipment.

Safe Work Practices

• Follow the company’s written hazardous-energy-control procedures.
• Perform lockout/blockout only when trained and authorized to do so.
• Notify affected employees before equipment is shut down.
• Shut down equipment using normal operating controls.
• Isolate all hazardous energy sources.
• Apply required locks and tags.
• Release, restrain, or otherwise control stored energy.
• Install blocking wherever equipment movement could expose workers to injury.
• Verify that isolation is effective before beginning work.
• Never bypass, remove, or operate another employee’s lock or tag.
• Never enter a danger zone based solely on the assumption that equipment has been shut off.
• Report damaged or malfunctioning lockout or blocking equipment immediately.

Verify Before You Work

After lockout and blockout devices have been installed, verify that the equipment is actually isolated. Attempt a normal start or use another appropriate verification method to ensure the equipment cannot operate. Return operating controls to the neutral or “off” position after the test.

Do not begin work until hazardous energy has been controlled and the effectiveness of the isolation has been verified.

Restoring Equipment to Service

Before removing lockout or blocking devices:

• Inspect the work area and remove tools and unnecessary materials.
• Make sure guards and equipment components are properly restored.
• Confirm that all employees are safely positioned or clear.
• Remove locks, tags, and blocking according to the established procedure.
• Notify affected employees before the equipment is returned to service.

Remember

Never take shortcuts because a repair, adjustment, or cleaning task will only take a few minutes. Unexpected startup or movement can occur without warning and can result in crushing injuries, amputations, electrocution, or death.