Demonstrate how to correctly apply a lockout device on a piece of machinery.

1. Identify the energy sources that need to be isolated before applying the lockout device. This may include electrical, hydraulic, pneumatic, or mechanical energy sources.

2. Shut off the machinery and ensure that it has come to a complete stop before proceeding.

3. Disconnect the machinery from its power source. This may involve unplugging it, turning off a circuit breaker, or shutting off a valve.

4. Attach the lockout device to the energy isolation point. This could be a disconnect switch, valve, or plug. Make sure the device is securely attached and cannot be easily removed.

5. Lock the device in place using a padlock. Only authorized personnel should have access to the key.

6. Test the machinery to ensure that it cannot be started or operated while the lockout device is in place.

7. Complete a lockout/tagout procedure form to document the lockout process. Include details such as the date and time of the lockout, the equipment being locked out, and the names of the personnel involved.

8. Once the work on the machinery is complete, remove the lockout device and restore the energy sources. Make sure to follow proper procedures for re-energizing the machinery.

9. Conduct a final check to ensure that the machinery is functioning properly before allowing it to be used again.

Materials:

- Lockout device (e.g., padlock or lockout tag)
- Key or removal device

Steps:

1. Identify and Isolate the Energy Source:

- Determine the main energy source(s) that power the machinery (e.g., electricity, compressed air, hydraulics).
- Locate the isolation points for each energy source.

2. Shut Down and De-Energize the Machinery:

- Turn off the power switch or disconnect the power cord.
- Bleed off any pressurized fluids or gases through pressure relief valves.

3. Apply the Lockout Device to the Isolation Point:

- Open the isolation point and ensure that the energy flow is stopped.
- Attach the lockout device to a location that prevents the isolation point from being reopened. Use a sturdy and tamper-proof device.
- Insert the key or removal device into the lockout and turn it to the locked position.

4. Verify Lockout Effectiveness:

- Attempt to reopen the isolation point to confirm that it is locked and cannot be accessed.
- Check that the lockout device is securely attached and cannot be easily removed.

5. Tag the Machinery with a Lockout Tag:

- Attach a lockout tag to the machinery, clearly indicating:
- The reason for the lockout.
- The authorized personnel who applied the lockout.
- The date and time of the lockout.

6. Secure the Key or Removal Device:

- Keep the key or removal device in a designated and secure location, accessible only to authorized personnel.

7. Test the Lockout System:

- After the lockout has been applied, briefly energize the machinery to ensure that the lockout is effective and prevents the machinery from operating.
- De-energize the machinery immediately and reapply the lockout.

Additional Considerations:

- Use multiple lockout devices and keys for complex machinery systems.
- Train all authorized personnel on how to properly apply and remove lockout devices.
- Regularly inspect lockout devices and tags for damage or tampering.
- Follow your organization's specific lockout/tagout procedures.