Here's a comprehensive lockout procedure for an overhead crane, designed to ensure worker safety during maintenance and servicing. This procedure outlines the steps for de-energizing, isolating, and locking out the crane to prevent unexpected start-up or release of stored energy .

1. Preparation and Planning:

• Hazard Identification: Identify all potential hazards associated with the maintenance task, including electrical, mechanical, and gravitational hazards. Consider the magnitude of energy and methods to control it .
• Qualified Personnel: Ensure that only trained and authorized employees perform lockout procedures and maintenance on the crane .
• Notification: Notify all affected employees about the planned shutdown and lockout of the crane before beginning the procedure .
• Written Procedure: Develop and document a specific lockout procedure for the overhead crane, outlining each step in detail. If a written procedure is not available, a lockout permit should be completed and approved before starting work .

2. Shutdown Procedure:

• Normal Shutdown: Turn off the crane using the established shutdown procedures. Utilize an orderly shutdown to avoid creating additional hazards .
• Positioning: If possible, position the crane in a location that minimizes interference with other operations during maintenance .

3. Isolation of Energy Sources:

• Identify Energy Isolating Devices: Locate all energy-isolating devices for the crane, including electrical disconnects, hydraulic valves, and any other sources of potential energy .
• De-energize: Disconnect all power sources to the crane. This may involve switching off circuit breakers or disconnecting the main power supply .
• Stored Energy Release: Relieve, disconnect, or restrain any stored or residual energy, such as potential energy from suspended loads or spring mechanisms . If there's a possibility of re-accumulation of stored energy, continue verification of isolation until servicing is complete .

4. Lockout/Tagout Implementation:

• Apply Lockout Devices: Affix lockout devices (locks) to each energy-isolating device in a manner that prevents them from being re-energized . Each authorized employee should apply their personal lock .
• Tagout (If Necessary): If lockout is not possible, use tagout devices (tags) to clearly indicate that the energy-isolating device should not be operated. Tags should be placed as close as safely possible to the device .
• Lockout/Tagout Stations: Establish designated lockout stations where locks, tags, and other necessary equipment are stored .

5. Verification of Isolation:

• Test the System: After applying lockout/tagout devices, verify that the crane is completely de-energized and isolated. Attempt to operate the crane controls to confirm that it does not respond .
• Continuous Monitoring: If there is a chance of energy reaccumulation, continue to verify isolation until the maintenance is complete .

6. Performing Maintenance/Service:

• Perform Work: Carry out the necessary maintenance or servicing tasks on the crane.

7. Removal of Lockout/Tagout Devices:

• Inspection: Before removing lockout/tagout devices, inspect the work area to ensure that all tools, materials, and non-essential items have been removed .
• Personnel Check: Ensure all employees are safely positioned or removed from the work area .
• Notification: Notify affected employees that the lockout/tagout devices are about to be removed .
• Device Removal: Each employee who applied a lockout/tagout device must remove their own device . If the authorized employee is unavailable, a specific procedure must be followed for device removal, including verification, notification attempts, and ensuring the employee is aware of the removal before resuming work .

8. Restarting the Crane:

• Re-energize: After all lockout/tagout devices have been removed, re-energize the crane according to the established startup procedures.

9. Group Lockout Procedures (for multiple workers):

• Designated Employee: Assign primary responsibility to an authorized employee for a set number of employees working under the group lockout .
• Lockbox System: Use a lockbox system where each authorized employee affixes a personal lock to the group lockout device, lockbox, or comparable mechanism . Keys from energy isolation locks are placed in a lockbox, and each worker attaches their personal lock to the box .
• Verification: The authorized employee must ascertain the exposure status of individual group members .
• Coordination: When multiple crews are involved, assign overall job-associated lockout control responsibility to an authorized employee to coordinate affected workforces .

10. Shift Changes:

• Orderly Transfer: Implement specific procedures for shift or personnel changes to ensure the continuity of lockout/tagout protection, including the orderly transfer of device protection between off-going and oncoming employees .

11. Training and Communication:

• Initial Training: Provide comprehensive training to all authorized and affected employees on the lockout/tagout procedures, including the recognition of hazardous energy sources, methods of energy control, and the requirements of the lockout/tagout standard .
• Retraining: Conduct retraining whenever there is a change in job assignments, machines, equipment, processes, or energy control procedures. Also, provide additional retraining when periodic inspections reveal deviations or inadequacies in the employee's knowledge or use of the energy control procedures .
• Certification: Certify that employee training is accomplished and kept up to date, including each employee's name and training dates .

12. Periodic Inspections:

• Annual Inspections: Conduct periodic inspections of the lockout/tagout procedures to ensure that they are being followed correctly and that the equipment is in good working order .

13. Additional Considerations:

• Outside Personnel: When outside servicing personnel are involved, the on-site employer and the outside employer must inform each other of their respective lockout/tagout procedures .
• Crane Safety: Do not operate the crane until all guards have been reinstalled and safety devices reactivated after maintenance .
• Alternative Procedures: If the standard lockout/tagout procedure is inappropriate or inadequate, an employer may substitute an alternative procedure that provides equivalent protection .

By following this detailed lockout procedure, you can significantly reduce the risk of accidents and injuries during maintenance and servicing of overhead cranes.