Rocky Mountain Arsenal National Wildlife Refuge
ENERGY LOCKOUT/TAGOUT PLAN
July 29, 2016
Within the US Fish and Wildlife Service, the guidance and requirements for Lockout/Tagout is
found in 241 FW 8, Energy Lockout/Tagout Program (Attachment 3). OSHA requirements can
be found in 29 CFR 1910.147, the Control of Hazardous Energy (Lockout/Tagout). Control of
hazardous energy and protection for employees working with it is the purpose of the LockoutTagout (LOTO) Program. This program establishes the requirements for isolation of both kinetic
and potential electrical, chemical, thermal, hydraulic, pneumatic, and gravitational energy prior
to equipment repair, adjustment, or removal.
1.
Authorized (Qualified) Employees are the only ones certified to lock and tagout
equipment or machinery. Whether an employee is considered to be qualified will depend
upon various circumstances in the workplace. It is likely for an individual to be
considered "qualified" with regard to certain equipment in the workplace, but
"unqualified" as to other equipment. An employee who is undergoing on-the-job training
and who, in the course of such training, has demonstrated an ability to perform duties
safely at his or her level of training and who is under the direct supervision of a qualified
person, is considered to be "qualified" for the performance of those duties.
2.
Authorized Employees Training. All authorized employees will be trained to use the
Lockout-Tagout Procedures. The training will be conducted by the Supervisor or CDSO
at time of initial hire. The training will consist of the following:
A. Review of General Procedures.
B. Review of Specific Procedures for machinery, equipment and processes.
C. Location and use of Specific Procedures.
D. Procedures when questions arise.
3.
Affected Employees are those employees who operate machinery or equipment upon
which lockout or tagging out is required under this program. Training of these individuals
will be less stringent in that it will include the purpose and use of the lockout procedures.
It will include the following:
A. Only trained and authorized employees will repair, replace, or adjust machinery,
equipment or processes.
B. Affected employees may not remove locks, locking devices or tags from
machinery, equipment or circuits.
C. Purpose and use of the lockout procedures.
4.
Other Employees are identified as those that do not fall into the authorized, affected or
qualified employee category. Essentially, it will include all other employees. These
employees will be provided instruction in what the program is and not to touch any
machine or equipment when they see that it has been locked or tagged out. Other
Employee training will include:
A. Only trained and authorized employees will repair, replace or adjust machinery or
equipment.
B. Other employees may not remove locks, locking devices or tags from machinery,
equipment or circuits.
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5.
Recordkeeping. The employer must certify that employee training has been accomplished
and is being kept up to date. All training and orientation regarding the Lockout/Tagout
program will be recorded on the Region 6 Employee Safety and Health Record, R6 Form
SAF01.
6.
A Lockout/Tagout survey of RMANWR has been completed and an inventory of
equipment, machinery, and systems that require LOTO has been developed, see
Attachments 1 and 2. This inventory describes the energy sources, hazard(s), location of
disconnects, type of disconnect, special hazards, and special safety procedures. The
inventory will be reviewed each time to ensure employees properly lock and tag out
equipment and machinery. If a particular piece of equipment, machinery, or system is not
on the inventory, it must be surveyed and added prior to conducting maintenance to
ensure required LOTO procedures are developed and followed.
7.
Preparation for lock and tag out procedures.
A. Each procedure that is used must be reviewed at least once a year by an authorized
employee other than the one(s) utilizing the energy control procedure, to ensure
that the procedure and requirements are up to date and are being followed and that
affected and other employees are properly trained.
B. Review the Lockout-Tagout inventory and procedures to locate and identify all
energy sources to verify which switches or valves supply energy to the equipment
or system.
C. Ensure that dual or redundant controls have been addressed.
D. Determine if any changes to the equipment or system has been made and if any
changes to the written procedure is needed.
8.
Routine maintenance & machine adjustments. Lockout-tagout procedures are not required
if equipment must be operating for proper adjustment. This rare exception may be used
only by trained and authorized employees when specific procedures have been developed
to safely avoid hazards with proper training. All consideration shall be made to prevent
the need for an employee to break the plane of a normally guarded area of the equipment
by use of tools and other devices.
9.
Locks, hasps, and tags. All Qualified Maintenance Personnel will be assigned a lock with
one key, hasp, and tag, and any necessary lockout/tagout hardware and tags necessary. All
locks will be keyed differently, except when a specific individual is issues a series of
locks for complex lockout-tagout tasks. In some cases, more than one lock, hasp and tag
may be needed to completely de-energize equipment and machinery.
10. General lockout-tagout procedures. Before working on, repairing, adjusting, or replacing
machinery, equipment, or systems, the following procedures will be utilized to place the
machinery and equipment in a neutral or zero mechanical state.
A. Preparation for Shutdown.
i. Before authorized or affected employees turn off a machine or piece of
equipment, the authorized employee will have knowledge of the type and
magnitude of the energy, the hazards of the energy to be controlled, and
the means to control the energy.
ii. Notify all affected employees that the machinery, equipment, or process
will be out of service
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11. Machine or Equipment Shutdown.
A. The machine or equipment will be turned off or shut down using the specific
procedures for that specific machine. An orderly shutdown will be utilized to
avoid any additional or increased hazards to employees as a result of equipment
de-energization.
B. If the machinery, equipment, or process is in operation, follow normal stopping
procedures (depress stop button, open toggle switch, etc.).
C. Move switch or panel arms to "Off" or "Open" positions and close all valves or
other energy isolating devices so that the energy source(s) is disconnected or
isolated from the machinery or equipment.
12. Machine or Equipment Isolation. All energy control devices that are needed to control the
energy to the machine or equipment will be physically located and operated in such a
manner as to isolate the machine or equipment from the energy source.
13. Lockout or Tagout Device Application.
A. Lockout or tagout devices will be affixed to energy isolating devices by
authorized employees. Lockout devices will be affixed in a manner that will hold
the energy isolating devices in the "safe" or "off" position.
B. Where tagout devices are used they will be affixed in such a manner that will
clearly state that the operation or the movement of energy isolating devices from
the "safe" or "off" positions is prohibited.
C. The tagout devices will be attached to the same point a lock would be attached. If
the tag cannot be affixed at that point, the tag will be located as close as possible
to the device in a position that will be immediately obvious to anyone attempting
to operate the device.
D. Lock and tag out all energy devices by use of hasps, chains, and valve covers with
an assigned individual locks.
14. Stored Energy
A. Following the application of the lockout or tagout devices to the energy isolating
devices, all potential or residual energy will be relieved, disconnected, restrained,
and otherwise rendered safe.
B. Where the re-accumulation of stored energy to a hazardous energy level is
possible, verification of isolation will be continued until the maintenance or
servicing is complete.
C. Release stored energy (e.g., capacitors, springs, elevated members, rotating fly
wheels, and hydraulic/air/gas/steam systems, etc.) must be relieved or restrained
by grounding, repositioning, blocking, and/or bleeding the system.
15. Verification of Isolation
A. Prior to starting work on machines or equipment that have been locked or tagged
out, the authorized employees will verify that isolation or de-energization of the
machine or equipment has been accomplished.
B. After ensuring that no employee will be placed in danger, test all lock and tag outs
by following the normal start up procedures (depress start button, etc.).
C. Caution: After Test, place controls in neutral position.
D. Extended Lockout – Tagout. Should the shift change before the machinery or
equipment can be restored to service, the lock and tag out must remain. If the task
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is reassigned to the next shift, those Employees must lock and tag out before the
previous shift may remove their lock and tag.
16. Release from Lockout/Tagout. Before lockout or tagout devices are removed and the
energy restored to the machine or equipment, the following actions will be taken:
A. The work area will be thoroughly inspected to ensure that nonessential items have
been removed and that machine or equipment components are operational.
B. The work area will be checked to ensure that all employees have been safely
positioned or removed. Before the lockout or tagout devices are removed, the
affected employees will be notified that the lockout or tagout devices are being
removed.
C. Each lockout or tagout device will be removed from each energy-isolating device
by the employee who applied the device.
17. Lockout/Tagout procedure for electrical plug-type equipment. This procedure covers all
electrical plug-type equipment, such as battery chargers, pumps, office equipment,
powered hand tools, powered bench tools, lathes, fans, etc.
A. When working on, repairing, or adjusting the cord-connected equipment, the
following procedures must be utilized to prevent accidental or sudden startup:
i. Unplug electrical equipment from wall socket or in-line socket.
ii. Attach a “Do Not Operate" tag on the end of the power cord. The cord &
plug must remain in the exclusive control of the employee working on,
adjusting, or inspecting the equipment.
iii. Perform required operations.
iv. Replace all guards removed.
v. Remove the tag.
vi. Inspect power cord and socket before plugging equipment into power
source. Any defects must be repaired before placing the equipment back in
service.
Note: Occasionally-used equipment may be unplugged from power source when not in
use.
18. LOTO procedures involving more than one employee. If more than one Employee is
assigned to a task requiring a lock and tag out, each must also place his or her own lock
and tag on the energy isolating device(s).
19. Management's removal of locks, tags, and/or LOTO hardware. Only the employee that
locks and tags out machinery, equipment or processes may remove his/her lock and tag.
However, should the employee leave the facility before removing his/her lock and tag, the
Supervisor may remove the lock and tag. The Supervisor must be assured that all tools
have been removed, all guards have been replaced, and all employees are free from any
hazard before the lock and tag are removed and the machinery, equipment or process are
returned to service. Notification of the employee who placed the lock is required prior to
lock removal.
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Rocky Mountain Arsenal National Wildlife Refuge
Lockout/Tagout Inventory
Entry
Number:
1
2.
3.
5.
Machinery, Equipment, or Systems Requiring Lockout/Tagout
Location
Equipment Description Hazard/Type of
on
Authorized
(Make/Model/Power
LO/TO
Station:
Employee(s):
Source):
Required:
Yard
Yard
Welding
bay
Woodshop
building
120
Agricultural Equipment:
Folding Disk Harrow
Alamo Rotary Cutter 15’
Alamo Rotary Cutter 20’
John Deere Mower 15’
John Deere Flail mower
15,20’
Heavy Equipment:
JD Backhoe
Cat Front end Loader
JD Motor Grader
JD Ag Tractors; 8300,
8100,7610,6430,5400,
5520
Hester fork lift
Clark Fork lift
JCB fork lift
Bobcat skid steer
Bobcat track loader
Welder
Radial Arm Saw
Table Saw
Band Saw
Chop Saw
Drill press
5
Hazard:
Counter
weight/Hydraulic
LOTO: Tag
See LOTO
Procedures #1
Scott Whiteaker
Tom Ronning
Steve Tukua
Will Kutosky
Nick Kaczor
Hazard: Hydraulic
release
LOTO: Tag
See LOTO
Procedures #2
Scott Whiteaker
Tom Ronning
Steve Tukua
Will Kutosky
Nick Kaczor
Hazard: Electrical
LOTO: Tag/lock
See LOTO
Procedures #2
Scott Whiteaker
Tom Ronning
Steve Tukua
Will Kutosky
Nick Kaczor
Hazard: Electrical
LOTO: Tag/lock
See LOTO
Procedures #2
Scott Whiteaker
Tom Ronning
Steve Tukua
Will Kutosky
Nick Kaczor
Attachment 2
SPECIFIC ENERGY CONTROL PROCEDURES FOR EACH PIECE OR
TYPE OF MACHINE OR EQUIPMENT
Procedure Number:
* Date:
#1
7/29/2016
Completed by:
Scott Whiteaker
MACHINES OR EQUIPMENT UTILIZING THIS PROCEDURE:
1. Agricultural Equipment:
3.
2.
4.
* Ensure Authorized Employee Review within one year - See Section 7.
PROCEDURE FOR CONTROLLING HAZARDOUS ENERGY:
1. Be familiar with the sources of hazardous energy for the machine or equipment that
will be serviced. Identify the sources of hazardous energy below for the above listed
equipment.
SOURCES OF HAZARDOUS ENERGY:
Electrical
Counterweight X
Pneumatic
Other:
Engine
Flywheel
Chemical
Spring
Hydraulic X
Thermal
2. Notify affected employees that the machine is about to be shut down and locked out.
3. Shut down the machine using the following procedures:
4. Isolate all energy sources listed in step 1 above using the following procedures:
5. Apply tags or locks as follows:
a. Apply personal lockout devices and/or padlocks to all isolation devices
operated in step 4
b. If a tag is used in lieu of a lock when the energy isolation device is
incapable of lockout, the following additional safety precaution(s) must be
taken:
i. Install LOTO tag in place at connection hitch of equipment.
ii. If need flag of the area of damage with flagging.
6. Block or dissipate all stored energy in rams, flywheels, springs, pneumatic or hydraulic
systems, etc.
6
7. Verify that the machine is locked out by attempting to start the machine using the
following procedures. The machine should not start. Return all controls to the neutral
or off position after attempting the start.
8. If work will not be completed by the end of your tour:
a. Inform your supervisor in advance. Advise your supervisor that an
employee from the oncoming tour will be needed to affix his/her lockout in
place of yours.
b. Have other employee(s) remove their lock(s) from your lockout device(s).
Ensure that all tools, lubricants, rags, etc., are removed from the work
area. Loose parts are to be gathered in a central area. Pass on any
pertinent information to the oncoming tour employee while having him/her
affix his/her lockout device in place of yours.
PROCEDURE FOR REMOVING LOCKS/TAGS:
1. Physically walk around the machine. Check to be sure that all safety covers, guards,
and panels have been replaced.
2. Check to be sure all employees are safely positioned.
3. Notify supervisor and all other affected employees that locks/tags are going to be
removed and the machine is ready for operation.
4. Remove all safety padlocks/devices, blocks, and other energy restraints.
5. Restore all energy to the machine using the following procedures:
a. Reconnect implement to tractor as per operators manual.
b. Clean off, inspect, and reconnect all hydraulic connections.
c. Test all hydraulic connections with in cab controls.
6. Operate the machine to ensure proper operation.
7. OTHER COMMENTS:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
8. Procedure Approved: ____________/s/ David Lucas______________ Date: _7/29/2016_
(Project Leader/Supervisor)
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Attachment 2
SPECIFIC ENERGY CONTROL PROCEDURES FOR EACH PIECE OR
TYPE OF MACHINE OR EQUIPMENT
Procedure Number:
* Date:
#2
7/29/2016
Completed by:
Scott Whiteaker
MACHINES OR EQUIPMENT UTILIZING THIS PROCEDURE:
1. Heavy Equipment:
3.
2.
4.
* Ensure Authorized Employee Review within one year - See Section 7.
PROCEDURE FOR CONTROLLING HAZARDOUS ENERGY:
9. Be familiar with the sources of hazardous energy for the machine or equipment that
will be serviced. Identify the sources of hazardous energy below for the above listed
equipment.
SOURCES OF HAZARDOUS ENERGY:
Electrical
Counterweight
Pneumatic
Other:
Engine
Flywheel
Chemical
Spring
Hydraulic X
Thermal
10.Notify affected employees that the machine is about to be shut down and locked out.
11.Shut down the machine using the following procedures:
12.Isolate all energy sources listed in step 1 above using the following procedures:
13.Apply tags or locks as follows:
a. Apply personal lockout devices and/or padlocks to all isolation devices
operated in step 4
b. If a tag is used in lieu of a lock when the energy isolation device is
incapable of lockout, the following additional safety precaution(s) must be
taken:
i. Notify supervisor that the unit will be locked out for repairs.
14. Block or dissipate all stored energy in rams, flywheels, springs, pneumatic or
hydraulic systems, etc.
8
15.Verify that the machine is locked out by attempting to start the machine using the
following procedures. The machine should not start. Return all controls to the neutral
or off position after attempting the start.
16.If work will not be completed by the end of your tour:
a. Inform your supervisor in advance. Advise your supervisor that an
employee from the oncoming tour will be needed to affix his/her lockout in
place of yours.
b. Have other employee(s) remove their lock(s) from your lockout device(s).
Ensure that all tools, lubricants, rags, etc., are removed from the work
area. Loose parts are to be gathered in a central area. Pass on any
pertinent information to the oncoming tour employee while having him/her
affix his/her lockout device in place of yours.
PROCEDURE FOR REMOVING LOCKS/TAGS:
9. Physically walk around the machine. Check to be sure that all safety covers, guards,
and panels have been replaced.
10.Check to be sure all employees are safely positioned.
11.Notify supervisor and all other affected employees that locks/tags are going to be
removed and the machine is ready for operation.
12.Remove all safety padlocks/devices, blocks, and other energy restraints.
13.Restore all energy to the machine using the following procedures:
14. Operate the machine to ensure proper operation.
15.OTHER COMMENTS:
____Use manufactures mechanical Hydraulic lock if
available.______________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
16.Procedure Approved: ____________/s/ David Lucas______________ Date: _7/29/2016_
(Project Leader/Supervisor)
9
Attachment 2
SPECIFIC ENERGY CONTROL PROCEDURES FOR EACH PIECE OR
TYPE OF MACHINE OR EQUIPMENT
Procedure Number:
* Date:
#3
7/29/2016
Completed by:
Scott Whiteaker
MACHINES OR EQUIPMENT UTILIZING THIS PROCEDURE:
1.
3.
Welders
Drill press
2. Saws
4.
* Ensure Authorized Employee Review within one year - See Section 7.
PROCEDURE FOR CONTROLLING HAZARDOUS ENERGY:
17.Be familiar with the sources of hazardous energy for the machine or equipment that
will be serviced. Identify the sources of hazardous energy below for the above listed
equipment.
SOURCES OF HAZARDOUS ENERGY:
Electrical X
Counterweight
Pneumatic
Other:
Engine
Flywheel
Chemical
Spring
Hydraulic
Thermal
18.Notify affected employees that the machine is about to be shut down and locked out.
19.Shut down the machine using the following procedures:
20.Isolate all energy sources listed in step 1 above using the following procedures:
21.Apply tags or locks as follows:
a. Apply personal lockout devices and/or padlocks to all isolation devices
operated in step 4
b. If a tag is used in lieu of a lock when the energy isolation device is
incapable of lockout, the following additional safety precaution(s) must be
taken:
i. Notify supervisor that the unit will be locked out for repairs.
22. Block or dissipate all stored energy in rams, flywheels, springs, pneumatic or
hydraulic systems, etc.
10
23.Verify that the machine is locked out by attempting to start the machine using the
following procedures. The machine should not start. Return all controls to the neutral
or off position after attempting the start.
24.If work will not be completed by the end of your tour:
a. Inform your supervisor in advance. Advise your supervisor that an
employee from the oncoming tour will be needed to affix his/her lockout in
place of yours.
b. Have other employee(s) remove their lock(s) from your lockout device(s).
Ensure that all tools, lubricants, rags, etc., are removed from the work
area. Loose parts are to be gathered in a central area. Pass on any
pertinent information to the oncoming tour employee while having him/her
affix his/her lockout device in place of yours.
PROCEDURE FOR REMOVING LOCKS/TAGS:
17.Physically walk around the machine. Check to be sure that all safety covers, guards,
and panels have been replaced.
18.Check to be sure all employees are safely positioned.
19.Notify supervisor and all other affected employees that locks/tags are going to be
removed and the machine is ready for operation.
20.Remove all safety padlocks/devices, blocks, and other energy restraints.
21.Restore all energy to the machine using the following procedures:
a. Remove tag and lock from unit.
b. Make sure all guards and safety devices are in place and operational.
c. Notify supervisor that repairs have been completed.
22. Operate the machine to ensure proper operation.
23.OTHER COMMENTS:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
24.Procedure Approved: ____________/s/ David Lucas______________ Date: _7/29/2016_
(Project Leader/Supervisor)
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