Food Safety Management System. Lockout Tag Out (L.O.T.O) Only electronic copies are controlled copies. Uncontrolled if printed

Transcription

1 Page 1 of 11 Machine: Uncontrolled if printed Standard Operating Procedures Task: Lockout Tag Out to prevent the unexpected energizing, start up, or release of stored energy from machinery during equipment clean-downs, maintenance, and servicing. Aim: To effectively and safely lockout equipment to prevent the unexpected energizing or start up of equipment and to ensure employee safety is not compromised. Responsibility: References: At all times work in a safe manner without causing injury or illness, observing the plants WH&S, GMP and HACCP requirements and practices to produce a safe product. Lockout Views of Machine Tag Out RCD (Residual Current Device) S.I.L.T. 1

2 Page 2 of 11 Lockout is a method of preventing the unexpected energising or start-up of equipment and preventing employee safety from being compromised by locking the machine. To prevent unexpected energising, start-up, or release of stored energy from machinery during equipment clean-downs, maintenance, or servicing. Energy is what causes movement. Whether the power is switched on or off, there is always energy present in any powered equipment. Energy comes from many sources, but consists of two types - Kinetic energy (force caused by motion). - Potential energy (force stored in an object). Types of energy include: Electrical (e.g., capacitors, lines) Chemical (e.g., cleaning agents, ammonia) Thermal (any liquid above 50 C) Hydraulic Pneumatic Gravity Pressure Steam, air, or water 2

3 Page 3 of 11 When to Lockout? Lockout must be used whenever you are working on or around equipment or machine where you could be injured by: The unexpected start-up or energising of the equipment. The release of stored energy. Common Lockout situations You must use lockout when: You need to remove or bypass a guard or safety device. You will be placing any part of your body where you could be caught by moving machinery, e.g., whilst cleaning equipment. Entering a confined space. Other Lockout situations Lockout is also required when: Repairing electrical circuits. More than one person working on / adjusting one machine. For Major shutdown / breakdown maintenance, repairs and cleaning Whenever identified as being hazardous to operator or equipment 3

4 Page 4 of 11 Lockout Devices Every lockout device must be: Supplied by Goodman Fielder. Individually issued or stored on the board. Durable. Substantial (so it will not come off easily). Attached with a name tag or a named lock to identify the person who applied the lockout. Single keyed. Locks are colour coded by user group as follows: Red = Fitters Blue = Electricians Yellow = Production Purple = Contractors 4

5 Page 5 of 11 ISOLATE The person responsible for the plant / Equipment and the person(s) carrying out the isolation shall complete hazard identifification risk assessment identifying the type and magnitude of the energy source This assessment will ensure that the type and location of every energy source control and isolation point are identified Equipment Shutdown Notify all relevant employees that shut-down for servicing, maintenance, or cleaning is required. Shut the system down using operational controls. Follow the correct procedure for the equipment using Risk Analysis and Safe Practices. Equipment Isolation Turn energy isolating devices to off position so that the equipment is isolated from energy sources. Ensure secondary power sources are also isolated. 5

6 Page 6 of 11 Uncontrolled if printed Application of lockout devices 1. Fill in the Lockout Register if using a production / contractors lock and key and retrieve your lock and key from the Safety Lockout Board. This lock and key is now solely your responsibility until it is signed back in. Each Lock must be accompanied by a danger tag, stating name of person applying lock, date and plant it is being used on. 2. Lockout the all the energy isolation devices by turning the Isolator to off (if applicable) 3., Apply the hasp to the isolation switch as pictured. Lock the hasp closed with padlock. 4. Release residual energy where applicable; hydraulic machinery and air gas, steam, or water pressure must be dissipated or restrained by grounding, repositioning, blocking etc. 5. Check the equipment / area is clear 6. Ensure equipment is isolated from its energy source by pushing the start button or normal operating device. The equipment is now locked out and is ready for cleaning / Maintenance. 6

7 Page 7 of 11 Only Standard electronic Operating copies are controlled Procedures copies. Task: Lockout Tag Out to prevent the unexpected Uncontrolled energizing, start-up, if printed or release of stored energy from machinery during For more than one person Each individual working on the locked out equipment must apply individual locks to the hasp. When each person no longer requires lockout protection, that person shall remove their lockout device. Shift or Personnel Changes When equipment is locked out prior to a shift change, the outgoing shift personnel must determine whether the equipment is hazardous in its current state. If the hazard has been eliminated, remove lock and inform incoming shift personnel of the state of the equipment. If the equipment is still deemed hazardous at shift changeover, personnel from the next shift must sign out a new key and lock and attach it to the hasp before the personnel from the current shift remove their lock. Each individual working on the machine must sign in and out their own locks. Changing keys at shift change is not acceptable. Or an out of Service tag may be placed on the equipment. NOTE the Author of an Out of service tag must Nominate personnel who have the authority to remove the tag. Forceful Removal of Locks and Tags Under certain circumstances it may be necessary to cut off a Lockout lock or Tag, for example, where a lock has been used incorrectly or a Lock or Tag has been left on equipment which is no longer hazardous and the employee who applied the lock has left the site, or the nominee can not be contacted (in the case of Out of service tags) The following people are the only personnel with authority to forcefully remove a lock but MUST FOLLOW specific procedures: Group / Team Manager for the specific area. - This person should be contacted via the line Process Specialist Procedure for Manager to cut off Lock or Tag: Identify the Lock or Tag owner. Contact them and get the information required to determine the equipment is in a safe condition before removing Lock Out or Tag Out devices. If unable to reach or contact the person then the Manager must then try to contact the Maintenance Manager or the Engineering Manager to determine who should inspect the equipment to ensure it is in a safe condition to remove the Lock or Tag and start up equipment. A person from the same Trade as the employee who placed the Lockout or Tag out must inspect the machinery to ensure there is no longer a hazard and that all guards are in place before cutting off the Lock. 7

8 Page 8 of 11 Forceful removal of locks and Tags (cont d) When the hasp is cut off, Group / Team Manager and Trades staff must ensure all tools and equipment are removed from the operation area and an ALL CLEAR sign is displayed across the operation area. When all of the above is completed the start up process should be followed. Once equipment has been started, the Group / Team Manager should inspect the operation area to ensure all is safe to continue. Details of the Lock removal should then be recorded in the Tag Out or Lockout Removal Register. Restoring the equipment to service 1. Check the equipment to ensure non-essential items are removed and that it is operationally intact. 2. Check the work area (i.e., tools, people, guards). 3. Verify controls are in the OFF position. 4. Notify relevant employees that the restoration of equipment task is now complete. 5. Remove Lockout devices. 6. Shout a warning to stand clear of the machine and re-energise the equipment. 8

9 Page 9 of 11 Restoring the equipment to service (cont d) If the equipment is Mobile Plant always test the RCD (Residual Current Device) before commencing work. Compliance with this procedure All employees of Goodman Fielder and contractors are required to comply with the lockout procedure. All contractors and employees upon observing a piece of equipment which is locked out shall not attempt to start, energise, or use the equipment. Failure to comply with this procedure may result in disciplinary action. 9

10 Page 10 of 11 Out of Service Tags Tag out is when a Out of Service Tag is connected by a recommended cable tie to an equipment isolating device to indicate it is operationally incomplete. Used primarily by electricians / engineers and sometimes during shift / personnel changes. Tag Out Procedure Attach completed Tag Out Tag to equipment with a cable tie. Record the following information in the Tag Out Register: Date the Tag was attached to the equipment. Name of person attaching the Tag. Name of the equipment and asset / virtual motor Number. Brief description of reason for Tag Out. Additional important Tag Out information Any person working on Tagged Out equipment must still apply their personal lock (as per Lockout Procedure). When the task is completed, remove Tag and Lockout devices after ensuring the equipment is safe to operate. 10

11 Page 11 of 11 Task:Lockout Tag to prevent the unexpected energizing, start-up, or release of stored energy from machinery during Summary of Lockout Tag Out Procedure 11