Elkhorn Construction, Inc. Safety Manual Title: Lockout/Tagout Policy Effective Date:

Transcription

1 1. General 1.1 The following are the safety precautions that shall be used when servicing and performing maintenance on machines and equipment. It also covers construction tie-ins to new equipment in which the unexpected release of energy, or equipment start up or the release of stored energy could cause injury. This policy specifies the minimum requirements for the control of energy. 1.2 Definitions that are applicable to the lockout/tagout policy are affected employee-owner, authorized employee-owner, and energy isolating device and energy source. An authorized employee-owner is a person who uses the energy control procedure. An affected employee-owner is a person who works in an area which the energy control procedure has been implemented. An energy isolating device is a mechanical device that prevents the unwanted transmission or release of energy. An energy source can be comprised of potential, stored, electrical, mechanical, hydraulic, pneumatic, chemical, nuclear, thermal, or any other energy source that could cause injury. 1.3 All energy sources that are associated with equipment that is to be worked on must be locked and/or tagged in the position which isolates personnel from the hazardous energy when maintenance/service/tie-in work is being performed by company or contract personnel. 1.4 Company supervisors will be responsible for ensuring that all equipment and energy sources are properly locked and tagged prior to starting work. A watch person (similar to a fire watch) is prohibited as a substitution for the lockout/tagout procedure. 1.5 The use and procedures that are employed in the lockout/tagout procedures shall be reviewed annually by the company personnel to ensure that the program is being used and that the procedures are effective. All affected personnel shall be trained annually in lockout/tagout procedures and this training shall be documented. 1.6 This program does not apply to: 16.1 Hand held power tools or stationary power tools whose electrical power may be controlled by unplugging the equipment from the energy source when the plug and cord are under the control of the employee-owner that is performing the service or maintenance Hot tap operations that involve transmission and distribution systems on pressurized pipelines. Document No: 2E-0180 Revision 1 Page 1 of 1

2 2. Lockout and Tagout Process 2.1 Employee-Owners that are involved in the lockout/tagout procedures must be knowledgeable of the type and amount of energy, the hazards of the energy to be controlled and the methods that will be employed to control the energy. This must be determined before turning off a machine or closing valves to isolate equipment. 2.2 Notify all affected employee-owners about the lockout/tagout procedure and the prohibition regarding any attempt to restart or energize equipment that is locked out and/or tagged out. 2.3 Machinery or equipment must be shut down using established procedures. The shut down procedure must not create any increased hazards to employee-owners. 2.4 All energy-isolating devices are to be physically located and operated as appropriate to isolate the machinery or equipment from the energy source. Lockout and/or tagout devices must be attached to each energy-isolating device by an employeeowner authorized by the supervisor in charge. The locking devices shall be attached in such a manner that they will hold the isolating devices in the safe or off position. No lock shall be attached without a tag stating who put the lock on, the date and reason that the equipment was locked out. 2.5 Affected employee-owners will lockout and/or tagout the isolating device with a personal lock that is approved by the supervisor in charge. The person that is performing the work should fill out the tag. 2.6 Tagout devices shall be attached to clearly indicate that the operation or movement of energy isolating devices from the safe or off position is clearly prohibited. 2.7 If more than one group is working on the same piece of equipment each authorized person from each craft will place a lock on the multiple hasp, either on the isolating device or on a lock box that contains the keys of all attached company locks and will sign and date the Danger Do Not Start tag. The decision to use a lock box will be made by the supervisor on charge. Each authorized person from each craft or group will test the start/stop station to determine that the equipment will not start. Each authorized person from each craft or group will also determine that the lockout device prohibits locked valves from being actuated. 2.8 Following the application of lockout/tagout devices to energy isolation devices, all stored or residual energy shall be relieved, disconnected, restrained or otherwise rendered safe. If there is a possibility of re-accumulation of stored energy, verification and monitoring of the energy buildup shall be monitored until the work is completed or until the possibility of energy build up no longer exists. 2.9 After ensuring that all personnel are clear, the equipment to be worked on must be tested to verify that it is properly locked out and will not operate At the end of each work shift, all affected employee-owners that are going off shift, will remove their personal locks and the affected employee-owners that are coming Document No: 2E-0180 Revision 1 Page 2 of 2

3 on shift will install their locks to ensure the continuity of protection of the lockout/tagout policy When safety devices must be temporarily removed to allow testing, the Supervisor is to ensure the following: Clear away tools Remove employee-owners Remove the lockout/tagout device Energize and proceed with testing De-energize and reapply control measures Re-establish lockout/tagout safety control measures. 3. Specific Energy Isolation Procedures The following methods and devices will be used either separately or in a combination, depending on the equipment to be locked out and/or tagged out. 3.1 Electrical (Motor Controllers, Capacitors, Circuit Breakers, etc.) Shut down the necessary equipment using the selector switch followed by the master disconnects Ensure that all power sources are locked and tagged out Stored electrical energy must be bled off to obtain zero energy state When working on or near exposed de-energized electrical equipment a qualified person shall use test equipment to ensure that all circuits are dead If additional energy sources are present follow the applicable methods of Energy isolation listed in this section. 3.2 Pneumatic (Air, Control Valves, Instrument Air, etc.) Identify the system to be isolated Close all block valves, both upstream and downstream of the section to be worked on Release all trapped pressure to reach zero state, utilizing a controlled bleed off Use chains, energy isolation air valves shut off valves, padlocks and lockouts to lockout the energy source. Disconnecting or blinding the line is the preferred method of isolation. Document No: 2E-0180 Revision 1 Page 3 of 3

4 3.2.5 If additional energy sources are present follow the applicable methods of energy isolation listed in this section. 3.3 Hydraulic (Valve Actuators, Presses, etc.) Identify the system to be isolated Isolate the system Use lockout valves, chains, padlocks, and lockouts to lockout energy source If additional energy sources are present follow the applicable methods of energy isolation listed in this section. 3.4 Fluids and Gases (Piping Systems, Vessels, Process Equipment, Storage Tanks, etc.) Identify the system to be isolated Isolate all inlet and outlet piping by disconnecting, inserting blinds or use a double block and bleed. (A double block and bleed is not acceptable for confined space entry.) Release stored pressure to zero energy state If additional energy sources are present follow the applicable methods of energy isolation listed in this section. 3.5 Mechanical (Flywheels, Counter weights, etc.) Release all stored mechanical energy. Be aware of gravity, springs, tension and other sources of energy that may be present Use blocks, pins, or chains to restrain the energy when equipment can not be brought to a zero energy state. 4. Restoring Equipment Back to Service 4.1 After each phase of work is completed, the locks for that crew may be removed. The work area shall be inspected to ensure that nonessential items have been removed and that equipment components are operationally intact. The work area shall be checked to ensure that all employee-owners have been safely positioned or removed from the area. The person authorized by the supervisor in charge will remove the last lock and remove the Do Not Start tag and notify the person that is responsible for the operation of the equipment that the repairs are complete and the equipment is ready to be placed in service. After lockout devices have been removed and before equipment is placed into service all affected employee-owners will be notified that the lockout/tagout devices have been removed. 4.2 The person that installed it must remove each lockout/tagout device. If the employee-owner that installed the device is not available to remove the device, then Document No: 2E-0180 Revision 1 Page 4 of 4

5 the supervisor in charge may remove the device after complying with the following procedure Determine conclusively that the job has been completed and that no personnel remain in the area Verify that the employee-owner that attached the device is not at the facility The project superintendent will notify the employee-owner that attached the device that his device was removed. This notification will occur before the employee-owner resumes work at the facility The superintendent may designate a project foreman or craft foreman to remove the device if it is determined that the designated person fully understands the scope of work involved in the lockout/tagout. 4.3 The individual restoring energy to the equipment must: 5. Locks and Tags Inspect the work to ensure that all nonessential items have been removed and that the work is completed Ensure that the systems components are operationally intact Check the work area to ensure that all employee-owners are safely positioned or removed from the work area. 5.1 All tags that are used by Elkhorn Construction, Inc. shall be standardized and all locks shall be uniquely keyed and shall be used for lockout/tagout only. 5.2 If our customers request a specific type of lock and/or tag we will honor their request and use that type of lock and/or tag provided it offers protection equal to or greater than the locks and tags that we normally use. 6. Periodic Inspection 7. Training 6.1 Elkhorn Construction, Inc. will inspect the lockout/tagout process at least annually and determine if the system has any flaws and that it is being used to protect company employee-owners. 6.2 Any deficiencies that are found during the inspection must be corrected immediately 7.1 All employee-owners who participate in the lockout/tagout program or who are affected must be trained prior to participation in the program and annually thereafter. The training shall consist of the recognition of energy sources, and the control of these types of energy. The training shall also include the procedures to Document No: 2E-0180 Revision 1 Page 5 of 5

6 follow to safely lockout/tagout energy sources. All personnel will be instructed about the prohibition relating to attempts to restart equipment, operating locked out and/or tagged out equipment and the disciplinary actions that will be implemented for these infractions as well as the disciplinary actions that will be implemented if they remove another person s lock or tag. 7.2 An explanation of tags and the means of their attachments will be given in lockout/tagout training as well as the intent of the tagout. 7.3 Retraining shall be provided each time there is a change in the lockout/tagout program and whenever job changes or work scope changes present a new hazard. 7.4 All training shall be documented on the Record of Training and Meeting Form 3E Additional training materials can be obtained from a Service District library and safety director. 8. Testing and Certification 8.1 Project Supervisor shall ensure that all testing is done in an ethical manner. 8.2 A written test shall be handed out after training material has been presented. The test is a closed book test. 8.3 All tests will be true or false with circles to be filled in for the correct answer. Each test will consist of 15 questions. 8.4 The test must be graded with a total of 12 questions answered correctly for a passing score. 8.5 Any trainee who completes the test, missing more than three questions will be required to review the training material and re-test. 8.6 The instructor can present the test questions orally, one on one, with a trainee when necessary. 8.7 The instructor shall complete the Record of Training and Meeting Form 3E-0220, for only those trainees who pass the test. The Record of Training Form shall be sent into the corporate payroll department. Written tests shall be confidentially disposed of in the field. 9. References 9.1 American National Standards Institute; ANSI National Fire Prevention Association; NIFPA 706, SHA29 CFR and and OSHA 29 CFR Document No: 2E-0180 Revision 1 Page 6 of 6

7 True or False Test 1. In a tagout, the energy-isolating device is placed in the safe position and a written warning is attached to it. 2. A worker may use any sturdy lock to apply a lockout. 3. Lockout/tagout should be used whenever you are performing service or maintenance around any machine where you could be injured by unexpected start-up or release of stored energy. 4. Each individual employee-owner can decide whether to use lockout, tagout, or both. 5. Applying locks or tags in the right places de-energizes the equipment. 6. Once energy isolation and lockout/tagout have been applied, you can be sure the equipment won t be re-energized while you are working on it. 7. Before removing lockout/tagout devices, you must make sure the danger area is clear of tools and workers. 8. When contractors perform maintenance in your workplace, you will be required to change your lockout/tagout procedure. 9. If you have to temporarily re-energize equipment while you are working on it, you must re-apply energy isolation and lockout/tagout as soon as energy is no longer needed in the system. 10. If a worker is not present to remove his own lock, any co-worker can remove it as long as he first makes sure it is safe. 11. You are not required to fill out all of the information on a lockout tag. 12. You can start work on a project before installing a lockout/tagout. 13. The energies that need to be isolated are electrical, pneumatic, chemical, hydraulic, mechanical, thermal, gravity, and radiation. 14. We have lockout/tagout to prevent possible injury to employee-owners and property. 15. Lockout/tagout pertains to other contractors. Print Name Date Document No: 2E-0180 Revision 1 Page 7 of 7

8 True or False Test Key 1. In a tagout, the energy-isolating device is placed in the safe position and a written warning is attached to it. 2. A worker may use any sturdy lock to apply a lockout. 3. Lockout/tagout should be used whenever you are performing service or maintenance around any machine where you could be injured by unexpected start-up or release of stored energy. 4. Each individual employee-owner can decide whether to use lockout, tagout, or both. 5. Applying locks or tags in the right places de-energizes the equipment. 6. Once energy isolation and lockout/tagout have been applied, you can be sure the equipment won t be re-energized while you are working on it. 7. Before removing lockout/tagout devices, you must make sure the danger area is clear of tools and workers. 8. When contractors perform maintenance in your workplace, you will be required to change your lockout/tagout procedure. 9. If you have to temporarily re-energize equipment while you are working on it, you must re-apply energy isolation and lockout/tagout as soon as energy is no longer needed in the system. 10. If a worker is not present to remove his own lock, any co-worker can remove it as long as he first makes sure it is safe. 11. You are not required to fill out all of the information on a lockout tag. 12. You can start work on a project before installing a lockout/tagout. 13. The energies that need to be isolated are electrical, pneumatic, chemical, hydraulic, mechanical, thermal, gravity, and radiation. 14. We have lockout/tagout to prevent possible injury to employee-owners and property. 15. Lockout/tagout pertains to other contractors. Document No: 2E-0180 Revision 1 Page 8 of 8