Appendix P. Lockout Tagout Procedure

Transcription

1 Appendix P Lockout Tagout Procedure

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3 CITY OF WEST RICHLAND Safety Program LOCKOUT TAGOUT Revision 1 March 2015

4 LOCKOUT TAGOUT TABLE OF CONTENT 1.0 Definitions: Lock and Tag Requirements Lockout/Tagout Procedures Stored Energy Verification of Isolation Removal of Lockout Devices Additional Requirements Shift or Personnel Changes: Cord and Plug Connected Equipment Outside Contractors Training Enforcement of Lockout Tagout... 8 APPENDIX A - Stationary Air Compressor Maintenance... 9 APPENDIX B H.P. Well Pump... 10

5 The purpose of this policy is to establish the minimum requirements for the lockout and tagout of energy sources associated with the public infrastructure systems (water, sewer, stormwater, parks, roads, and facilities) of the City of West Richland. Lockout/Tagout procedures shall be followed anytime servicing or maintenance activities associated with the hazardous energy sources at applicable systems are required. 1.0 Definitions: Affected Employee An employee who is required to operate, use, or be in the area where a machine or equipment could be locked or tagged out for service or maintenance. Authorized Employee An individual who locks out machines or equipment in order to perform servicing or maintenance. Other Employee An individual who could be in the area of a lockout/tagout. Energy Control Device An energy-isolating device that can be locked in the off or safe position. Energized Connected to an energy source or containing direct, residual or stored hazardous energy. Energy Isolating Device A mechanical device which will physically prevent the transmission or release of energy. This includes, but it not limited to: Manually operated electrical circuit breakers Electrical disconnect switches Manually operated switches that disconnect the conductors of a circuit from all ungrounded supply conductors so that no pole of the switch can be operated independently Flow control valves Bolted slip blinds or blank flanges Other similar devices used to block or isolate energy Hazardous Energy Source Any source of hazardous electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other energy, including gravity. Hot Tap A procedure which involves welding on pressurized pipelines, vessels, or tanks to install connections or accessories. It is commonly used to replace or add sections Page 3 March 2015

6 of pipeline used in air, gas, water, steam, and petrochemical distribution systems without interrupting service. Lockout Placing a lockout device on an energy-isolating device, using an established procedure, to make sure the machine or equipment can not be operated until the lockout device is removed. Lockout Device A device that uses a positive means, such as a keyed or combination lock, to hold an energy-isolating device in the safe or off position. This includes blank flanges and bolted slip blinds. Normal Production Operations Using a machine or equipment for its intended production function. Primary Authorized Employee An authorized employee who has overall responsibility for implementing the requirements of the lockout/tagout procedures. Service and Maintenance Activities such as constructing, installing, setting-up, adjusting, modifying, repairing and maintaining. Setting-Up Work done to prepare a machine or equipment for normal production operations. Tagout Placing a tag on an energy-isolating device using an established procedure to indicate the energy-isolating device and the machine or equipment being controlled may not be operated until the tag is removed. Tagout Device A prominent warning device consisting of a tag and a means of attachment. It can be securely fastened to an energy-isolating device to indicate the energyisolating device and the machine or equipment being controlled may not be operated until the tagout device is removed. 2.0 Lock and Tag Requirements 2.1 Locks and tags shall be capable of withstanding the environment to which they are exposed for the maximum period of time that is expected. Locks must be capable of isolating the equipment in such a manner that the equipment can not be operated until the lock is removed. A tag stating This lock and tag to be removed only by authorized personnel shall accompany all locks. All tags must contain the authorized Page 4 March 2015

7 employee s name, date of application of the lock, equipment name, and reason for lockout and/or tagout. 3.0 Lockout/Tagout Procedures 3.1 Due to the system design, it is important that specific procedures be followed when shutting down the energy to a system or piece of equipment. Anytime maintenance or servicing is to be performed, lockout of the energy supply to the system is required. Prior to performing maintenance or servicing, the system must be shut down in accordance with the manufacturer s recommendations and/or approved procedures. The following presents procedures to be followed for the lockout/tagout of each system: Preparation for Shutdown: In preparation for lockout, an initial survey must be made to locate and identify all energy isolating devices to be certain which switch, valve, or other energy-isolating device(s) apply to the machine/equipment to be locked out. Please note that more then one energy source may be involved! Before an authorized or affected employee turns off a machine/equipment the authorized employee must have knowledge of the type and magnitude of the energy to be controlled, and the methods or means to control that energy. Machine/Equipment Shutdown and Isolation All affected employees must be notified that a lockout/tagout system is going to be utilized, and the reason for it, before the lockout/tagout controls are applied. If the machine/equipment is operating, shut it down using the normal shut down procedures Apply the appropriate lockout/tagout device(s) to the switch, valve or other energy isolating device(s) Physically locate and operate the switch, valve or other energy isolating device(s) to verify that the equipment is isolated from its energy source(s) and will not start. Return the switch, valve or other energy isolating device(s) to the off or neutral position after you make one attempt to start the equipment. Lockout Device Application Authorized employees shall lockout the energy isolating devices with their assigned individual lockout locks. Lockout devices shall be applied so they will secure the energyisolating devices in the Neutral or Off position. Page 5 March 2015

8 4.0 Stored Energy 4.1 All stored or residual energy in rams, flywheels, springs, pneumatic, or hydraulic systems, etc. shall be blocked or dissipated. If there is a possibility of re-accumulation of stored energy, verification of isolation must be continued until servicing or maintenance is completed. 5.0 Verification of Isolation 5.1 Prior to starting work on machines or equipment that have been locked out, and after ensuring that no personnel are exposed, the first authorized employee shall operate the push button or normal operating control(s) to verify the appropriate equipment or machine has been de-energized and make certain it will not operate. Then they must return the push button or normal operating controls to Neutral or Off position after attempt to start test. 6.0 Removal of Lockout Devices 6.1 After the servicing and/or maintenance the lockout devices are removed and energy is restored by the authorized employee only. The authorized employee will notify the affected employees the devices were removed. If the authorized employee who applied the lock fails to remove the lockout device the supervisor may take the following steps: Clear the machine/equipment of tools and materials Remove employees form the machine/equipment Attempt to contact the employee who applied the lockout device and failed to remove it before leaving the area Remove the lockout device by cutting the lockout or lock hasp Energize and proceed with testing or positioning Energize all systems and reapply energy Notify the authorized employee (who locked out the equipment) that the lockout device was removed before they return to work on the equipment that had been locked out. 7.0 Additional Requirements 7.1 In the preceding steps, if more than one individual is required to lockout machines, the following procedures shall be implemented to provide protection to all employees. Each authorized employee will place his/her own personal lockout device on the energy isolating device(s) When an energy-isolating device cannot accept multiple locks, a multiple lockout system must be used. Page 6 March 2015

9 8.0 Shift or Personnel Changes: 8.1 If a lockout procedure will extend into the next shift, the authorized employee for the next shift shall place his/her lock on the equipment prior to the authorized employee for the current shift removing his/her lock. 9.0 Cord and Plug Connected Equipment 9.1 If servicing or maintenance is performed on cord and plug connected equipment, the following procedure shall be performed to protect employees Outside Contractors Unplug equipment from its electrical socket Place a lockable cover over the plug and a lock over the plug cover during machine/equipment servicing or maintenance If outside contractors perform servicing or maintenance that requires lockout, the City of West Richland person responsible for contractor safety shall take the following steps: Inform the outside contractor of the City s lockout/tagout procedures and supply then with a current copy of the policy. Obtain and review a copy of the outside contractor s lockout procedures. Ensure City of West Richland Public works employees understand and comply with the responsibilities and prohibitions of the outside contractor s lockout procedure Training 11.1 Public Works employees will be trained annually regarding: The Lockout/Tagout policy, How to understand and recognize applicable hazardous energy sources, The different types and magnitudes of available energy, The means for isolation, and The control of the energy source(s) Additional retraining shall be provided when periodic inspections reveal deviations from the written procedures or inadequacies in the employees knowledge of the Lockout/Tagout procedures or to introduce new procedures Training will be documented and the records retained permanently in the employees personnel file. Page 7 March 2015

10 12.0 Enforcement of Lockout Tagout 12.1 Accidents involving the failure to use lockout/tagout procedures have resulted in serious injuries, amputations and deaths. Therefore, management must strictly enforce these practices. Failure to use identified lockout/tagout practices will result in disciplinary action up to and including discharge. Page 8 March 2015

11 APPENDIX A - Stationary Air Compressor Maintenance Lockout/Tagout Procedure Authorized Personnel: Maintenance and General Crafts workers Procedure: 1. Shut off and lock the local disconnect at the air compressor or the breaker (#) at the electrical panel. 2. Apply a tag to the lock that contains the name of the authorized person, the date, and nature of the maintenance being performed, if known. 3. Attempt to turn the local on/off switch on, if present, to ensure compressor cannot be started. If the compressor will not start, return the on/off switch to the off position. 4. Perform maintenance. If maintenance is on the compressor tank or on compressor discharge line piping/fittings, residual air pressure will need to be released to a pressure of 0 psig. Please note the following procedure. For Compressor Tank, Discharge Piping and Fitting Maintenance: a) Partially open drain valve at the bottom of compressor tank to bleed off the air pressure slowly to 0 psig. b) Once no system pressure is present, perform the required maintenance. c) When maintenance is complete, close the drain valve. 5 Upon completion of maintenance, remove your lock and tag and return all breakers or disconnects to their original energized positions. 6 Restart the compressor. 7 Inspect the compressor for proper operation. Page 9 March 2015

12 APPENDIX B H.P. Well Pump Lockout/Tagout Procedure Authorized Personnel: Maintenance and General Crafts Workers Procedures: 1. Shut off and lock the local disconnect at the well pump soft start panel. 2. Apply a tag to the lock that contains the name of the authorized person, the date, and the nature of the maintenance being performed if known. 3. Place the local on/off switch, if present, in the on position to ensure that the pump motor cannot be started. 4. Perform maintenance. 5. Upon completion of maintenance, remove lock and tag and return all breakers or disconnects to their original energized positions. 6. Restart the pump motor. 7. Inspect the pump and motor for proper operation. Page 10 March 2015