Houston Controls, Inc Safety Management System

Transcription

1 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 1 f 11 Purpse The purpse f this prgram is t establish prcedures fr affixing apprpriate lckut/tagut equipment t energy islating devices and t therwise disable machines r equipment t prevent unexpected energizatin, start up r release f stred energy t prevent injury r incident. Scpe This prgram cvers the servicing and maintenance f machines and equipment where the unexpected energizatin r start up f the machine r equipment, r the release f stred energy culd cause an incident. This prgram establishes minimum perfrmance requirements fr the cntrl f such hazardus energy. When wrk is perfrmed n a nnwned r perated site, the peratr s prgram shall take precedence, hwever, this dcument cvers HOUSTON, INC emplyees and cntractrs and shall be used n wned premises, r when an peratr s prgram desn t exist r is less stringent. Definitins Affected emplyee - An emplyee whse jb requires them t perate r use a machine r equipment n which servicing and maintenance is being perfrmed under lckut/tagut, r whse jb requires the emplyee t wrk in an area in which such servicing r maintenance is being perfrmed. Authrized emplyee - A persn that perfrms lckut/tagut prcedures n machines r equipment in rder t perfrm servicing r maintenance n that machine r equipment. An affected emplyee becmes authrized when that emplyee s duties include perfrming servicing r maintenance cvered under this prgram. Capable f being lcked ut - An energy islating device is capable f being lcked ut if it has a hasp r ther means f attachment t which, r thrugh which, a lck can be affixed, r it has a lcking mechanism built int it. Other energy islating devices are capable f being lcked ut if lckut can be achieved withut the need t dismantle, rebuild r replace the energy islating device r permanently alter its energy cntrl capability. Energized - Cnnected t an energy surce r cntaining residual r stred energy. Energy islating device - A mechanical device that physically prevents the transmissin r release f energy including, but nt limited t, the fllwing: A manually perated electrical circuit breaker, a discnnect switch, a manually perated switch by which the cnductrs and n ple can be perated independently, a line valve, a blck and any similar device used t blck r islate energy. Push buttns, selectr switches and ther cntrl circuit type devices are nt islating devices. Energy surce - Any surce f gas, electrical, mechanical, hydraulic, pneumatic, chemical, thermal, r ther energy surces. Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

2 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 2 f 11 Ht tap - A prcedure used in the repair, maintenance and service activities that invlves welding n a piece f equipment (pipelines, vessels r tanks) under pressure, in rder t install cnnectins r ther appurtenances. Lckut - The placement f a lckut device n an energy islating device in accrdance with an established prcedure, ensuring that the energy islating device and the equipment being cntrlled cannt be perated until the lckut device is remved. Lckut device - A device that utilizes a psitive means, such as either a key r cmbinatin type lck, t hld an energy islating device in the safe psitin and prevent the energizing f a machine r equipment. Included are blank flanges and blted slip blinds. Nrmal peratin - The utilizatin f a machine r equipment t perfrm its intended peratin. Servicing and/r maintenance - Wrkplace activities such as cnstructing, setting up, adjusting, inspecting, mdifying and maintaining and/r servicing machines and equipment, where the emplyee may be expsed t an unexpected energizatin r startup f the equipment r release f a hazardus energy surce. Setting up - Any wrk perfrmed t prepare a machine r equipment fr perfrming its nrmal peratin. Tagut: - The placement f a tagut device n an energy islating device, in accrdance with an established prcedure, t indicate that the energy islating device and the equipment being cntrlled may nt be perated until the tagut device is remved. Tagut device - A prminent warning device, such as a tag and a means f attachment, which can be securely fastened t an energy islating device in accrdance with an established prcedure, t indicate that the energy islating device and the equipment being cntrlled may nt be perated until tagut device is remved. Key Respnsibilities Managers and Supervisrs Respnsible t cntrl and enfrce this plan and t see that all their emplyees and cntractrs that are affected by lckut/tagut prcedures, have the knwledge and understanding required fr safe applicatin, usage, and remval f all energy cntrls and devices. Ensure emplyees are trained and cmply with the requirements f this prgram. Emplyees Emplyees wh are affected by this prgram are required t attend training n an annual basis. Are required t fllw the prvisins f this prgram. Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

3 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 3 f 11 Prcedure General Only an authrized emplyee r emplyees perfrming the servicing r maintenance shall perfrm lckut r tagut. Devices Lckut Device - If an energy surce can be lcked ut a device that utilizes a lck t hld an energy islating device in a safe psitin shall be used. Each site shall have the same type f lck as specified by HOUSTON, INC. Tagut Device If an energy surce cannt be lcked ut with a lckut device then a tagut device shall be used. Tagut devices are a warning nly level f prtectin and shall be weather and chemical resistant, standardized in clr with clear written warning f hazardus energy; i.e. D Nt Operate, D Nt Start, D Nt Energize, etc. Each site shall have the same style f tags specified by HOUSTON, INC. Specific Energy Cntrl Prcedures Each manager r supervisr is respnsible fr develping specific step-by-step shutdwn and startup prcedures fr a particular machine r piece f equipment in their respective area. A written, step-by-step islatin prcedure fr shutdwn and startup shall be prepared fr each type f machine r piece f equipment. This prcedure shall include: Equipment number if assigned. Equipment lcatin. Energy Surce(s) (i.e. electrical, hydraulic, gas pressure, etc.) Lcatin f islating cntrls (i.e. breaker switches, valves, etc.) Quantity f islating cntrls Quantity f lcks required t islate the equipment Other hardware required t islate the equipment (i.e. chains, valve cvers, blcks, etc.) List any residual energy required t be dissipated befre wrk begins. Specific Sequence fr Applicatin f Energy Cntrl 1. Ntificatin Authrized emplyees must ntify all ther affected emplyees f the applicatin and remval f lckut/tagut devices. Ntificatin shall be given befre the cntrls are applied and befre they are remved frm the machine r equipment. Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

4 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 4 f Preparatin fr Shutdwn Befre an authrized r affected emplyee shuts dwn a machine r equipment, the authrized emplyee shall have the knwledge f the type and magnitude f the energy, the hazards f the energy t be cntrlled, and the methd r means (lcks) t cntrl the energy surces. 3. Machine r Equipment Shutdwn The machine r equipment shall be shut dwn using the prcedures established fr that machine r piece f equipment. The shutdwn shall be rderly t avid any additin hazards t emplyees as a result f the stppage. 4. Machine r Equipment Islatin All energy islating devices that are needed t cntrl the energy t the machine r equipment shall be physically lcated and perated in such a manner as t islate the machine r equipment frm the energy surce(s). 5. Lckut/Tagut Devices and Applicatin Each authrized emplyee shall have the prper number f lcks and devices t be able t perfrm prper lckut/tagut prcedures fr machines r equipment that they may be wrking n. Lckut r tagut devices shall be affixed t each energy islating device by authrized emplyees. Each lckut and tagut devices shall include the name f the individual placing the device. Lckut devices shall be affixed in a manner t hld the energy islating devices in a safe r ff psitin. Tagut devices shall be affixed in a manner that will clearly indicate that the peratin r mvement f islating devices frm the safe r ff psitin. Tagut devices used with energy islating devices with the capability f being lcked ut shall be fastened at the same pint at which the lck wuld have been attached. If a tag cannt be directly attached t the energy islatin device it shall be lcated as clse as safely as pssible t the device in a psitin that will be immediately bvius t anyne attempting t perate the device. Each energy surce shall be lcked ut cmpletely islating the equipment. Islating machines r equipment shall include, but are nt limited t: Pumps, cmpressrs, generatrs, electric distributin, strage tanks, etc. Each type f equipment t be islated shall have specific prcedures fr islatin, i.e. fr cmpressrs: suctin, discharge, pwer, starting, fuel, dumps shall be clsed, lcked and tagged ut prperly. The blw-dwn valve shall be pened, lcked and tagged ut prperly. (NOTE): If cmpressr has a side stream hked up, the side stream shall be clsed, lcked and tagged ut prperly. 6. Stred Energy and the Pssibility f Reaccumulatin Fllwing the applicatin f lckut r tagut devices t energy islating devices, all ptentially hazardus stred r residual energy shall be relieved, discnnected, restrained and therwise rendered safe. If there is a pssibility f re-accumulatin f stred energy, verificatin f islatin shall be cntinued until the servicing r maintenance peratin is cmpleted, r until the pssibility f such accumulatin n lnger exists. Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

5 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 5 f Verificatin f Islatin The authrized emplyees perfrming the lckut prcedure verifies/ensures that the equipment is islated r discnnected frm the energy surce(s) by first checking that n persnnel are expsed, then verify the islatin f the machine r equipment by perating the cntrl(s) r by testing t make certain the equipment will nt perate. Multiple Wrkers A crew f authrized emplyees may use a grup lckut r tagut device. This will affrd the grup f emplyees a level f prtectin equal t that prvided by a persnal lckut r tagut device. A tailgate meeting shall be cnducted t review the lckut prcedures and ther infrmatin as required fr safe wrk t cntinue all crafts and effected departments shall be invlved. An authrized emplyee will islate the equipment and ascertain the expsure status f individual grup members. All wrkers will then place their individual lcks n the device s grup lckut r tagut device after they have verified the prcedure. The crew leader r an assigned authrized emplyee shall be respnsible f assuring the cntinuity f the lckut prcedures including dcumenting lckut infrmatin passed alng during a shift r persnnel changes. Release frm Lckut/Tagut When servicing r maintenance is cmpleted r when Lckut / Tagut devices must be temprarily remved, the equipment requires testing and the machine r equipment is ready fr testing r t return t nrmal perating cnditins, the fllwing steps shall be taken, in this rder: Check the machine r equipment and the immediate area surrunding the machine r equipment t ensure that all nnessential items such as tls have been remved and that the machine r equipment cmpnents are peratinally intact. Check the wrk area t ensure that all persnnel have been safely psitined r remved frm the area. Remve the Lckut/Tagut device Energize and prceed with testing Deenergize and reapply cntrl methds including Lckut / Tagut devices Dcument the prcedure by use f the cmpleted islatin lg and prvide t supervisr fr filing. Remval f Lcks The authrized emplyee wh applied the lck shall be the ne t remve their lck. Hwever, after all wrk has been cmpleted, certain cnditins may arise which prhibit this persn frm being present t remve the lck. The fllwing prcedures shall be fllwed t allw fr the remval f a lck that anther persn has applied: Every effrt shall be made t cntact the authrized emplyee wh applied the lck t btain the key(s). If the key(s) cannt be made available, the emplyee wh requests remval f the lck shall cntact their supervisr. Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

6 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 6 f 11 The supervisr shall verify that every effrt was made t cntact the riginal authrized emplyee wh applied the lck and t btain the key(s). The emplyee remving the lck shall nte n the Service Reprt that the lck(s) were remved with permissin by supervisr. All reasnable effrts will be made by supervisr t ntify that emplyee their lck has been remved, ensuring that the authrized emplyee has this knwledge befre they return t wrk. If the equipment is client wned, the supervisr r emplyee requesting t remve the lck(s) shall cntact the client t get the lck remved. Clients must remve their lck(s). NOTE: HOUSTON, INC emplyees shall nt remve any client lcks. Shift r Persnnel Changes In the event shift r persnnel changes ccur during maintenance and/r repair activities, the designated HOUSTON, INC emplyee in charge shall take the necessary steps t maintain the cntinuity f the lckut/tagut prtectin. This includes maintaining that all prvisins in this prcedure are adhered t and the transfer f lckut/tagut devices between authrized emplyees is accmplished. Cntractrs Cntractrs perfrming lckut prcedures n HOUSTON, INC prperty shall cmply with this prcedure. Cntractrs shall supply their wn lcks. HOUSTON, INC shall initially lckut HOUSTON, INC machines and equipment befre the cntractr will be allwed t apply their wn lck in additin t the HOUSTON, INC s. Annual Audits Each year the manager r supervisr, r his representative, will perfrm an inspectin f the Lckut Prgram in their respective areas t verify the effectiveness f the prgram. An authrized emplyee ther than the ne(s) utilizing the energy cntrl prcedure being inspected shall perfrm the audit and shall verify that: Each authrized and/r affected emplyee has been trained as required. Any new equipment added has specific lckut prcedures develped and dcumented. Current prcedures are adequate fr perfrming cmplete islatin f equipment and resulting in a zer energy state. The annual audit will be certified in writing and a cpy f the audit maintained n file at the managers/supervisrs ffice. TRAINING HOUSTON, INC shall prvide training t ensure that the purpse and functin f the energy cntrl prgram are understd by authrized emplyees and that the knwledge and skills required fr the safe applicatin, usage, and remval f the energy cntrls are acquired by emplyees. The training shall include the fllwing: Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

7 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 7 f 11 The recgnitin f applicable hazardus energy (lckut/tagut) surces, the type and magnitude f the energy available in the wrkplace, and the methds and means necessary fr energy islatin and cntrl. The purpse and use f energy cntrl prcedures. When tagut systems are used, emplyees shall als be trained in the fllwing limitatins f tags: Tags are essentially warning devices affixed t energy islating devices, and d nt prvide the physical restraint n thse devices that is prvided by a lck. When a tag is attached t an energy islating means, it is nt t be remved withut authrizatin f the authrized persn respnsible fr it, and it is never t be bypassed, ignred, r therwise defeated. Tags must be legible and understandable by all authrized emplyees, affected emplyees, and all ther emplyees whse wrk peratins are r may be in the area, in rder t be effective. Tags and their means f attachment must be made f materials which will withstand the envirnmental cnditins encuntered in the wrkplace. Tags must be securely attached t energy islating devices s that they cannt be inadvertently r accidentally detached during use. Tags may evke a false sense f security, and their meaning needs t be understd as part f the verall energy cntrl prgram. All ther emplyees whse wrk peratins are r may be in an area where energy cntrl prcedures may be utilized, shall be instructed abut the prcedure, and abut the prhibitin relating t attempts t restart r reenergize machines r equipment which are lcked ut r tagged ut. Retraining Retraining shall be cnducted whenever a peridic inspectin reveals, r whenever HOUSTON, INC has reasn t believe that there are deviatins frm r inadequacies in the emplyee's knwledge r use f the energy cntrl prcedures. Retraining is als required when there is a change in jb assignments, in machines, a change in the energy cntrl prcedures r a new hazard is intrduced. The retraining shall reestablish emplyee prficiency and intrduce new r revised cntrl methds and prcedures, as necessary. Training Dcumentatin HOUSTON, INC shall certify that emplyee training has been accmplished and is being kept up t date. All training and/r retraining must be dcumented, signed and certified. Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

8 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 8 f 11 SPECIFIC EQUIPMENT LOCKOUT PROCEDURES Department Equipment N. Energy Surce Prcedure fr Shutdwn and Islatin: (List number f steps required t islate machine r equipment - write N/A n lines nt used r add additinal steps if necessary) STEP NO Additinal Infrmatin: Prepared By: Date: (This prcedure t be cmmunicated t all authrized and affected emplyees and kept n file at lcatin f machine r equipment) Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

9 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 9 f 11 SAMPLE TAG WARNING MINIMUM LOCK/OUT TAG/OUT PROCEDURES Inlet Suctin Blck Valve Discharge Blck Valve Fuel Gas Valve Start Gas Valve Liquid Dump Line Blw Dwn (Lck Open) When wrking n this cmpressr package the fllwing items must be LOCKED OUT & TAGGED OUT. Residual pressure must be blwn dwn. Open all valves n surge bttles and piping t relieve any pressure that may be trapped. Side Stream (Fr Units Set up with Side Streams) When wrking n the cmpressr each persn must lck and tag the cmpressr package! Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

10 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 10 f 11 Date f Islatin: Descriptin f Wrk: ISOLATION LOG List f Equipment ut f Service: Necessary Requirements f Clear Islatin: Authrized Emplyee Signature: Persn Cntinuing Wrk Signature: Lcks/Tags fr GROUP LOCKOUT r Multiple Lcks/Tags Print Name (fr Lck # r Tag Date Installed Date Remved Grup Lckut) Signature (If additinal space is needed, please attach an additinal page) Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM

11 Hustn Cntrls, Inc Dc N: Revisin Date: 3/16/2011 Revisin N. 1 Next Revisin Date: 3/16/2012 Preparatin: Safety Mgr Authrity: Dennis Jhnstn Issuing Dept: Safety Page: Page 11 f 11 ANNUAL AUDIT OF THE CONTROL OF HAZARDOUS ENERGY PROGRAM I certify that an audit f the HOUSTON, INC Cntrl f Hazardus Energy Prgram was cnducted and that each emplyee has been trained in the recgnitin and prcedures t lckut equipment they may be required t wrk n r may be affected by. I further acknwledge that the current prcedure is adequate t safely lckut equipment in this department fr servicing and maintenance. Department: Manager (r representative): Date: Original t file: Uncntrlled cpy if printed. Valid n day f printing nly. Printed n: 16 March :33 PM