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HomeMy WebLinkAboutHUR130-007 Equipment and Power Lockout/TagoutCid off, PICKERING CITY PROCEDURE Procedure Title: Equipment and Power Lockout/Tagout Procedure Number: HUR 130-007 Reference: Occupational Health & Safety Act Date Originated: January 30, 2009 Date Revised: Approval: Chief dmini ive Officer Point of Contact: Coordinator, Health & Safety Procedure Objective The objective of this procedure is to establish uniform methods for the disabling of powered equipment, machinery and electrical circuits prior to the performance of inspections, maintenance, or repairs. Contractors must also follow this lockout/tagout procedure while performing work for the City of Pickering when the City is the constructor or the employer as defined by the Occupational Health & Safety Act. Index 01 Definitions 02 Procedures 01 Definitions 01.01 Affected Employee - An employee who operates or uses machinery or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires them to work in an area in which servicing or maintenance is being performed. 01.02 Authorized Employee - A person who locks out or implements a tagout system on machines or equipment to perform servicing or maintenance on that machine or equipment. An authorized employee and an affected employee may be the same person. 01.03 Competent Person/Worker - A person who is qualified because of knowledge, training and experience to organize the work and its performance, is familiar with the Occupational Health & Safety Act and the regulations that apply to the work and has knowledge of any potential or actual dangers to health or safety in the workplace. 01.04 Energized - Anything connected to an energy source or containing residual or stored energy. 01.05 Lockout - The placement of a locking device(s) on the equipment and or energy source(s) which ensures the equipment cannot be operated or energy sources cannot be released during the servicing or maintenance work and until the locking device(s) are removed. 01.06 Lockout Device - A device(s) utilizing a positive means such as a single keyed lock, to render switches, valves, equipment, etc. inoperable and thus preventing the energizing of a machine or equipment. Removal of a lockout device is the responsibility of the person (or department, in the case of a shop lock) who installed it. 01.07 Servicing/Maintenance - Workplace activities such as constructing, installing, modifying, repair, maintaining, adjusting, or servicing of machines and equipment. 01.08 Tagout - The placement of a written notice at the control switch/device of an electrical circuit (less than 300volts), line, valve, machine, equipment, etc., indicating that the energy isolating device and or the equipment being controlled may not be operated until the tagout device is removed. 01.09 Tagout Device - A prominent warning device, such as a tag, which can be securely fastened to a lockout device to indicate that the energy being controlled may not be operated until the tagout device is removed. Tags must indicate the name of the person who installed the tagout device, date and time the tag was attached, and the reason for the tag. Removal of a tagout device is the responsibility of the person (or department, in the case of a department tag) who installed it. 02 Procedures 02.01 Before locking or tagging out any piece of equipment, ensure those operating the equipment or those in the area affected by the lockout or tagout are made aware of what is to take place. Procedure Title: Equipment and Power Lockout/Tagout Page 2 of 10 Procedure Number: HUR 130-007 02.02 Determine what source(s) of energy are being used to power the equipment and what controls will be used to ensure against accidental start-up or release of energy. 02.03 Proceed with general provisions in the lockout and tagout of equipment. 02.04 Prepare For Shutdown a) determine the types of energy that is powering the equipment; b) determine what hazards may be present; and c) determine what controls will be used to control the energy. 02.05 Shut Equipment Down a) follow normal shut down procedure for the equipment; and b) shut equipment down at the operating controls (pressing the "Stop" button does not ensure equipment shut down and is therefore not adequate). 02.06 Isolate Equipment a) check all operating switches to ensure against accidental start- up; b) apply energy -isolating devices (locks, blanks, etc); c) check for secondary sources of energy; and d) never isolate equipment by pulling an electrical switch or fuses while under load. Electrical disconnects should by carried out by a qualified electrician or competent person. 02.07 Apply Lockout/Tagout Devices a) attach a lock or comparable device to each and every energy - isolating device to prevent anyone from re -energizing the equipment during service or maintenance; b) all locks shall only have one key that is not common to other locks; Procedure Title: Equipment and Power Lockout/Tagout Page 3 of 10 Procedure Number: HUR 130-007 c) multiple lock hasps shall be used if more than one person is working on the equipment; d) tagout devices shall be attached to each lock and filled out completely; and e) wherever possible, lockout tags should be clearly visible and identifiable as a lockout tag. Red lockout tags are preferred. 02.08 Control Stored Energy a) ensure all parts have stopped moving; b) install ground wires to discharge electrical capacitors (performed by a competent person only); c) relieve stored pressure; d) blank pipe flanges; e) release spring tension or block the movement; f) block or brace parts that could fall or move due to gravity; g) Bleed lines and leave vent valves open; h) Block hydraulic and pneumatic systems that could move from loss of pressure; i) Purge reactor tanks and process lines whose contents could create a hazard; and j) monitor for any possible re -accumulation of energy. 02.09 Equipment Isolation a) ensure all danger zones are clear of personnel; b) verify that the main disconnect switch or circuit breaker cannot be operated; c) test switches with a volt meter or voltage potential testing device; d) ensure the correct system has been locked out and isolated by testing all operating buttons and activating controls; Procedure Title: Equipment and Power Lockout/Tagout Page 4 of 10 Procedure Number: HUR 130-007 e) shut off all equipment controls when testing is completed; and f) periodically verify isolation until service or maintenance is complete (especially after each day, extended periods of absence, after lunch and breaks). 02.10 Equipment Start-up and Testing At the completion of the work requiring the lockout/tagout the following process shall be used prior to, during, and after the equipment is returned to service: a) inspect work area to ensure that all non-essential equipment that could potentially interfere with equipment start-up has been removed; b) confirm employees in the area are aware equipment start-up will begin; c) ensure all personal lockout and tagout devices are removed only by the person who installed them; d) inform supervisor that the equipment is now safe to operate; e) if fuses need to be re -installed or main switches activated this shall only be done by a qualified electrician or competent person; f) energize equipment and proceed with testing; and g) ensure all guards and other barriers have been replaced. 02.11 Lockout/Tagout Devices and Equipment The supervisor shall be responsible for providing and maintaining the necessary lockout and tagout devices. The devices and equipment required may include but is not limited to the following; individually keyed locks (with one key), shop locks, hasps, chains, blanks, tags, switch lockouts, valve lockouts, plug lockouts, breaker lockouts, fuse pullers, electrical test devices, etc. Wherever possible, a red lockout tag should be used to clearly identify that equipment as being locked out. Procedure Title: Equipment and Power Lockout/Tagout Page 5 of 10 Procedure Number: HUR 130-007 02.12 Equipment Servicing Lockout/Tagout Procedure The following is a step-by-step procedure to be followed when equipment is being serviced. This Equipment Servicing Lockout/Tagout Procedure is to be use only for the cleaning, lubrication, oiling, setup or adjustment of equipment where guards do not have to be removed, and the accidental or unintended release of energy does not represent a hazard. If the starting of the machine or equipment during servicing has the potential to endanger the safety of a worker, use Equipment Repair Lockout/Tagout Procedure described in 02.15. 02.13 Equipment Shut Down 1. Press "Stop" button. 2. Apply latch or lock to "Stop" button. Note: If equipment is equipped with start/stop mechanism that does not provide a Locking Ring or if the only stop button incorporates a SCADA screen button, then proceed to disconnect switch, pull handle to "Off' position and install lockout device. 3. Confirm all motion that may endanger a worker has stopped. 4. Block any part that has stopped and that could potentially endanger a worker if it were to move during servicing. 5. Attempt to start machine with "Start" button. 6. If equipment does not start, begin servicing. 02.14 Equipment Start Up after Servicing 1. Ensure machine can be returned to operating conditions. Ensure no obstructions exist, tools have been removed and guards remain in place. 2. Remove any blocking devices and the latch or lock from "Stop" button or lock from disconnect switch. 3. Ensure workers are free and clear of machine to allow for safe starting. Procedure Title: Equipment and Power Lockout/Tagout Page 6 of 10 Procedure Number: HUR 130-007 4. Press "Start" button and visually check equipment is operating properly. 02.15 Equipment Repair LockoutlTagout Procedure The following is a step-by-step procedure to be followed when equipment is being maintained or repaired or the starting of the machine or equipment while being maintained or repaired may endanger the safety of a worker. If in doubt as to the hazards or whether to use this procedure or the Equipment Servicing Lockout / Tagout Procedure described in 02.12, workers must use the more stringent Equipment Repair Lockout / Tagout Procedure described below. 02.16 Equipment Shut Down 1. Stop or shut down machine in normal manner. 2. Inform Supervisor of the nature of problem pertaining to the particular machine (if supervisor has not already provided direction to worker). 3. Locate main disconnect switch and pull handle to "Off' position. 4. Install lockout device to disconnect switch in the "Off' (open) position. 5. Each person to work on equipment must add their personal padlock in series. 6. Physically attempt to switch disconnect handle to "On" position. 7. Attach completed "DO NOT START" tag on disconnect handle or lockout device. 8. Attempt to start machine with "Start" switch/button. 9. If equipment starts, repeat procedure beginning at step 3, and attempt to identify additional energy sources. 10. If you are unable to identify other energy sources feeding the equipment contact a supervisor for instructions. 11.Test with an Approved Electrical Test Device to ensure all power is de -energized. Procedure Title: Equipment and Power Lockout/Tagout Page 7 of 10 Procedure Number: HUR 130-007 12. Confirm all motion that may endanger a worker has stopped. 13. Block any part that has stopped and that could potentially endanger a worker if it were to move during servicing. 14. Proceed with repairs to machine, once equipment cannot be started. 02.17 Equipment Start-up after Repair 1. Responsibility for removing the lock(s) rests with each individual who installed a lock. 2. Inform Supervisor repairs have been completed and equipment is safe to operate. 3. Check equipment stop/start switch is "Off' by physically pressing "Stop" button. 4. Safety tag to be removed by person who attached it to disconnect handle or padlock. 5. Ensure workers in the area who may be impacted by the start up are aware equipment is being returned to service. 6. Return disconnect to "On" position. In the event that fuses have to be reinstalled, an Electrician or competent person shall perform the task. 7. Ensure machine has been returned to operating condition. Check to confirm no blocks or obstructions exist and guards are in place. 8. Press "Start" button and visually check equipment is operating properly. Note: Only the individual instructed by the Supervisor will have the responsibility and permission to start machine, after ensuring it is safe to do so. 02.18 Lock and Tag Removal by Other than the Authorized Employee Removal of a lockout and tagout device is the responsibility of the individual who installed it. If the equipment is required to be locked out beyond the shift or if an employee is called to another task, the Procedure Title: Equipment and Power Lockout/Tagout Page 8 of 10 Procedure Number: HUR 130-007 employee shall remove their lock. If the equipment has not been returned to a safe operational mode or represents a continued hazard, the employee will contact their supervisor to arrange for the installation of a shop lock. Department locks are not to be used in place of an individual lock while the authorized employee is working on the equipment. In the event a personal lock is found in place and a need arises to remove it, the following precautions must be exercised: 1. verify that the authorized employee who attached the lockout/tagout device is not in the facility; 2. all reasonable efforts shall be made to contact the authorized • employee and have them return to remove the lockout or tagout device; 3. only a supervisor shall remove lockout and tagout devices in the presence of an "affected employee" after testing and/or inspection has been completed by a competent person or worker. All parties involved in the removal of another individual's lockout device shall agree to the removal of the locking/tagging device; 4. the authorized employee who's lockout/tagout device has been removed shall be informed at the start of their next shift and issued a new lockout/tagout device; and 5. ensure that others who may be in the area of the equipment are aware that the lock/tag has been removed and that start-up may occur. 02.19 Shift Changeover Shift changes or personnel changes will be coordinated by the authorized employee or supervisor. The following steps must take place: 1. Lockout/tagout devices to be removed and a shop lock installed. Where an oncoming authorized employee has been assigned the job they must install their personal lockout/tagout devices. 2. The oncoming authorized employee(s) shall verify the equipment is in a state of zero energy before proceeding to work. Procedure Title: Equipment and Power Lockout/Tagout Page 9 of 10 Procedure Number: HUR 130-007 3. A supervisor may approve the authorized employee to leave their personal lockout/tagout devices in place if no other employee will work on the machine before the authorized employee returns for their next scheduled shift. 02.20 Group Lockout When servicing or maintenance is being conducted by more than one person, each individual shall install their own personal lockout and tagout devices which they personally remove when their work is complete. 02.21 General Additional controlmeasures may be required to protect against exposure to other forms of energy e.g. hydraulic, pneumatic, steam, chemical, etc. that will require the stored energy be reduced to a zero state and/or blanking of supply lines. Supervisor must discuss these additional requirements upon assignment of the work. Workers in doubt about the need for additional controls must consult with their supervisor. Procedure Title: Equipment and Power Lockout/Tagout Procedure Number: HUR 130-007 Page 10 of 10