Big 5 Site Training Support Information

Transcription

1 Big 5 Site Training Support Information Line Break July & August 2008

2 Safety Standard Philosophy Our Safety Standards are in place to address Occupational Safety Hazards they do not address the Process Safety for the units. Process Safety concerns are addressed through Standard Operating Procedures and Process Design. While turning valves out of sequence during normal operations could pose a process safety hazard, the Big 5 Safety standards are in place to protect workers when they perform activities supporting the process that could expose them to hazards.

3 2.26 Zero Energy State The point where all potential Hazardous Energy Sources have been verified to be De-Energized Zero Energy State Verification All activities shall be performed, to the extent possible, under a Zero Energy State that has been verified, at a minimum, by Operating/Owning Department personnel. For permitted work, verification of Zero Energy State shall be documented on the permit. When Zero Energy State verification is not possible, proper PPE and/or additional administrative/engineering controls shall be utilized to minimize exposure to hazards.

4 4.1.2 Control of Work involving Hazardous Energy Sources Personnel, excluding Operating/Owning Department personnel when proper criteria is met ( ), shall not perform activities involving the control of Hazardous Energy Sources without prior written authorization in the form of a safe work permit issued by a Permit Issuer. The applicable equipment specific Hazardous Energy control procedure(s) shall, at a minimum, be referenced on the permit. To meet the requirements of the four eyes concept the permit issuer and the permit accepter can not be the same person.

5 3.2 This procedure does not apply to the following: Work on cord and plug connected electrical equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the Hazardous Energy Source if the plug is under the exclusive control of the employee performing the service or maintenance. The plug is under the exclusive control of the employee if: It is physically in the possession of the employee or It is in arm s reach and in the line of site of the employee or The employee has affixed a Lockout/Tagout Device on the plug.

6 3.2.5 The following procedures/processes may be exempted from a site s/unit s Hazardous Energy Source control program if a risk assessment has been documented and approved by management identifying the risks and control measures necessary to protect personnel: Activities performed by Operating/Owning Department personnel where the work is routine, repetitive and integral to the use of the equipment and under the exclusive control of the individual(s) performing the work. Exclusive control means within 10 feet. One example of such an activity could be changing a filter on a filter pot with integrated isolation and proper draining. (See attached Permit vs Procedure Flow Chart, Sec. 11.0)

7 Show guidance document for determining if a task can qualify for an exemption. Hazardous Energy Isolation Exemption Procedure - Rev 1.doc Permit vs Procedure Flow Chart BCF doc

8 Show example TJA s for Filter cleaning or element swap. Generic Filter or Strainer cleaning TJA.doc

9 2.16 One-Plus System utilizing a mechanism of physical protection to make equipment inoperative. This is intended to prevent unintentional operation of an Energy Isolation Device when Lockout cannot or is not used. All quarter turn piping valves that do not have a locking mechanism will use one plus to secure them. Some examples include, but are not limited to: Removing an isolating circuit element; Taking off the valve handle; Chaining the valve handle; Using tie wraps to secure a valve in the proper position; Taping or securing non-lockable electrical breaker devices; Securing equipment shafts that could be rotated while being worked on; Stationing a stand-by person at the equipment Energy Isolation Device.

10 (bullet 7) On equipment and controls that operate on circuits in excess of the 480 volt rating, Lockout shall be accomplished by lock and tag of disconnect and/or breakers opened, racked out, and tagged. Verification shall be made by a Qualified Electrician (bullet 2 & 3) If work is being performed on mechanical parts only (gearbox, seal, belt, fan, etc.), verification of electrical isolation must be by a means that provides a direct indication of power, that is not affected by an interlock or shutdown. A light, screen, display or voltage reading directly off of the power source are acceptable examples, but attempts to verify a local field switch on equipment controlled automatically or remotely (such as by DCS systems) can not serve as the sole means to verify Isolation. If work is being performed on electrically operated devices in such a manner that failure to de-energize the circuit could put workers in contact with exposed live circuits (unwire motor, switchgear parts, switch replacement, etc.), voltage will be tested by a Qualified Electrician to verify that the power is de-energized.

11 4.1.5 New and Replacement Equipment Whenever replacements, major repair, renovation, modification of a machine or equipment is performed, and whenever new machines or equipment are installed, Energy Isolating Devices for such equipment shall be designed to accept a Lockout Device. All new and replacement quarter-turn piping valves shall be designed to accept a locking mechanism.

12 Specifications for equipment specific hazardous energy control procedures A list of the specific types and magnitudes of Hazardous Energy Sources Specific steps, with proper sequence if necessary, for safely shutting down, isolating, blocking, positioning and/or otherwise securing the equipment Specific steps necessary for safely releasing any stored or contained Hazardous Energy Sources When the sequence of returning equipment to service has impact on safety the sequence must be included in the procedure Guidelines for equipment specific Hazardous Energy control procedures Proper Isolation of systems with remote start capabilities, including the ability of such systems to have multiple methods for energizing equipment (i.e. field start/stop and DCS)

13 4.2.1 Work Authorization (last bullet) If a MIP or SWP is not used, the isolation procedure must be placed in a designated location.

14 2.17 Operating /Owning Department Under certain documented circumstances individuals, departments, or companies that would not normally be considered members of the Operating/Owning Department (i.e. service and maintenance personnel) may be authorized to perform work under the permitting exemption described in this section. The following circumstances must be met in order to consider such individuals as Operating/Owning Department personnel: They must be trained and qualified to perform the subject activities They must have a level of knowledge and experience with the operation/process (equipment, hazards, and controls) that is equal to any existing Operating/Owning Department personnel. They are specifically authorized by the OM/SM in writing (individually/department/company as appropriate) as a member of the Operating/Owning Department for the specific tasks they are to perform. Check this box when they supply isolation One of two selected

15 4.2.2 Worker or Crew Leader Responsibilities prior to work When the equipment has been properly isolated per department procedures, the person performing the work, or the crew leader, will for himself and/or his crew determine that the provisions of the site/department procedures have been properly applied and: Attach an isolation tag to each energy isolation device on the equipment to be worked on, or sign Acceptance on the respective Master Isolation Procedure(s)

16 4.4.5 Isolation tags must include: Equipment number/identification: The reason for tagging; Name, date and department of person attaching the tag; Person/Position authorized to remove the tag Danger tags must: Indicate the name, date and department of person attaching the tag The reason for tagging Person/Position authorized to remove the tag.

17 4.4 Isolation Tags Isolation tags are to be used, as applicable, in conjunction with lockout devices and One-Plus restraint methods to ensure the integrity of the isolation Isolation tags must be the only tag used for controlling energy and shall not be used for any other purpose In-use Isolation tags must be updated if they are no longer legible, but do not have renewal requirements based on time.

18 4.5 Master Isolation Procedure

19 Additional sheets must be attached to the original MIP if more sign-on locations are needed. Attachment F must be used and header filled out.

20 4.6.3 The WCAF must reference all associated MIP s or energy isolations if the WCAF is on a separate sheet from the permit. (Back of SWP no longer lists MIP # s)

21 5.1.1 Danger tags are used to convey information on hazards where the use or improper operation of equipment may cause personal/environmental injury or equipment damage. They should be used for notification and securing of damaged equipment, air mover valve position, and/or transmission/security of any other condition that could pose a safety risk to anyone.

22 5.1.4 Only the Authorized person or position designated on the tag is authorized to remove the tag. If they are not available, Operations Team Leader may authorize removal after it has been determined that it is safe to do so.

23 5.2 Process Information tags are used to convey process information. They can show material status, equipment out of service, or any specific instructions needed to be communicated at a given position in the process. A comment section is provided for more detail info. Check boxes are provided near the edge of tag to allow for hole punching for long term tagging. No time based renewal requirements apply to this tag.

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