Isolation Lockout and Tagging

Transcription

1 PURPOSE To define the minimum system requirements for isolation of plant and equipment from hazardous substances, mechanical, electrical or other energy sources to protect all workers from personal injury and equipment from damage. 1 SCOPE This procedure applies to all Isolation, Lockout and Tagging practices at the University of Canberra. This procedure does not apply to HV Isolation. Refer to following procedures: PRO-1071 Isolation for High Voltage Circuits This procedure shall be read in conjunction with the Permit to Work System Guideline POL-1000 and other relevant Permit to Work Procedures. The Personal Isolation, Information and Out of Service Tags included within the Appendix of this document shall be the only tagging allowable onsite to ensure compliance is maintained with Australian Standard AS 1319:1994 Safety Signs for the Occupational Environment. 2 PROCEDURE All persons working on any plant or equipment shall ensure that the plant or equipment is isolated and apply their own Personal Isolation Tag and Isolation Lock and confirm the isolation is effective as defined in this procedure. 2.1 Isolation There are two (2) reasons for using isolation processes, namely: personal protection equipment or plant protection Personal Isolation This isolation is used to prevent injury to a person by an uncontrolled hazard whilst working on the equipment or plant. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 1 of 20

2 Equipment or Plant Isolation Equipment or Plant Isolation is used when equipment or plant that if started, or operated in its current state may cause damage or injury to personnel Plant and equipment shall be isolated at the primary/main energy source (not the control circuits or systems) e.g. an Emergency stop is not an acceptable isolation point as it is in the control circuit. Area Isolation Typically it is an exclusion zone that may need establishing to prevent personnel and/or equipment entering into or impacting on the working area. PRO-1080 Barriers and Barricades procedure shall be followed where an exclusion zone is required 2.2 Lockout Lockout is the process used to ensure that plant and or equipment is maintained in a secure and safe condition: 2.3 Isolation Lock whilst personnel are working on it to protect the equipment from damage to prevent injury to personnel when plant and or equipment is in a state not suitable for operational purposes A padlock meeting the required specifications (2.3.2), and is being used with an appropriate tag for isolation purposes. It is then known generically as an Isolation Lock All locks used for isolation purposes shall only be supplied with a single key for operation and have as a minimum, a 6 pin tumbler The name of the lock is taken from the tag which is attached to it at the time of use. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 2 of 20

3 2.3.4 It is an essential item required in the lockout process. Personal Isolation Lock This is an Isolation Lock with an attached Personal Isolation Tag, and is known as a Personal Isolation Lock until that tag is removed This Lock and tag combination is used by an individual worker to provide protection whilst working on isolated equipment The requirements for the use of a Personal Isolation Lock are as follows: Personal Isolation Lock and Personal Isolation Tag shall be attached in a manner that ensures the isolation point cannot be inadvertently operated Personal Isolation Locks shall only be removed by the person who placed them or by their Supervisor in an emergency. The person applying the Personal Isolation Lock shall have control of the key at all times. 2.4 Lockout Accessory Not all equipment or plants have a built-in facility to use a lock as the means of preventing it from being operated while it is isolated. Other devices shall be needed to render it inoperable and these are locked in place by the Isolation Lock These may include but not limited, to devices such as: covers chains gate valve lockout devices ball valve lockouts flexible steel ropes with eyes 2.5 Lockout Scissors (as per appendix 5) A Lockout Scissor is a device that can be used in isolation cases where there are several users and the isolation point does not have sufficient positions to allow the use of more than one lock. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 3 of 20

4 2.5.2 When using this device it shall be fitted in a manner such that the isolation point can only be operated when all locks are removed ONLY one (1) Lockout Scissor is to be fitted to an isolation locking point When Daisy Chaining Lockout Scissors on isolation points consideration shall be given to the stress placed on the isolation locking point. 2.6 Tags Personnel shall ensure that the Lockout Scissors are closed completely before attaching their Personal Isolation Locks This procedure defines the three tags that are required for Isolation, Lockout and Tagging: Personal Isolation Tag - This tag is attached by personnel to the isolation point (s) with an Isolation Lock Out of Service Tag - This tag is attached to the isolation point to protect equipment and to alert others of potential danger or equipment is inoperable. This tag may also be secured with a device to prevent inadvertent operation Information Tag - This tag is attached to equipment or plant to pass on information including: 1. expired or used fire extinguishers 2. equipment condition 3. To any barricading to explain it s placement all tags shall be used for their intended purpose all sections of the tag shall be completed and shall always be legible Personal Isolation Tag Personal Isolation Tags shall be used with Isolation Locks to protect personnel while working on isolated equipment. See Appendix The minimum details required to be completed on the tag shall include: name contact number Supervisor PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 4 of 20

5 Out of Service Tag Out of Service Tags shall be used to protect equipment and to alert others of potential danger see Appendix An Out of Service Tag shall be fitted to an isolation point in order that is clearly visible If an Out of Service Tag is to be applied to prevent the operation of the plant or equipment, it shall be fitted in a manner that inhibits the operation of the isolator to which it is attached If the equipment does not have an isolation point such as an electrical power tool, the Out of Service Tag is attached to the plug top. This may also include the removal of a plug top Out of Service Tags shall only be removed by one of the following: the person who placed it the person responsible for the repair with the approval of the supervisor of one of the above Out of Service Tag attached with a padlock may be used: during shift changes within the same section for extended lockouts when personnel are not working on the plant or equipment when the plant or equipment can cause injury to personnel in the event of inadvertent operation when work is incomplete as waiting for parts etc. when the worker has been called away to another job When an Out of Service Tag is attached with a padlock, the following points shall be used: the Out of Service Tag and padlock is attached to the isolation point by an individual the key for this lock is to be controlled by the section that applies it this key may be handed over to the section responsible for the repairs PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 5 of 20

6 The minimum details required to be completed on the tag shall include: date name contact number reason Information Tag Information Tags shall be used to pass on information about equipment condition or any barricading see Appendix Where equipment displays an Information Tag it shall be read and understood before operated Information Tags shall only be removed by personnel familiar with the operation of the equipment when the information is no longer relevant Information Tags shall be used for expired fire extinguishers The minimum details required to be completed on the tag shall include: Information Tag side: reason for placing tag (ensure it s as clear as possible and include a contact phone number if possible) tag placed by date section (to be contacted about the reason for placement) Extra information when placed on Fire Extinguisher: vehicle Type Number (if from a vehicle) employee s Name supervisor extinguisher delivery/exchange date PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 6 of 20

7 2.7 Isolation Requirements All new items of plant, equipment or systems shall be designed and installed with the ability to be isolated in accordance with this procedure Each Department shall determine their isolations that, for reasons of complexity, irregularity of use, or especially hazardous nature, require a written isolation procedure. These procedures shall be documented Isolation from stored mechanical energy and hazardous substances shall comply with the requirements of Appendix Only suitably trained and competent persons shall perform isolations. 2.8 Isolation Basic Steps At all times, if concerns or doubts are raised or defects in the isolation system are noticed, the employee shall stop the task, make the area safe and seek immediate advice from the Supervisor. Isolation 1. Prior to commencing the task, collect all appropriate isolation equipment. 2. Determine the risk potential for the task. 3. Gain approval to work from equipment owner e.g. Permit to Work, if applicable. 4. Identify the equipment to be isolated (including associated equipment). 5. At the job site, determine potential risk. And complete JSA FRM Identify all isolation points and check the effectiveness of the isolation can be proven by starting/stopping. 7. Stop the equipment. 8. Isolate the equipment. 9. Prove the effectiveness of the isolation by attempting to start the equipment. 10. Place an Isolation Lock and Personal Isolation Tag on the isolation device(s). PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 7 of 20

8 Personal Isolation Continuity If a person is to leave the job over a shift or is required to work on another job for an extended period the following shall apply: De-isolation Isolation Locks and Personal Isolation Tags are to be removed Out of Service Tags shall be placed on the isolation points when work is to recommence any Out of Service Tag(s) is (are) in place on the isolation points shall be removed and replaced with Personal Isolation Tag(s) and Isolation Lock(s), checking that the isolation points are still in the de-energised state 1. Ensure all personnel are clear and cannot be injured. 2. Ensure all equipment is clear and cannot cause injury. 3. Ensure all Guarding/Barriers are in place. 4. Remove the isolation devices. 5. Re-check that personnel are clear. 6. Restore energy source (de-isolate). 7. Test-run equipment if/as required. 8. Hand control of equipment back to the owner and where a Permit to Work is in place have this closed by Authoriser. NOTE: Where the isolation point(s) is within the guarded area, steps 3 and 4 of the deisolation process may not be possible in the above order. Department Managers shall ensure Formal Risk Assessments are conducted to Engineer such Isolation Point/s outside the guarded area. 2.9 Failure to Remove Personal Isolation Tag and Isolation Lock Personnel failing to remove their Personal Isolation Tag and Isolation Lock shall be required to return to site to remove them Where all attempts to contact the worker have failed and / or the Supervisor can verify the worker has left site and is unable to return, the Supervisor shall require the documented permission from EFM Manager prior to removing the Personal Isolation Tag and Isolation Lock. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 8 of 20

9 2.10 Isolation Test Equipment Isolation Test equipment shall: comply with Australian Standards be checked before and after to ensure correct functioning be function tested in accordance with manufacturer s recommendations 2.11 Audits The Estate and Facilities Manager shall ensure that isolation and lockout is included in the workplace observations program for the department Training All workers shall receive Isolation & Tagging training All workers required to isolate and lockout plant / equipment as described within this procedure shall be trained and competent in Isolation, Lockout & Tagging. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 9 of 20

10 3 DEFINITIONS Hazardous Substances Hazardous Substances are toxic, flammable, corrosive, asphyxiate, radioactive, pyrophoric, explosive, extremely hot or cold, or otherwise capable of causing harm to people Information Tag Tag used to pass on information about equipment condition Isolation The process of removing hazards by isolating energy sources and hazardous substances, locking and tagging out Isolation Accessory A device that is used in conjunction with an Isolation Lock to inhibit the operation of an isolation point. Isolation Equipment Includes but not limited to, Isolation Tags, Out of Service Tags, Personal Isolation Locks, Lock box, Lockout Scissors, Signs, Chains and barricades Isolation Lock An individually keyed padlock with a minimum of 6 pin tumbler which is used to lock a piece of plant or equipment in a safe state to protect personnel from hazards. Out of Service Tag Tag used to protect equipment, or to alert others of potential danger. Personal Isolation Tag Tag attached by an individual to their Isolation Lock. Plant and Equipment Includes units, mobile equipment, appliances, pressure vessels, implement tools, personal protective equipment, or a component of plant and a fitting, connection, accessory or adjunct to plant. Technical Expert A person that has knowledge of plant / equipment or process that requires isolation. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 10 of 20

11 4 ACCOUNTABILITIES Role Responsibilities General Managers Ensure compliance with the requirements of this procedure within their Department or school Maintain and support a risk management culture by endorsing the risk management requirements within this procedure Ensure adequate resources are provided to meet the requirements as defined within this procedure Estate and Facilities Management Manager Ensure systems are established and maintained to support the requirements of this procedure Department Managers Ensure systems are established and maintained to support and comply with the requirements of this procedure within their department Ensure adequate resources are provided to meet the Departments requirements as identified in this procedure Ensure that all new items of plant, equipment or systems shall be designed and installed with the ability to be isolated in accordance with this procedure Ensure Training programs applicable to the task being peformed on the job are recorded appropriately in Training Plans / Role Requirements Ensure appropriate Training programs exist applicable to the tasks being performed Ensure Isolation, Lockout and Tagging is included in any workplace observation audit program for the department Safety Manager, Officers or Advisors Workplace Supervisor, Workers and Contractors Support the Departments Manager to achieve the requirements of this procedure Support Department personnel and contractors to meet the requirements of this procedure Facilitate and/or participate in any risk management activities associated with lockout and tagging processes Ensure that Isolation, Lockout & Tagging observations are conducted on a random basis to ensure compliance with this procedure. Ensure the requirements of this procedure are met during daily work activities and the identified Isolation, Lockout and Tagging tools are used as required Report any potential new risks or hazards that are identified during work activities Participate in risk management activities as and when requested PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 11 of 20

12 5 REFERENCES POL-1000 Permit to Work System - Guideline PRO-1070 PRO-1071 PRO-1080 Electrical Safety Management Isolation for High Voltage Circuits Barriers and Barricades FRM-1063 Authority to Remove Lock in a singular instance Guidance Note QGN01 Out of Service Procedures, October 2008 Version 5 QLD Government Guidance Note QGN02 Isolation Procedures, October 2008 Version 3 QLD Government Guidance Note Isolation of Plant 2010 WA Government AS 1319: 1994 Safety signs for the occupational environment AS Locksets Part 4: Padlocks SafeWork Australia Code of Practice How to Manage Work Health and Safety Risks 2011 SafeWork Australia Code of Practice Managing the Risks of Plant in the Workplace 2012 SafeWork Australia Code of Practice Managing Electrical Risks in the Workplace 2016 SafeWork Australia Code of Practice Managing the Work Environment and Facilities Work Health and Safety Act 2011 Work Health and Safety Regulation 2011 PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 12 of 20

13 APPENDIX Appendix 1 Appendix 2 Appendix 3 Appendix 4 Appendix 5 Appendix 6 Personal Isolation Tag Out of Service Tag Information Tag Isolation from Stored Mechanical Energy and Hazardous Substances Lockout Scissors (and correct use with locks and tags) PTW system PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 13 of 20

14 APPENDIX 1 PERSONAL ISOLATION TAG For personal protection while working on isolated and locked equipment. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 14 of 20

15 APPENDIX 2 OUT OF SERVICE TAG For the protection of equipment and to alert others of potential danger PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 15 of 20

16 APPENDIX 3 INFORMATION TAG To pass on information about equipment condition or a barricade Can be placed by anyone PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 16 of 20

17 APPENDIX 4 ISOLATION FROM STORED MECHANICAL ENERGY AND HAZARDOUS SUBSTANCES Before any work is commenced on, or entry made to equipment under pressure or vacuum, the pressure shall be returned to atmospheric level. In pneumatic and hydraulic drives the power supply shall be isolated, pressure vented, vent lines and drain valves isolated, and any lines or valves which may leak and pose a hazard shall be broken and/or slip plates inserted. Exhaust, let down or drain valves shall be locked and tagged in the "open" position. Any moving parts, which could cause injury through free movement, or could fall, even though disconnected from sources of motive power, shall be physically restrained and tagged. Blocks, wedges or lashings may be used as appropriate. Prior to initial break in and positive isolation, hazardous materials shall be removed from the systems to be worked on. After isolation, consideration shall be given to the removal of residual hazards by flushing, draining or purging and tests carried out as appropriate. Where there is a chance of hazardous material leaking past a valve or slip plate, a double block and bleed isolation shall be installed, or a length of supply line or pipe shall be removed and slip plates installed. Where hazardous substances are enclosed within a system, backflow shall be considered when isolating that system. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 17 of 20

18 APPENDIX 5 LOCKOUT SCISSORS and ISOLATION EXAMPLES Two commonly used varieties of scissors Examples of Lockout Scissor use with Isolation Lock and Tag PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 18 of 20

19 APPENDIX 5 cont. Correct use of Locks, Tags with Scissors. Pictorial from SafeWork Australia Code of Practice Managing the Risks of Plant in the Workplace 2012 PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 19 of 20

20 APPENDIX 6 Permit to Work (PTW) SYSTEM This document provides a guide and overview of isolation and tagging that forms part of the University of Canberra PTW system. The PTW is a formalised process to identify high risk activities and to ensure that appropriate controls are in place to remove or control these risks. The PTW is designed to provide measures to reduce the occurrence of incidents, illness or injuries to employees, students, visitors, contractors and damage to property. PRO-1060 V1.0 Isolation Lockout and Tagging.doc Page 20 of 20