Lock Tag Try Procedure

Transcription

1 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 PRC-SAF-02 S014 Zachary EHS&S Management System SITE SAFETY POLICIES and PROCEDURES Lock Tag Try Procedure REVISION # 1.0 Revision Date - 8/26/2013 Record of Revisions Date Reason For Change Changed/Reviewed By Jan Revision Number rest to 1.0 at transfer into Documentum R. Hall, EHS&S Specialist, Zachary EHS 08/26/2013 Annual Review conducted R. Hall, EHS&S Specialist, Zachary EHS 09/29/2014 Annual Review; removed Revision Number Reset message found R. Hall, EHS&S Specialist, in footer; Minor changes made to document Zachary EHS 10/20/1014 Section 10.0 on Annual System Management added; Notification R. Hall, EHS&S Specialist, given to site via Safety Notification Zachary EHS 04/2015 Major revisions to align with BASF requirements Tanner Martinez 03/21/17 Annual Review Conducted Travis Schexnaydre Page 1 of 30

2 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/ PURPOSE To establish minimum standard work practices and procedures for isolating Hazardous Energy Sources and otherwise disabling machines or equipment to prevent unexpected or unintentional energizing, start-up, or release of stored energy that could cause personal injury or equipment damage. 2. SCOPE This procedure applies to all Service/Maintenance, Line Breaking, entry into a Confined Space, equipment preparation, and other work where there is the potential for exposure to a Hazardous Energy Source, unless exempt as specified below. This procedure does not apply to the following activities: Activities performed, in accordance with a written procedure (ex. SOP, TJA, JSA, etc.), by Operating/Owning Department personnel where the work is routine, repetitive and integral to the use of the equipment and within the Exclusive Control of the individual(s) performing the work. For line breaking activities, the procedure must provide protection that is equal to what would have been included in the permitting process. Hot Taps done in accordance with site procedures that are consistent with API Recommended Practice 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries. Routine electrical tasks that can only be done in an energized state, when done by a Qualified Electrician. 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 unplugging the equipment from the Hazardous Energy Source and by the plug being under the Exclusive Control of the person performing the work. Note: The electrical cord must be tagged with a Lockout Tag if the plug is not within Exclusive Control. Other permit types that may be linked with this procedure. Typically they are: a. Confined Space Entry b. Safe Work Permit/Low Energy c. Hot Work Permit d. Excavation 3. DEFINITIONS 4 Eyes Review: The use of 2 or more individuals to review a job or task in the field to ensure all hazards are identified and eliminated/controlled through the use of safe work practices or PPE, communication/awareness, etc. At a minimum this must include a Permit Issuer and a Work Crew Representative. Affected Employee: An employee whose job requires him/her to operate or use a machine or equipment on which service or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed. Authorized Employee: A person who locks out or tags out machines or equipment in order to perform service or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee's duties include performing service or maintenance covered under this procedure, and they apply a personal lock. Confined Space: A space which is large enough and so configured that a person can bodily enter and Page 2 of 30

3 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 S014 perform assigned work, has limited or restricted means or egress, and is not designed for continuous personnel occupancy. Exclusive Control: When the Energy Isolation Device is within line-of-site and 10 feet of the individual(s) performing the work. Energy Isolation Device: A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electrical circuit breaker; a disconnect switch; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not energy isolating devices. Equipment Owner: The unit or department that operates or is responsible for the process, area, or facility where work is being conducted. Equipment Testing or Positioning: The temporary removal of lockout or tag out devices and the reenergizing of machines or equipment ONLY during the limited time necessary for the testing or positioning of machines, equipment or components. After the completion of the temporary reenergizing, the authorized employee shall again de-energize the equipment and resume the lockout/tag out procedures. Hazardous Energy Source: Any electrical, mechanical, hydraulic, kinetic, pneumatic, chemical, thermal, or other energy (e.g., radiation), including stored or residual energy, that if unexpectedly or inadvertently released, could cause injury to personnel, or if introduced into a process could be hazardous. Hot Tap: A procedure used in the repair, maintenance, and service of equipment, which involves welding on a piece of equipment (pipelines, vessels or tanks) under pressure, in order to install connections or appurtenances. It is commonly used to replace or add sections of pipeline without the interruption of service for air, gas, water, steam, and petrochemical distribution systems. Line Breaking: The actual opening/separation/removal of equipment to a point where it can be positively determined that no residual materials (liquid, gas, solid) or pressure are present or are controlled to the extent that they n longer pose a hazard to personnel. Equipment includes but is not limited to all types of flanges, man-ways/hatches, screwed pipe, fittings, exchanger tube plugs, valves, tubing, hoses or other types of connections/opening in process or utility service. Lockout Hasp: A device designed to extend the number of locks that can be applied to the locked out Energy Isolation Device. Lockout Tag: A uniquely numbered tag used exclusively to identify an Energy Isolation Device covered under the scope of this procedure. Each tag must identify the reason for tagging, the name (or other appropriate identifier), date and work area of the Authorized Person attaching the tag, and identification of the tagged equipment; or a system to provide the same information. Refer to Appendix A. Lockout / Tagout Log Sheet: The form used to document equipment preparation for lockout/ tag out and line breaking. Refer to Appendix B. One Plus Isolation: Using a mechanism of physical protection to make Energy Isolation Devices inoperative, when they cannot be locked. This is intended to prevent unexpected or inadvertent Page 3 of 30

4 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 operation of an Energy Isolation Device. Such mechanisms may include removing a valve handle, securing a valve handle with a chain, cable, valve cover or locking arm, etc., as approved by the Safety Department. Out of Service Tag: Tags used to secure equipment which has been placed out of service, but on which Service/Maintenance is not being performed. Refer to Appendix C for an example tag. Qualified Electrician: An individual who has received training that meets the requirements of 29 CFR 1910, Subpart S. Service/Maintenance: Work place activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where personnel may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy. Try: An attempt to start or operate equipment, which has been locked/tagged out, for the purpose of verifying that isolation and de-energization of the equipment is effective. Unit Locks: Red locks, used by each Equipment Owner, which are used exclusively to secure Energy Isolation Devices for Service/Maintenance work. The locks for each Equipment Owner must be keyed alike, so that keys to locks for one Equipment Owner will not open locks in another area. The locks must identify the Equipment Owner (ex. Electrolytes, Customs, etc.). Verification: Means to ensure that isolation has been achieved for each Hazardous Energy Source. Work Crew: The individuals assigned to perform Service/Maintenance work. This may include both BASF and non-basf personnel working together and/or separately. Zero Energy State: The point where all potential Hazardous Energy Sources have been verified to be deenergized. 4. RESPONSIBILITIES Area Management: Has overall responsibility for the application of this procedure within their area of responsibility. This includes the implementation, review, and regular auditing of this procedure. Area Managers have the responsibility for authorizing people to carry out this procedure. Ensure that suitable and sufficient training is available for all BASF employees who will have duties under this procedure. Authorized Employee: Has responsibility for the correct application of this procedure. This includes determining the nature and extent of the work to be carried out and of the hazards that it and the plant presents, and for ensuring that the plant is made safe for that work to be carried out. Affected Site Personnel: Have responsibility for adhering to warnings and cautions signs and following instructions given to them in regards to the plant and its condition before, during, and after work is carried out under this procedure. Site Safety: Responsible for review of this procedure, audits of completed permits, notification to site management when failures of the system are apparent, and assistance if interpretation of procedure implementation is required. Page 4 of 30

5 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/ TRAINING S All Authorized Employees, who issue permits and/or prepare equipment for work covered by this procedure, and Affected Employees shall be trained initially on the following: A. Details of this written procedure. B. Types, hazards, and magnitudes of Hazardous Energy Sources potentially present during work covered by this procedure. C. Established methods used to isolate Energy Sources for work covered under this procedure. D. Means of verification of effective energy control. E. Use of equipment specific hazardous energy control procedures. F. The requirements for issuing a permit, and the necessary means to safeguard against the hazards posed during these activities. 5.2 Refresher training for Affected Employees and Authorized Employees shall occur whenever: A. There is a change in job assignment affecting the level of participation in the program; or; B. An applicable equipment specific hazardous energy isolation procedure has been changed due to equipment or process changes or a new hazard is introduced; or C. Inspection, individual performance, or other activity reveals there are deviations from or inadequacies in employee s knowledge or use of the energy control procedures; or D. As otherwise required by the BASF EHS Curriculum Assignment Process. 5.3 BASF and Contracted personnel not directly involved in the hazardous energy control program will receive awareness training for this and other safe work practices in accordance with the EHS curriculum assignment process. 6. PROCEDURE 6.1 General Requirements A Safe Work Permit and Lockout / Tagout Log Sheet must be issued to perform activities under the Scope of this procedure. Refer to PRC-SAF-06 (Work Permits) for expectations related to issuance of Safe Work Permits. A Confined Space Entry Permit will also be issued for any work requiring entry into a Confined Space. Refer to PRC-SAF-011 (Confined Space Entry) for expectations related to issuance of Confined Space Permits. Refer to PRC-SAF-16 for specific requirements related to Line Breaking A Zero Energy State must be achieved and verified before performing any work covered under the Scope of this procedure. Equipment Owners, following the requirements of this procedure along with any unit-specific procedures (e.g., TJAs, JSAs, SOPs, etc.), must address the following: A. Identification of the covered equipment or group of equipment; B. Identification of the specific types and magnitudes of Hazardous Energy Sources; Page 5 of 30

6 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 C. Steps for safely shutting down, isolating, blocking, positioning and/or otherwise securing the equipment; D. Identification of the safe position for each Energy Isolation Device; E. Specific steps necessary for safely releasing any stored or contained Hazardous Energy Sources; F. Specific methods (i.e. Locks, One Plus/Tag Plus, etc.) and isolation location(s) necessary for each Energy Isolation Device; G. Methods to confirm Verification; and H. Steps necessary to safely return the piece of equipment to service. Generic equipment isolation procedures (ex. Appendices D - I) may be used for the identified categories of equipment provided they address the hazards and necessary steps for proper isolation Isolation of Hazardous Energy Sources A. Following preparation of the equipment, a Lockout / Tagout Log Sheet must be completed to identify each Energy Isolation Device needed to make the job safe. Use of a marked up drawing (ex. P&ID) is the preferred approach to ensure all necessary Energy Isolation Devices are identified. B. Each electrical source must be shut down. Work on equipment (ex. breakers, electrical lines, electrically traced lines, motor leads, etc.), that has the potential for shock hazard, must ensure that the electrical component(s) is locked out and verified as de-energized by a Qualified Electrician. C. Capacitors must be fully discharged or removed. D. Process, utility, feed, and/or discharge sources must be drained, depressured, purged, flushed, or cleaned as much as possible. Low point bleeds should be opened to prevent accumulation of residual material. E. Hydraulic pressure sources must either be completely depressured or adequate blocking devices must be in place to prevent inadvertent movement. F. Use of automatically actuated valves for isolation requires all energy sources (electrical, air supply, air reservoirs, springs, hand jacks, etc.), that could operate the valve, to be identified, isolated, and locked or tagged at the supply connection. G. Isolation of nuclear devices shall be performed under the direction of the EHS Team Leader. The nuclear device must first be placed in the closed position, locked out, and then verified as isolated with a radiation survey meter. H. Equipment interlocks, where applicable, must be verified that they are not engaged such that they prevent the Isolation. Verification of isolation when interlocks are involved can be performed by one of the following methods: 1. Installation of a local disconnect. 2. Following one of the methods described in Appendices J & K. Page 6 of 30

7 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 S Following an alternative equipment-specific isolation and verification procedure I. Each Energy Isolation Device must be locked out with a red Unit Lock by the Equipment Owner and the Unit Lock must be affixed with a Lockout Tag. Red Unit Locks and Lockout Tags must only be used to isolate equipment for activities covered under the Scope of this procedure. These lockout devices may not be used to isolate equipment that will be placed out of service or for other activities not covered under the Scope. An Out-of-Service Tag is the preferred tag to be used for such purposes. J. If an Energy Isolation Device cannot be locked then One-Plus Isolation shall be used, upon consultation with the EHS Specialist. K. Following isolation, the Try step shall be employed on applicable equipment (ex. motors, pumps, conveying systems, etc.) to ensure a Zero Energy State has been achieved Following isolation of the equipment, the Permit Issuer and a member of the Work Crew must meet at the specific work location to conduct a 4 Eyes Review. At a minimum this review shall confirm the following, as applicable to the work: A. All Line Break locations have been identified and all Line Break precautions taken as identified in PRC-SAF-16. B. Bleeders nearest each line break are open and unplugged. C. There is no pressure or purges on the equipment on which the Work Crew is to perform work. D. The immediate piping/equipment is cool. E. Any associated Start/Stop switch has been tried. F. Equipment has been verified as de-energized and is ready for work as indicated on the Lockout / Tagout Log Sheet. G. The job scope is mutually agreed upon and documented as such on the Work Permit The Work Crew representative is then given the yellow copy of the Lockout / Tagout Log Sheet Each member of the Work Crew must be accounted for during the work by one of the following methods, as determined by the Permit Issuer: Use of Individual Locks A.1 Each Work Crew member shall hang their individual lock(s) on each Energy Isolation Control Device identified on the Lockout / Tagout Log Sheet. A.2 Each Work Crew Member shall initial the Crew Lock On location of the Lockout / Tagout Log Sheet for each Energy Isolation Control Device. A.3 Following completion of work each Work Crew Member shall remove all locks and initial the Crew Lock Off section of the Lockout / Tagout Log Sheet. Page 7 of 30

8 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/ Group Lock Box B.1 A designated member of the Work Crew shall hang their individually keyed locks on each Energy Isolation Control Device identified on the Lockout / Tagout Log Sheet and then initial the Crew Lock On section of the Lockout / Tagout Log Sheet. B.2 The designated Work Crew member shall then place his/her key in the lock box and every other member of the Work Crew shall place their individual lock on the lock box. B.3 The lock box must be maintained by the Owning Department during execution of the work. B.4 Following completion of the work, each Work Crew member shall remove their individual lock from the lock box. Once all locks are removed from the lock box then the designated Work Crew member can retrieve his/her key and begin removing their locks from the Energy Isolation Control Devices. Once all locks are removed then the Crew Lock Off section shall be initialed Following removal of all Work Crew locks from the equipment the yellow copy of the Lockout / Tagout Log Sheet will be returned to the Equipment Owner The Equipment Owner will review the Lockout / Tagout Log Sheet and lock box (if applicable) to ensure all Work Crew members are off the job before beginning the process of placing equipment back into service. 6.2 System / Equipment preparation. The following steps should normally be carried out by the operator of the equipment, who would make the plant/equipment safe for the pending work. The operator shall determine the primary isolation points (extent of isolation) in preparation for work to be carried out. Step Action Notes 1 Operator is informed of the need for a Work Permit and determines if the work requires equipment to be isolated. 2 Identify equipment that needs to be isolated for Service/Maintenance. 3 Determine the method(s) for making the plant safe, such as steps for shutdown, draining, decontamination, isolation, etc. 4 Visit the work site. Review the scope of work and identify associated hazards such as electrical, chemical, mechanical or physical. 5 Identify all Energy Isolation Devices necessary to isolate the equipment. 6 Identify the safe position of each Energy Isolation Device and means to render each safe (ex. Locked, One Is there an SOP for conducting the work? If no, then initiate a Lock Out/Tag Out permit. Follow unit operating procedures for shutdown and isolation requirements. Refer to Appendices D - I for guidance on isolating different groups of equipment. Document the types and magnitude of the hazards on the Lockout / Tagout Log Sheet. Review the P&ID for the equipment to ensure all Energy Isolation Devices are identified. Document on the Lockout / Tagout Log Sheet. Page 8 of 30

9 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Plus, etc.). 7 Select LOTO equipment (ex. Unit Locks and Lockout Tags, chains, etc.) required to isolate the equipment. 8 Notify other Affected Employees of the work activities to be performed. 9 Shut down and prepare equipment following unit operating procedures. 10 Carry out isolations by locking and tagging each Energy Isolation Device and initialing the white copy of the Lockout / Tagout Log Sheet. 11 Contact the Maintenance Manager to have a Qualified Electrician test electrical components with a voltage meter to verify de-energization, when the work has the potential for exposure to shock hazards. The Electrician must initial the Work Permit. 12 Perform the Try step by testing the Start button (if applicable). 13 Check equipment for the presence of flammable / toxic gases or vapors and document the result on Work Permit. 14 Sign and date the bottom of the Lockout / Tagout Log Sheet. Must use red Unit Locks and Lockout Tags This can be just a verbal notification (ex. to other operators). Refer to Appendices D - I for typical equipment procedures. Contact the EHS Specialist if Lockout cannot be accomplished, so that an appropriate One Plus method can be identified. Electrical disconnections (e.g. fuse removal or wire disconnection) can only be carried out by a Qualified Electrician. Example: Work on electrical leads, electrical disconnects, etc. If there is a DCS interlock involved then refer to Appendices J & K. Use LEL meter for flammables. Consult EHS Specialist for detection of toxics. Continuous or periodic monitoring may be needed depending upon the work being done. In signing you are stating that you have prepared the plant as documented for the scope of work. S Issue the LOTO document This procedure will usually be carried out by the equipment operator who is the owner of the equipment. He/she will issue the LOTO in conjunction with a representative of the Work Crew carrying out the work. Step Action Notes 1 Complete a Work Permit applicable to the communicated scope of work. 2 The equipment operator and a representative of the party performing the work shall meet at the work site to conduct a 4 Eyes Review. This is a key step. You should walk through the plant with them, check isolations, tell them what hazards remain in the plant, discuss the work they are to carry out and state what precautions they should take including the requirements for PPE. 3 If Line Breaking is to be performed Consider the need for catch pans, barricades, Page 9 of 30

10 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 then identify the specific location(s) for each line break and discuss precautions for line breaking. 4 Locate and test the closest safety shower. 5 Issue a copy of the Work Permit and Lockout / Tagout Log Sheet to the Work Crew. defensive positioning communication to adjacent personnel, etc. PPE cannot be downgraded unless approved by the Permit Issuer. Issue the yellow copy to the Work Crew 6.4 Work Initiation / Execution (Work Crew) Step Action Notes 1 Work Crew representative, who received the Work Permit and Lockout / Tagout Log Sheet, reviews the equipment preparation and hazards of the job with personnel doing the work. 2 Work Crew representative reviews the permit and all applicable precautions with the Work Crew. 3 Each Work Crew representative signs the Work Permit. 4 Each Work Crew member then hangs individual locks as directed by the Permit Issuer (lock box versus a lock on each Energy Isolation Control Device). 5 The Work Crew copy of the Work Permit is posted or maintained near the work location. 6 Work is performed per the requirements of the Work Permit. 7 If the scope of work changes during the day, then the Permit Issuer must be consulted to determine if the Work Permit needs to be updated. 6.5 Signing off the job. If a Work Crew member joins the job later in the day then steps 1-4 must be conducted with / by the new member. Step Action Notes 1 If the work is not completed by the end of the shift then the Work Crew locks are left in place and the Work Permit is returned to the Permit Issuer. 2 Once work is completed then all Work Crew locks are removed. If Work Crew locks are removed then all steps under 6.2 must be completed upon return of the work crew. Page 10 of 30

11 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/ The Work Permit and Lockout / Tagout Log Sheet are returned directly to the Permit Issuer. S Placing Equipment Back Into Service. Step Action Notes 1 The equipment operator should ensure the work area was left in satisfactory condition by the Work Crew. 2 Upon acceptance of the Work Permit and Lockout / Tagout Log Sheet, the equipment owner verifies that all Work Crew members have removed their locks from the equipment and/or lock box. 3 The equipment owner then removes all Unit Locks /Lockout Tags and initials locks off for each Energy Isolation Device identified on the Lockout / Tagout Log Sheet. 4 Affected Employees are notified that equipment is going to be placed back into service. 5 Equipment is placed back into service following unit operating procedures. 6 Unit Locks and Lockout Tags are returned to their designated storage areas. This may be a verbal discussion with the Work Crew representative, but may require an inspection of the actual work area. This assumes that all service/maintenance work is complete. This step can happen at any point after their removal. 6.7 Removal of Work Crew lock If for some reason a Work Crew lock is not cleared and the crew left the site, the specific actions must be taken to remove the lock before the Equipment Owner can begin placing equipment back into service. In all cases of a forced lock removal, an incident/accident form must be completed with investigation as to why the key was lost. Step Action Notes 1 Contact the supervisor of the lock owner. Production Superintendent for production lock; Maintenance Manager for BASF maintenance or electrician's lock; 2 The supervisor must visit the work site and make a decision as to whether the lock can be removed by force. 3 Cut lock once the supervisor determines that it is safe to do so. 4 The supervisor of the lock owner Contractor's supervisor for contractor's lock. Contact the Production Superintendent if the supervisor cannot be located. Notify the EHS Specialist of the incident. Page 11 of 30

12 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 must complete an investigation to determine why the lock was left in place by the lock owner and send a notice to EH&S 6.8 Testing/Positioning of Equipment If locks or tags must be temporarily removed during the course of work for testing or positioning of equipment (ex. for pressure testing, steaming, etc.), then the following sequence must be used: The operator must obtain approval from the Work Crew working on the equipment The Work Crew must remove all tools, equipment, etc., which would be a hazard during the testing or positioning All Work Crew locks and tags must be removed from each Energy Isolation Device, and the Lockout / Tagout Log Sheet must be completed and returned to the Permit Issuer All Unit Locks and Lockout Tags, necessary for testing and positioning, must be removed by the Equipment Owner The equipment must be re-energized per the equipment specific procedure as appropriate for testing/positioning The equipment must be de-energized again per the equipment specific procedure after testing/positioning is complete and prior to resumption of work by the Work Crew Equipment must be locked and tagged by the Equipment Owner per procedures Eyes Review must be conducted with the Work Crew representative Work Crew members must apply their individual locks per 6.1.6, as directed by the Permit Issuer. 6.9 Annual Management System Review EHS will conduct an annual review of the effectiveness of the site s LOTO program by evaluating the following minimum elements: A. A comparison of the program with actual practices and corporate requirements. B. A review of incident reports involving Hazardous Energy Source control activities, including Line Breaking activities that have occurred since the last annual management system review. C. Interviews with Permit Issuers, Authorized employees, and other Affected Employees, including contractor employees where applicable, regarding their roles and responsibilities Results of the annual management system review must be documented and communicated to site management Annual Review of Equipment Specific Isolation Procedures A representative number of equipment specific Hazardous Energy isolation procedures shall be reviewed annually by the Equipment Owner. Appendix L may be used to document each inspection and Appendix M identifies the different groupings of equipment that must be inspected by each Owning Department. The review must be Page 12 of 30

13 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 S014 performed by an Equipment Owner representative, who is not currently utilizing the procedures under review, and shall include: A. A comparison of the procedure(s) and Lockout / Tagout Log Sheet with existing equipment design and layout; B. A comparison of the procedure(s) with actual implementation practices; C. Review of the Lockout / Tagout Log Sheet and any associated paperwork for correctness; D. Interviews with Authorized Employees utilizing the procedure(s) that includes: A discussion with each employee regarding their responsibilities under the procedure(s) A discussion of any limitations of the isolation methods specified by the procedure(s) Determination if the procedure is adequate to provide the necessary protection, and if inadequate, what modification are needed. E. The name of the person performing the inspection, date of the inspection, name(s) of Authorized Employee(s) interviewed, identification of the equipment on which the procedure is being used, findings of deficiencies and corrective actions. F. Completed inspections must be forwarded to the EHS Specialist The review will be documented with the results communicated to Affected Employees. The following minimum information must be documented: A. Name of the person(s) performing the review and the names of the employees interviewed; B. Date of the review; C. The identity of the equipment-specific hazardous energy control procedure and the machine or equipment on which the energy control procedure was being used. D. Findings of any deviations or deficiencies identified during the review and any associated corrective actions, which must be tracked in the Action Tracker system. 7. REFERENCES 29 CFR Control of Hazardous Energy BC Control of Hazardous Energy Sources BC Line Breaking BC Safe Work PRC-SAF-011 Confined Space Entry PRC-SAF-06 Work Permits PRC-SAF-16 Line Breaking Page 13 of 30

14 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix A Lockout Tag Page 14 of 30

15 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix B Image of Lockout / Tagout Log Sheet S014 Page 15 of 30

16 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix C Example Out-of-Service Tag Page 16 of 30

17 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix D Typical Storage Tank Energy Isolation Procedure S014 Notify all Affected Employees of the requirement to implement this procedure. Shut down and empty / purge/ de-pressure all equipment using standard operating procedures. Isolate the energy sources from the equipment using the following steps: Identify energy sources for isolation using plant drawings and visually walk down the system (as applicable). Isolate electrical power from the pump at the breaker and install a Unit Lock/tag on the breaker. Shut pump suction, discharge and re-circulation valves; install lock/tag (valves A, B and C). Isolate jet mixer isolation valve (if applicable) and install lock/tag (valve D) if installed. Isolate air/nitrogen sparge supply valve; install lock/tag (valve F) if installed. Isolate nitrogen blanket supply valve; install lock/tag (valve H) if installed. Isolate storage tank fill valve; install lock/tag (valve E). If level transmitter is to be removed, isolate level transmitter valve; install lock/tag (valve G). Verify energy sources have been isolated by: Attempting to start the pump. Verify lockout of all energy sources has been attained and locks/tags are in place. Prior to release from lockout, the area will be inspected for loose equipment and unnecessary tools, workers safely positioned or removed from the area, and a reversal of above lockout procedures accomplished. This is an example only. Actual lockout/tagout isolation points are dependent on work scope and field verification of equipment. For instance, vessel entry requires two points of isolation for each Hazardous Energy Source. Page 17 of 30

18 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix E Typical Pump Energy Isolation Procedure Notify all affected employees of the requirement to implement this procedure. Shut down all equipment using standard operating procedures. Blow or flush pump housing clear of product and release residual pressure. Isolate the energy sources to the equipment using the following steps: Identify energy sources for isolation using plant drawings and visually walk down the system (as applicable). Isolate electrical power from the pump at the breaker and install a lock/tag on the breaker. Isolate pump suction, discharge and re-circulation valves; install lock/tag (valves B and C). Isolate blow back air supply; install lock/tag (valves F and G) if installed. Isolate nitrogen/air supply to seal reservoir; install lock/tag (valve D) and open seal reservoir vent valve (valve E) to release pressure, if pump is equipped with reservoir. Verify energy sources have been isolated by: Having a Qualified Electrician use a voltage meter to verify electrical energy has been isolated (as applicable to the scope of work). Attempting to start the pump. Checking that installed pressure gauges read zero. Verify lockout of all energy sources has been attained and locks / tags are in place. Prior to release from lockout, the area will be inspected for loose equipment and unnecessary tools, workers safely positioned or removed from the area, and a reversal of above lockout procedures accomplished. This is an example only. Actual lockout/tagout isolation points are dependent on work scope and field verification of equipment. Page 18 of 30

19 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix F Typical Agitated/Non-Agitated Vessel Energy Isolation Procedure Notify all affected employees of the requirement to implement this procedure. Shut down and empty / purge/ de-pressure all equipment using standard operating procedures. Isolate the energy sources from the equipment using the following steps: Identify energy sources for isolation using plant drawings and visually walk down the system (as applicable). Isolate electrical power to the pump at the breaker; install a lock/tag on the breaker. Isolate electrical power to agitator at the breaker; install lock/tag on the breaker. Isolate pump suction, discharge and re-circulation valves; install lock/tag (valves A, B and C). Isolate raw material inlet and transfer inlet valves; install lock/tag (valve D). Isolate air/nitrogen supply valve; install lock/tag (valve E). If level transmitter is to be removed, isolate valve; install lock/tag (valve F). Isolate air/nitrogen sparge valve; install lock/tag (valve G). Verify energy sources have been isolated by: Having a Qualified Electrician use a voltage meter to verify electrical energy has been isolated (as applicable to the scope of work). Attempting to start the pump. Attempting to start the agitator. Verify lockout of all energy sources has been attained and tags are in place. Prior to release from lockout, the area will be inspected for loose equipment and unnecessary tools, workers safely positioned or removed from the area, and a reversal of above lockout procedures accomplished. This is an example only. Actual lockout/tagout isolation points are dependent on work scope and field verification of equipment. S014 Page 19 of 30

20 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix G Procedure for Installing System/Equipment/Line Blinds for Hot Work Flame / Spark Producing Hot Work on containers and equipment that previously contained Flammables or greases, tars, or other materials must be isolated by any of the following methods: a. A blind (i.e., blank or stopper plate)o is inserted in the line and secured by locks or tags. Blinds must be of the construction and thickness to sustain the pressure for which the line is rated; b. Double block and bleed valve arrangement where the two block valves are closed and the bleed, in between, is opened and secured by locks or tags; and / or c. Lines are disconnected and misaligned from the equipment. When blinds are used then the Owning Department personnel shall shut down the equipment per normal shutdown procedures, isolate and prepare equipment by closing valves, de-pressuring, and draining equipment. Valves that require closing for blinding procedures will be locked / tagged and logged by the Owning Department on the Lockout / Tagout Log Sheet. 1. Permit Issuer will conduct a 4 Eyes Review with the work crew to ensure that the equipment is safe for blind installation. In some cases, the equipment will have to be flushed or steamed. Checking for these conditions will also take place at this time. 2. The Permit Issuer will then issue a Work Permit and Lockout / Tagout Log Sheet to install the blinds. 3. The work crew will place their personal locks on valves required to be closed for blinding and any other isolation devices as required by the specific job. 4. The work crew shall install the blinds and the operator will install a Lockout Tag on each blind. The operator will update the Lockout / Tagout Log Sheet to ensure tracking of the blind. 5. If the work crew installing blinds will not be performing the hot work, they shall remove all personal lock(s) from each energy isolation devices, update the Lockout / Tagout Log Sheet, and return the Work Permit to operations. 6. The normal Work Permit procedure will be followed for execution of the Hot Work. 7. Following completion of the Hot Work, the work crew will be issued a Work Permit to pull the blinds. The work crew will follow the normal procedure for hanging locks and updating the Lockout / Tagout Log Sheet before pulling the blinds. 8. After all blinds have been pulled and piping systems re-installed, the work crew will remove their locks, update the Lockout / Tagout Log Sheet, and return the Work Permit to operations. Page 20 of 30

21 Appendix H Specific Procedure for Lockout for Confined Space Entry 1. Operations personnel shall shut down the equipment per normal shutdown procedures, isolate and prepare equipment by closing valves, de-pressuring, and draining equipment. A confined space shall be isolated from ALL adjoining piping that contains potential sources of hazardous energy, including relief headers, drains and overflow lines, in order to ensure that liquid, vapors or gases will not enter the confined space. A line shall be deemed isolated if one or more of the following steps are taken: A blank or stopper plate (i.e., blind) has been inserted in the line(s). The construction and thickness of the blind must sustain the pressure for which the line is rated. A physical disconnect is created by removing a spool piece or mis-aligning the process or utility piping so as to prevent liquids or vapors from entering the space. The line has a double block and bleed, where two block valves are closed and the bleed is opened between the two valves and red tags affixed. 2. If the confined space contains an internal power driven mechanism, such as an agitator, all fuses must first be pulled and all switchgears locked out. 3. Lines going to jackets, coils, re-boilers and other similar equipment, which in themselves are not open to the confined space, must be closed and tagged. Exception, the use of external cooling water on vessel jackets or coils may remain lined up during hot weather to add in cooling of the confined space. 4. Each Energy Isolation Device must be locked / tagged per this procedure and the Lockout / Tagout Log Sheet completed. This includes blinds that are installed per #1 above. Page 21 of 30

22 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix I Specific Lockout Procedures for Warehouse Equipment The equipment operator will isolate the specific piece of equipment (ex. conveying system) using the respective electrical disconnect device and install a Unit Lock and Lockout Tag on the electrical disconnect. This may require voltage testing by a Qualified Electrician depending upon the repairs that are needed. The operator will ensure that the equipment is isolated from all potentially stored or residual hazardous energy source(s). Stored energy such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, air, gas, steam, hazardous chemicals in equipment or water pressure must be dissipated or restrained by methods such as repositioning, blocking, or bleeding down and locking out the appropriate valves and installing blinds as necessary. Following isolation from all potentially stored or residual hazardous energy sources, the operator will document isolation of the Energy Isolation Device on the Lockout / Tagout Log Sheet. The operator will then try the Start/Stop switch to verify that the equipment will not start. Page 22 of 30

23 Appendix J Isolation and Verification of Motors/Starters with Interlocks Using Qualified Electrician A. General Procedure 1) Work is to be performed on a motor and/or associated equipment (ex. Pump), such that inadvertent start-up of the motor would pose a direct hazard to the work crew. 2) The associated switchgear is identified and thrown by an Authorized Employee; however, no red Unit Lock/red tag is applied until a qualified electrician verifies isolation of the motor/starter. a. Owning Department can continue to prep and tag/lock other equipment as needed. 3) Qualified electrician receives a Safe Work Permit for verification step. 4) Qualified electrician verifies that the correct starter (and other electrical equipment as applicable) has been de-energized by following the specific steps identified in Section B. a. This will require a standby person for the qualified electrician until verification is complete. b. This will involve an outside operator or board operator to Try to Operate the equipment depending on the specific equipment/control configuration. 5) Qualified electrician hangs a Special Instructions tag stating that the starter has been verified as deenergized. The tag must include the following information: a. Specific equipment number b. Statement that the equipment has been verified as de-energized (ex. Equipment #XXXX has been verified as de-energized ) c. Name of qualified electrician d. Date 6) Operations locks/tags the starter 7) Operations issues the Lockout / Tagout Log Sheet and Safe Work Permit to work crew 8) Work crew walks job to verify LOTO 9) Work crew places locks and tags as required 10) Work crew completes work, removes locks / tags, and turns in Safe Work Permit and Lockout / Tagout Log Sheet. 11) Once all work is completed and turned back over to the Owning Department, then an Authorized Employee will pull and discard the Special Instructions tag when the red Unit Lock/tag is removed from the starter. B. Verification Steps for Specific Equipment/Interlock Configurations I. Motors with interlock (field process switch or DCS) and field start-stop wired to starter (Diagram #1) 1. Operator turns off breaker or switch on starter that has correct equipment nameplate and locks it out. 2. Qualified electrician verifies, with meter, that starter is de-energized. 3. Qualified electrician connects meter, set to read resistance, across field Start button terminations 2 and 3 (each unit # s may be different) in the motor starter cubicle. 4. Operator tries the Start button while qualified electrician at MCC verifies resistance change from infinite to near zero ohms on the meter. This indicates that the correct starter breaker has been turned off. DIAGRAM #1 II. Motors with interposing relay/dcs Interlock and no field Start/Stop (Diagram 2) Page 23 of 30

24 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/ Operator turns off breaker or switch on starter that has correct equipment nameplate and locks it out. 2. Qualified electrician verifies, with meter, that starter is de-energized. 3. Qualified electrician pulls control power fuse. 4. Qualified electrician connects meter, set to read resistance, across the interposing relay contact or DCS output contact terminations 1 and 2 in the motor starter cubicle. 5. Board operator activates the Start from the control station while the qualified electrician at the MCC verifies resistance change from some significant ohm reading on the meter to near zero. This indicates a direct short through the interposing relay contact or the DCS output contact, which indicates that the correct starter breaker has been turned off. a. The Start shall be operated several times to ensure that an interlock, other than the Start, is not toggling the contact. If another interlock is controlling the motor circuit interlock, the other interlock must be bypassed (Note: Bypassing of a SIS interlock requires Management of Change (MOC) before proceeding). 6. Board operator removes any interlock bypasses after the test. 7. Qualified electrician re-installs the control power fuse. DIAGRAM #2 V. Variable speed drive with DCS permissive and Start/Stop switch (Diagram 5) 1. Operator turns off breaker or switch on MCC cubicle that has correct equipment nameplate and locks it out. 2. Qualified electrician verifies, with meter, that starter is de-energized. 3. Qualified electrician verifies, with meter, no voltage across VFD terminals L1, L2 and L3. 4. Qualified electrician connects meter, set to read resistance, across field start button terminations 2 and 3 (each unit # s may be different) in the VFD Control panel box. 5. Operator tries the Start button while the qualified electrician at the MCC verifies resistance change from infinite to near zero ohms on the meter. This indicates that the correct VFD has been has been powered off. Diagram #5 DIAGRAM #5 Page 24 of 30

25 Appendix K Isolation and Verification of Motors/Starters with Interlocks Using Pre and Post-Bump Checks Note: The motor must have a means to visibly verify that it is running for this procedure to be used. For instance, canned motor pumps may not have such a capability. If the motor cannot be visibly verified as running then another method of verification must be used. In addition, some pumps cannot be run dry so precaution must be taken to ensure that use of this procedure will not damage equipment. Consult your I/E Engineer regarding questions related to use of this procedure. A. General Procedure 1) Work is to be performed on a motor and/or associated equipment (ex. Pump), such that inadvertent start-up of the motor would pose a direct hazard to the work crew. 2) Once a particular motor is ready to be shut down and isolated, the specific motor is Tried (i.e., bumped) to verify it has power. The motor must be observed moving during the bump step. a. The motor must be tried by both the field Start and DCS, if both are available in the equipment/interlock configuration. 3) The associated switchgear is then immediately identified and thrown by Operations and locked/tagged. b. Isolation of the switchgear must occur immediately after observing the bump step. 4) Operations then Tries the motor again to observe that it does not start. c. The motor must be tried by the field Start and DCS if both are available in the equipment/interlock configuration. 5) If the motor does start then it has not been properly isolated. Otherwise, work can then proceed assuming all other equipment isolation is complete and Safe Work Permits are issued. B. Verification Steps for Specific Equipment/Interlock Configurations I. Motors with interlock (field process switch or DCS) and field start-stop wired to starter (Diagram #1) 1. The motor is tried using one or both of the following methods, as applicable: a. Field operator tries the motor using the field Start and observes the motor turning. b. DCS operator tries the motor from the control board, while the field operator observes the motor turning. 2. Operator turns off the breaker or switch on the starter that has correct equipment nameplate and locks it out. 3. The motor is then tried using the applicable methods described in step #1. a. If the motor does not start then work can proceed. DIAGRAM #1 Date Issued: 10/26/10 Copy: 1 Revision: 5 Supersedes: 05/10/07 Page 25 of 30

26 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 II. Motors with interposing relay/dcs Interlock and no field Start/Stop (Diagram 2) 1. The motor is tried from the DCS and observed to be turning by the field operator. a. The motor is stopped from the DCS. 2. Operator turns off breaker or switch on starter that has correct equipment nameplate and locks it out. 3. The motor is tried again from the DCS and observed by the field operator to not turn. DIAGRAM #2 III. Motors with field hand-off-auto switch, with DCS or field interlock (Diagram 3) 1. Operator switches hand-off-auto switch from the Off position to the Hand position to verify the motor turns. 2. Operator turns off breaker or switch on starter that has correct equipment nameplate and locks it out. 3. Operator switches hand-off-auto switch from the Off position to the Hand position to verify the motor cannot turn. 4. Operator switches back to Off position after test. DIAGRAM #3 Page 26 of 30

27 IV. Variable speed drive with DCS permissive and hand-off-auto switch, (Diagram 4) 1. Operator receives a DCS permissive and switches the hand-off-auto switch from the Off position to the Hand position to verify the motor turns. 2. Operator turns off breaker or switch on MCC cubicle that has correct equipment nameplate and locks it out. 3. Operator receives a DCS permissive and switches hand-off-auto switch from the Hand position to the Off position several times to verify the motor cannot turn. 4. Operator switches back to Off position after test. diagram#4.pdf DIAGRAM #4 V. Variable speed drive with DCS permissive and Start/Stop switch (Diagram 5) 1. Operator receives a DCS permissive and then tries the field Start to visibly verify that the motor turns. a. Motor is then stopped from the DCS. 2. Operator turns off breaker or switch on MCC cubicle that has correct equipment nameplate and locks it out. 3. Operator receives a DCS permissive and then tries the Start button to visibly verify that the motor does not turn. Diagram #5 DIAGRAM #5 Date Issued: 10/26/10 Copy: 1 Revision: 5 Supersedes: 05/10/07 Page 27 of 30

28 PRC-SAF-02 WHEN PRINTED, THIS IS AN UNCONTROLLED DOCUMENT 8/14/2017 Appendix L Certification of Annual Inspection of Equipment-Specific Isolation Procedures Name of Reviewer: Lockout/Tagout Log Sheet# Description of Equipment: Date: Operating Procedure# (if applicable) *Attach copy of Lockout/Tagout Log Sheet Review and confirm the following: 1. Does the equipment shutdown / preparation / isolation procedure and practices, including Lockout/Tagout Log Sheet, adequately address the equipment design and layout to ensure proper isolation? Yes No 2. Were the equipment shutdown / preparation / isolation / verification practices and Lockout/Tagout Log Sheet adequately implemented in the field? Yes No 3. Based on interviews with Authorized Employee(s) who used the Lockout/Tagout Log Sheet and performed equipment shutdown / preparation / isolation / verification: a) Does each Authorized Employee (ex. Operator, Qualified Electrician) understand their responsibilities related to use of the equipment shutdown / preparation / isolation / verification practices? Yes No b) Does the Authorized Employee(s) have any concerns with the isolation methods specified by the procedure(s)? Yes No c) Were the procedure and practices adequate to provide the necessary protection? Yes No 4. List the names of the Authorized Employees who were interviewed. If this inspection represents a group of equipment as identified in Attachment M of PRC-SAF-02, then a representative number of Authorized Employees should be interviewed. Document any findings and necessary corrective actions below Notes: Inspection must be performed by someone who is not actually performing the equipment isolation. Send completed forms to the Cluster Safety Specialist. Page 28 of 30

29 ZACHARY SITE PROCEDURE NUMBER TITLE: PRC-SAF-02 (Lock Tag Try Procedure) Page 29 of 30 Rev. 1.4 Date: 04/13/15 Appendix M Zachary Site Equipment Groupings for Annual Inspections of LOTO Procedures Are procedural steps for shutting down, isolating, blocking, securing, and dissipating stored energy in machines or equipment the same or similar? Are procedural steps for the placement, removal, and transfer of the lockout or tagout devices and the responsibility for them the same or similar? Are requirements for testing a machine or equipment to determine and verify the effectiveness of Lockout Devices and other control measures the same or similar? Types of Equipment (If the answer to all questions is "yes" then the equipment can be grouped for the purposes of performing the annual inspection.) Yes/No Yes/No Yes/No Yes/No Motor/starter with interlock (electrician required). Refer to Appendix J. Yes Yes Yes Motor/starter with interlock (pre / post bump). Refer to Appendix K. Yes Yes Yes Compressors/pumps/centrifuge/homogenizer Yes Yes Yes Vessels (ex.tank, process drums, reactor, tower) without extraneous energy source Yes Yes Yes Vessels with extraneous energy source (ex. agitators, coils, etc.) - exchangers, tanks, reactors, etc. Yes Yes Yes Refrigeration unit Yes Yes Yes Fans (cooling tower, fin fan) Yes Yes Yes Flare/Thermal oxidizer Yes Yes Yes Hot box Yes Yes Yes Conveyor system Yes Yes Yes Boilers Yes Yes Yes HPU Shaker Cooler Yes Yes Yes Electrolytes Vessel Cleaning Station Yes Yes Yes Annual Inspection Completed?