Isolation Standard - Tags

Transcription

1 Isolation Standard - Tags

2 1. Purpose To provide Nyrstar Hobart with a procedure designed to ensure anyone working on plant and equipment is kept free from injury or incidents resulting from uncontrolled hazards by providing safe access to plant and equipment. 2. Scope This procedure applies to all personnel working at Nyrstar Hobart under the tagging isolation system. This procedure does not apply to personnel working under the Lockout Isolation System. Refer to Lockout Isolation Standard HP

3 3. Process Flowchart Emergency / Breakdown Work Planned Work Personal Pre-Start / JSEA Completed (Refer to Personal Risk Management Procedure) N Isolations required? Y Identify Isolation requirements E.g.: Isolation Officers required, Equipment Requirements etc. Colour Key Live Testing / Energised Work General Isoaltions Commence work once risk assessed Work Scheduling N Live Testing / Energised Work required? Y Single Point isolation? N Y Live Testing / Energised Work Process Single Point Isolation Multiple Point Isolation N Task Complete N Task Complete Y Equipment returned to owner Y

4 4. Definitions 4.1. Live Testing / Energised Work Process covering testing, faultfinding and inspections that cannot be performed with equipment isolated. Energised Work shall only be conducted as a last resort and must be approved by Superintendent prior to commencing. Work is defined as all activities involving access or the direct use of tools on any live or energised machinery or plant. All diagnostic testing that is conducted while the equipment is live or energised needs to follow the live testing procedure (eg fault finding using a multimeter, post and pre maintenance tasks, visual inspections, re-start checks) De-isolation The cancellation of any Isolation Process and re-energisation of the energy source Energy / Hazardous Substances Includes mechanical, electrical, pneumatic, hydraulic, radioactive, chemical, biological, steam or liquid gases under pressure, potential stored energy or any other type of energy capable of activating a given item or piece of equipment that would be required to be isolated to ensure people s safety Forced Removal The authorised removal of any Personal Danger Tag, or signing off an Isolation Form when it is not possible for the Personal Danger Tag Holder to remove their tag, or sign off the Isolation Form Isolation The de-energisation of all sources of energy identified as a hazard 4.6. Isolation Form Written form that details the isolation points and any necessary precautions to isolate a piece of plant or equipment. Includes details of personnel who have completed the equipment isolations, and personnel who are working on the isolated equipment. This form may be printed from the WPCC Isolation Database, or completed under the Defined Hazardous Work Isolations process. The Defined Hazardous Work Procedure must be followed HP Isolation Point The point at which a hazard is isolated

5 4.8. Isolation Verification Isolation verification is the process that a Personal Danger Tag Holder shall complete before applying their Personal Danger Tags. The verification process is defined as checking for the presence of an Out of Service tag, and that it is attached to the correct Isolation Point, and the Isolation Form has been completed fully and signed by the Person Responsible for Isolations. 5. Responsibilities 5.1. Competent Person A person suitably qualified and/or tested, assessed and trained to identify and control hazards associated with work performed under this standard Equipment Owner The person in the organisation identified as the Owner s Representative and accountable for the safekeeping of the identified equipment 5.3. Isolation Assessor An Isolation Assessor is defined as an individual who provides training and practical competency assessment of Isolation Officers. This person must have received Isolation Officer Training and be suitably qualified to perform training and assessment Isolation Officer A Person who is authorised to isolate equipment. The Isolation Officer must be assessed competent in both theory and practical, and be familiar with the plant / equipment they are isolating. The Isolation Officer is not required to be in attendance at the workplace for the duration of the isolation. If the Isolation Officer is working on the plant / equipment that they have isolated they must apply their Personal Danger Tags on each isolation point as per the Isolations Form, and sign onto the Isolation Form as a Personal Danger Tag Holder Personal Danger Tag Holder A person who has successfully completed Level 1 PTW training and is competent to work on isolated equipment Site General Manager Appointed Site General Manager or his/her designated nominee carrying the same or similar authorities (e.g.: Acting General Manager) 5.7. Visitor A person who visits site and has not completed Isolation Training. They must be directed and fully supervised by a competent Person Danger Tag Holder when placing or removing their Personal Danger Tags from isolation points. Visitors must have completed all required inductions prior to commencing any work.

6 6. Training and Competency Requirements 6.1. Frequency Personal Danger Tag Holder and Person Responsible for Isolation refresher training is to be carried out at a maximum of 2 yearly intervals on the Nyrstar Isolation Standard This training is to include a theoretical assessment or competency. Training records shall be maintained in SAP. 7. Isolation Equipment Overview 7.1. Tags The following tags referred to in this procedure are summarized below: Personal Danger Tags A red and white tag It is used to indicate that the Personal Danger Tag Holder is working on equipment under isolation. Details of the Personal Danger Tag Holder must legible. Isolation Statement A statement attached to the hasp with details of the isolation. Note Alternative approved documents that meet the intent of the Isolation Statement may be used to accommodate isolation complexity or Legislative requirements. These must be approved by the SHEQ Department prior to use. Caution Out of Service Tag A yellow and black tag used to identify that: - Equipment is out of service. - An area is hazardous and not to be entered. Tags shall be used to protect plant / equipment from damage or to alert people to potential hazards.

7 Information Only Tag A blue tag attached to operating controls or other locations to restrict the operation of equipment in accordance with the limitations of the tag to prevent possible injury or damage. Live Testing / Energised Work Statement A statement attached to the primary point of control, or lock box and used in conjunction with the Person in Control Tag(s) to allow testing and work when the equipment is energised. Person in Control Tag A tag used to identify the Person In Control of energised equipment undergoing Live Testing. It warns unauthorised people not to operate any isolation or control points associated with the work. Roast Shutdown Person in Control Tag will not have a photograph.

8 8. Single Point Isolation Process Isolations shall only be carried out by an Isolation Officer who has been assessed competent, and is familiar with the plant / equipment that is being isolated. The process for isolation is described below Isolation Officer must: 1) Obtain the Isolation Form from the WPCC Isolation Database, or complete an Isolation Form in accordance with the Defined Hazardous Work Standard (HP ). 2) Identify and control the hazards 3) Release stored energy 4) Apply an Isolation Statement with Side One details as follows: a) The full name of the person who applied the tag b) Date the isolation was completed c) Contact details for the Isolation Officer Tags / Forms required - Isolation Statement 8.2. Personal Danger Tag Holder must: 1) Verify isolations 2) Attach a Personal Danger Tag the isolation point Tags / Forms required - Personal Danger Tags 8.3. Isolation of Portable, Plug-in, or Workshop Equipment Isolation of equipment that is permanently connected to an energy source shall be carried out as per the requirements of this Tagging Isolation Standard. Minimum standard for isolating portable plug-in or workshop equipment is disconnection and removal from the energy source. An appropriate tag (Out of Service, or Information Only) must be attached to indicate work is being conducted on the equipment.

9 9. Single Point De-Isolation Process (Work Complete) De-Isolation process involves the Isolation Officer and Personal Danger Tag Holder(s). The procedure for each role is described below Personal Danger Tag Holder(s) must: 1) Remove all Personal Danger Tags 9.2. Isolation Officer must: 1) Verify equipment status as ready to return to service 2) Ensure all Personal Danger Tags are removed 3) Remove Isolation Statement and de-isolate the isolation point 4) Complete the equipment de-isolated section of the Isolation Statement Note: If Live Testing / Energised Work is required, the Live Testing / Energised Work Process must be followed (section16) 10. Multiple Point Isolation Process Isolations shall only be carried out by an Isolation Officer who has been assessed competent, and is familiar with the plant / equipment that is being isolated. The process for isolation is described below Isolation Officer must: 5) Obtain the Isolation Form from the WPCC Isolation Database, or complete an Isolation Form in accordance with the Defined Hazardous Work Standard (HP ). 6) Identify and control the hazards 7) Release stored energy 8) Apply an Isolation Statement to each Isolation Point with Side One details as follows: a) The full name of the person who applied the tag b) Date the isolation was completed c) Contact details for the Isolation Officer 9) Compete the Isolation Form and sign section 5 10) Attach completed Isolation Form to the Work Permit Clearance Certificate Tags / Forms required - Isolation Form - Isolation Statement

10 10.2. Personal Danger Tag Holder must: 3) Verify isolations 4) Attach a Personal Danger Tag to each isolation point 5) Complete the Personal Danger Tag Holders section of the Isolation Form with the following details: a) The full name of the Personal Danger Tag Holder b) Date c) Signature Tags / Forms required - Personal Danger Tags - Isolation Form 11. Multiple Point De-Isolation Process (Work Complete) De-Isolation process involves the Isolation Officer and Personal Danger Tag Holder(s). The procedure for each role is described below Personal Danger Tag Holder(s) must: 2) Remove all Personal Danger Tags 3) Sign off the Isolation Form Isolation Officer must: 5) Verify equipment status as ready to return to service 6) Ensure all Personal Danger Tags Holders have signed off the Isolations Form 7) Ensure all Personal Danger Tags are removed 8) Remove Isolation Statement and de-isolate each isolation point 9) Complete the equipment de-isolated section of the Isolation Form 10) Archive the completed Isolations Note: If Live Testing / Energised Work is required, the Live Testing / Energised Work Process must be followed (section16)

11 12. Leaving Work Incomplete All Personal Danger Tag Holders If all Personal Danger Tag Holders need to leave the work incomplete (i.e.: at the end of the shift), the procedure below must be followed Personal Danger Tag Holder(s) must: 1) Remove their Personal Danger Tags 2) Sign off the Isolation Form 3) Inform the Isolation Officer that work is incomplete 13. Resumption of Incomplete Work When work is resumed on an isolated piece of equipment, either within the same shift or a different shift, the following procedure shall be followed Isolation Officer (incoming) must: 1) Verify isolations 2) Sign onto Isolation Form Personal Danger Tag Holder(s) must: 1) Verify isolations 2) Apply Personal Danger Tags as per the Isolation Form 3) Sign onto the Isolation Form as a Personal Danger Tag Holder 14. Live Testing and Energized Work Process Live Testing is the process covering testing, fault finding, jogging, post and pre-maintenance checks, re-start checks and inspections that cannot be performed with equipment isolated. Energised Work is any work on plant or equipment that is not isolated, and shall only be conducted as a last resort and approved in alignment to the Site Risk Matrix. Work is defined as all activities involving access or the direct use of tools on any live or energised machinery or plant. A Standard Procedure or JSEA shall be carried out prior to undertaking any Live Testing or Energised Work. Approvals for the Live Testing shall be dependent on the JSEA outcomes and aligned to the Site Risk matrix approval process. Energised Work must be approved by a Superintendent prior to commencing. The Person in Control must direct all Live Testing / Energised Work. The Person in Control must either be an Isolation Officer or be accompanied by Isolation Officer, and assessed competent as a Person In Control.

12 A Standby Person shall be present throughout the Live Testing / Energised Work Process. The requirements, qualifications and competencies required for the Standby Person shall be identified during the JSEA process. A Live Testing / Energised Work Statement and a set of Person in Control tags are required for Live Testing and Energised Work. Prior to carrying out any Live Testing / Energised Work a JSEA or Standard Procedure is required. The procedure below shall be followed for each role under Live Testing / Energised Work: Person In Control Must: 1) Obtain the Standard Procedure or complete a JSEA and obtain required approvals. 2) Obtain a WPCC for Live Testing or Energised Work. 3) Identify and control hazards. 4) Complete any isolations as per the JSEA or Standard Procedure. 5) Complete the Live Testing / Energised Work Statement and attach to the lock box or point of control. 6) Ensure all personnel who are not part of the Live Testing or Energised Work Team are clear of the area. 7) Remove Caution Out of Service Tag (if attached). 8) Attach Person In Control tag(s) to: 9) Primary point of control 10) All nominated isolation / control points that may influence the task if operated and/or access points that are clearly visible to a user 11) Conduct a face to face meeting with all members of the Live Testing / Energised Work team. 12) Direct all Live Testing processes Personnel engaged in Live Testing Must: 1) Have a face-to-face meeting with the Person in Control to discuss the Live Testing / Energised Work and safety precautions. 2) Place Red Personal Danger Tags as required by the JSEA or Standard Procedure. 3) Complete back of Live Testing Statement with the following: - Name - Date - Signature - Follow the directions of the Person In Control On completion and / or stoppage of work, or the Person In Control leaves the task, the procedures below must be followed.

13 14.3. Personnel engaged in Live Testing Must: 1) Inform Person In Control they are leaving the job. 2) Sign off Live Testing / Energised Work Statement. 3) Remove their Red Personal Danger Tags Person In Control Must: 1) Make sure all personnel have signed off Live Testing / Energised Work Statement and removed their Red Personal Danger Locks. 2) Remove Live Testing / Energised Statement and Person In Control Tag(s). 3) Ensure the equipment and area is clear of personnel. 4) Ensure the plant / equipment is safe to start. If the Person In Control Tag(s) and the Live Testing / Energised Work Statement are removed, but the plant / equipment remains inoperable (eg at shift change or absence from the job), the Person In Control shall ensure the plant / equipment is left in a safe condition by isolating and/or attaching a Caution Out of Service Tag Note: If the Person in Control is required to leave the Live Testing or Energised Work location, the work must cease and a Caution Out of Service Tag shall be attached, and / or the equipment isolated. If another Person in Control is to be assigned to the Live Testing or Energised Work then the Live Testing / Energised Work process must be repeated for the incoming Person in Control. 15. Forced Removal Process Forced Removal is the authorised process for removing a Personal Danger Tag when it is not possible for the Personal Danger Tag Holder to remove tags themselves. The process will also apply in instances where personnel have failed to sign off an Isolation Form or Statements to allow the de-isolation process to proceed. Personal Danger Tags protect individuals and must not be attached or removed by unauthorised persons. Anyone who has left site without removing his or her Personal Danger Tag or does not sign off the Isolation Form, must return to site immediately to remove the tag or sign off the Isolation Form or Statements to allow de-isolation to proceed. If the Personal Danger Tag Holder cannot be contacted or is unable to return to site to remove the tag or sign off the Isolation Form, the Department Manager or their designated nominee may remove it according to the Forced Removal procedures below Isolation Officer must: 1) Advise the Equipment Owner that de-isolation cannot proceed

14 15.2. Equipment Owner must: 1) Verify that the Personal Danger Tag Holder is unable to return to work to remove the tag, or sign off the Isolation Form. 2) Contact the Personal Danger Tag Holder s Manager to initiate the Forced Removal Process Department Manager or Designated Nominee must: 1) Confirm: - No person is working on the equipment, and; - No person is endangered by the operation of the plant or equipment, and; - Equipment is safe to return to operation 2) Authorise the removal of the tag, or signing off the Isolation Form 3) Remove, or supervise the removal of the tag, or signing off the Isolation Form 4) Personal Danger Tag Holder s access card is to be stopped 5) Initiate the incident report Incident investigation and record of removal: 1) Attachment 1, Record of Forced removal shall be completed when forced removal is required. This information shall be entered into RIMS as a Near Miss. 2) An incident investigation into the failure to remove Personal Danger Tags, or sign off Isolation Forms shall be initiated. An incident investigation record of events is required for all instances where a tag or Isolation Form is not signed off, even if the Personal Danger Tag Holder returns to site. 3) Upon returning to site, the Personal Danger Tag Holder shall report to their Superintendent to have their site access reinstated. 4) The Superintendent shall then complete the investigation.

15 16. Equipment Tags Personal Danger Tags A Personal Danger Tag is used to protect the Personal Danger Tag Holder from injury by preventing the plant / equipment the person is working on or near, from being started or operated. If a Personal Danger Tag is attached it indicates that the Personal Danger Tag Holder is working on the equipment under isolation. Personal Danger Tag displays the following information: 1) Full name of the Personal Danger Tag Holder 2) Department details of the Personal Danger Tag Holder 3) Date the Personal Danger Tag is placed (not required for photo Personal Danger Tags) Each Personal Danger Tag Holder is accountable for their Personal Danger Tags and shall ensure the details are legible. Personal Danger Tags shall be used as follows: 1) Attached by the Personal Danger Tag Holder when they are working on a piece of isolated equipment / plant. 2) Placed by the Personal Danger Tag Holder only 3) Removed by the Personal Danger Tag Holder: - When the Personal Danger Tag Holder leaves site - When the Personal Danger Tag Holder is no longer working on the isolated piece of equipment - When work under isolation is complete - To meet the requirements of a specific SOP/SMP Isolation Statement An Isolation Statement is a statement attached to the isolation with details of the Isolation. The Isolation Statement may be reused where the task remains the same for the duration of the work Live Testing / Energised Work Statement The Live Testing / Energised Work Statement is attached to the Lock box or primary point of control to allow testing, fault finding, jogging. Inspecting and work when the equipment is energised and personnel may be at risk. It is always used in conjunction with the Person in Control Tag(s) Only the Person In Control may attach and remove a Live Testing / Energised Work Statement.

16 16.4. Person in Control Tag The Person In Control Tag is used to identify the Person In Control of energised equipment undergoing work. It warns unauthorized people not to operate any isolation or control points associated with the work. The Person In Control Tag displays the Person In Controls: - Photo - Department - Site - Full Name The Person in Control Tag must be: - Attached by the Person In Control - Attached to all isolators and / or points of control that will influence the task if tampered with in any way - Used in conjunction with a Live Testing / Energised Work Statement - Removed buy the Person In Control when: a) All personnel have signed off the Live Testing / Energised Work Statement b) The task is ceased c) The task is complete d) The Person In Control leaves the task e) The Plant / equipment is safe to start and operate Out of Service Tag Out of Service Tags are used to identify that: 1) Equipment is out of service and shall not be started or operated 2) Equipment has been isolated 3) An area is hazardous and is not to be entered. Out of Service tags shall be used to protect plant / equipment from damage or to alert people to potential hazards. It is applied primarily to warn personnel that starting or operating the equipment could result in damage to the equipment and / or injury to people. Note: When an Out of Service Tag has been attached, appropriate supervision must be notified. An Out of Service Tag is placed by the person wishing to take the plant / equipment out of service, or designate an area as not to be entered. Examples include: 1) Withdrawal from service due to a fault. 2) Withdrawal from service awaiting repair or spares. 3) Withdrawal from service due to operational reasons. An Out of Service Tag can only be removed after:

17 1) Inspection of the plant or equipment has been undertaken by a suitably qualified person. 2) The necessary repair work has been undertaken to ensure the plant or equipment is safe to operate. 3) It has been deemed by a suitably qualified person that the area can be entered. A suitably qualified person is: For Mobile Equipment such as FLT and Push Tractors: A qualified mechanic employed for undertaking maintenance and repairs. For Process Plant and Equipment: A Team Leader, Process Leader or Maintainer Note: If equipment is taken out of service because of redundancy, the Equipment Owner will need to advise if it is available for re-use before the competent person can remove the tag.

18 16.6. Information Only Tag An Information Only Tag is used to: 1) Restrict the Operation of plant / equipment to prevent possible injury or damage. It is attached to the operating controls or other visible locations. 2) Provide information about a hazardous area. It is attached to Blue and White barrier tape in visible locations. An Information Only Tag is: 1) Completed and attached by a person competent in the use of the plant / equipment, or who identifies a hazard. 2) Attached to the operating control, barrier tape or other location (in a prominent position) so that it is clearly visible to any person who may operate the equipment, or enter the area. 3) Removed by the person repairing the defect and / or placing the equipment back into unrestricted operation. 17. References Forced Removal Form (HF )