Issue Date: 24/03/17 Last Reviewed: 24/03/17 Next Review Date: 24/03/18 Authorised By: Mike Muir Safe Operating Procedure Control of Energy - Isolation Process Purpose: This SOP is based on a Generic 12-step Isolation Process and applies to all types of work where exposure to uncontrolled hazardous energy release creates an unacceptable risk to persons and/or assets. Critical and complex isolation tasks should be identified and carried out following the Generic 12- step Isolation Process. CAUTION: Power on maintenance tasks shall be avoided wherever reasonably practicable. Where power on tasks are required, they shall be approved, and safe work procedures or a Job Safety Analysis developed and referenced prior to the task. Precautions and Hazards: WARNINGS: Ensure you are familiar with all safety and operating aspects of the machine as per the Manufacturers Operator s Instruction Manual. Park the machine on firm level ground and apply the hand brake (if applicable). Ensure the machine is in a position to be safely worked on (stabilised / supported) Front end loaders lowered to the ground or locked above 2.2 m with safety strut Any folding attachments or linkages are either lowered to the ground, secured in Transport position with locking system or supported by suitably rated stands, or securing device (correctly rated chains/straps/shackles) Ensure all fluid systems are discharged of any pressure & allowed to cool before inspecting (including but not limited to): o Hydraulic circuits, valves, cylinders and accumulators o Coolant systems Electrical systems are switched off / discharged of any current as necessary Remove the key (self-propelled machinery) or remove the PTO shaft from trailed or mounted implements. Isolate the power to the machine by means of isolation switch or remove the battery cables. Ensure cables are secured in such a way that contact with the battery terminals is not possible. Sign and Secure the lock out Do Not Start warning label (or similar) in the most obvious location on the machine where the energy source could be activated from, Machine Keys shall be attached to an identification tag and placed in a lock out station. Discuss the control of energy process with all workers working on or near the machine being isolated. 1
Special Tools and Equipment Required: Personal Protective Equipment (PPE) Required Other PPE relevant to Task Appropriate Footwear Tools/Equipment: Tools and Training Requirements Training Required Personal Lock Warning Labels/Tags Isolation SOP Isolation SOP Lock Out Station Lock issue register 2
Reference to Relevant Documents: Health and Safety Management Plan Scope and Responsibilities: This safe operating procedure applies to all Maintenance workers and activities relating to hazardous energies at Landpower and the Company s CLAAS Harvest Centres in NZ and Australia. This SOP also applies when work is carried out in another workplace. The Generic 12-step Isolation Process is illustrated in Figure below: Initial Conditions to be satisfied before Starting: Ensure all energy sources to be worked on are isolated Ensure other persons working in close proximity are communicated to around the controls put in place to control the hazardous energy Procedure: Isolation Lock Out Resp Doc Ref Identify all plant or equipment energy sources that require isolation for the task Key notes: 1. Take 5 Identify all energy sources that may pose an unacceptable or JSA risk to persons or assets. Identify a method of isolation (for example, circuit breakers, 3
Procedure: Isolation Lock Out Resp Doc Ref contactors, whole current isolators, battery isolators, valves, switches, mechanical devices and other) and confirm it is correct for the plant or equipment and appropriate to the task. Where appropriate, refer to the manufacturer s information to confirm that the isolation is complete isolation. Develop specific procedures to address software overrides where applicable. Isolation can only be achieved by isolating the plant or equipment from all relevant energy sources. While plant or equipment may be electrically isolated, other energy sources shall be considered, including hydraulic, water, air pressure, spring or gravitational energy e.g. elevated loader bucket. Determine the type and level of energy isolation/s that shall be required, for example, Individual or Group and check to confirm if any specific isolation procedure may apply to the task, equipment or circuit. 2. Advise relevant parties Notify all persons whom shall be affected by the isolation, to confirm that no safety or operational problems shall be created. Where necessary, advise operators that the plant or equipment is to be isolated, to allow for machines to be left in a safe position prior to isolation. 3. Isolate and secure energy sources Isolate the primary energy sources in an approved manner, or using the site specific procedures and/or manufacturer s recommended instructions. For example; Operate whole current isolator, remove plug, close valve, support gravitational load, etc. Shedding of loads prior to operating primary isolator may need to be considered in some instances. For work on electrical conductors that are energised above extra low voltage when in service, a visible break is required unless an approved safe work procedure is available on the job. Isolate, secure or control all secondary energy sources relevant to the task. For example: Bleed off stored hydraulic or pneumatic pressure from pressure vessels, accumulators, other Release stored energy such as springs, in a controlled and appropriate manner. Secure, barricade or chock elevated equipment or material performing the task 4
Procedure: Isolation Lock Out Resp Doc Ref held in buckets Chock machinery and equipment to prevent unplanned movement WARNING: Do not use auxiliary devices for isolation (for example, push buttons, control circuit devices, emergency stop buttons, keyswitches, conveyor lanyards, etc.) except where these devices control an approved whole of current isolation device. 4. Apply Personal Danger Locks and Tags A Personal Danger Lock and Tag is to be placed on the appropriate isolation point by a competent person. Where a lock cannot be used, an out of service Tag must still be used. NOTE: Where multiple persons are working on a machine, all members of the work party shall date and sign onto the Tag, or attach their Personal Danger Lock to, the appropriate control mechanism. This may include: To the steering wheel or ignition console (machines with cabins) to the steering wheel (for ROPS machines) to the headstock or drawbar for implements Each Technician writes his name on the Do Not Start labels. Only that Technician is permitted to remove the label on completion of the maintenance or repair project. The tag must be completed with all relevant information relating to what has been isolated and by whom. All workers performing work on equipment 5. Verify the effectiveness of the isolation All isolations shall be checked to verify the isolation has been effective by: Testing the test equipment is in good operating condition and is set to correct scale; for example, check pressure gauges, non-contact voltage detector, multi-meters, other Checking the operation of test equipment before and after isolation Testing the isolation has been effective by: o o Checking for the presence of voltage for electrical isolations Attempting to start the equipment; for example, attempt to start mobile equipment or machinery o Opening valves in pipelines for isolations 5
Procedure: Isolation Lock Out Resp Doc Ref involving water or compressed air o Confirming secondary energies are secured; for example, chocks, other Suitable test methods shall be determined to suit the various isolation circumstances 6. Commence Work Carry out the required tasks. Monitor the work area for any new introduced hazards. 7. Complete Work Complete all tasks related to the isolation. 8. Check Work Review all work that has been carried out to confirm the work-area has been left in a safe condition. For example, guards and covers are back in position, other. Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service. If different work groups are to continue/complete the task, appropriate handover procedures are to be implemented. It is important that on coming work groups are supplied with all relevant information to allow safe completion of the task/s. 9. Clear Area Check that persons working on the affected plant or equipment have completed their tasks and are clear of the work area. Confirm area associated with restoring energy has been cleared. Remove rubbish from rotating parts, roll up hoses, remove spare or replaced parts, other. 10. Remove Personal Danger Locks and Tags Remove Personal Danger Locks and Tags associated with the work being done. Each person is to remove only their own Personal Danger Lock where multiple isolations was used. In the case of a Tag only, each individual is to sign off, or remove their Personal Danger Lock associated with the Tag. The Tag Holder may then cancel the Tag once confirmed all users have signed off. 11. Restore Energy Advise all relevant or affected parties of your intention to restore energy. Restore energy to the plant or equipment in accordance with energy restoration procedures ALL ALL ALL ALL performing task 6
Procedure: Isolation Lock Out Resp Doc Ref 12. Check Operation Test run the plant or equipment to confirm that the work carried out has been successful and that the plant or equipment is operating normally. Attach an Out of Service Tag to the plant or equipment isolation point if it is not safe or ready for service, or if testing is required using approved procedures. Fill out a report or work order of status and works completed and communicate details of work undertaken to all relevant persons. Notify persons in charge of the plant or equipment that the plant or equipment is available to be placed back into service. performing task Types of Isolation There are two common types of Isolation. These are: Individual Isolations The individuals are competent / authorised (as the case may be) to carry out the work. Persons undertaking individual isolations shall follow the generic 12-step Isolation Procedure and shall use a personal danger lock (red) with an out of service tag. Group Isolations This refers to a situation requiring isolation where: The number of isolation points exceed two; or The number of persons involved exceeds two; or The individuals doing the task are not confident they can carry out the isolation as an individual isolation; Persons undertaking Group Isolation shall follow the generic 12-step Isolation Procedure and shall use the following Permits and Locks: Personal Danger Lock The following tags shall also be used: Out of Service Tags 7
Locks In applying the generic isolation procedure, locks shall be provided as below: The Company shall provide hardware for the use of locks to isolate plant and equipment where its possible they can be fitted When a lock is attached to a device, it shall prevent the device being activated A traceable register of issued locks shall be maintained for each Branch Individual locks shall be applied by an approved device that allows additional locks to be attached to the isolation point; for example, a multi-lock adaptor, scissor clip or hasp Shall not be combination locks Not have an unauthorised second-party master override key Be kept under the exclusive control of the owning individual, and key(s) shall not be transferred to another person for lock removal Types of locks include: Personal Danger Locks, red in colour, used at the isolation point for personal protection. Locks shall be clearly labelled with the person s name or identity number, and (for contractors) the employer, and be of a type approved by the Company Maintenance Manager. Tags The intent of this SOP is to use a locking device for energy isolation. However, it is acknowledged that in most circumstances the use of a tag is the only practical means of effecting isolation. Where these circumstances exist a JSA should be conducted to provide adequate protection to personnel, plant and equipment. Tags relating to this SOP shall be limited to the two types: Personal Danger Tags. These tags are only to be used at isolation points, for personal protection, where locking devices are not provided. Out of Service Tags. These tags are used to advise personnel that the plant or equipment is Out of Service and shall not be operated normally, without precluding authorised and controlled operation to facilitate remedial repairs or to test the operation of equipment 8
Out of Service Tag (Minimum Standard to be used at the Company) OUT OF SERVICE Do Not Operate Personal Danger Tag (Minimum Standard to be used at the Company) WARNING: Tags should be placed in a prominent position where they can be easily seen by anyone attempting to start, operate or access the plant or equipment. Placement and Removal of Isolation Tags/ Locks Danger tags / locks shall be securely attached to the isolation point, and, in the case of Danger Tags, shall be clearly visible with all relevant details recorded. No person may operate any switch, valve or other isolation device when there is a Personal Danger Tag / Lock attached to it. The only exception here is in the case of an extreme emergency which is life threatening. Where a person has to leave equipment in an unserviceable condition at any time, that person shall remove their Personal Danger Tag / Lock and attach a completed Out of Service Tag in its place. The only person permitted to remove a Personal Danger Tag or Lock is the person who placed it 9
there. Where this person is not able to be located, the tag/lock may be removed by the area Manager, example; Workshop Manager, only after the Manager has personally investigated the situation and confirmed that person/s are not in a position of danger. The circumstances of such removals of Danger Tags or Locks are to be reported in writing to the Branch Manager within 24 hours and investigated. Competent Persons (The following persons have read and understand this procedure and acknowledge their responsibilities relating to this procedure). Date: Name: Dealership: 10