5 WHS PROCEDURE P29-02 Page 1 of 7 Issue: 2 1. Intent The Salvation Army Australia Eastern Territory (TSA-AUE) is committed to the provision of a safe, healthy and injury free environment within the mission / ministry for all persons and operations under its control. TSA-AUE recognises the need to establish a system for locking and tagging out energy systems to prevent injury to personnel and to prevent damage to equipment which can result from unintended equipment start up. 2. Purpose To provide guidance to officers / employers and workers on the appropriate isolation procedures for plant and equipment undergoing maintenance, servicing, cleaning, repair, alteration or construction. 3. Definitions Competent Person: Danger Tags Contractor: Department: Hazard: Hazard Identification: Lock Out / Tag Out (LOTO) Officer: Plant: A person who has, through a combination of training, education and experience, acquired knowledge and skills enabling that person to perform a specified task correctly. A red, black and white tag with the words DANGER or DANGER DO NOT OPERATE clearly marked on the top of the tag. Danger Tags are to be used for personal protection only. A person or company engaged under a contract for service to carry out work for and on behalf of TSA-AUE. An entity within TSA-AUE organization with specific responsibilities to carry out the various functions and activities of, although ultimate control remains under TSA-AUE leadership. A source or a situation with a potential for harm in terms of human injury or ill-health, damage to property, damage to the environment, or a combination of these. The process of recognizing that a hazard exists and defining its characteristics A safety procedure used to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work. A person who is specifically commissioned for ministry within TSA. This ministry ranges from evangelical to pastoral duties as well as community service and administrative responsibilities. any machinery, equipment, appliance, implement or tool, any component of any of those things, and anything fitted or connected to any of those things.
Page 2 of 7 Issue: 2 Personal Device Lockout a device that can be fitted to an isolation mechanism that will ensure no inadvertent operation of the plant, equipment or process can occur Positive Verification Responsible Person Risk: Demonstrate or prove that all energy sources have been isolated by attempting to activate / operate the plant or that part of the plant which has been isolated as if it was not. A competent person that has the necessary skills and experience to plan, execute and supervise an isolation of plant or equipment including the identification and proving safe all potential energy sources for the purpose of authorising a Group Lock Out. (In relation to any potential injury or harm) The likelihood and consequence of that injury or harm occurring. 4. Methodology All energy sources that present the potential for injury because of unexpected energisation or movement shall be identified, labelled and provided with bleeding, blocking or separate lockable isolating devices that remove the hazard, provides personal control, and presents and maintains a safe condition. Examples: de-energise sources of stored energy such as electrical, pneumatic, hydraulic, gravity, tensioned springs, charged capacitors block hazardous fluids such as natural gas, steam, asphyxiating gases (CO2/N2), heated materials, chemical solutions such as CIP (Clean-In-Place) block supply to mechanical, pneumatically or hydraulically, gravity or electrically operated components, systems, or processes, where appropriate. 5. Procedure Safety of Personnel working on Equipment. The isolation process shall be as follows: 1. Identify all power sources and isolate them. In the case of electrical equipment, whole current isolation such as the main isolator should be used instead of control isolation by way of the stop button on a control panel. 2. Lock or otherwise secure all isolating points using padlocks, multi-padlock hasps and danger tags (LOCK) 3. Dissipate all stored energy. This may include ensuring inertia in mechanical parts, parts likely to move by gravity, electrical capacitors, accumulators, springs and pressurized fluids. 4. Verify that the isolation is effective (TEST & TRY). If the system does not allow for verification of isolation then a risk assessment must be undertaken to identify and implement appropriate control measures to deal with the potential release of energy.
Page 3 of 7 Issue: 2 5. Identify the safe area of work TSA-AUE officers / management shall ensure that before any officer / worker commences work on energized equipment the sources of hazardous energy connected to the work are isolated and then Locked Out / Tagged Out, Cleared and Tried. This application of this procedure shall apply to all work associated with maintenance, repair, installation and cleaning. LOCK means to apply a lock to switches and / or valves to ensure they cannot be reenergised. TAG means to apply a danger tag to the lock. This identifies who has locked out the equipment. CLEAR means to clear all personnel and materials from the equipment to a safe distance, and this can also mean to drain or depressurise a line. TRY means to push buttons, test circuits, etc., depending upon the type of equipment being locked out. This assures that the energy source is off and the equipment is safe to work on. The try must be positive with positive verification. Locks and Danger Tags. Isolation locks shall only be used for PERSONAL PROTECTION LOCK OUT and will have one key to be used only by the person who fitted the lock. If more than one key is available the spare must be under control of the Site Manager. DANGER tags must always be used in conjunction with locks and in cases where there is no provision for a lock to be fitted the DANGER tag shall take the place of the lock. A DANGER tag may be integrated with a lock. The name of the person fitting the tag is to be clearly indicated. When the work is being handed over to another person the outgoing person shall remove their PERSONAL PROTECTION LOCK and DANGER tag and the incoming person shall place theirs on the equipment. When leaving site without a handover the PERSONAL PROTECTION LOCK and DANGER tag must be removed and replaced with an OUT OF SERVICE tag as outlined in this procedure If it is anticipated that others are required to fit locks then the person initially fitting a lock and tag should also fit a lock hasp (a device to allow multiple locks to be used on the same isolation point). All people working on the equipment must fit a separate lock and tag at each isolation point, unless using Group Lockout as outlined in this procedure. Group Lockout For instances where individual lockout is impractical, a group lockout may be performed. For example, due to the magnitude or complexity of large jobs requiring numerous energy sources to be isolated. TSA-AUE shall identify a Responsible person, who is competent, to perform an assessment in conjunction with relevant workers to identify, assess and control all relevant energy sources and
Page 4 of 7 Issue: 2 their isolation points relevant to the component of the plant / machinery / equipment in question and the work to be performed by the workgroup. As part of this assessment process, the Responsible person will use the Group Lock Out Register form that identifies all relevant isolation points and personnel. The Responsible person is the person accountable for the work being performed. Under the Group Lockout process the requirement to remove Personal Locks and Tags if leaving the site or when doing a handover is not applicable. The Group Lockout Locks and Tags will be applied at the commencement of work and not removed until the work is complete and ready for recommissioning. This Responsible Person shall: BEFORE ANY WORK COMMENCES. Show each member of the group the points of isolation and demonstrate that the equipment is safe. Ensure that each member of the group signs the Group Lock Out Register form. The form is to be displayed at the job site and includes information on the work area, the equipment isolated, the Responsible person, and the names and signatures of each person in the group. AT THE COMPLETION OF WORK. Ensure that each member of the group signs off the Group Lock Out Register form. Ensure that each member of the group removes their personal locks and returns equipment to operational status by notifying appropriate people. Use of Contractors The general principles outlined in the Contractor Management policy shall apply to contractors working on site. However, in relation to equipment access, only contractors who have completed training and an assessment in relation to TSA-AUE Lock out / tag out LTCT Procedures shall be allowed to undertake equipment isolations. The individual contractors who have successfully completed the training session and an assessment shall be listed as approved for the purposes of undertaking equipment isolations within a site held register. In relation to equipment isolation, such contractors work to the same procedures as workers. Training. An outline of the LTCT procedures and the reason for their existence shall be part of site safety inductions, as shall the consequences of failing to follow these procedures. The term "Lock, Tag, Clear and Test (Try) Procedures" shall be used to emphasize the testing component of the procedure. Those officers / workers whose roles will involve access to equipment shall receive specific training in relation to this procedure and LTCT process before undertaking those roles, and shall be provided with refresher training at least annually. Refresher training is the responsibility of each senior officer / manager who has people involved in equipment access. Up-to-date training records are to be maintained.
Page 5 of 7 Issue: 2 Register of Locks. All locks must be able to be traced back to the user. Where numbered locks are used an up-todate register of personal locks is to be maintained by the site and be readily available. Taking Equipment out of Service. When it is necessary to take equipment out of service, OUT OF SERVICE Tags shall be used. The name of the person fitting the tags together with the date and the reason for the equipment being out of service is to be clearly printed in the space provided. OUT OF SERVICE tags are for protection of equipment and are NOT to be used for the protection of personnel. Lock out tag out Procedure 1. Prepare and announce the shutdown. Identify all affected officers / workers / personnel and notify them that a lockout/ tag out system is going to be utilized, identify the plant, equipment and processes involved and the reasons behind the isolation. Verbal communications are acceptable. 2. Shutdown. Where plant, machine, equipment or process is operating, shut down using the safe and normal stopping procedure. 3. Isolate / disconnect all energy sources. Physically locate the energy isolating device that is needed to control the energy to the plant, machine, equipment or process and isolate in such a manner to ensure all energy sources are isolated. 4. Lock and Tag application. The authorised person shall affix their personal lock and properly signed and dated personal tag to the energy isolating device to hold in a safe or off position. 5. Clear all personnel and materials from the equipment to a safe distance, and this can also mean to drain or de-pressurise a line. 6. Test and try to verify isolation. Perform required test, push buttons, test circuits, etc., depending upon the type of equipment being locked out. This assures that the energy source is off and the equipment is safe to work on. The try must be positive with positive verification. 7. Keep a lock and tag in place. The plant, machine, equipment or process is now locked out. Every person working on the equipment shall keep their personal lock and tag on until they have finished working on or near the equipment. 8. Perform the required work safely Return to service procedure 1. The Responsible person shall determine if all personnel and tools other equipment and such are clear and that it is safe to energise the plant, machine, equipment or process. 2. Check to ensure that the plant, machine, equipment or process components are operationally intact and sound and that there is no mechanical hazard. 3. Notify all operators and other affected persons that the plant, machine, equipment or process is ready to be energised and that lock and tag are to be removed. 4. Remove the locks and tags from energy isolating device. NB A lock or tag must not be removed by anyone other than the individual who installed it.
Page 6 of 7 Issue: 2 Removing of Locks / tags by another 1. If a personal lock or tag is required to be removed and the person who fitted the lock/ tag is off site they will be contacted and will be required to return to site to remove it. 2. If the person who fitted the lock/ tag is unable to return, the authorized holder of the master key shall make a thorough analysis of the safety and integrity of the equipment and complete the Lock Out / Tag Out Removal form. 3. The Senior Officer / Senior Manager will provide designated personnel with a master key. These keys will be registered and all personnel issued with master keys will be specifically trained in the procedures to be followed for lock / tag removal check and approval. 4. Only if safe operation can be assured may the lock be removed and returned to the owner when they return, with an explanation of the circumstances requiring the removal of the lock. 5. This action shall only be taken as a last resort measure and the completed form copied to the relevant Officer / Manager and the person who fitted the lock and the Senior Officer / Senior Manager. 6. Unauthorised removal of another person's lock or tag shall constitute a breach of Company Policy resulting in disciplinary action up to and including dismissal. Undertaking Work on Energised Plant & Equipment Work on energised (live) plant and equipment shall only occur under the following circumstances:- It has been established that there is a proven risk of greater harm from working on the plant or equipment in a de-energised state. It is essential for testing or maintenance processes that the plant or equipment is energised. To work on energised (live) plant or equipment as identified above, the following requirements shall be complied with:- A risk assessment has been completed on the task involving the energised plant or equipment and the controls identified from this assessment have been implemented. The manager responsible for the person(s) undertaking the work and the manager responsible for the item of plant or equipment in question have reviewed the risk assessment and subsequently authorised the work to be performed. The person(s) that are to work on the plant or equipment are competent to do so. Arrangements have been put in place for immediate access to first aid personnel and appropriate emergency response equipment.
Page 7 of 7 Issue: 2 6. Monitoring and Review Compliance with this procedure shall be reviewed and its effectiveness evaluated across TSA- AUE, in accordance with the WHS Planning, Monitoring and Review and Auditing Procedures. Key aspects of this procedure s implementation shall be monitored via:- Completed Group Lockout Register forms Completed Lock Out / Tag Out Removal forms Management meeting minutes shall record the outcomes of any discussions relating to monitoring and review activities. 7. Auditable Records Auditable Record Responsibility Location Training records Group Lockout Register forms Lock Out / Tag Out Removal forms Lock Register Risk assessments Preventative Maintenance Schedules Maintenance records WHS Committee / consultative forum meeting minutes Management Review Meeting minutes Internal references TSA-AUE WHS Hazard Management policy WHS 004 TSA-AUE WHS Hazard Management procedure WHSP4-01 TSA-AUE WHS Hazard Identification procedure WHSP4-02 TSA-AUE WHS Risk Assessment and Control Procedure WHSP4-03 TSA-AUE WHS Plant and equipment policy WHS 029 TSA-AUE WHS Safe plant and equipment management procedure WHSP29-01 TSA-AUE WHS plant hazard identification and risk assessment F29-01 TSA-AUE WHS plant and equipment register F29-02