Module General Isolation Procedures
Definitions Worker: an employee; a contractor or subcontractor; an employee of a contractor or subcontractor; an employee of a labour hire company who has been assigned to work in the business or undertaking; an outworker; an apprentice or trainee; a student gaining work experience; a volunteer (Source: Workplace Health & Safety Act 2011)
What is an isolation? Isolation is the temporary removal of an energy source, (eg. electrical, mechanical, pneumatic, etc) using such tools as tags, locks and permits for the purpose of conducting work on or around plant and equipment. The correct isolation of plant and equipment is essential in ensuring the health and safety of all employees. Bundaberg Sugar s General Isolation Procedures is a document that outlines details on the practical processes of isolation on site.
It is a condition of employment that all workers carry out the Isolation Procedures. All personnel working on, maintaining, or cleaning any plant or equipment shall first ensure the isolation rules have been followed and implemented. Failure to do so will result in disciplinary action and / or summary dismissal.
Tags and their purpose: Danger tags are: Used when personally working on equipment Red, black and white. Front of Tag Fill out name, department, date and time Reasons for work and the initials of the Isolation controller if required Back of Tag Reasons for work and the initials of the Isolation controller if required. Main reason for use: Used by a worker when they are personally working on equipment which has been isolated. It is only to be removed by that workplace participant.
Out of Service tags are: Used by a person to indicate a piece of equipment is faulty or out of service. Yellow and black Main reason for use - you have identified a hazard in equipment and you believe that its operation could cause personal injury or damage to equipment. Do Not operate equipment when an Out Of Service tag is attached to it or its controls. Workers are to notify their supervisor as soon as possible that an out of service tag has been placed on any equipment so that corrective action can be taken. Only the worker who placed an Out of Service tag may remove it or someone who is authorised to do so after the equipment has been repaired and tested.
Special Instruction tags are: Green and Must Not be used for isolation Used for equipment which must be left in a certain state (on/off), that is not faulty, out of service, or a danger to person/s working on equipment, or to pass on instructions in regard to that equipment Allows information to be passed to personnel next shift or next day and used for leaving instruction, eg a switch is left on or a valve is required to be half open. Workers must follow the written instructions on a Special Instruction Tag which is attached to any equipment or its controls. Only the worker who placed the tag or a senior supervisor may remove the tag or authorise the instructions relevant to the equipment on which the tag is placed.
Isolated tags are: Used by an Isolation Controller to attach to an isolation point that has been isolated and locked to prevent operation by any person. Usually found on group isolations where complex isolations pass on from one shift to another. Orange and black This tag must only be removed by an Isolation Controller.
Danger Tags and Lock Out Isolation points must be locked as well as tagged Tie the danger tag securely to the lock and install the lock on the device or lock box Chains, padlocks, calipers and valve locks are provided at sites. Equipment isolated and marked with a tag stating "DANGER DO NOT OPERATE" must not be operated UNDER ANY CIRCUMSTANCES.
DO NOT USE SOMEONE ELSE S TAG under any circumstances. Each worker must take responsibility for their safety and the safety of others. Only the person who placed a danger tag and lock (an isolation) on an item of equipment may remove it. Any worker who removes another person s danger tag and lock will be dismissed if an investigation confirms an offence under the General Isolation procedure.
Locks and Lock Boxes Red Locks Full-time Employees directly employed by Bundaberg Sugar. Yellow Locks - Seasonal Employees, Fixed Term Employees, Labour Hire, Contractors, Visitors Green Locks - Groups of locks kept in Lock Boxes for Complex Isolation lock-outs A lock box is a lockable box able to contain a group of isolation locks (keyed alike) with one key for the group of locks within the box. Boxes contain sets of green locks keyed alike for complex and group isolations.
Isolation Methods Electric Switch Turn the switch off. Tie the danger tag securely to the lock and place lock through hole on switch provided. Remember to test the isolation before commencing work. Valve Turn the valve off. Place chain around valve so that valve can not be opened. Tie the danger tag securely to the lock and hang tag and lock on chain.
An Isolation Controller may be for a specific area, site, or system. For example, pan stage, refinery or computer control system. An Isolation Controller is: a person who is competent to perform correct and safe complex isolation procedures for themselves and others. designated as an Isolation Controller by the Company (any additional training that may be required to satisfy this task will be conducted as in-house company training).
Types of Isolation: Simple Isolation Where there are 3 or less isolation points for the equipment being worked on. Full-time employees engaged directly by Bundaberg Sugar can use their 3 red locks to lock out in conjunction with danger tags. Seasonal, labour hire and fixed term workers still need to use a lock box for 2 and 3 point isolations.
Complex Isolation Any equipment or task which has greater than three isolation points or is designated as requiring a Safe Work Permit.
Group Isolation When a number of workers are working on one piece of equipment, the group s supervisor, UPON AGREEMENT BY THE GROUP, may perform an isolation for the group and be responsible for its effectiveness and the safety of those working on the equipment. The isolation must be checked by someone within the group as well as the supervisor and tested prior to work commencing as per normal procedures. Main isolation point locked out by all persons working. A Safe Work Permit must be used. Must be coordinated by a supervisor.
Always follow the WAIT System. Remember WAIT ASSESS ISOLATE TEST Don t jump in! all RISK. all sources of energy. the system to ensure the isolation is effective.
Other important points: Remove your locks and tags and return the equipment as you found it prior to starting the isolation procedure. Written procedures are available for some plant, but not all complex isolations. If the work is incomplete, remove your Danger tag and locks and replace them with the Out of Service tag and advise your supervisor. Incoming persons commencing work on the job will carry out an isolation check and place their own tags and locks over the Out of Service tags. Paper danger and out of service tags must be destroyed after one use. Do not cross information out and use again.
You have now completed the training segment for this module. Please complete the assessment questions.
TRAINING ASSESSMENT QUESTIONS General Isolation Procedures DO NOT WRITE ON THIS QUESTION SHEET. Please complete the questions by providing your answers on the answer sheet provided. Question 1 - Isolation is the temporary removal of an energy source? True False Question 2 - Equipment isolated and marked with a Red/White/Black Danger Do Not Operate tag A Can be operated if you remove the tag first B Must not be operated under any circumstance C Can be operated if you are sure that no risk exists D None of the above Question 3 - If an out of service tag is placed on an item of equipment you can A operate with care B operate under supervision C Do not operate as it may cause personal injury D none of the above Question 4 - If you have placed an out of service tag on a piece of equipment you believe could cause personal injury or damage to equipment who should you report it to in the first instance A Factory Manager B Supervisor C A work colleague D Safety Officer Question 5 - Written instructions supplied on a special instruction tag attached to the equipment or controls A Must be followed by all workers B Must be followed by electricians only C Must be followed by supervisors only D Are only suggestion and open to individual interpretation.
Question 6 - True False Question 7 - True False Question 8 - True False Isolated tags are Orange and Black and can only be used by an Isolation Controller. They are usually found on group isolations where complex isolations are passed from one shift to another. Isolation points must be locked as well as tagged Equipment isolated and marked with a tag stating Danger do not Operate must not be operated under any circumstances Question 9 - Relying on someone else to tag out for you is.. A Acceptable if you tell that person first B Acceptable if you tell your supervisor C Never to be done D Acceptable if you tell your Supervisor and Safety Officer Question 10 - An Isolation Controller is a competent person who can perform correct and safe complex isolation procedure for themselves and others True False