QP29.20 Revision 15 Safety

Transcription

1 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 1.0 PURPOSE Ensure isolation of energy source is carried out to prevent injury to personnel caused by: The accidental or unexpected start-up of machinery or movement of materials during servicing, maintaining or any other interaction. Contact with or exposure to hazardous energy. This procedure describes the minimum requirements for the control of potentially damaging energy (and substances) to provide personnel protection. 2.0 SCOPE Applies to all people working (where isolation is required for personal protection) on SIMEC Mining and Liberty OneSteel Steelwork s sites. When personnel would be endangered by the unexpected start-up of machinery or release of stored energy. When personnel are required to bypass any guard, interlock or other safety device. When personnel are required to place any part of their body into an area where work is being performed. This procedure does not cover operations (e.g., hot-tap, fault finding electrical testing or calibration) where equipment shutdown is impossible, provided that special equipment and/or procedures are used that will ensure proven effective personal protection. This document covers responsibilities, training, procedures, audits, variations, nonconformance and hardware. The major components of the isolation system are that it is: - planned - locked - verified, and - carried out by appropriately authorised personnel. 3.0 REFERENCES GFG Alliance Australia Code of Practice - Isolation MM Safety Management Systems Manual QP Event Recorder / Audit Database and Issues Management QP Incident Investigation and Reporting QP Plant Safety Management and Inspections QP Safety Risk Management QP Warning Tag Regulations QP Health and Safety Training WI Management Review of Disciplinary Action Arising From Safety Breaches FORM Variation Approval Form FORM Operational Access Approval Form FORM Isolation Code Variation Approval Form Any PRINTED copies of this procedure are UNCONTROLLED Page: 1 of 13

2 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 4.0 DEFINITIONS Affected Person Authorised Personnel Central Isolation Board Complex Isolation Energy Energised Green Group Lock Hot Tap Individual Isolation Isolated Isolator Isolation Checker Person whose job requires them to use or operate equipment which is isolated for personal protection or work in an area influenced by equipment which is isolated for personal protection A person authorised to undertake one of the following roles, Plant Owner, Planner, Isolation Leader or Isolating Person A board set up by an isolation leader to protect groups of people in an isolation. (Also known as a group lock board) An isolation where there are more than two energy sources or more than three isolators. Complex Isolations require a written isolation procedure and / or permit. All types of potentially hazardous energy including: electricity, heat, gas, pressurised fluids, steam, and chemicals. It may also be kinetic or potential energy, toxic, biological substances or radiation. Connected to an energy source or containing residual or stored energy. A lock (coloured green) used by an isolation leader to lock a central isolation board. An isolation leader may only remove this lock. A procedure used in the repair, maintenance and servicing activities, which involve welding on a piece of equipment under pressure in order to install connections. A non-complex isolation where, following verification of the isolation, a multilock device and equipment lock are attached to the isolator to signify the isolation has been verified. The equipment lock has a label or tag attached that identifies the isolating person. Protected persons then lock each isolator by placing their personal lock(s) on the multilock device(s). The condition into which equipment or plant is placed when all sources of potentially damaging energy are prevented or blocked by the operation and securing of isolating devices. A device that physically prevents the transmission or release of potentially damaging energy. A central isolation board is an isolator when used under an approved group isolation procedure. A person who confirms that the Isolation Permit is completed and verified correctly, in situations deemed necessary by the Isolation Planner. The Isolation Checker is only responsible for checking the isolation and the verification process and not doing the physical isolation. Any PRINTED copies of this procedure are UNCONTROLLED Page: 2 of 13

3 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety Isolation Committee Isolation Leader Isolation Permit Isolating Person Isolation Planner Locked Multilock Device Non-Complex Isolation Operational Access Plant Owner Protected Person Red Personal Lock Responsible Manager Representatives from Safety, Engineering, Procurement and Operating departments who, on behalf of the management team, act as the custodian of the Isolation and Warning Tag procedures. Their role is to; review isolation incidents, review, and where appropriate grant variations Constantly review, and where required, update the procedures. An isolating person who co-ordinates the isolation activities of isolating personnel. The person who applies the group lock to a central isolation board. Identifies the person who authorises the isolation permit, isolation leader, the person who locks the isolators and the person who verifies the effectiveness of the isolation. Any changes to an Isolation Permit must be re-authorised by the appropriate person. A person assigned by the responsible manager to apply equipment locks to isolators. A person who plans and documents plant specific isolation procedures. Placement of a lock on an isolating device, in accordance with an established procedure, so that accidental or inadvertent operation of the equipment is prevented. An accessory attached to an isolator, which permits the device to accept multiple locks. The presence of a multilock device signifies that the isolation has been verified. A multilock device is essential hardware for every isolation An isolation where there are no more than two energy sources or no more than three isolators. Non-complex Isolations do not require a written isolation procedure or permit. In some cases a procedure or permit may be used. Operational Access refers to the day-to-day operation of machinery. It covers loading and unloading parts, adjustment, inspection, housekeeping and tool changes A person designated responsible (by the responsible manager) for the plant area and equipment. A person who places their red personal lock on a multilock device or a central isolation board for personal protection. A lock (coloured red) and identification used by a protected person for personal protection. Person responsible for the planning, direction and control of personnel safety within a recognised production area. Any PRINTED copies of this procedure are UNCONTROLLED Page: 3 of 13

4 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety Safety Breaches Disciplinary Committee Satellite Board Securing Device Verification Yellow Equipment Lock Two members of the Steelworks Management Team and a Human Resources Manager/Superintendent (plus Contractor Principal if Contractor employee involved). A satellite board is joined to a main isolating board. A yellow equipment lock is placed on the isolating bar of the main board and its key is placed in the window of the satellite board. The main isolation is set up first and then the satellite board. The satellite board permit refers to the main board as the isolator on a line of the permit. A device used to allow the locking of an isolator where the isolating device cannot be directly locked. Securing devices include lockable valve covers, chains, wire ropes etc. Is the act of confirming that the isolation procedure as practiced achieves its objective i.e. protects personnel by blocking potentially damaging energy. An isolating person is responsible for any verification. A lock (coloured yellow) with identification that is applied to equipment that is to be isolated. Yellow equipment locks must be attached to a multilock device after verification has occurred. 5.0 PROCEDURE 5.1 General A hazard identification and evaluation survey shall be performed to identify all energy sources and related exposures in the equipment, systems and machines. All equipment shall be locked to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Each person required to lock an isolator for personal protection shall place a lock on: a) Each isolator locked with a multilock device and a yellow equipment lock. or b) A central isolation board which is locked with a green group lock. All isolators shall be uniquely and permanently labelled to indicate their function for isolation purposes. No person may affix or remove the personal lock of another person. New isolators shall have the capability to be locked in the safe position. Any PRINTED copies of this procedure are UNCONTROLLED Page: 4 of 13

5 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 5.2 Responsibilities The following are functional responsibilities, which shall exist for every isolation. All personnel: Be trained to recognise isolators. Not attempt to operate a locked isolator. Not remove any lock, tag or mechanism, other than their own. Only use locks and tags on specified equipment they are authorised to work on. First preference for labelling red or yellow locks, is a personally labelled lock (encapsulated), second preference is the OneSteel purple identification tag; third preference is a personal identification tag e.g. (ASCO card). Ensure that red personnel locks are clearly labelled with the person s name and department number or if the employer is a contractor then the contractors name. Yellow equipment locks identify the person or department who has placed the lock and in group isolation situations, the board number. Ensure that during isolation, all keys are secured. Bring any isolation problems to the attention of their supervisor. Responsible Managers: Ensure that plant and equipment can be isolated safely and appropriately. Assign ownership (for isolation purposes) for all process, plant and equipment within their area of control, this must be documented in a department register. The register must provide a list of current authorised persons. Ensure that service providers and contractors are authorised to supervise the attachment of red personal locks and that this is documented in a department register. Ensure personnel receive appropriate isolation training. Establish and sustain a departmental isolation system. Assign responsibility for the development, modification and authorisation of Isolation Permits. Ensure that management controls (for locks and keys) are in place, which ensure that individuals always have control over the potentially damaging energy. Audit and evaluate the application of isolation system in all areas within their jurisdiction. The aim of the audit shall be to improve the system by correcting any deviations or inadequacies. Plant Owner: Be aware of those working under an isolation. Grant permission for equipment to be isolated. Isolation Planner: Have a thorough knowledge of all energy sources associated with the equipment. Ensure a hazard analysis is conducted to determine the isolation requirements. Identify the relevant isolators. Identify the method to isolate all necessary energy sources. Identify the method of locking the isolators. Identify the method to verify the isolation. Ensure that all the necessary requirements are included in the Isolation Permit. Identify a situation where an Isolation Checker is required. Authorised and responsible for completing or altering the task list. Also refer to FAQ P32 Currently employed in the department at the time the isolation permit is generated. For emerging work or break in work another planner may plan the isolation provided that they are authorised and deemed competent by the plant manager. Any PRINTED copies of this procedure are UNCONTROLLED Page: 5 of 13

6 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety Isolation Leader: Gain permission from the plant owner before isolating. Coordinate the activities of the isolating personnel. Ensure that all relevant isolators are locked and the isolation verified. Notify personnel that the isolation is ready for use and any other relevant matters. Isolating Personnel: Completely understand (knowledge and skills) equipment operational characteristics, associated hazards and its isolation requirements and undertaken a practical on-the-job assessment. Place isolators under their control in the safe position and lock with an equipment lock. Verify that the isolation is effective. For Non-Complex Isolations:- Provide sufficient locks and multilock devices. Ensure protected personnel comply with isolation procedures. For Complex Isolations:- Carry out the isolation in accordance with isolation Procedure/Permit. Initial Isolation Permit at the time of attaching equipment lock. Initial Isolation Permit at the time of verifying isolation. Protected Personnel: Follow established procedures Only place personal locks on isolators that are locked by the isolating person with an equipment lock and a multilock device or the Central Isolation Board which is locked with a group lock. Affected Personnel: Be able to identify personnel who are using isolation for personal protection. The department must ensure that only personnel listed on the isolation permit or task list are able to supervise first time locking. Examples of authorised personnel who are able to supervise first time locking are the isolation planner, isolation leader, and project controller or contractor supervisor. The department shall indicate, in the task list, which service providers or contractors are able to supervise the first time locking of isolations. Service Providers and Contractors: Ensure that the attachment of their peoples red personal lock is supervised. If the service providers attaching their red locks are Yellow or Green lock trained, there is no requirement to be supervised. If unsupervised, Service Providers must be yellow lock trained if they are placing their red locks on individual isolations and Green lock trained if they are placing their red locks on central isolation boards. Contractor supervisor s can supervise locking when trained to Isolation Leader level to supervise isolation boards and trained to yellow lock level for individual isolations and their names are listed on the isolation permit task list. Use and enforce the isolation requirements. Whyalla Operations Management: Conduct periodic reviews of the application of isolation procedures across the site. Any PRINTED copies of this procedure are UNCONTROLLED Page: 6 of 13

7 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 5.3 Training Isolation training shall be listed as critical safety training for all personnel working on Whyalla Steelworks sites. Isolation training shall be carried out at start of employment and periodically thereafter. Site specific training shall take place for job assignments, machines, equipment, processes and procedures that present hazards to personnel or as deemed necessary by the responsible manager. Retraining shall take place for changes to job assignment, machines, equipment, processes and procedures that present new hazards to personnel or as deemed necessary by the responsible manager. Isolation training and assessment shall be knowledge based for theory components and competency based (knowledge and skill) for practical components. Competency based assessment for isolating persons shall include an on-the-job assessment using the approved checklist. Isolation training shall include purpose, function and restrictions of this isolation procedure. Planners shall complete the competency assessment that is provided in the isolation code of practice to demonstrate competency. The plant equipment that the planner is responsible for isolating shall be utilised for this assessment. Red Personal Lock Protected Personnel and Affected Personnel shall be red personal lock trained to:- Recognise that isolation is in place. Understand the importance of not interfering with isolated equipment. Understand the safety significance, purpose and use of this procedure. Understand the use of a Personal Red Lock and ensure that the key is kept secure during isolations. Yellow Equipment Lock Plant Owner, Isolation Planner, Isolation Leader and Isolating Person, performing Non- Complex Isolations shall be Yellow Equipment Lock trained to:- Recognise potentially damaging energy sources. Use methods and means necessary to isolate and lock potentially damaging energy. Use methods to verify the effectiveness of the isolation. Confirm that a situation is a Non-Complex Isolation Recognise a situation that is a Complex Isolation, and that a Permit is needed. Understand the use of a Yellow Equipment Lock and a Multilock Device and ensure that yellow equipment lock keys are kept secure during isolations. Green Group Lock Plant Owner, Isolation Planner, Isolation Leader and Isolating Person and Isolation Checker shall be Green Group lock trained to :- Recognise potentially damaging energy sources. Use methods and means necessary to isolate and lock potentially damaging energy. Use methods to verify the effectiveness of the isolation. Understand the procedure for completing Isolation Permits and setting up a Central Isolation Board and ensure that green group lock keys are kept secured during isolations All green group lock keys shall be stored in designated labelled key cupboards or similar controlled container for access by authorised persons only. All other personnel shall be instructed :- about this procedure. understand the importance of not interfering with isolated equipment. Any PRINTED copies of this procedure are UNCONTROLLED Page: 7 of 13

8 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 5.4 Isolation Procedures and Permits Isolation procedures and permits for personal protection shall be developed, documented and used for isolation of potentially damaging energy. The procedure and/or permit shall clearly state the scope, purpose, authorisation, rules, and techniques to be used for the isolation of potentially damaging energy. Attachment 1 outlines the necessary features of any isolation procedure. Written isolation procedures and/or permits are required for all complex isolations. 5.5 Isolation Practice Group Isolation Practice A written procedure and/or permit shall exist before group isolation can be used. Group isolation may be used if many persons are involved, the isolation is in place for more than one shift, many isolation points are involved or as deemed necessary by the responsible manager. The personnel setting up the isolation must be provided with the steps necessary to be protected from stored energy. The permit shall reference the pertinent work procedures. When there is a sequence of isolations required to do a job safely a work procedure shall explain the stored energies and what personnel who are setting up the isolation must do to be safe when setting up the isolation. A greater level of detail should be included in the work procedure generally more so than on the isolation permit. If any doubt exists then a safe system of work should be completed. If a permit is one in a sequence then this must be clearly indicated. For example if isolating the counter balance on a conveyor is the second isolation of three for removing a conveyor belt. An isolating person shall place the isolators in the safe position and lock them with equipment locks and central isolation board identification. An isolating person shall verify that the isolation is effective. The yellow equipment lock will be attached to a multi-lock device to indicate that the isolation has been verified. The completed Isolation Permit and Equipment List is displayed on the Central Isolation Board. Where isolation boundaries cross normal access and egress areas the boundary of the isolation must be marked. If this causes major difficulties then a diagram of the isolated area must be displayed at all access and egress points so that a person following normal practices could not unknowingly enter an area controlled by the isolation. The diagram must also be kept on the isolation board with the permit. The keys of each equipment lock shall be placed in the central isolation board by the isolation leader affixing the group lock. Green group lock keys shall be stored in designated labelled key cupboards or similar controlled container for access by authorised persons only. Then and only then shall individuals lock the central isolation board with their personal lock. Any PRINTED copies of this procedure are UNCONTROLLED Page: 8 of 13

9 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety Satellite central isolation boards may be set up: the isolation leader shall lock the master central isolation board with an equipment lock. the key of the equipment lock shall be placed in the satellite central isolation board and locked by the isolation leader affixing a group lock. then and only then shall individuals lock the satellite central isolation board with their personal locks. For more detail on Satellite Boards see Attachment 9, Section Use of an Isolation Checker In some circumstances, due to the risk or nature of a particular isolation, it may be deemed necessary by the Isolation Planner to have an independent Isolation Checker. Where this is the case the requirements and responsibilities of the Isolation Checker must be documented in the isolation procedure and/or permit. Using checkers is optional however when utilised they must be appropriately trained (trained to the same level as the isolating person) and must check the process of verification. The isolation planner will decide if a checker should be used and will provide a permit with the appropriate sign-off box Individual Isolation Practice An isolating person shall: Place the isolator in the safe position and lock with an equipment lock. This step is to ensure that the person conducting the verification has control over the isolator. It also demonstrates to others that the isolation has not yet been verified for individual isolation. If verification is immediate and visual, e.g. a knife switch or slip plate, then the multilock device may be fitted immediately. When the lock prevents the verification step being carried out, the verification step can be carried out without the yellow equipment lock in place provided that the isolating person is in total control of the isolator during the verification step. Verify the isolation is effective. Remove the equipment lock, fit a multilock device and lock with an equipment lock and isolating person identification. Yellow equipment lock keys shall be stored in designated labelled key cupboards or similar controlled container for access by authorised persons only. (When the isolation doesn t progress beyond the current shift, the Isolating Person can keep the yellow lock keys secure without the need for the keys to be placed in a designated key cupboard). Protected person lock each isolator with a personal lock on the multilock device, which has been locked with an equipment lock Contractor Yellow Equipment and Green Group locking Contractors can isolate individual isolations and group isolations when: The contracting isolating personnel are trained, competency assessed and authorised by the plant manager. The department keeps a register of authorised contractors and what plant the contractor can isolate. The department shall keep a record of the contractor s training assessment. Any PRINTED copies of this procedure are UNCONTROLLED Page: 9 of 13

10 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 5.6 Equipment Restoration Checklist The equipment lock list can be used to restore plant when the restoration of the plant equipment is in the reverse order. When the plant to be restored is not in the reverse order than an equipment restoration checklist must be used, see Attachment No Removal of Locks An isolating person shall not remove any equipment lock from an isolator unless all personal locks are first removed. An isolation leader shall not remove a group lock from a central isolation board unless all other personal locks are first removed. Personnel shall only remove their own personal locks. Personal locks must be removed at the end of the person s shift or if the requirement for personal protection is no longer needed for the particular job/task. If a person is leaving the works they are required to remove their personal lock. NOTE: If removal of personal locks is required for other reasons, this shall be communicated via the A.T.W. and toolbox meetings at the commencement of the job. 5.8 Shift and Personnel changes The continuity of personal protection must be ensured during shift or personnel changes. The following steps shall be observed if changeover of the isolation leader is required using a group isolation procedure. The on-coming isolation leader shall be fully conversant with all aspects of the isolation. The on-coming isolation leader receives custody of the group lock key from the offgoing isolation leader. The on-coming isolation leader shall satisfy themselves of the integrity of the isolation. The on-coming isolation leader shall change the name in the isolation leaders position on the central isolation board. 5.9 Emergency Removal of Locks Red Personal Locks and Individual Yellow Equipment Locks Where a person has failed to remove a personal lock or equipment lock the responsible manager may authorise the plant owner to remove the lock provided that all the following requirements are met: ensure that the plant is safe to operate. all practical efforts have been made to locate the individual and have them remove their lock. all practical efforts have been made to contact the person to ensure that the person could not return to the job and be endangered by the equipment being operated. The emergency removal check list in Attachment No. 4 must be completed before cutting off the lock.where a person has lost the key to their personal lock Identification of the person must be confirmed with the lock in question The emergency removal check list in Attachment No. 4 must be completed before cutting off the lock. Any PRINTED copies of this procedure are UNCONTROLLED Page: 10 of 13

11 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety Green Group Locks If, for some reason, the Isolation Leader cannot be located to remove the group lock from a Group Isolation Board, the responsible manager may authorise an isolating person to remove the green group lock provided the following requirements are met: ensure that the plant is safe to operate, all practical efforts have been made to locate the Isolation Leader and have them remove the lock, ensure all red personal locks and/or yellow equipment locks have been removed from the group isolation board Emergency Removal Of Locks Checklist When emergency removal of a personal lock, equipment lock or group lock occurs the checklist in Attachment 4 should be completed as a record that the correct process has been followed and authorised. Follow-up actions should also be documented on this attachment Intermittent Operation Intermittent or remote operations, which do not conform to the requirements of this procedure, shall be considered a variation (ref. 5.13) 5.11 Non-conformance Any non-conformance from this procedure shall be reported and investigated immediately. The responsibility for the investigation rests with the responsible manager. Corrective action and incident investigation procedures shall be used. Any disciplinary action taken for a breach of this procedure shall be referred to the responsible manager s one-up supervisor (see WI ). All non-conformance s are to be reported in writing to the Safety Breaches Disciplinary Committee Audit Periodic audits shall be conducted (at least annually) to ensure that plant isolation practices comply with the requirements of this isolation procedure. Personnel other than those using the procedure shall conduct audits. The aim of the audit shall be to correct any deviations or inadequacies identified. A record of any audit shall be retained for seven years. The record shall identify the equipment on which the procedure was being used, the date of the audit, personnel included in the audit and the person performing the audit Variations Any variations in the application of this procedure shall be formulated in consultation with the appropriate Safety Representative and committee. Variations to the application of this procedure are only valid where submitted by a member of the Whyalla Operations management team and approved by the Isolation Committee. Variations shall only apply to a particular procedure detailed in the variation. The Variation Procedure is detailed in Attachment 8. Any PRINTED copies of this procedure are UNCONTROLLED Page: 11 of 13

12 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 5.14 Hardware Isolation equipment shall be standardised (colour, shape, size, print, format) as specified in Attachment 2. Locks Locks shall be substantial enough to prevent unauthorised removal. Shall be clearly identifiable as for personal protection only. Personal locks shall identify the person applying the lock. Securing Devices Devices used to allow the locking of isolators where the isolating device cannot be directly locked. Securing devices include lockable valve covers, chains, locks etc. Central Isolation Boards Equipment locks keys shall be captured and locked. Isolation permit shall be readable. Group lock shall activate the central isolation board. Equipment covered by the central isolation board shall be listed. The equipment locked list must be secured by the green group lock The permit shall identify the isolation leader who set up the isolation and the board shall identify the position of the isolation leader eg. Maintenance Shift Supervisor. Central isolation board may be portable or fixed. Central isolation board shall be uniquely identified. Isolation Permit Identifies the isolation leader, the person who locks the isolation and the person who verifies the effectiveness of the isolation -refer Attachment 5. Date of the isolation. Cross reference to the isolation procedure. Identify all isolators. Identifies the isolation planner. The permit can only be altered by an authorised isolation planner Modification Control A modification control process shall be used if plant equipment is modified. Isolation practices shall be reviewed to ensure that isolation permits reflect any equipment modifications Intermittent Operation Form An Intermittent Operation form may be used in situations when the plant is required to be frequently locked and unlocked eg Isolation practice for maintenance on kilns. Refer to Attachement 13. Any PRINTED copies of this procedure are UNCONTROLLED Page: 12 of 13

13 GFG Alliance Whyalla ISOLATION FOR PERSONAL PROTECTION QP29.20 Revision 15 Safety 6.0 DOCUMENTATION Attachment 1 Attachment 2 Attachment 3 Attachment 4 Attachment 5 Attachment 6 Attachment 7 Attachment 8 Attachment 9 Attachment 10 Attachment 11 Attachment 12 Attachment 13 Necessary Requirements for an Isolation Procedure Hardware Specification Verification Emergency Removal of Locks Checklist Isolation Permit A Basic Guide for Isolating Persons Yellow and Green Locks A Basic Guide for Using Red Personal Locks Variation Procedure QP Guide Lock Management Isolation of Vehicle keys, Best Practice Equipment restoration checklist Intermittent Operations Form Any PRINTED copies of this procedure are UNCONTROLLED Page: 13 of 13

14 Isolation for Personal Protection Attachment 1 Necessary Requirements for an Isolation Procedure ISOLATION: Note steps 1 11 shall be carried out by the person assigned by the responsible manager. 1. NOTIFY PLANT OWNER Notify the plant owner (reason and duration). - the plant owner shall notify all affected personnel 2. HAZARD ANALYSIS - Identify type and magnitude of energy - Understand hazards of the energy - Know the methods of controlling the hazards. - Ensure the area of isolation is adequately defined or barricaded so accidental entry will not occur. 3. COMPLEX ISOLATIONS For group or board isolations the procedure in is followed to set up the board. In some departments an independent checker signs off when the correct isolator is locked and after it has been verified. 4. MACHINE CONTROLS IN SAFE POSTION Identify the type and location of every machine and its controls and their safe position. Place controls in their safe position. 5. ISOLATORS IN SAFE POSITION Identify the type and location of every isolator and its safe position. Place the isolators in the safe position. Confirm that the correct isolator(s) have been identified and placed in the safe position. 6. IDENTIFY THE METHOD FOR SECURING ISOLATORS. 7. ATTACH EQUIPMENT LOCKS TO ISOLATION SECURING EQUIPMENT 8. IDENTIFY STORED ENERGIES AND DISSIPATE OR RESTRAIN Identify the type of stored energy and the method of dissipation or restraint. Dissipate or restrain stored or residual energies. 9. VERIFY THAT ISOLATIONS ARE EFFECTIVE Identify the methods of verification. Verify that the isolations are effective and if a permit is used sign off verification on the isolation permit. 10. MULTILOCK Remove equipment lock and place multilock onto isolator then place the equipment lock onto the multilock. For complex isolations sign off on the permit that the equipment has been locked. 11. PERSONAL LOCK For individual isolation individuals place their personal lock onto the multilock. For group isolations Individuals place their personal lock onto an activated isolation board. QP 29.20/1 7/05/2014 Page 1 of 2

15 Isolation for Personal Protection Attachment 1 RESTORATION: Note the restoration shall be carried out by the person assign by the responsible manager. 1. Check machine or equipment for : - operational integrity (e.g., safety guards replaced) - removal of non-essential items. 2. Check work area (personal locks removed and personnel clear). 3. Verify controls in Off or Neutral. 4. Remove equipment locks. 5. Place the isolators in the required position. 6. Notify plant owner. QP 29.20/1 7/05/2014 Page 2 of 2

16 Isolation for Personal Protection Attachment 2 Hardware Specification Locks Lock Type Material Number Description Personal Padlock Safety Lockout -Red - keyed differently - Master Cat No 410 Group Padlock Safety Lockout -Green - keyed differently - Master Cat No 410 Equipment Padlock Safety Lockout -Yellow - keyed differently - Master Cat No 410 Equipment Padlock Safety Lockout -Yellow - set of six(6) keyed alike - Master Cat No 410 Equipment Padlock Safety Lockout -Yellow - set of twelve (12) keyed alike - Master Cat No 410 Equipment Padlock Safety Lockout -Yellow - set of eighteen (18) keyed alike - Master Cat No 410 Equipment Padlock Safety Lockout - Yellow - set of twenty four (24) keyed alike - Master Cat No 410 Equipment Padlock Safety Lockout -Yellow - set of thirty (30) keyed alike - Master Cat No 410 Multilock Device Material Number Master multilock device - 25mm ID # Material Number Master multilock device - 38mm ID # QP 29.20/2 3/12/2010 page 1 of 2

17 Isolation for Personal Protection Attachment 2 Central Isolation Board Material Number Central Isolation Board Material Number Portable Central Isolation Board Identification Tags Material Number Identification Tags QP 29.20/2 3/12/2010 page 2 of 2

18 Attachment 3 VERIFICATION Verification Is the act of confirming that the isolation procedure as practised achieves its objective i.e. protects personnel. An isolating person shall be responsible for any verification. The isolation shall be tested for zero state energy (specialised test equipment and qualified personnel may be required), and/or tried (operate the normal controls (return all controls to the off or neutral position)). If stored, residual or accumulated energy was present the isolating person shall ensure that all stored, residual or accumulated energy is dissipated or restrained e.g. inspect each moving part to see if it is at rest. Where re-accumulation of stored energy is possible periodic or continuous verification is required to ensure that the energy level or intensity is not harmful. QP 29.20/3 10/06/2005 Page 1 of 1

19 Emergency Removal Of Locks Checklist Circle appropriate response Attachment 4 Personal Lock Yes / No Details:... Equipment Lock Yes / No Details:... Group Lock Yes / No Details:... Plant Assessed Safe To operate Yes / No Details:... All Reasonable Efforts Made To Locate key and/or Key Holder Yes / No Details: All Personal and/or Equipment Locks Removed Yes / No (for Equipment or Group Lock Removal) Details:... Administered By: / / Print Name Sign Date (Plant Owner - Personal Locks) (Isolation Leader - Equipment or Group Locks) Authorised By: / / (Responsible Manager) Print Name Sign Date Follow-up Discussion: Details: (Lock Owner) / / Print Name Sign Date (Supervisor) / / Print Name Sign Date QP 29.20/4 10/06/05 Page 1 of 1

20 EQUIPMENT LIST Isolation Permit No.... QP 29.20/5 3/12/2010 Page 1 of 3

21 Issued for Tasks Work Order Number Description Permit No... Work Group & Supervisor of first time locking Work Group: Work Group: Work Group: Work Group: Work Group: Work Group: Work Group: Work Group: Work Group: Date: Isolation Leader... QP 29.20/5 3/12/2010 Page 2 of 3

22 Isolation Permit No Prepared By Authorised By: Plant Owner: Equipment Description Revision No. Date of Job Duration 1. ISOLATOR METHOD of Name Identifier Location Securing Initial Verifying Initial Date: Isolation Leader... QP 29.20/5 3/12/2010 Page 3 of 3

23 A Basic Guide for Isolating Persons Yellow & Green Locks What is an Equipment Lock? Attachment 6 An Equipment Lock is a yellow lock that is attached to an Isolator. It identifies the Isolating Person or a Central Isolation Board. Why use an Equipment Lock? Use an Equipment Lock to secure an Isolator in the safe position and to prevent its accidental or inadvertent operation. Who can use an Equipment Lock? Only a person (Isolating Person) assigned by the Responsible Manager shall attach yellow Equipment Locks. What is a Central Isolation Board? It is a special purpose board with a place for - An Isolation Leader s name or position title A receptacle and hook for Equipment Lock key(s) A Green Group Lock. Red Personal Locks. A list of equipment. An Isolation Permit. When is a Central Isolation Board used? If many persons are involved in the isolation. If many isolation points are involved. If the isolation is to be in place for more than one shift. If the Responsible Manager deems it necessary. How does the Central Isolation Board work? An Isolating Person shall - Use a written Isolation Permit. Secure each Isolator with a yellow Equipment Lock. Verify that the isolation is effective. Place all the keys for each Equipment Lock in the place provided on the Central Isolation Board. QP 29.20/6 7/05/2014 Page 1 of 3

24 Attachment 6 The Isolation Leader shall - Ensure that all requirements of the isolation are completed. Place the completed Permit in the place provided on the Central Isolation Board. Place the Equipment Locks key(s) in the place provided on the Central Isolation Board and secure with a green Group Lock. Print their name or position title on the Central Isolation Board. Then and only then shall individuals attach their red Personal Lock to the Central Isolation Board. What must be done before Personal Locks are used? Gain permission from the Plant Owner. Assess all hazards. Stop the machine. Place each Isolator in the safe position. Confirm that each Isolator is locked in the safe position. Secure each Isolator with a yellow Equipment Lock. Dissipate or restrain any stored energy. Verify that the isolation is effective. Lock each isolating device with a Multilock Device and a yellow Equipment Lock. Ensure that individuals can secure the isolation with a red Personal Lock. What must be done before the equipment is returned to service? Check that all persons are clear. Check that all red Personal Locks have been removed from Isolator multi-lock devices or Central Isolation Board. Check that all guards etc. are in place. Check that all tools etc. have been removed. Check that all controls are in the safe position. Remove each Equipment Lock. Notify the Plant Owner. Remember Never remove a yellow Equipment Lock if a red Personal Lock is still in use. QP 29.20/6 7/05/2014 Page 2 of 3

25 Attachment 6 QP 29.20/6 7/05/2014 Page 3 of 3

26 Attachment 7 A Basic Guide For Using Red Personal Locks - Level 1 What is a Personal Lock? A Personal Lock is a red lock marked DANGER - Locked Out - Do Not Remove and a person s name on the other side. The Red Personal Lock is attached to a multilock device on an Isolator or Central Isolation Board. Why should you use a Red Personal Lock? Use a Red Personal Lock to protect yourself by stopping others accidentally or inadvertently operating equipment, which could injure you. When do you use your Red Personal Lock? Whenever you could be at risk by: the operation or movement of equipment or materials. contact with or exposure to hazardous energy or substances. How do you use your Red Personal Lock? Make sure that each Isolator is placed in the safe position and secured with a yellow Equipment Lock. Attach your Red Personal Lock to the multilock device on each Isolator or the Central Isolation Board, which is secured with a green Group Lock. What must be locked? All plant, machinery and equipment where isolation is required for your personal protection. REMEMBER Never attempt to bypass or operate a locked Isolator. Never try to start equipment that is isolated and locked. Never attach or remove another person s Red Personal Lock. Never depend on someone else s Red Personal Lock. Never lend your Red Personal Lock or key to anyone. Always attach your own Red Personal Lock. Report loss of your Red Personal Lock or key immediately. If in doubt ask your supervisor. IT S YOUR LOCK! - YOUR LIFE! QP 29.20/7 10/06/05 Page 1 of 1

27 Attachment 8 Variation to the Code of Practice: Approval is required from: Business Manager, 2 Isolation Committee members, Safety Manager and the General Manager Must use the Code of Practice Variation Form (Refer FORM29.007) Requires a review every 2 years Operational Access Approval (for use of non-positive isolations) Approval is required from: Business Unit Manager, 2 Isolation Committee members and the Safety Manager Must use the Operational Access Approval form (Refer FORM29.006) Requires a review every 2 years QP 29.20/8 3/08/2015 Page 1 of 1

28 ATTACHMENT 9 GF GGFG Alliance Whyalla ISOLATION GUIDE Frequently Asked Questions of Isolation For Personal Protection QP QP 29.20/9 7/05/2014 Page 1 of 21

29 Attachment No. 9 Liberty OneSteel Whyalla ISOLATION FOR PERSONAL PROTECTION IT S YOUR LOCK - IT S YOUR LIFE This Guide contains frequently asked questions about Isolation. To ensure compliance to the requirements of QP Isolation for Personal Protection refer controlled (Intranet) document. Isolation of energy sources is carried out to prevent injury to personnel caused by:- the accidental or unexpected start up of machinery or movement of materials during servicing, maintaining or other interaction contact with or exposure to hazardous energy Energy sources include all types of potentially hazardous energy. This may include electricity, pressurised fluids, steam, chemicals, rotating or kinetic energy, potential energy, toxic or biological substances or radiation. TYPES OF ISOLATION There are two types of isolation individual isolation group isolation Some isolation information is common to both Individual and Group isolation, however there is specific information for each type of isolation MORE INFORMATION? The following information is to provide some understanding of why the various parts of isolation are used to protect you and others. Other information is also available in QP29.20 QI13.30P QP QP WI Isolation for Personal Protection Rolling Mill Isolation practices manual Hazard Assessment Warning Tag Regulations Disciplinary Process for Safety Breaches by Contractors QP 29.20/9 7/05/2014 Page 2 of 21

30 Attachment No. 9 CONTENTS Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Group and Individual isolation Group Isolation Individual Isolation Isolation Planning Setting up Satellite Boards Changing the Isolation, Two Scenarios It s Your Lock - It s Your Life Acknowledgment This booklet was created by the Rolling Mills with valuable input from all employees QP 29.20/9 7/05/2014 Page 3 of 21

31 Attachment No. 9 SECTION 1 GROUP AND INDIVIDUAL INFORMATION What is the role of each of the following? Plant Owner to be aware of those working under the isolation and grant permission for the equipment to be isolated Isolation Planner plan the isolation have a thorough knowledge of all energy sources associated with the equipment ensure a hazard analysis is conducted to determine the isolation requirements identify the relevant isolators identify the method to isolate all necessary energy sources identify the method of locking the isolators identify the method to verify the isolation ensure all necessary requirements are included in the isolation permit Isolation Leader gain permission from the Plant Owner co-ordinate the activities of Isolating Personnel ensuring that all the relevant isolators are locked and the isolation is verified (ie all securing and verifications are initialled by an Isolating Person) notify personnel that the isolation is ready for use and any other relevant matters Isolating Person completely understand (knowledge and skills) equipment operational characteristics, associated hazards and its isolation requirements carry out the isolation in accordance to an isolation plan provide sufficient locks and multilock devices place isolators under their control in the safe position and lock with an equipment lock (initial securing on the permit if a group isolation) verify that the isolation is effective (initial verification on the permit if a group isolation) ensure that protected personnel comply with isolation procedures What are each of the following used for? Red lock personal lock for your protection Yellow lock equipment lock to secure an isolator Green lock group lock for central isolation board Multilock device highlights verification is complete for individual isolation, can be used when more than 1 equipment lock is required on the isolator for group isolation QP 29.20/9 7/05/2014 Page 4 of 21

32 Attachment No. 9 Can I put my personal lock directly onto an isolator? No! A personal lock must not be placed directly on to an isolator. You can only place your personal lock onto a Central Isolation Board locked with a group lock or an Isolator locked with a multilock device which has an equipment lock identifying the Isolating Person being used for Individual isolation If the verification step (as specified in the permit) could not be done correctly, what would you do? STOP the isolation, contact the appropriate specialist (mechanical or electrical) DO NOT continue until suitable solution is determined If the isolator I should use for an isolation does not work, what should I do? STOP the isolation, contact the appropriate specialist (mechanical or electrical) DO NOT continue until suitable solution is determined There are 2 types of training required to become an Isolation Leader or Isolating Person, these are theory and practical What is the purpose of each? Theory training is to provide the understanding of the isolation procedures and responsibilities Practical training - To demonstrate an understanding of the isolation procedures and responsibilities. Site-specific training is required for a task/area to demonstrate a practical understanding of the energy sources and how to identify and control them Competency will be assessed and approval to isolate based on a specific task/area will be given by the Plant owner. When should I use Group isolation? Group isolation may be used if many persons are involved the isolation is in place for more than one shift many isolation points are involved as deemed necessary by the responsible manager Removal of locks. An Isolating Person shall not remove any equipment locks from an isolator unless all Personal locks have been first removed An Isolation Leader shall not remove a group lock from a central isolation board unless all other Personal locks are first removed Personnel shall only remove their Personal lock QP 29.20/9 7/05/2014 Page 5 of 21

33 Attachment No. 9 Emergency removal of locks Personal Locks Where a person has failed to remove a personal lock, the Responsible Manager may authorise a plant owner to remove the lock, provided that ALL the following requirements are met all practical efforts have been made to contact the person to ensure that the person could not return to the job and be endangered by the equipment being operated ensure that the plant is safe to operate Group Locks If, for some reason, the Isolation Leader cannot be located to remove the group lock from a Group Isolation Board, the responsible manager may authorise an isolating person to remove the green group lock provided the following requirements are met: ensure that the plant is safe to operate, all practical efforts have been made to locate the Isolation Leader and have them remove the lock, ensure all red personal locks and/or yellow equipment locks have been removed from the group isolation board. Emergency Removal Of Locks Checklist When emergency removal of either a personal lock or group occurs the checklist in QP Attachment 4 should be completed as a record that the correct process has been followed and authorised. It s Your Lock - It s Your Life QP 29.20/9 7/05/2014 Page 6 of 21