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LOTO procedures

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LOTO procedures

    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 1 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

POLICY

It is a policy of BioLab Canada to implement and maintain a Lockout Tagout

    Program. Unexpected machinery movement or electric shock while an employee is servicing a process or equipment may cause a serious and even fatal accident or injury. This policy and procedure is designed to prevent injury to employees or damage to equipment caused by the accidental release of energy.

PURPOSE

The purpose of the Lockout Tagout Policy and Procedure is to control the

    unexpected release of stored energy. Included, but not limited to electricity, fluid pressure, air, kinetic, potential, and pressurized liquids which could cause injury to an employee during equipment maintenance, set up and adjustment. This procedure establishes minimum guidelines for an effective Lockout- tagout Program to protect employees and equipment from injury or damage.

SCOPE

    The Lockout Tagout Program of BioLab Canada applies to all employees and contractors, working on equipment, where the unexpected start up or release of stored energy could cause injury or damage at the BioLab location. This policy and procedure will include but is not limited to power sources involving electricity, fluid pressure, air, kinetic, potential, pressurized liquids and stored energy such as found in capacitors or accumulators.

REFERENCES

Occupational Health & Safety Act R.S.O. 1990

    Regulation for Industrial Establishments (Reg. 851) Sections 42, 74, 75 & 76

RESPONSIBILITY

Management Responsibilities

    ; The Maintenance Manager is responsible for the implementation and

    enforcement of the Lockout Tagout Program.

    ; Each supervisor shall ensure that new employees are trained regarding

    provisions and requirements of this Lockout Tagout Policy and Procedure.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 2 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

; Each supervisor shall effectively enforce compliance of this Lockout Tagout

    Policy and Procedure including the use of corrective disciplinary action where

    necessary.

    ; Each supervisor shall assure that the locks and tags and devices required for

    compliance with the Lockout Tagout Policy and Procedure are provided to

    their employees.

EDUCATION AND ENFORCEMENT

    The review of the Policy and Procedure will be performed annually by the Health & Safety. In addition, the Health and Safety Committee will include inspections of lock-out log books and maintenance of lockout centres in their monthly workplace inspections.

MINOR SERVICING TASKS AND TROUBLESHOOTING

    Employees performing minor tool changes and adjustments and/ or other minor servicing activities during normal production operations that are routine, repetitive, and integral to the use of the production equipment are not covered by the Lockout- Tagout Program.

    However, if the employee must either remove or bypass machine guards or other safety devices or place their body where they could be caught or trapped by moving machinery, the equipment must be de- energized, isolated and locks and tags must be applied to the energy isolating devices. This Lockout- Tagout Program does not apply to electrical testing or troubleshooting or work performed above 750 volts.

DEFINITIONS

Affected Employees

    Those individuals whose job requires them to operate equipment or machines subject to Lockout Tagout.

Authorized Employees

    Those individuals who will physically lock and tagout equipment for servicing/ maintenance. These individuals may not necessarily be the employees who normally operate the equipment. This would be the Maintenance Department and/ or Outside Contractors.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 3 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

Blankout

    A device which prevents hazardous material or energy from flowing in a pipe

Blockout

    A device which prevents the movement or rotation of equipment because of stored energy. (i.e. a stored energy source may be hydraulic, air pressure, gravity, etc.)

Hazardous Energy Source

    An energy source when uncontrolled, may provide a risk of injury to the person repairing or otherwise working on equipment. Examples of hazardous energy include mechanical, electrical, pneumatic, hydraulic, chemical and gases or any combinations of the foregoing sources.

Lockout

    The act of making equipment or a hazardous energy source inoperable by preventing the equipment from being operated or inadvertently started by means of a padlock and/or multiple hasp hardware.

Tagout

    A warning tag, which shall be attached with a lock, to communicate that, the energy source should not be re-energized. A tag should communicate the name of the employee, date, and description or work being performed.

APPLICATION

1.0 LOCKS - MAINTENANCE

    ; Each Authorized (Maintenance) Employee shall be issued 3 locks, the locks

    will be issued through the Human Resources Department and a record of all

    locks and tags issued shall remain there. The Human Resources Dept shall

    also keep a record of all authorized employees.

    ; Each employee given such locks will be given one (1) key for their own

    personal use.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 4 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

    ; Combination locks or locks with duplicate keys shall not be permitted.

    ; Only the employee shall have a key to their locks. Bolt cutters shall be

    secured in the Maintenance Manager’s office. ( See Lock Removal Procedure)

    ; The locks shall be used for Lockout purposes only, not for toolboxes or other

    devices.

; Locks and keys must not be lent or transferred amongst employees.

    ; The individual locks issued to the employee’s shall have their employee name

    inscribed on the lock.

; All individual Lockout Locks shall be of the same shape and size.

    ; All Lockout Locks shall be colour coded to distinguish between Maintenance,

    Trade, Outside Contractor and Production.

    ; Equipment Locked out for an extended period of time, without someone

    working on it, shall have a Trade Lock installed on all Isolating Devices, a tag

    shall also be installed stating the name, date and why the lock was installed.

; A logbook will be kept with the Trade Locks in the Maintenance Supervisors

    office. This Logbook must be kept current with notes indicating name, date,

    machine and the reason for the use of the Trade Lock

    ; When a Trade Lock is installed, the key to that lock must be returned to the

    Maintenance Supervisors office on the Lockout Tagout Board, a special tag

    will accompany the key indicating the name, date, machine and the reason for

    the use of the Trade Lock

    ; The Maintenance Manager, their delegate, (Lead Hand) or a member of the

    Maintenance Department may only remove the Trade Lock when a trade

    person has installed their personal lock or when work has been completed ( re-

    commissioning).

    ; Under no circumstances shall any maintenance employee work under the

    Trade Lock. Their individual lock and tag must be installed on the Isolating

    Device.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 5 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

2.0 LOCKOUT TAGOUT CONTROL CENTRES

    When it is determined that a production/ operator employee requires to perform

    Lockout Tagout. For the purposes of cleaning, tool adjustments, clearing of

    jams etc. the employee shall obtain a lock and tag from the shift superintendant or

    Maintenance Manager.

    ; The locks and tags shall be used for Lockout Tagout purposes only

    ; The locks shall be colour coded to distinguish them from other Lockout

    Tagout locks

    ; When the production/ operator employee has completed the work, they shall

    inform their supervisor to have the lock removed.

3.0 TAGS

    ; An approved tag shall be installed with all Lockout Locks.

    ; The tag shall be legible and understandable by all authorized and affected

    Employees and all other employees working in the area.

    ; The tag must be durable capable of withstanding the environment to which

    it is exposed to for the maximum period of time that exposure is expected.

    ; The tag shall bear the name of the authorized employee who installed it, the

    date, and the reason for the Lockout.

    ; Substantial, including their means of attachment, so that accidental removal is

    prevented.

4.0 GROUP LOCKOUT TAGOUT

    When more than one employee services the same equipment and Lockout the

    same energy-isolating device, this is called Group Lockout Tagout.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 6 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

    ; A multiple locking device (hasp) shall be issued to each authorized employee

    when the individual locks are issued.

    ; The first authorized employee to arrive on the job shall install a multiple lock

    hasp and their own individual lock. That authorized employee shall be the

    person in charge of the job.

    ; Each authorized employee shall attach their own lock and tag to the hasp; this

    is to ensure that they are protected.

    ; Each Employee will retain the key to their lock.

    ; In group lockout situations it must be clear to all employees that each

    employee is not considered protected until their own lock is in place.

5.0 OUTSIDE CONTRACTORS

    ; When Outside Contractors or SubContractors are performing service or

    maintenance on site; they must comply with the BioLab Lockout Tagout

    Policy and Procedure.

    ; A review of the Lockout Tagout Policy and Procedure shall be conducted at

    the Safety Orientation Meeting for any Outside Contractors and Sub-

    Contractors.

    ; All Outside Contractors and Sub-Contractors are responsible for reporting to

    the shift superintendant or Maintenance Manager to obtain their locks.

6.0 SHIFT CHANGE

    ; If servicing or maintenance lasts more than one work shift, Lockout Tagout

    must not be interrupted.

    ; If it is determined that servicing or maintenance is going to last more than one

    shift, a Trade Lock shall be installed. This is to be the first lock installed and

    the last one to be removed on the isolating device.

    ; The Trade Lock shall be installed by the Maintenance Manager or their

    delegate.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 7 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

    ; Information must be recorded in the logbook located in the Maintenance

    Manager’s office.

    ; The Trade Lock may only be removed by the Maintenance

     Manager, their delegate, or a member of the maintenance department.

7.0 PROCEDURE

7.1 PREPARATION FOR THE SHUT DOWN

Notify all Affected Employees and/or the supervisor in the area that a Lockout Tagout

    System is going to be performed and the reason thereof. All Authorized personnel shall know the type and magnitude of energy that the machine or equipment utilizes and the hazards associated.

7.2 SHUT DOWN THE EQUIPMENT

    Use the normal stopping procedure for the equipment being serviced. This may be putting a switch in the “off” position, or pressing a “stop pushbutton”. It may involve a

    more complex operation.

7.3 ISOLATE THE EQUIPMENT

    Carefully isolate the system from every energy source supplying it. Close valves, de-energize main disconnect switches or circuit breakers. It must be noted, the extreme

    importance of practicing the “Left Hand Rule” when de-energizing and especially

    energizing an electrical disconnect switch; standing to the right side of the switch, activate the handle with the left hand while facing away from the switch.

    Disconnect or cap any auxiliary power sources such as secondary electrical, steam, hydraulic, or pneumatic systems, valves, and other energy-isolating devices.

7.4 APPLY LOCKOUT TAGOUT DEVICES

Attach a lock and tag to the energy isolating device to prevent someone from restoring

    the flow of energy. Any personal lock shall be installed and removed only by the owner. The key to the lock shall remain in the possession of the owner at all times. Any Lockout

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 8 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

     Tagout devices i.e. ball valve, circuit breaker, plug lockout device shall be installed at this time.

7.5 CONTROL OF STORED ENERGY

    Relieve, disconnect or restrain any residual hazardous energy that could be present, check that all moving parts have stopped turning, relieve trapped pressure, blank pipe flanges (Confined Space Entry), discharge any electrical capacitors, accumulators, block or support elevated equipment.

7.6 VERIFY ISOLATION OF EQUIPMENT

Ensure that all employees are clear of the Lockout Tagout area. Test to make sure the

    right system has been locked out and cannot be operated, do this by pressing all start buttons or other activating controls, then return them to the “off” position this will

    prevent the equipment from being started by itself when energy is restored. Electrical testing is to be only performed by a licenced electrician, with an approved electrical tester.

7.7 RE-COMMISSIONING OF EQUIPMENT OR MACHINERY

    When work has been completed, be sure the equipment is operationally intact and that tools and other non-essential items are cleared.

    Inform affected employees and/or the supervisor of the area that locks and tags will be removed.

Conduct a head count to be sure that everyone is clear of the area.

Remove Lockout Tagout devices, each worker must remove his or her own lock.

Follow the equipment or machines start up procedure. Perform a test run to ensure it

    functions as planned.

    Notify affected employees and/or the supervisor of the area that the equipment or machine is ready for use.

7.8 LOCK AND TAG REMOVAL

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 9 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

In the event that an employee or contractor has left their lock and tag on an energy

    isolating device, and has left the premises, the following procedure shall be followed and documented.

Ensure the employee or contractor has left the premises.

Attempt to contact the employee or contractor.

    If the employee or contractor is contacted, they shall return to the premises, if practical to remove their lock and tag.

    If the employee or contractor cannot be reached or is unable to return to the premises, the Maintenance Manager or their delegate shall first determine the reason for the Lockout

    Tagout.

Determine the status of the job.

    A thorough inspection of the equipment or machine is to be conducted by the Maintenance Manager or their delegate and all employees who were involved with the Lockout Tagout. This is to determine whether it is safe to remove the lock and tag.

    Once it has been determined that it is safe to remove the lock and tag, that Maintenance Supervisor or their delegate shall complete the Lock and Tag Removal Report and access

     which is to be secured in the Maintenance Manager’s office. the bolt cutter

    The lock and tag shall be removed with a witness present, and the lock and tag secured by the Maintenance Manager or their delegate.

    A special Warning Tag shall be placed at the employee’s time card indicating to the employee that their lock and tag has been removed and to report to their supervisor immediately.

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    BIO-LAB Canada Inc.

    SAFETY POLICY & PROCEDURE

    Distribution: Employees Subject: Lockout-Tagout Procedures

    Effective: September 2002 Page No. 10 of 11

    Revision: 1 Issue : 1 File Under Section: 4:00

LOCKOUT TAGOUT LOCK REMOVAL REPORT

     Department: __________________________Team:

    Employee’s/Contractor’s Name: _____________________

    Machine or Equipment: _________________

    Date Lock and Tag Removed: ____________ Time: ______________

    Reason for Removal of Lock and Tag

    __________________________________________________________________

    __________________________________________________________________

    _____________________________________________

    Was every reasonable attempt made to contact the employee/contractor? Please

    check:

    ______ Verification was made that the employee/contractor was not in the facility.

    ______ An attempt was made to contact the employee/contractor at home.

    ______ The time the employee/contractor was contacted.

    ______ The employee/contractor was given the choice of coming in immediately

    and removing the lock, but refused.

    ______ The employee/contractor could not be reached.

    ______ The reason the lock and tag were installed has been determined

    ______ A status of the work performed has been determined.

    ______ Other employees/contractors working on the machine or equipment have

     been consulted with

    ______ Witness to the lock and tag removal

    Other Comments: _________________________________________

     _________________________________________

    Manager’s Signature: ____________________ Date: ___________

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