BACKGROUND
Persons require protection from unintended release of energy or machine motion that could cause injury during set up, adjustment, repair, service, installation, or maintenance work on equipment, machinery or processes. Hence, safe job procedures are essential to provide information and guidelines necessary to assist all persons, contractors & other stakeholders to perform their tasks safely.
These procedures will also assist in providing training & orientation to new staff in the hazards of the tasks performed, as well as provide them with the rules necessary to ensure safe work practice.
SCOPE
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s guideline applies to all cement manufacturing units, RMX, aggregates and service units involved in service and maintenance of machines and equipment in which the unexpected energizing or startup or release of stored energy could cause injury to personnel.DEFINITIONS
Affected Person – A person whose job requires him/her to operate or use equipment on which service or maintenance is being performed, or whose job requires them to work in an area where such service is being performed.
Authorized Person – A person who locks or implements a lockout/ tag-out procedure on equipment or processes to perform maintenance or service.
Contractor – A firm or person employed under a contract to provide services to ACC as distinct from a contract of employment.
Energy-Isolating Devices – A physical device that prevents the transmission or release of energy including but not limited to the following:
• A manually operated electrical circuit breaker,
• Disconnect switch,
• Manually operated switch,
• Slide gate,
• Slip blind,
• Line valve
• Similar devices used to block or isolate energy.
Note: push buttons, selector switches, and other control circuit type devices are not energy isolating devices.
Energy Sources –
Energy is defined as movement or the possibility of movement. Potential energy sources are:
• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Chemical
• Thermal and
• Gravitational
High Voltage Electrical Equipment –
Equipment used for power transmission and distribution using power between 11KV to 66 KV.
• Low Voltage - 1.1 KV
• Medium Voltage - 1.1 KV to 11 KV
• High Voltage - 11KV to 66 KV
• Extra High Voltage - more than 66 KV
Lockout Device –
A device that uses a lock and key to hold an energy isolating device in a safe position and prevent the inadvertent energizing of equipment for the purpose of protecting personnel.
Tag-out Device –
A prominent warning device capable of being securely attached, which forbids the operation of an energy-isolating device, for the purpose of protecting personnel. The tag shall indicate the name of the authorized person, the affected equipment or installation of the equipment, the date, the reason for tag-out and the estimated duration of downtime.
Qualified Person –
Those who have had training/license as per provisions of Indian Electricity Act, 1920 and Indian Electricity Rules, 1956 in avoiding electrical shock and are permitted to work on or near exposed energized electrical parts or to test circuits because they are familiar with the operation of the equipment and the hazards involved.
Service and/or Maintenance –
Workplace activities such as construction, installation, set up, adjustment, inspection, modification, maintenance and/or service of machines or equipment. These activities include lubricating, cleaning or un-jamming machines or equipment and making adjustments or tool changes, where a person may be exposed to the unexpected energizing or start-up of the equipment or release of hazardous energy.
ROLES & RESPONSIBILITIES
Plant Head and Department Heads:
The responsibility for implementation of these guidelines rests with Plant Heads/ Departmental Heads. An environment where Line Managers/ supervisors and other personnel are encouraged to follow this Guideline must be ensured. It is expected that Departmental Heads will provide advice and feedback to Plant Heads on action needed to comply with these guidelines.
Departments Hiring Contractors must ensure that contractors comply with all applicable state regulations and contract specifications. Inform contractors about Lockout/Tag-out procedures wherever appropriate.
Line Managers/ Supervisors
The line Managers/ Supervisors shall train employees on the specific equipment they will be working with and how to properly de-energized and lock it out. Provide employees with locks, tags and other equipment necessary under this Guideline. Conduct inspections periodically to assure that the procedures outlined below are properly implemented.
Departments Hiring Contractors must ensure that contractors comply with all applicable state regulations and contract specifications. Inform contractors about Lockout/Tag-out procedures wherever appropriate.
Employees
Employees shall follow the procedures outlined in this Guideline whenever servicing or maintaining machines or equipment. Conduct assigned tasks in a safe manner, wear appropriate personal protective equipment and only use equipment for which they have been formally trained. Report any job-related injuries or illnesses, questions on health and safety, or any unsafe or unhealthy work conditions to their Line Managers/ supervisor.
PROCEDURES
1. GENERAL REQUIREMENTS
1. General
Procedures should be developed, documented, and utilized for the control of potentially hazardous energy when personal service and maintain machines and equipment. The goal is to give the person a clear understanding and exclusive control over the energy sources so that accidental startup cannot occur. This Guideline provides the basis of required procedures but must be supplemented with departmental procedures for each specific machine or equipment, unless the EXCEPTION below is met.
EXCEPTION: Persons are not required to document procedures for a particular machine or piece of equipment when all of the following elements exist:
1. The machine/equipment has no potential for stored energy or accumulation of stored energy after shutdown, which would endanger employees.
2. Isolating and locking out the energy source will completely de-energize the machine/equipment.
3. The machine/equipment is isolated from the energy source and is locked out during service or maintenance.
4. A single lockout device will achieve a locked out condition.
5. The lockout device is under the exclusive control of the authorized person performing the service or maintenance.
6. The service or maintenance does not create hazards for other persons.
7. There have been no previous accidents involving the unexpected activation or re-energizing the machine/ equipment being locked out/ tagged out during service or maintenance using this exception.
Shutdown Procedure:
1. Notify any affected person(s), supervisor(s) and line manager(s) of the affected areas before any piece of equipment or machine is shut down. Advance notice of the shutdown must be given to the affected person(s).
2. Have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the correct lockout/tag-out procedures, before shutting down a machine or piece of equipment.
3. Shut down the machine/equipment using the sequence of steps established for that piece of equipment. An orderly shutdown must be followed to avoid adding or increasing the hazards of equipment stoppage. Make sure that all energy-isolating devices (switches, circuit breakers, etc.) have been located and turned off or shut down.
Locking and/or Tagging:
1. The appropriate lockout/tag-out devices are applied to the equipment by each authorized person working on the equipment or process.
The authorized person must use lockout devices unless the supervisor approves and can demonstrate that de-energizing introduces additional or increased hazards, or is not feasible due to equipment design or operational limitations.
In this case, attach the tag to the same location that a locking device would have been attached. Where feasible, supplement each tag with additional safety measures, such as isolating circuit elements, blocking control switches, opening extra disconnect devices, or opening or closing a valve. Also, refer to paragraph D below.
Lockout devices must meet the following:
• Hold the energy isolating device in a safe or “off” position;
• Be standardized in color, shape, or size;
• Be substantial enough to prevent removal without the use of excessive force (e.g., bolt cutters); a
• Be accompanied by a tag-out device that identifies the employee applying the device.
Tagging devices:
When only tag-out devices are used, all affected persons will be trained on the following topics:
• The limitations of tags
• That a tag is not to be removed without consent of the person who attached it
• That a tag-out device is never to be bypassed, ignored, or otherwise defeated.
2. Tags must be legible and understandable and attached in a manner that will clearly indicate the safe or “off” position.
3. Tags and their means of attachment must be made of materials which will withstand the environmental conditions of the workplace.
4. Tags must be securely attached to energy isolating devices so that they cannot be inadvertently or accidentally detached during use.
1. The release of stored energy and verification of de-energizing:
1. Following the application of lockout/tag-out devices, all potentially hazardous stored or residual energy will be relieved, released, disconnected, or otherwise rendered safe. The machine or equipment should be at a zero energy state.
2. Prior to working on equipment that has been locked or tagged out, verify isolation and de-energizing of that machine by trying to start the equipment.
1. Lockout/Tag-out Device Removal:
1. Before lockout/tag-out devices are removed:
2. Remove all non-essential items such as tools and materials from the work area.
3. Check that equipment/machine components are operationally intact.
4. Ensure that all persons are at a safe distance from the affected machine or equipment.
5. Notify affected persons, supervisor(s) and line manager(s) that equipment/machine/processes are going to have the lockout/tag-out devices removed.
2. Only the authorized person(s) who placed the lock and tag on the machine or equipment will remove it.
EXCEPTION: If the authorized person(s) that applied the lockout/tag-out device to the machine or equipment is not available to remove the lock/tag, the authorized person’s supervisor may remove the lockout/ tag-out device after:
1. Verifying that the authorized person is not at the facility;
2. Making all reasonable efforts to contact the authorized person to inform them that their lockout/ tag-out device is going to be removed; and
3. Ensuring that the authorized person(s) who applied the device will be properly informed that the lockout/ tag-out has been removed, upon returning to work.
4. Verifying that all persons working on the system/equipment are safely accounted for.
SPECIAL REQUIREMENTS
Group Lockout/Tag-out
1. When service or maintenance on a machine or equipment will be conducted by more than one person, then group lockout/tag-out devices will be used to provide protection to all authorized persons. Each authorized person must have their own individual device as part of the group lockout/ tag-out device. Locks will be applied to prevent the machine/equipment from being re-energized until all the individual lockout/ tag-out devices of each authorized person have been removed.
2. One of the authorized persons will be assigned primary responsibility for the entire group’s lockout/tag-out protection.
3. The authorized person with primary responsibility shall be able to ascertain the exposure status of each individual authorized person within the group, with regard to the locked out/tagged out equipment/machine. When more than one group of authorized persons are working on a machine or equipment, the authorized person with primary responsibility must be able to coordinate between groups and ensure the continuity of protection for all authorized persons in each group.
Shift or Personnel Changes
When work on a locked out/tagged out machine or equipment continues through a change in authorized persons servicing and/or maintaining the machine or equipment, the authorized persons continuing to service or maintain the machine or equipment will apply their lockout/tag-out devices prior to the removal of the lockout/ tag-out devices of the authorized persons ending their work. At no time will all lockout/ tag-out devices be removed from a machine or equipment without first implementing the removal procedures listed above.
Electrical Equipment
1. Energized sources to which an employee may be exposed shall be de-energized before the person works on or near them. Energized parts that operate at less than 50 volts to the ground do not need to be de-energized; if there will be no increased exposure to electrical burns or to explosion due to electric arcs.
2. Only qualified persons are permitted to work on energized circuits/equipment. They must be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools. When work involves electrical equipment that could permit exposure to 440 volts or greater, 2 qualified persons must work together.
3. When de-energizing electrical devices, the qualified person conducting the work will:
1. Place lockout/ tag-out devices on the disconnecting means used to de-energize the equipment and circuits.
2. Test the circuit or equipment to ensure it is de-energized and that no energized condition exists as a result of feedback.
3. Before re-energizing, the qualified person will ensure that all lockout removal procedures have been followed and that equipment-guarding panels are installed, prior to removal of lockout/tag-out devices.
High Voltage Equipment
In addition to the requirements in section C above, the following steps must be taken when isolating high voltage electrical equipment:
1. The high voltage qualified person shall write a step-by-step switching order.
EXCEPTION: The switching order may be written by the high voltage supervisor or omitted in the event of an emergency.
2. No one other than a high voltage qualified person will lockout/ tag-out or energize primary equipment, or remove lockout/ tag-out devices, up to and including secondary mains.
EXCEPTION: The high voltage supervisor may remove lockout/ tag-out devices and restore power after a thorough inspection is made to ensure that no one will be exposed to hazardous energy when power is restored.
3. All high voltage switching shall be performed by at least two (2) high voltage qualified person or one of the following:
1. One (1) high voltage qualified person and their supervisor;
2. One (1) high voltage qualified person and one (1) non-high voltage qualified person under direct supervision of a high voltage supervisor; or
3. In the case of secondary main shutdowns, one (1) high voltage qualified person and one (1) non-high voltage qualified a person.
Compressed Gases or Air:
1. Compressed gas pressure systems are required to be locked out/tagged out if pressures could result in unexpected movement of the equipment or components.
2. Equipment using air or other compressed gas must be equipped with a mainline shut off valve capable of being locked out or tagged out in the "off" position.
3. Unless the compressed gas valve allows pressure release, a portion of the pipe shall be disconnected from the flange portion to allow pressure release if the trapped energy could create a possible hazard.
4. Sliding dummy plates must be placed in the pipeline at the flange portion after main shut off valve is in “off” position and after releasing the trapped energy.
5. All compressed gas lines will be labeled.
Hydraulic Energy
Equipment using hydraulic pressure shall be locked out by placing the hydraulic pump motor electrical disconnect switch in "OFF" position and applying a lockout/ tag-out device to the disconnect switch. Bleed off residual pressure in the piping system and block using dummy plate at the flange portion.
Gravity and Stored Energy
1. Regardless of the lockout/ tag-out procedure used, safety blocks or mechanical devices will be used to protect persons from any accidental equipment movement.
2. Bleed off, or otherwise dissipate, residual pressure in steam, air, gas, electrical, mechanical, and/or hydraulic systems.
OUTSIDE CONTRACTORS
Whenever outside contractors plan to engage in activities covered by the scope of this Guideline, the company representative, and the outside contractor will sit together to understand the lockout/ tag-out procedures for the job. They will both ensure their personnel understand and comply with any restrictions and prohibitions of the energy control procedures to be used. It can also be done during induction program.
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