I-D-03.00SOSOPage 1of 24
Rev # 22
SAFETY / SOSO / Current Issue: 07/28/15Revision: 22
By: P. R. Daigle
Verified by:___
Date:______ / LOCK-OUT ELECTRICAL AND MECHANICAL
Date Reviewed:
07/28/15
/ I-D-03.00 Page 1 of 24 / Original Issue: 03/22/82Originator: P. R. Daigle
STATEMENT OF PROCEDURE:
This procedure provides a uniform electrical and mechanical lock-out method which must be followed in order to avoid accidents. This procedure also establishes a standardized method for identifying and tagging of equipment, lines, or vessels for maintenance and to insure the safety of personnel during repairs. It is the intent of this procedure that all equipment changed from its normal operating condition is to be tagged and listed on a Master Clearance Card. An exception is equipment within the immediate continuous control of an individual. Immediate continuous control is defined further in the procedure. The MCC is a communications tool and all changes in status of the equipment must be so written on the MCC and communicated to all personnel involved. Failure to follow this procedure increases the potential for injury, release of toxic and/or flammable chemicals, or electrical shock hazard. This procedure does not eliminate the need for HOT WORK or CONFINED SPACE ENTRY PERMITS.
No procedure can be written which will cover all possibilities. Cases not specifically covered should be handled along the same lines of thought as expressed in this document, keeping in mind that safety of personnel is a prime factor in each of our jobs. This procedure supplements and does not replace present safe practices for isolating by blinding, disconnecting, etc.
Simplified Lock Out Process Flow:
- Production prepares equipment.
- All locks and tags are attached to equipment and noted on MCC.
- Equipment lock-out key carsealed to the board.
- Work group representative places their lock on the lockout board securing the Production equipment lock-out key and signs on to individual lock installed block.
- Production verifies MCC with work group representative.
- Both Production and work group representative initial off oneach lockout verification blank.
- Shift manager or designee signs on to approval to begin work.
- Production gives work group lock box.
- Work group signs onto appropriate work group block, e.g., blanking, deblanking and locks onto the lock box.
- Permit To Work
- Work can now begin.
- Work complete –work group representative removes locks from board and signs off the card. Work Group representative returns lockbox to Production.
- Shift manager or designee signs off operations acceptance of work.
- Production clears card.
- Supervisor to initial to detag.
- Production returns equipment to service.
Detailed Lock Out Procedure
Electrical Circuits
Definitions
Immediate Continuous Control
When Is a P&ID Required?
What Do I Do If I Misplace a MCC?
Electronic & Pre-made MCC’s
Routine
Responsibilities
Contractor Oversight
Where Lock Out is Required
Mechanical Equipment
Piping Systems
Electrical Systems
Responsibilities
Process Technician
Operations
Maintenance
I&E
Pre-hanging
Master Clearance Cards
MCC Section 1
MCC – Signing On and Off
Sign On Sequence
Safety Device Defeated
Car Seal Replaced and Logged
Sign On By Workers
Sign Off By Workers
Production Approval to Begin Work
Supervisor’s Acceptance of Work
Supervisor’s Acceptance to Detag
Temporaries
Specials
Lock Specifications
Nitrogen Drops
Definitions:
Immediate Continuous Control - What is intended by immediate continuous control is to exempt low hazard items such as, air conditioning repairs, transmitter calibration, etc. The equipment must be able to be returned to service when the technician leaves it, otherwise a MCC is required. The employee must be within 6 feet and within visual range of all isolation points. The employee performing the work must be in control of all energy isolation points.
When is a P&ID required? - To aid in identifying the energy sources that will require isolation, a P&ID of the involved system should be used for reference. A P&ID must be used and attached to the Master Clearance card if the particular piece of equipment or system that is to be locked, 1) does not have a pre-made MCC, spelled out/listed in SOP, or a pre-planned and prepared MCC package pertaining to it. 2) if the pre-made MCC is revised (additions or strikeouts). In using the P&ID, the energy isolation points are to be highlighted to pin point the locations and these locations should then match what will be listed on the MCC.
In some cases, a particular piece of equipment or system may have a computer file MCC, but the particular scope of work may extend outside of this existing MCC. In this situation, for the energy sources outside of the existing MCC a P&ID is to be used for the identification of these sources and attached to the MCC. In some cases several P&ID’s may have to be used and attached to the MCC if the system being isolated is large.
What do I do if I misplace a MCC card? - If an MCC is lost, a complete new card will be made covering all tags involved in the clearance, and the appropriate comments made on the card to indicate it is a replacement for a lost card. The replacement card must then be signed by Department Heads of all crews involved in clearance. Only after these steps are complete, can work continue.
Electronic Pre-Made Master Clearance Cards- Each piece of equipment has a pre-made MCC card that dictates the level of lock out required to safe the equipment out. The pre-made MCC is based on a risk assessment to identify proper energy isolation including specific blanking for each piece of equipment. If an electronic copy pre-made MCC must be modified, prior approval must be obtained from the shift manager (or step-up). Field verification will be performed if deemed necessary. The shift manager will initial off all changes/additions made to a pre-made MCC. Any modifications to the pre-made MCC will need to also be approved by the Day Manager over the area in which the equipment is located.
Modifications that need to be a standard part of the electronic copy pre-made MCC should be submitted to the Controlling Secretary through the Day Shift Manager of that area for updating of the master document.
If an electronic copy pre-made MCC is not on file or a lock-out tag-out procedure is not available, the shift manager or step-up must walk the card through in the field with a senior technician trained in the area in which the MCC is being written. The walk-through should include the P&ID with isolation points highlighted. The shift manager or step-up needs to verify the valve position listed on the MCC is appropriate for isolation. These requirements are included in the shift manager or step-ups signature for approval to begin work.
Routine – Means task has been performed within the last 30 days.
Responsibilities - For the purpose of this procedure, I&E Technicians are considered Process Technicians and Supervisors/Coordinators are considered Shift Managers. Master Clearance Cards can be filled out by the responsible Green Lake Company party over a particular area. Maintenance personnel can be referring to non-resident contractors.
Process Technicians:
It is recognized that in some areas the "Operation Department" will mean Maintenance, such as I&E in the shop areas.
Preparation of Equipment for Maintenance
This includes washing, steaming, cleaning, properly tagging and locking out, and listing all appropriate information on the MCC.
Consideration must be given for all energy sources including heat tracing systems.
Properly fill out the Master Clearance Card listing all "Danger Tags" and information required.
Must know and understand the full scope of the job through discussions with the Shift Manager, technical staff, maintenance personnel, and reading daily notes or SOSO's.
Check the work activities frequently for changes in conditions that may require new atmospheric testing, different protective equipment, or even stopping the work immediately when conditions do not allow the job to proceed safely.
As a part of the clearing process, the Process Technician will take high point readings and low point readings for the system they are locking out. Readings taken as a part of the clearing process will be documented on the reading sheet as referenced in SOSO I-D-04.90 Atmospheric Monitoring. If the system is drafting, testing the high point will ensure that a representative sample of the atmosphere internal to the vessel is tested.
When opening bleeds after steaming, the Process Technician should test the open bleed with a piece of flagging tape. If the flagging tape is being pulled toward the bleed, this could indicate the system is under a vacuum. If there is an indication the system is under vacuum stop the job. Additional resources will be needed to troubleshoot. A representative from Production management will need to be involved in the troubleshooting process.
In the process of clearing equipment, if the results of the high point and low point readings are not what is anticipated this is a job stop. Additional troubleshooting will be required to determine if there is an issue with the lock out or more clearing is needed.
If a Process Technician has to deviate from normal clearing practices this is a job stop.
IMPORTANT Be absolutely certain that all electrical switch gear is locked out in the "off position" and that the local start/stop switch has been tried to assure the rotating equipment's power is off. The stop button should always be pushed last to insure electrical equipment is de-energized.
Operations:
The Shift Manager is responsible for the following items. He/she may choose to delegate his/her authority in justified cases by designating a process technician to sign for him/her.
Production is responsible for all operating equipment in their respective areas.
To ensure that the equipment is properly prepared and made safe for maintenance to work on.
To be sure the MCC is properly completed with all the necessary information listed.
To be sure maintenance work does not start until the equipment is properly prepared and verified, that all details of the job are discussed and understood by all parties involved, the MCC is properly signed and that maintenance has physically been shown the equipment to be worked on. The verification step requires Production and Maintenance to check all energy sources for isolation and de-energization. This step includes checking to see that all hoses connected to energy sources, such as steam, nitrogen, etc., have been disconnected from the equipment. For work which involves contact with electrical circuits SOSO I-D-05.80, Electrical Safety-Related Work Practices, must be followed. Some work will require the placement of numbered electrical verification tags. Once these tags are applied they will be recorded on the MCC along with other "DO NOT OPERATE" tags.
To verify the maintenance work progress is checked frequently to be sure it is proceeding safely and that conditions have not changed that would create unsafe working conditions.
To initiate action to notify second level supervision and/or Safety Department personnel when difficulties develop that indicate a deficiency in the MCC procedure.
Maintenance:
The Maintenance Supervisor or his/her designated representative is responsible for:
The maintenance supervisor in charge of off site or non operating assigned areas will issue their own MCCs and be responsible for the task involved. In all cases the area supervisor for the area where the new equipment will be installed will be notified of the task.
To assure that all equipment is properly cleaned, prepared, and isolated for repairs.
To be certain danger tags and locks have been placed on the equipment by Operations. This means a field verification with operation personnel of the lockout prior to beginning work. The verification step requires that all energy sources be checked for isolation and de-energization. This step includes checking to see that all hoses connected to energy sources, such as steam, nitrogen, etc., have been disconnected from the equipment. This walk through must be done by the first work group reporting to work on a job. Subsequent work groups as a minimum must verify the lockout is still intact by reviewing the MCC and checking the car seal on the lockout board.
To review the MCC to be sure all necessary information is listed and discuss all details of the job with the Production representative.
To sign on the MCC indicating "work can begin" and sign off when the work and housekeeping are complete. Closely review the job to be sure all is repaired and ready to return to normal service.
To have a work group lock on the lockout board anytime the work group has someone physically working on a job requiring lockout.
Issue lock boxes to work groups that require them. Small work groups (3 or less) may lock directly onto the board.
To monitor the progress of the job to be sure
it is proceeding safely and that conditions have not changed to create unsafe working conditions.
To be aware of "Special Conditions" that may require working especially close with Operations to temporary release and even doing adjustments on equipment in service, but not under the conditions of a MCC.
Instrument & Electrical (I&E)
I&E shall be responsible for:
Completing all master clearance cards which are required for work only on plant electrical power distribution equipment rated 480 volts and above.
Performing all switching required to de-energize sections of the plant electrical power distribution system rated 480 volts and above. REFERENCE I&E SWITCHING PROCEDURES.
Establishing an electrical safe work condition for any exposed energized electrical conductors or equipment before an employee works on or near them. An electrical safe work condition may only be established by two qualified employees who are trained in and familiar with the hazards involved with working on or near electrical conductors or equipment.
An electrically safe work condition will be achieved and verified by the following process:
Determine all possible sources of electrical supply to the specific conductors or equipment. Check applicable up-to-date drawings, diagrams, and identification tags.
Interrupt load current using a circuit breaker or switching device capable of breaking load currents, and open any other disconnect device(s) for each source. REFERENCE I&E SWITCHING PROCEDURES.
Where it is possible, visually verify that all blades of the disconnecting devices are fully open or that drawout type circuit breakers are withdrawn to the fully disconnected position.
Apply lockout/tagout devices in accordance with Lock-Out Electrical and Mechanical as defined in this procedure.
Use an adequately rated voltage detector to test each phase conductor or circuit part to verify that they are de-energized. Before and after each test verify that the voltage detector is operating satisfactorily.
Ground the phase conductors or circuit parts before making bare-handed contact. Where it could be reasonably anticipated that the conductors or circuit parts being de-energized could contact other exposed energized conductors or circuit parts, apply ground connecting devices rated for the available fault duty.
After all electrical conductors and/or equipment located inside an enclosure, which requires an authorization tag to open, have been de-energized and placed in an electrically safe work condition attach an "Authorization to Open Tag" to the outside of the enclosure. If all electrical conductors and/or equipment located inside an enclosure which requires an authorization tag to open, cannot be de-energized and placed in an electrically safe work condition attach a special "Authorization to Open Tag" to the outside of the enclosure. The special "Authorization to Open Tag" shall provide a caution note to indicate that energized electrical conductors and/or equipment are located inside of the enclosure where the tag is placed.
Document the installation of all "Authorization to Open Tags" on the backside of the Master Clearance Card.
Tag No. - "Authorization to Open Tag" number.
Location - Location of electrical equipment enclosure where "Authorization to Open Tag" is placed and associated equipment numbers.
Tags On/Off - The person placing the "Authorization to Open Tag" on the enclosure must initial for each tag put on or removed from an enclosure. In other words, initial to indicate a tag has been put on an enclosure, and initial to indicate a tag has been removed.
When work must be performed on or near electrical conductors and/or equipment which cannot be placed in an electrically safe work condition, the work shall be performed in accordance with SOSO I-D-05.80, Electrical Safety-Related Work Practices.
Contractor Oversight - To ensure contractor proficiency with the MCC process, the Green Lake Company coordinator (or their designee) must accompany the contractor through the actual physical process (signing onto a card, hanging their locks on the board, use of lock boxes, verification, signing off, etc) until they are satisfied the contractor understands the process.
1.Where Lock-Out is Required:
(a)Mechanical Equipment:
Equipment where the release of mechanical energy will create a hazard or cause harm must be locked out, or otherwise protected against accidental or inadvertent movement when such motion could cause injury to personnel or damage to equipment. Both the driving and the driven-end shall be considered in the search for possible sources of motion. This includes all machinery regardless of the source of power. Immobilization is required in addition to lock-out if movement (i.e. hydraulic equipment) is a potential hazard.
(b)Piping Systems:
All valves isolating a piping system to be worked on must be locked in the appropriate position.
All piping systems are to be made safe against accidental or inadvertent release or contamination before an opening is made in them.
Each job shall be considered individually to determine the best protection and method to be used on the job involved. The best method is the safe method.