| Department | Manufacturing | Document no | MAN-050 | ||
| Prepared by: | Date: | Supersedes: | |||
| Checked by: | Date: | Date Issued: | |||
| Approved by: | Date: | Review Date: | |||
Document Owner
Operations Manager
Affected Parties
All operation’s colleagues
Purpose
To prevent the risk of personal injury, or damage to equipment likely to be caused by operating or attempting to operate machinery or equipment diagnosed as being unsafe, in need of repair or maintenance, or formally removed from service.
Scope
The SOP covers all isolation, condemning, repair or maintenance work that necessitates a device or machine to be taken out of service.
This SOP applies to any situation where energy (either supplied to equipment, or stored within it) needs to be isolated to ensure the safety of any person working on or near equipment, processes or services – for any reason whatsoever. This SOP applies to Sydco Employees, Contractors, Sub-contractors, and External Service personnel.
Definition
| “Do Not Operate” Tag | A tag stating: “DO NOT OPERATE”, which details who has temporarily isolated equipment, processes, or devices, in order to work upon such equipment, processes, or devices. See Diagram 1. |
| “Out of Order” Tag | A tag stating: “OUT OF ORDER”, which details who has permanently isolated equipment, processes, or devices, pending removal. See Diagram 2. This tag may only be affixed with the approval of the Engineering Manager. |
| Disconnect | Physical separation of components to introduce an air gap break & positively prevent flow through a system. |
| Isolate | Blocking a flow path to prevent flow through a system e.g. Closing a valve. |
| Isolating Device | The particular valve, switch or circuit breaker that isolates either stored or supplied energy from the work area. |
| Initiator | A person requesting repairs or maintenance to an item of machinery or plant. |
| Tradesperson | The suitably experienced holder of a Trade Certificate |
| “Removing” tags | Focuses on removal of the procedural control that prevents a machine from being re-energised – whether the tag is physically removed or not. |
| Locking Device | A of series devices that allow padlocks to positively isolate items, such as circuit breakers, etc. |
Related Documents
| VD-035 | Out Of Order Tag |
| VD-030 | Do Not Operate |
| MAN-125 | Permit to Work |
EHS Statement
“Do Not Operate” or “Out of Order” tags are to be fitted by personnel performing isolations in ANY and ALL situations where the isolation of a service or device is required in order to protect against physical, mechanical, electrical, chemical, or otherwise harmful substances, processes or events.
Where padlocks are not used, “Do Not Operate” and “Out of Order” tags are a procedural control and are therefore only as effective as the respect they are given. Anyone ignoring tags, or removing another’s tag without the correct authorisation may be putting lives in danger – and could be summarily dismissed from the Company.
Procedure
1. Circumstances where “Do Not Operate” Tags should be used
“DO NOT OPERATE” TAGS are to be placed on equipment which is:
a) To be isolated for any reason and shall be attached to the ISOLATING DEVICE(S). The correct use of “Do Not Operate” (VD-030) tags will ensure the safety of both the personnel and the equipment.
b) One “Do Not Operate” Tag is required FOR EACH PERSON who is working on the isolated equipment, process or device, ie if the work requires 3 people there will be 3 tags attached to the isolating device(s).
c) Padlocks and Locking Devices shall accompany “Do Not Operate” tags when the isolation is Electrical.
2.1. If a machine must be shut down and taken off line due to a safety or other high priority problem, then it should be stopped, isolated at the main switch/valve and by the initiator immediately – DO NOT wait for a tradesperson. Upon hand over to Maintenance, the tradesperson shall place their own tags and the initiator will then remove theirs. The changeover of tags MUST be performed with both people present so the machine IS NOT left untagged at any time.
If the machine is being isolated for routine work to be performed, then the machine is to be isolated by the maintenance tradesperson after hand over from Production.
2.2. Review SOP MAN-130 in conjunction with this SOP to determine if a ‘Permit To Work’ is also required.
Note: If a ‘Permit To Work’ is necessary, both SOP MAN-130 & this SOP must be adhered to.
2.3. Primary isolation and tagging is to be done on the main isolating device and any high risk service isolation, i.e. Electrical isolator, steam supply valve. In the case of Electrical isolations, the isolating device shall be physically disabled by the Danger Tag and Padlock plus Locking Device.
2.4. Secondary isolation and tagging shall isolate any and all sources of energy that pose a hazard to the task being performed. Examples include, but are not limited to:
Electricity, steam, compressed air, hydraulic systems, pressurised lines, etc.
2.5. If portable equipment, plugged into an outlet needs to be isolated, unplug the machine and Tag / Lock off the supply lead. Plug locks are available from Electrical department.
2.6. “Do Not Operate” Tags shall be filled in and attached by the person performing each isolation. Information shall include the name of the individual to whom the Tag belongs, their contact phone number, their department or Contracting Company name, the date and time. A description of the isolation, e.g. “Main Electrical Isolation”, “Compressed Air Isolation”, shall be noted on the tag.
2.7. A completed ”Do Not Operate” tag should be firmly attached to each isolation device – in a readily visible position. Tags should be placed as isolations are performed.
2.8. The tradesperson is not to remove the “Do Not Operate” Tags / Lock until the task has been completed and the specific isolation is safe to return to service. Note the following:
2.8.1. If it is necessary to restore motive power to the machine to effect repairs or to test, the repairer must have the Tags / Locks of other personnel removed by those personnel, ensuring their own Tag/s or Locks remain in place, and accept the responsibility to ensure that the operation is carried-out safely.
2.8.2. In instances where a new shift or changeover of personnel occurs during an ongoing repair, the tradesmen must perform a verbal hand over detailing the status of the job and any special circumstances that exist. The tradesperson starting work on the job will then place their own Tags / Locks, and the outgoing tradesperson will then remove their Tags / Locks. The changeover of Tags / Locks, MUST be performed ON THE JOB with the both people/groups present so the machine IS NOT left untagged at any time.
2.8.3. It is essential that Tags / Locks are only removed by the person who applied them to the equipment. Under exceptional circumstances the Engineering Services Manager, or his delegate, may remove another person’s Tag / Lock after positively identifying that the owner is not on the premises, or for some other reason is physically incapable of removing their own Tag / Lock. The Engineering Services Manager, or his delegate, must thoroughly investigate the original reason for the Tag / Lock and ensure that it has been made good. The Engineering Services Manager may then assume full responsibility for any ramifications; then he (or his delegate) may remove the Tag / Lock.
2.8.4. Should a Tag / Lock need to be removed from an isolating device while the person who placed them is not on site, the Engineering Manager is to be immediately notified. The Engineering Manager may recall the individual to remove the Tag / Lock, or remove it himself as in 2.8.3 above.
Note: The Engineering Manager holds a Master key for all Padlocks for this purpose.
2.8.5. In the event that there are multiple Tags / Locks, indicating more than one person is involved in the task each person may only remove THEIR OWN Tag / Lock.
2.8.6. Information pertaining to the isolation must only be written on the Tag – use more than one tag if necessary. Information informally written on a wall or on the face of the equipment, etc. is not permitted.
3. Circumstances where “Out of Order” Tags should be used
“Out of Order” (VD-035) tags are to be placed on equipment which has the approval of the Engineering Manager to be removed from the site.
4.1. Seek approval to permanently tag an item out of order from the Engineering Manager. The Engineering Manager will determine the appropriate course of action and record the details of the application and system. The Engineering Manager will then grant authority to place the Tag/s.
4.2. Prior to “Out of Order” tagging the actual piece of equipment, all sources of supplied energy to that piece of equipment are to be physically disconnected at the source.
4.3. NOTE – Any disconnections must be carried out as per normal safe working practice, which may include the use of “Do Not Operate” tags.
4.4. After disconnecting supplied energy, any stored energy within the piece of equipment is to be discharged and rechecked.
4.5. Prior to physical removal of the actual piece of equipment, the disconnections are to be checked and verified as safe by the person who placed the “Out of Order” tag or other suitably qualified person as designated by the Engineering Manager.
4.6. Upon removal notify the Engineering Manager that the equipment has been physically removed. The Engineering Manager is to ensure that the Asset Register, drawings etc are updated to reflect the removal.
| Version # | Revision History |
| MAN-050 | New. |