MAINTENANCE PROCEDURE

Lock Outs are required under the Occupational Health & Safety Act. Lock Out procedures are to be strictly adhered to when maintenance work is being performed on a machine or equipment at ABC Limited. The use of correct lock out procedures can prevent fatalities and serious injuries which may occur where maintenance work is being completed, and a source of power could inadvertently be turned on, valves in pipelines opened etc.

GENERAL MAINTENANCE PROCEDURE:

1) A Maintenance Personal will then Lock Out the Machine or equipment being worked on utilizing the Lock Out Procedure, The Maintenance Department will retain a copy of the Maintenance Procedure and General Maintenance and repair of machines or equipment.

2) All Maintenance Personal will then lock out the machine or equipment being worked on utilizing the lock out procedure. The Maintenance department will retain a copy of the maintenance procedure and the lock out procedure and will be required to utilize during general maintenance and repair of machines or equipment.

3) The machine Operator will be assigned alternate work, by their supervisor until the work is completed on the machine or equipment; this measure is to ensure the safety of the operator and all other personal that could be injured due to exposure to hazard.

4) All maintenance personal when working on equipment or machinery will cordon off the area and place a sign up identifying that maintenance work is being done in this area. This will warn all employees of hazards, which may exist but to work being performed on the equipment.

5) All maintenance personal will notify the Supervisor when the work is completed. The Supervisor will notify the operator that it is safe to return to their work area and begin working on their machine or equipment.

6) All Maintenance Personal will ensure the lock has been removed and the equipment, machine and areas are safe for the operator to begin working. GENERAL PROCEDURE FOR PADLOCK LOCKOUT SYSTEMS:

1) Use, sturdy key-operated padlocks.

2) All maintenance personal will be insured a lock with their name and clock number stamped on it, or a tag with their name and clock number will be placed on a tag and attached to the lock. Each maintenance personal member will be issued a key for their lock. If spare keys are kept then they will be secured in a locked cabinet or other secure place.

LOCKOUT PROCEDURES MUST BE USED TO LOCK OUT THE POWER TO:

Electricity, Steam, Air, Hydraulic, Spring, and also for entry into a Confined Space.

ELECTRICAL LOCKOUT:

All electrical lockouts must be completed by a designated, qualified person, to ensure electrical lockout, lock the correct disconnect switch in the off position. Where possible remove the fuses. All fuses are pulled with a proper fuse puller. Some equipment has built-in locks. Where there are no such locks, the padlock lockout procedure must be utilized, and all lockouts should be properly tagged.

PROCEDURE:

1) The machine to be locked out is designated, and the supervisor and the operator are alerted.

2) Turn off the point of operation switch.

3) Turn off the main disconnect switch for the machine, or equipment. Where possible open the disconnect box to make sure that all connectors are disengaged. Take out the fused where applicable, using approved fuse pullers. The disconnect switch should be operated with the left hand, with the body to the right of the switch and with the face averted or turned away from the switch.

4) The lock of the person doing the work should be placed on the disconnect switch first and be removed last.

5) Once the padlock is on the disconnect switch to make sure that it cannot be moved.

6) Test the disconnect switch to make sure that it cannot be moved.

7) When the work is finished, tell the supervisor and the operator before the power turned on and Make sure that the pint of operation switch is in the: OFF" position so that the disconnect switch Will be turned on under "No Load". 8) Remove the locks and tag from the disconnect switch.

9) The machine should be locked out at the point of operation, with the use of switches, attachments, enclosures over the switch brackets etc.

STEAM, AIR, GAS AND HYDRAULIC LOCKOUT: Steam, air, gas and hydraulic power can be locked out by chains attached to the valves, valves with built-in lockout devices, or by designing special attachments for the valves.

Pneumatic or hydraulic pressure between the locked out valve and the machine must be reduce to zero to eliminate the possibility of the machine cycling, The pressured should be released slowly, through the bleed-off valve, to avoid injury. This should be part of the lockout procedure. Valves that have automatic bleeders eliminate this hazard.

COMMON ERRORS IN LOCKOUT SYSTEMS:

1) The system is not enforced and supervised.

2) Failure to use a lock or removing the lock before the next shift lock is attached.

3) Locking through the shackle of another lock.

4) Leaving the key in the lock.

5) Asking others to do the locking out.

6) Failure to use tags.

7) Failure to check inside the switch box to make sure the connectors is disengaged.

8) Removing the fuses and not locking out.

9) Not identifying all switches and valves.

10) Assuming the equipment is inoperable.

11) Assuming the job is too small to warrant locking out.