VALE DATED 7.0 APPENDICES
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1 MAINTENANCE STANDARD PROCECURE ONTARIO OPERATIONS TITLES: VALE PAGE ZES - Zer Energy State Designated Tagger Installing Prtectin with Lck Bx DATED MPROC Page 1 f 25 REV 5 Training Cde (If applicable): Dcument Owner: Name: Dave Duczeminski Psitin: Reliability Manager, Department: Maintenance & Engineering (Mines) Table f Cntents 1.0 PURPOSE APPLICATION EXCEPTIONS REFERENCES DEFINITIONS DESIGNATED TAGGER INSTALLING PROTECTION WITH A LOCK BOX ZES PROCEDURE FLOWCHART # FC: 1.1 Initiate Lck Bx fr a Prject... 6 FC: Assign a Designated Tagger... 6 FC: FC: Identify All Surces f Energy and All Islating Devices t be Lcked and Tagged... 7 Get Permissin frm Persn in Charge f Equipment r Prcess... 8 FC: Obtain a Lck Bx Cmplete the Lck Bx Frm... 9 FC: Use an Islatin Equipment Operatr t Islate all Energy Surces FC: De-Energize all stred energy FC: Install Red Prject Persnal Prtectin Lcks and Tags n the Energy Islating Device(s) FC: Verify Zer Energy State FC: Place the Keys in the Lck Bx FC: Is this a Cascading Lck Bx Applicatin? FC: a Yes This is a cascaded lck bx applicatin Refer t MPROC USING Cascading Lck Bxes FC: N This is nt a cascaded lck bx Lck the bx with the blue prject lck FC: 1.2 FC: New Designated Tagger Taking Over New Designated Tagger Receives Key fr Blue Prject Lck frm Existing Designated Tagger FC: FC: Print Name n the Lck Bx Frm Verifying the Integrity f the Lck Bx Frm, the Lck Bx and its Cntents APPENDICES Appendix A: Material Illustratins Appendix B: Using Cascading Lck Bxes Jb Aid Appendix C: Revisin Ntes and Apprvals Page 1 f 25 Rev
2 1.0 PURPOSE This prcedure describes the mandatry prcess t assign a single persn that will be accuntable fr the islatins required fr a particular prject using a single lck bx (nt a cascading lck bx applicatin). 2.0 APPLICATION The ZES (Zer Energy State) Prgram is applicable at all Vale Ontari peratins. Parameters fr Electrical Lcking & Tagging Up t 600 vlts Emplyees must be trained and qualified t ZES003 Greater than 600 vlts and up t 15kV Emplyees must be trained and qualified t ZES003 Pwer Department will fllw MPROC High Tensin Lines, High Tensin Switching Prcedure between 600 vlts and up t 15kV All ther departments will fllw MPROC Electrical Department Switch Rm and Substatin Access Prcedure Emplyees must be trained and qualified electrical tradespersns r have been trained, qualified and permitted thrugh MPROC Requires cmmunicatin with the plant s Electrical Department t establish the level f invlvement required frm them Greater than 15 kv Requires Pwer Department 2.1. EXCEPTIONS High tensin pwer lines and related equipment are under the direct cntrl f the Pwer Department i.e. all 230kV, 69kV, and 44kV lines and equipment. All persnnel must fllw Pwer Department prcedure MPROC High Tensin Lines, High Tensin Switching Prcedure Overhead lines and related equipment belw 15kV must fllw plant specific plicies and prcedures Equipment greater than 15kV nt wned by the Pwer Department e.g. Cttrell, must fllw plant specific plicies and prcedures 3.0 REFERENCES The fllwing references were used in the develpment f this dcument r are related t it. Reference shuld always be made t the mst current fficial versin f these regulatins. Occupatinal Health and Act Ontari Regulatin 854, Sectins 160, 185 Ontari Regulatin 632/05, Cnfined Spaces Sectin 14 CSA-Z460 Cntrl f Hazardus Energy Page 2 f 25 Rev
3 4.0 DEFINITIONS Authrized: a persn wh has been given permissin t perfrm the task Cascaded Lck Bck: a lck bx that cntains the keys frm an identified red prject lck that has been affixed t the exterir f anther lck bx r lck bxes De-energized: discnnected frm all energy surces and nt cntaining residual r stred energy. D Nt Operate Tag: a yellw reusable tag that indicates authrizatin frm the System Operatr must be btain befre remving tag r perating f the device (used by Electrical Tradespeple) Delayed Starts: used t delay the peratin f a prcess r start f a mtr, pump, fan, etc. The time can be varied depending n the requirements and typically uses time delay relays t accmplish it. Designated Tagger: a qualified wrker r anther persn wh installs and remves prject persnal prtectin and manages status tags Device: a piece f equipment r a mechanism designed t serve a special purpse r perfrm a special functin Energy Surce: any surce f electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravity, pressurized, flw f material r ther stred energy. Energy Islating Device: a mechanical device that physically prevents the transmissin r release f energy, such as a discnnect f switches, valves, spades, r blcks Equipment: any machine driven by electricity r any ther prime mver, and/r cmbinatin f machines that perates as a system / prcess, such as pumps, fans, electric mtrs, mbile machines, vessels, piping, valves, etc. Frequency Drive: a type f mtr cntrller used with AC mtrs t vary the frequency and vltage supplied t the mtr (In ding s, it can vary the mtr speed t match the lad requirements f the mtr such as cntrlling the speed f a cnveyr belt, fan, mine hist, etc.) Grunding Device: an apprved device t mechanically cnnect electrical cnductrs t grund Grund Tag: a green tag identifying that a grunding device has been installed n the circuit Hld Off Tag: Affixed t fused discnnects r breaker cntrl handles by a linesman r P&C technician (tag issued by the Systems Operatr) t prevent individuals frm reclsing a tripped device Interlcks: Used in electrical circuits, it is usually a device (cmmn switch, infrared beams, pht detectrs, etc.) used t prevent undesirable actins in a piece f equipment, machine r prcess. Islate: a prcess use r actin taken t intrduce any number f apprved physical barriers between the equipment and surces r frms f energy and/r prcess material. Islatin Equipment Operatr: a qualified persn wh perates the Energy Islatin Device (i.e. cntrls, valves, etc.) Islatin Equipment Operatr: a qualified persn wh perates the energy islatin device. Lck Bx: a lckable device with prvisin t secure/see and cunt keys and hld frms that can be used in tw applicatins: 1) By a Designated Tagger t secure keys and hld the lck bx frm 2) By a Lcal Tagger t secure the remte tagging frm and hld the lck bx frm Page 3 f 25 Rev
4 Lck Extender: a red device used t allw multiple persnal prtectin lcks t be installed n an energy islating device Lckut Device: a mechanical means f lcking an energy islatin device, using a Persnal Prtectin Lck. Lcal Tagger: a qualified persn wh uses a Remte Tagger t install the Lcal Tagger s persnal prtectin lcks and tags n energy islating devices Persnal Prtectin Lck: an apprved single keyed red lck capable f lcking an energy islating device r a lck bx Persnal Prtectin Tag: an apprved red tag that is used in cnjunctin with a persnal prtectin lck t lck and tag an energy islating device Prject Lck: an apprved single keyed blue lck that is used by a Designated Tagger t secure keys in a lck bx Prtected Wrker: a Tagger wh has installed persnal prtectin and has verified a Zer Energy State Qualified: a cmpetent persn designated by his/her emplyer as being qualified because f knwledge, training and experience t safely perfrm an assigned task. Remte Tagger: a qualified persn wh perates, lcks and tags energy islatin devices n behalf f a Lcal Tagger Running Repairs: a repair t a piece f mbile equipment that is in an energized state (Tw types f running repairs: 1. Running repairs with pwer ON + key ON / engine nt running and the electric/hydraulic mtr is nt energized persnal prtectin tag required in peratrs cntrl area 2. Running repairs with key ON / engine running r electric / hydraulic mtr energized persnal prtectin tag and a qualified peratr required in peratr s cntrl area) Sft Starts: Used with AC mtrs t reduce the lad and trque n the pwertrain and current surge during start up. Allw the mtr t slwly (sftly) ramp up t full speed. Status Tag: an apprved white tag identifying why an energy islating device may nt be perated s as t prtect equipment Statin Guarantee Tag: a white, reusable numbered tag used by Pwer Department t identify the fact that a certain device is being used t prtect a persn r grup f persns while wrking n r near equipment Superintendent: the level f management that supervisrs wh are in charge f equipment and/r prcesses reprt t. Tagger: a qualified wrker wh installs and remves his/her persnal prtectin and manages status tags. Variance: an apprved plant specific measure put in place when it is impractical r unsafe t fllw the Zer Energy State Lcking and Tagging Prcedure Zer Energy State: a state where all hazardus energy has been islated and de-energized, r therwise cntrlled t manage risk. Page 4 f 25 Rev
5 5.0 DESIGNATED TAGGER INSTALLING PROTECTION WITH A LOCK BOX The fllwing flwchart utlines the mandatry steps required fr a Designated Tagger t install prtectin with a lck bx. This flw chart must be used nce fr each prject that will have a lck bx. D nt use this flw chart if a lck bx is nt being used. 6.0 ZES PROCEDURE FLOWCHART #1 Page 5 f 25 Rev
6 FC: 1.1 INITIATE LOCK BOX FOR A PROJECT The purpse f the steps in this prcess flw is t utline requirements fr a Designated Tagger Installing Prtectin with a Lck Bx. Hazardus energy must be islated and de-energized befre wrk begins n a particular prject. Cntrls required vary fr different tasks being perfrmed n the same machine. Example: Wrkers replacing an air cmpressr must cntrl mre energy surces than a wrker wh is just changing belts n the air cmpressr s prime mver. This prcess assumes that a decisin has been made t use a lck bx fr the prject. The fllwing sectins describe in detail the requirements related t a Designated Tagger installing prtectin with a lck bx r cascading lck bxes. FC: ASSIGN A DESIGNATED TAGGER The purpse f this step is t assign ne persn that will be accuntable fr the islatins required fr a particular prject. On a jb that requires energy islatin fr the prtectin f multiple wrkers, it needs t be explicitly clear wh is ging t be accuntable t perfrm thse islatins. If it is nt explicitly clear wh is accuntable fr the islatins, then there is the pssibility that the wrkers will assume that smene else perfrmed the islatins and inadvertently expse them t a hazard. An example might be I thught yu went t islate right after the line-up! N, I went fr tls, I thught yu islated while I was getting the tls? Using a Designated Tagger eliminates the ptential fr this cnfusin and ensures that all hazardus energy is identified and cntrlled in a safe and cnsistent manner. Each prject requires a Designated Tagger. The Designated Tagger must be: Qualified n Zer Energy State Lcking and Tagging prcedures which they will implement Familiar with the islatin / de-energizatin required fr the prject. Page 6 f 25 Rev
7 FC: IDENTIFY ALL SOURCES OF ENERGY AND ALL ISOLATING DEVICES TO BE LOCKED AND TAGGED The purpse f this step is t identify all persnal prtectin lcking and tagging requirements fr a particular prject. It is imperative that all hazardus energy be islated and de-energized fr the prtectin f wrkers. The Designated Tagger must knw all f the energy surces and hw they can affect the wrk t be dne. Every energy surce must be identified. The Islatin Device fr each energy surce must be identified. The Designated Tagger is accuntable fr perfrming this task. Resurces include: Equipment-specific hazardus energy cntrl prcedures. SAP Task Lists (Standard Jb Prcedures) Blueprints and/r Prcess Drawings/Maps Other subject matter experts/plant resurces * * Fr cmplex prjects, ther subject matter experts/plant resurces may prvide infrmatin t the Designated Tagger. Fr example, a Designated Tagger may be prvided with the Lck Bx Frm ppulated with the sme f the details required fr the wrk t be dne such as any f the fllwing: Date Specific Prcedure N. (if applicable) If n specific prcedure, the risk assessment methd used (i.e. SLAM, JHA) Prject Descriptin (Wrk t be Dne) Sign ffs fr Wrk t be Dne and Equipment/Prcess Energy Islatins Number f Energy Islating Devices List f Energy Islating Devices The fllwing is an example f the sectins already cmpleted fr the Designated Tagger: Sign ffs fr the Wrk t Be Dne and Equipment/Prcess Energy Islatins sectins can be cmpleted by a supervisr, planner, designated tagger, peratr, r trades persn (as is applicable t the prject). Page 7 f 25 Rev
8 FC: GET PERMISSION FROM PERSON IN CHARGE OF EQUIPMENT OR PROCESS The purpse f this prcess is t btain permissin frm the persn in charge befre cmmencing the wrk. The persn in charge f the equipment r prcess must be aware f all wrk t be perfrmed. They must crdinate this wrk with prductin schedules and maintenance schedules. Sme f the things that the persn in charge is cncerned abut include the fllwing: The equipment may nt be ready and culd result in injury r prductin upset. The wrk may be started n the wrng equipment and culd result in injury r prductin upset. The wrk may affect the safety f ther wrk in the area. Other wrk in the area may affect the safety f this wrk. Accunting fr peple during an emergency situatin. The Designated Tagger is respnsible fr perfrming this step. Cmmunicatin shuld clarify: The scpe f the wrk The expected duratin f the wrk Any hazards that may exist in the wrkplace Any hazards that the wrk intrduces t the wrkplace (i.e., ht wrk) Any burning permits, cnfined space permits r ther wrk permits required. The persn in charge f the equipment must explicitly grant permissin befre remving the equipment frm service. Page 8 f 25 Rev
9 FC: OBTAIN A LOCK BOX COMPLETE THE LOCK BOX FORM The purpse f this step is t get a lck bx and utline the lck bx frm requirements. The Designated Tagger has determined that a lck bx will be used fr this prject and is respnsible fr btaining an unused lck bx and cmpleting the lck bx frm. One lck bx frm must be filled in fr each lck bx. The initial infrmatin required n the lck bx frm includes the fllwing: Date Prject descriptin Plant Specific Prcedure Number (if applicable) If n specific prcedure, the risk assessment methd (i.e. SLAM, JHA) Prject Descriptin (Wrk t be Dne) detailed enugh s that thers can determine what is being dne Wrk t be Dne Name and Signature* Equipment/Prcess Energy Islatins Name and Signature* Number f Energy Islating Devices List f Energy Islating Devices type f device, device identificatin, equipment name, and lcatin SAMPLE: LOCK BOX FORM * The Wrk t be Dne and Equipment/Prcess Energy Islatins sectins may be cmpleted by a supervisr, planner, designated tagger, peratr r trades persn (as is applicable t the prject). Page 9 f 25 Rev
10 FC: USE AN ISOLATION EQUIPMENT OPERATOR TO ISOLATE ALL ENERGY SOURCES The purpse f this step is t islate the equipment frm all energy surces. Energy Islatin Devices must be in the islated psitin befre they are lcked and tagged. Yu can be injured if yu imprperly perate an Energy Islating Device. Only an Authrized Islatin Equipment Operatr can perate an Energy Islating Device In sme instances, the Designated Tagger may be the Authrized Islatin Equipment Operatr. The Designated Tagger is accuntable fr identifying the energy surces. The Islatin Equipment Operatr is accuntable fr using prper methds fr islatin. Islatin is perfrmed nce fr each energy surce. Islating must be perfrmed befre persnal prtectin is installed. Mre than ne persn may be invlved in the islatin step and the time invlved will vary depending n the type f islatin that is required. Example: An electrician may perate the field discnnect fr an air cmpressr in less than five minutes, while a utility peratr may require 30 minutes t valve ff, bleed and drain the air cmpressr. Islatin must be perfrmed befre persnal prtectin is installed. FC: DE-ENERGIZE ALL STORED ENERGY The purpse f this step is t de-energize the equipment. All equipment/prcesses that have been identified fr this lck bx must have all energy surces brught t Zer Energy State. Sme prcesses require knwledge f hw t purge, wash r drain accumulatrs that may affect the taggers persnal prtectin. Errrs r unfreseen cmplicatins may allw prtins f the machine t remain energized. One pssible scenari wuld be an air valve n the cmpressr discharge pipe having a slw leak that culd re-pressurize the cmpressr. The methd f zer-energy verificatin shuld take int accunt the cmmn failure mdes f the energy islatin devices. Anther scenari wuld be unintentinally the lcking and tagging an energy islating device in the energized psitin instead f the de-energized psitin De-energizatin is perfrmed in every instance that hazardus stred energy culd exist. The Islatin Equipment Operatr is respnsible fr de-energizing hazardus energy. This step must be perfrmed befre the lcks and tags are installed n the energy islatin device(s). Page 10 f 25 Rev
11 FC: INSTALL RED PROJECT PERSONAL PROTECTION LOCKS AND TAGS ON THE ENERGY ISOLATING DEVICE(S) The purpse f this step is t effectively lck and tag the energy islatin devices in the islated psitin. Every Energy Islatin Device must be lcked and tagged in the islated psitin. Since a lck bx is being used, the lcks and tags are installed as prject lcks and tags by the Designated Tagger. The Designated Tagger perfrms this step after the Energy Islating Devices have been mved t the islated psitin. Lcks will be installed n each energy islatin device listed n the lck bx frm. The lcks will be red persnal prtectin lcks. The tags will be red persnal prtectin tags installed as prject tags (i.e. with the Prject Tag bx check marked). They will be affixed t each lck. Each red Prject Tag will cntain the fllwing infrmatin: Prject Tag Check Bx: Enter a check mark Time and Date: The time and date that the lck and tag are installed Equipment: The name f the equipment that is being wrked n Reasn: Prject descriptin Cmpany / Vale Dept.: Enter the Vale dept. name r the cntracted cmpany name. Installed by: Printed the name f the Designated Tagger EMPLOYEE # r NORCAT / I.D. #: Enter ID number Wrk Phne: Enter phne number SAMPLE: PERSONAL PROTECTION PROJECT TAG Page 11 f 25 Rev
12 FC: VERIFY ZERO ENERGY STATE The purpse f this step is t prve that the energy islatin is effective. Yu must verify a zer energy state after the equipment has been islated and de-energized. Errrs r unfreseen cmplicatins may allw prtins f the machine t remain energized. Cnsider the fllwing scenaris: One pssible scenari wuld be an air valve n the cmpressr discharge pipe having a slw leak that culd re-pressurize the cmpressr. The methd f zer-energy verificatin shuld take int accunt the cmmn failure mdes f the energy islatin devices. Anther scenari wuld be unintentinally the lcking and tagging an energy islating device in the energized psitin instead f the de-energized psitin. A third scenari wuld be lcking and tagging the wrng machine. Verificatin is perfrmed in every instance that hazardus stred energy culd exist after islatin has taken place. Mre than ne methd may be required if there is mre than ne energy surce. This step is perfrmed after the lcks and tags have been installed n the energy islatin device(s). The Islatin Equipment peratin is respnsible fr de-energizing all hazardus energy The Designated Tagger is respnsible t recrd n the Lck Bx Frm the methd used t verify Zer Energy State fr each Energy Islating Device. SAMPLE: Lck Bx Frm Page 12 f 25 Rev
13 FC: PLACE THE KEYS IN THE LOCK BOX The purpse f this step is t prvide a place t secure the keys f the lcks n the energy islatin devices while allwing them t be viewed. This step is perfrmed after the zer-energy state has been verified and immediately befre the lck bx is lcked. The keys are secured in the lck bx t prvide persnal prtectin fr each prtected wrker wh uses the lck bx. There must be nly ne key fr each lck. The lck bx shall remain empty until after zer energy has been verified. All f the keys listed n the lck bx frm shall be placed inside the lck bx at the same time. Example: Wrkers replacing an air cmpressr must cntrl multiple energy surces. If the key fr the electrical discnnect is put in the lck bx befre the air pressure is de-energized a wrker may be expsed t the pressure hazard. The Designated Tagger will place the keys int the lck bx. FC: IS THIS A CASCADING LOCK BOX APPLICATION? The purpse f this step is t determine if this bx is the main lck bx fr a prject, r if it is part f a Cascading Lck Bx System. A Cascaded Lck Bx is a lck bx that cntains keys frm an identified red prject lck that has been affixed t the exterir f anther lck bx r lck bxes. In many cases due t cmmissining r testing requirements, it is necessary t access and remve the lcks frm a subset f energy islating devices assciated with a lck bx at sme pint during a prject. With prper planning, a cascaded lck bx will simplify the remval f lcks and tags frm a subset f equipment identified fr cmmissining fr testing purpses. If the answer t the questin is N, the Designated Tagger cntinues with the prcess utlined in sectin FC: Lck the bx with the Blue Prject Lck. If the answer t the questin is Yes, the Designatr Tagger must fllw steps related t the type f cascading lck bx being utilized. There are three ways cascading lck bxes can be used: 1. Extending a Lck Bx Used when large grup r grups wrking at different sites are wrking n the same prject but need t lck in different lcatins. This allws multiple lckut pints fr the same prject. 2. Cascading Multiple Existing Lck Bxes Used when a secndary prject is being cmpleted that can take advantage f existing lck bxes, r when a prject has multiple phases (i.e. installatin and cmmissining, r rtating a piece f equipment midprject). 3. Cascading a Lck Bx + Additinal Islatin Pints Used when a secndary prject is being cmpleted that can take advantage f existing lck bxes, r when a prject has multiple phases (i.e. installatin and cmmissining, r rtating a piece f equipment midprject). Page 13 f 25 Rev
14 FC: A YES THIS IS A CASCADED LOCK BOX APPLICATION REFER TO MPROC USING CASCADING LOCK BOXES Refer t full details n the prcedural steps fr using a cascading lck bx applicatin utlined in MPROC Using Cascading Lck Bxes. A Jb Aid entitled Using Cascading Lck Bxes is als available t further supprt the requirements utlined in MPROC Using Cascading Lck Bxes. FC: NO THIS IS NOT A CASCADED LOCK BOX LOCK THE BOX WITH THE BLUE PROJECT LOCK If the answer t the questin Is this a Cascading Lck Bx Applicatin is N, the Designated Tagger cntinues with this prcess t secure the keys f the lcks n the energy islatin devices while allwing them t be viewed in the lck bx. The lck bx shall be lcked shut with a blue prject lck as sn as the keys fr red persnal prtectin lcks have been placed inside it. The blue prject lck n the lck bx signifies that the Designated Tagger has cmpleted the islatin, de-energizatin and the zer energy state verificatin as listed n the lck bx frm fr the prject. The blue prject lck secures keys in the lck bx t prvide persnal prtectin fr each prtected wrker wh uses the lck bx. The blue prject lck secures the keys fr the duratin f the prject. The Designated Tagger must always keep the key fr the blue prject lck secure. The filled-in lck bx frm remains with the lck bx. The Designated Tagger may pass the key fr the blue prject lck t a new Subsequent Designated Tagger. An example might be when the existing Designated Tagger cannt be available at the cmpletin f the prject. (Refer t FC: 1.2 New Designated Tagger Taking Over) The Designated Tagger fills in the Prject Lck Installatin sectin f the lck bx frm. Prints his r her name in the Designated Tagger Name field. Checks-ff that Islatin has been cmpleted in the Islatin Cmpleted field. Checks-ff that Zer Energy has been verified in the Zer Energy Verified field. Prints the time and date in the Prject Lck Installed Date and Time field. SAMPLE: Lck Bx Frm IMPORTANT: Once all signatures are affixed t the Lck Bx Frm, the lck bx is authrized fr the number f energy islating devices identified n Page 1 and described in the subsequent pages. NO MODIFICATIONS ARE TO BE MADE. If additinal equipment r prcess islatins are required, r if changes need t be made, yu must start a new Lck Bx prcess r fllw MPROC Using Cascading Lck Bxes (if applicable). Page 14 f 25 Rev
15 EXAMPLE: LOCKED LOCK BOX WITH FILLED-IN FORM FC: 1.2 NEW DESIGNATED TAGGER TAKING OVER The purpse f this step is t reassign the duties f a Designated Tagger t a new Designated Tagger. An example might be the existing Designated Tagger will nt be available at the cmpletin f the prject. The new Designated Tagger receives the key fr the blue prject lck frm the existing Designated Tagger. The new Designated Tagger must always keep the key fr the blue prject lck secure and assumes the duties f the Designated Tagger. The blue prject lck secures the keys fr the duratin f the prject. The new Designated Tagger must be: Qualified n the zer energy state lcking and tagging prcedure Familiar with the islatin/de-energizatin required fr the prject FC: NEW DESIGNATED TAGGER RECEIVES KEY FOR BLUE PROJECT LOCK FROM EXISTING DESIGNATED TAGGER The purpse f this step is t cntinue securing the keys fr the lcks n the energy islatin devices. There is a single key fr the blue prject lck. The Designated Tagger can pass his r her duties t anther wrker. The wrker wh accepts the duties then becmes the new Designated Tagger. The existing Designated Tagger cmmunicates with the new Designated Tagger t pass n the fllwing infrmatin: The prject that the lck bx is installed fr The lcatin f the lck bx The new Designated Tagger secures the key fr the blue prject lck. The passing f the duties is recrded n the lck bx frm. The key fr the blue prject lck must always be secured by the Designated Tagger identified n the lck bx frm. The blue prject lck secures keys in the lck bx fr the duratin f the prject. Page 15 f 25 Rev
16 FC: PRINT NAME ON THE LOCK BOX FORM The purpse f this step is t recrd the name f the Subsequent Designated Tagger n the lck bx frm. The Subsequent Designated Tagger fills in the frm: Prints his r her name in the Subsequent Designated Taggers: Name field Prints the date in the Date field SAMPLE: Lck Bx Frm Anther page can be attached t the first page if rm fr mre Subsequent Designated Tagger recrds as required. The Subsequent Designated Tagger fills in the extra page. Prints his r her name in the Subsequent Designated Taggers: Name field Prints the date in the Date field Specify the Plant Specific Prcedure number. Cpy the number frm the first page Attach the additinal page t the Lck Bx Frm A Subsequent Designated Tagger is respnsible fr perfrming this task and in ding s becmes the current Designated Tagger. FC: CONTENTS VERIFYING THE INTEGRITY OF THE LOCK BOX FORM, THE LOCK BOX AND ITS The purpse f this step is t verify the integrity f the Prject Lck Bx while accepting the accuntabilities f the previus Designated Tagger. This step is perfrmed each time the key passes frm a Designated Tagger t a Subsequent Designated Tagger. The existing Designated Tagger cmmunicates with the new Designated Tagger t pass n the fllwing infrmatin: The prject that the lck bx is installed fr The lcatin f the lck bx The new Designated Tagger secures the key fr the blue prject lck. The lck bx must remain lcked shut until the Designated Tagger determines the lck bx is n lnger required. It is suggested that the Subsequent Designated Tagger check all the islating devices lcks listed n the lck bx frm t ensure prper islatin is still intact. Page 16 f 25 Rev
17 7.0 APPENDICES APPENDIX A: Material Illustratins APPENDIX B: Jb Aid Using Cascading Lck Bxes APPENDIX C: Revisin Ntes and Apprvals Page 17 f 25 Rev
18 Appendix A: Material Illustratins Red Persnal Prtectin Lcks Red Persnal Prtectin Lck (Plastic) Supplier: Vallen Supplier Part Number: BRD Shrt Descriptin: PADLOCK SAFETY 1.5 IN KD RED 1 KEY Red Persnal Prtectin Lck (Aluminum) Supplier: Vallen Supplier Part Number: BRD Y Shrt Descriptin: LOCK CUSTOM ALUM 1KD RED -PN: BRD Y37 Page 18 f 25 Rev
19 Blue Prject Lcks Blue Prject Lck (Plastic) Supplier: Vallen Supplier Part Number: BRD Shrt Descriptin: PADLOCK SAFETY 1.5 IN KD BLUE 1 KEY Blue Prject Lck (Aluminum) Supplier: Vallen Supplier Part Number: BRD Y Shrt Descriptin: LOCK CUSTOM ALUM 1KD BLUE -PN: BRD Y3 Page 19 f 25 Rev
20 Lck Extenders Lck Extenders Supplier: Vallen Supplier Part Number: BRD Shrt Descriptin: LOCKOUT HASPS 1 IN DIA Full Size Lck Bx Red Grup Lck Bx (Size 11 inches by 12.5 inches) Supplier: Vallen Shrt Descriptin: LOCKOUT BOX: GROUP; RED Material Number: Shrt Descriptin: HOLDER; PAPER; FOR LOCKOUT PROCEDURES Material Number: Page 20 f 25 Rev
21 Small Size Lck Bx Clear Small Lck Bx (Size 6 inches by 5.5 inches) Supplier: Vallen Shrt Descriptin: LOCKOUT, SAFETY;BX,CLR;FFT: GROUP Material Number: Status Tag White Status Tag CAUTION DO NOT OPERATE Supplier: Nickel Acme Printers Inc. Shrt Descriptin: TAG, SAFETY;CAUTION DO NOT OPRT Material Number: Plyethylene ptin: TAG; TYPE: SAFETY; CAUTION DO NOT OPERATE EQUIPMENT STATUS; MATERIAL: POLYETHYLENE; COLOR: BLACK/RED/WHITE; ORIFICE: W/O ORIFICE; SIZE: 3.125X6.25IN; BOX 1000 UNITS T NICKEL ACME PRINTERS NOTE: Requires use f permanent marker fr marking, and scissrs t cut tag Page 21 f 25 Rev
22 Persnal Prtectin Tag Red Persnal Prtectin Tag DANGER DO NOT OPERATE Supplier: Nickel Acme Printers Inc. Shrt Descriptin: TAG; DANGER PROJECT TAG; DO NOT OPERATE Material Number: Plyethylene ptin: TAG; TYPE: SAFETY; DANGER DO NOT OPERATE PERSONAL PROTECTIO; MATERIAL: POLYETHYLENE; COLOR: BLACK/RED; ORIFICE: W/O ORIFICE; SIZE: 3.125X6.25IN; BOX 1000 UNITS T NICKEL ACME PRINTERS NOTE: Requires use f permanent marker fr marking, and scissrs t cut tag Nte: When using a red Persnal Prtectin Tag n a Lck Bx, it is suggested t remve the string frm the tag and then attach the tag directly t the shackle f the red Persnal Prtectin Lck by sliding the shackle thrugh the prvided hle in the tag (as shwn belw). Page 22 f 25 Rev
23 Appendix B: Using Cascading Lck Bxes Jb Aid A cpy f this Jb Aid Frm is available n the ZES Website. Page 23 f 25 Rev
24 Appendix C: Revisin Ntes and Apprvals Revisin ntes describe what was changed, and if applicable, why it was changed, and the plan t implement the change, including whether changes are retractive. The revisin ntes are a summary f the changes and may nt necessarily be a cmplete list. A risk cde is entered fr each revisin and if applicable, the revisin ntes will describe hw risk was addressed fr the revisin Risk Cde: A B C The revisin is a minr change and/r intrduces n risk. Risk Categry Risk has been addressed fr this revisin by the reviewer and apprver. Lw risk r n new hazards identified. Fr this revisin, a risk management tl has been used t address risk and minimize hazards. This risk assessment has been dcument and is available thrugh Maintenance Engineering. Revisin Ntes 5 Last Revised by: Garwin Pitman, Maintenance Supprt Superintendent, Maintenance Engineering, Ontari Operatins Risk Cde: A Lck Bx Frm graphics have been updated t reflect the changes t the Lck Bx Frm being rlled ut in Ontari Operatins during Added references fr new plyethylene tag ptins fr Status and Persnal Prtectin Tags. 4 Revisin f Sectin 2 - Applicatin t clarify lcking and tagging requirements fr different vltages and invlvement levels required f Electrical Department and Pwer Department. Risk Cde fr this revisin is A The revisin intrduces n risk. 3 Dec 30, 2015 Published Ontari Operatins Zer Energy State Lcking & Tagging Prgram, Sectin 6 Prcedures, 6.1 Flwchart 1 and its related CPQQRTs 1. Frmatted cntent int a ne maintenance standard prcedure dcument: MPROC Designated Tagger Installing Prtectin with a Lck Bx. The reasn fr refrmat: T update the frmat t meet the minimum requirements f dcuments maintained in the Maintenance Standard Dcument Management System T maintain the prcedure n the Maintenance Standards Website fr easy access fr internal and external reference. 2. Separated step De-energize all stred energy. Verify Zer Energy State int tw steps: Renumbered steps as fllws: De-energize all stred energy prir t Install Red Prject Persnal Prtectin Lcks & Tags n the Energy Islating Device(s) prir t Verify Zer Energy State. 3. Added a decisin bx: a Is this a Cascading Lck Bx Applicatin? t address the requirements fr cascaded lck bx scenaris. Reference added t direct users t a prcedure dcument that utlines the prcess steps required fr Using Cascading Lck Bxes MPROC Using Cascading Lck Bxes Jb Aid has updated inserted referring users t the new prcedure references: i.e., Reference t ZES 002/003 prcedures updated t MPROC Tagger Remving Persnal Prtectin and MPROC Designated Tagger Remving Lck Bx. 2 March 31, 2009 Ontari Operatins Zer Energy State Lcking & Tagging Prgram Ontari Divisin changed its rganizatinal structure. ZES Prgram dcument updated: Sectin 7 Accuntabilities t reflect the new rganizatin structure. 1 June 15, 2008 Implemented the Ontari Operatins Zer Energy State Lcking and Tagging Prgram Page 24 f 25 Rev
25 Reviews & Apprvals Name and Psitin Signature Date Dcument Owner Dave Duczeminski, Manager Maintenance Engineering (Mines) Dave Duczeminski, Reliability Manager Maintenance Engineering (Mines) On behalf f Ontari Operatins Maintenance Leadership Grup Glen O Neill, Manager Maintenance Engineering (Surface Plants) Ontari Operatins Bruce Bichel, Manager Prductin Services and Supprt Page 25 f 25 Rev
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