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QGN 01 Out of Service final Oct 2008

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QGN 01 Out of Service final Oct 2008 Powered By Docstoc
					                          Guidance Note
                                QGN 01

          Out of Service Procedures

                       For Preventing
                  Unserviceable Plant
           Being Used at Metalliferous
                  Mines and Quarries

Mining and Quarrying Safety and Health Act 1999




                       October 2008, Version 5
GUIDANCE NOTE – QGN01 OUT OF SERVICE PROCEDURES


  This Guidance Note has been issued by Safety and Health of the Department of
  Natural Resources and Mines to provide guidance in the use of out of service
  procedures to manage the risk associated with unserviceable plant.


  This Guidance Note is not a Guideline as defined in the Mining and Quarrying Safety
  and Health Act 1999. In some circumstances, compliance with this Guidance Note
  may not be sufficient to ensure compliance with the requirements in the legislation.


  Guidance Notes may be updated from time to time. To ensure you have the latest
  version, either check the Department of Mines and Energy website or contact your
  local inspector of mines.



  North Region                North Region                North Region
  PO Box 1752                 PO Box 334                  PO Box 210
  Townsville Qld 4810         Mount Isa Qld 4825          Atherton Qld 4883
  (07) 4760 7404              (07) 4747 2158              (07) 4095 7023
  Fax (07) 4760 7400          Fax (07) 4743 7165          Fax (07) 4091 2844

  Central Region              Central Region              South Region
  PO Box 1801                 PO Box 548                  PO Box 1475
  Mackay Qld 4740             Rockhampton Qld 4700        Coorparoo Qld 4151
  (07) 4953 0860              (07) 4938 4187              (07) 3238 3722
  Fax (07) 4953 2761          Fax (07) 4938 4331          Fax (07) 3405 5346




                                                                               Page 2 of 11
TABLE OF CONTENTS
1     PURPOSE AND SCOPE ............................................................................................................................4
2   SCOPE THIS GUIDANCE NOTE APPLIES TO OUT OF SERVICE PROCEDURES DESIGNED
TO: 4
3     APPLICATION FRAMEWORK ..............................................................................................................4
    3.1       GENERAL .............................................................................................................................................4
    3.2       LEGAL REQUIREMENTS .........................................................................................................................5
4     TECHNICAL GUIDANCE - OUT OF SERVICE...................................................................................6
    4.1       OUT OF SERVICE PROCESS STEPS ..........................................................................................................6
    4.2       OUT OF SERVICE TAGS ..........................................................................................................................8
5     ACCOUNTABILITIES AND COMPETENCIES .................................................................................10
    5.1       ACCOUNTABILITIES ............................................................................................................................10
    5.2       COMPETENCIES ..................................................................................................................................10
6     DEFINITIONS ..........................................................................................................................................10




                                                                                                                                             Page 3 of 11
1 PURPOSE AND SCOPE

The purpose of this Guidance Note QGN01 is to provide practical guidance to
companies, employers and employees about the use of out of service procedures to
prevent the use of plant that is not fit for use, or would otherwise create an
unacceptable level of risk if used.

This Guidance Note does not prevent other ways of achieving an acceptable level of
risk from being adopted and followed when dealing with unserviceable plant.



2      SCOPE

This Guidance Note applies to out of service procedures designed to:
  (a) warn persons of the condition of plant which is not fit for use;
  (b) prevent the use of such plant;
  (c) prevent the operation of such plant except for the purpose of repair,
       maintenance, inspection or testing.

This Guidance Note does not cover:
  (a) procedures to keep persons clear of plant that can not be brought to a safe
       state;
  (b) procedures to protect workers who are carrying out work on plant.




3 APPLICATION FRAMEWORK
3.1   General

When plant is being used, operated, controlled, monitored or maintained, it may be
found that the plant is unfit for further use, or for some other reason will create an
unacceptable level of risk if used. It is then necessary to warn workers intending to
use the plant of its condition, and to prevent its use until it has been made
serviceable. An example of an out of service procedure for this is given in Section
4.

Out of service procedures will not provide protection for persons from plant that has
already failed or is in the process of failing, and that cannot be readily brought to a
safe state. In such cases, it may be necessary to clear persons from the area and
to initiate emergency procedures.

Out of service procedures are not intended to provide protection for workers working
on plant. For this, isolation procedures, live work procedures, and permits to work
procedures must be used. Isolation procedures are covered in Guidance Note
QGN02.




                                                                            Page 4 of 11
3.2   Legal requirements

Section 36 (2) of the Mining and Quarrying Safety and Health Act 1999 imposes
obligations on workers and other persons at a mine or quarry to manage the risk of
injury or illness, so that the risk is at an acceptable level. Each person must
manage risk in their own work and ensure it is managed in any work under their
control, supervision or leadership. Workers and other persons on site are also
required to comply with the operation’s procedures and standard work instructions.

Plant that is not fit for use, or would otherwise create an unacceptable level of risk if
used is a hazard. If such plant is used, there is a high risk of serious injury or
illness. The level of risk can only be kept to an acceptable level if appropriate out of
service procedures are used to make workers and other persons aware of the
condition of the plant, and so prevent its use.

The Mining and Quarrying Safety and Health Regulation 2001 has the following
specific requirements relevant to out of service procedures:

      “PART 4 – ELECTRICAL
      Isolation facilities
      27. (1) The operator and site senior executive must ensure each item of
      electrical equipment used at the mine has a full current isolation facility in
      a location that is easily accessible by a person required to carry out the
      isolation.
        (2) The operator and site senior executive must also ensure the isolator
      is –
               (a)     clearly marked or labelled as the isolator for the plant: and
               (b)     compatible with the mine’s isolation and lock-out
               procedures.

      PART 10 – PLANT GENERALLY
      Isolation facility
      103 (1) If, having regard to the nature and level of risk from plant used at
      a mine, it is necessary for managing the risk, the site senior executive
      must ensure the plant has a facility for –
              (a)     preventing its operation;
              (b)     preventing or controlling the release of its stored energy;
              or
              (c)isolating its energy supply.
        (2) The site senior executive must ensure the facility is capable of
      being locked-out and tagged or otherwise secured.

      Operating plant
      106     A person who has an obligation under the Act to manage risk at a
      mine in relation to the operation of plant must ensure the plant is not
      operated –
              (a)     in a way that creates an unacceptable level of risk; or
              (b)     if inspections, tests or monitoring show the plant is unfit for
              use; or
              (c)if the plant is locked-out and tagged.



                                                                              Page 5 of 11
     Isolating, locking-out and tagging plant
     107 (1) A mine’s safety and health management system must provide for
     the following–
              (a)     isolating plant, including effectively isolating plant to control
              the risk from a release of energy;
              (b)     taking plant out of service;
              (c)testing plant or its energy source for zero potential;
              (d)     returning plant to service.
       (2) The site senior executive for a mine that is not required to have a
     safety and health management system must ensure the mine has a
     standard work instruction for the activities mentioned in subsection (1)(a)
     to (d).
       (3) If the safety or health of a person is directly affected by the
     operation or non-operation of plant, the system or standard work
     instruction must also provide for locking-out and tagging the plant.”




4 TECHNICAL GUIDANCE - OUT OF SERVICE


4.1 Out of service process steps
This sub-section contains examples of matters that need to be considered and
provided for in any out of service procedure and its constituent standard work
instructions. The precise contents of the procedure and instructions for any
particular site will have to allow for the specific conditions and practices on that site.

     A:       Bringing plant to a safe state.
     Any worker who finds plant that is not in a fit condition for further
     use, or for some other reason will create an unacceptable level of
     risk if used, shall bring the plant to a safe state if he or she is
     competent to do so. The plant shall be brought to a safe state by:
     (a) stopping the plant; and
     (b) isolating, dissipating or restraining any significant sources of
           energy as appropriate.

     Note: Isolation of energy sources should be done by physically
     interrupting the supply of energy. This can be done by turning off
     isolating switches in electrical circuits, by closing valves, by disconnecting
     leads, cables or hoses, by blanking off pipelines, etc. The means of
     isolation should act directly on the supply, not on control circuits, and be
     of a type that can be readily checked by a visual inspection. The point of
     isolation should be close to the plant concerned.

     Note: Dissipating sources of energy in the plant can be done by opening
     valves to drain pipelines, pressure vessels and hydraulic accumulators,
     by earthing electrostatic separators, by releasing springs, by dropping
     counterweights, etc.




                                                                                Page 6 of 11
Note: If internal sources of energy can not be dissipated, they can be
restrained by securing mechanical sources of energy such as springs or
gravity devices, by closing cover plates on radioactive gauges, etc. Plant
that can move can be restrained by applying brakes, by inserting chocks
or sprags, etc.

If the plant cannot be brought to a safe state, the worker shall:
(a) inform a supervisor of the situation;
(b) arrange for persons to be kept clear of the plant;
(c) take other action as appropriate to ensure that the risk from the
      plant is reduced to an acceptable level.

Note: If the plant cannot be brought to a safe state, it may be necessary
to barricade the area, or to initiate evacuation and other emergency
procedures. In such cases, it may not be safe to approach the plant to
follow the out of service procedure.

B:       Tagging.
After bringing the plant to a safe state, the worker shall then attach
an out of service tag to the controls of the plant or some prominent
position near the controls. The out of service tag shall be filled in
with the equipment reference, the reason for tagging, the date and
time of tagging, and the name of the person placing the tag.
If the plant can be started inadvertently and it is fitted with a lockable
isolation device, the worker may also lock it out with his or her own
lock or a lock provided for the purpose. If so, the worker shall
attach an out of service tag to the isolation device.

C:      Prohibition on use of tagged plant.
All persons shall be prohibited from attempting to use or operate
plant that has been taken out of service and tagged, except that a
worker may operate the plant for the purposes of repair,
maintenance, inspection or test.

Note: The out of service procedure is not a substitute for an isolation
procedure. Workers carrying out repairs, maintenance, inspection or
testing need to follow isolation and/or other appropriate procedures to
protect themselves from sources of energy associated with the plant.

D:      Removal of tags and locks.
An out of service tag and any lock shall not be removed by any
person, except that:
(a) a worker who has carried out repairs or maintenance to the
    plant may remove the tag and any lock if the plant has been
    returned to a condition fit for use;
(b) a worker who has inspected or tested the plant may remove the
    tag and any lock if the plant has been found to be in a condition
    fit for use.




                                                                     Page 7 of 11
      A worker who has removed tags in accordance with the above shall
      then tear up or otherwise destroy the used tags to prevent re-use
      and to indicate that the tag has not been inadvertently removed.

      E:      Detached tags.
      Any person finding a loose undestroyed out of service tag shall
      assume that it has been unintentionally detached from the plant.
      The person shall place a substitute tag on the plant, and refer the
      matter to the worker named on the tag or to a supervisor.

      F:      Use of tags.
      Out of service tags shall not be used for any other purpose.



4.2   Out of service tags

This sub-section is an example of specifications for out of service tags.

Out of service tags shall:
  (a) conform to the requirements of AS 1319 - 1994 Safety signs for the
        occupational environment;
  (b) be sufficiently durable to withstand the environment in which they are used;
  (c) be standardised throughout the site;
  (d) be sufficiently substantial to minimise the likelihood of accidental removal;
  (e) be identifiable:
  (f) be large enough to be readily identified, at least 80mm x 50mm (see AS
        1319 Section 5.2);
  (g) be provided with a substantial tie or other means of attachment.




                                                                            Page 8 of 11
                Figure 1: Example of preferred out of service tag

                                     Hole for
                                     tie

                                      Black
                                      symbol


            !                80mm
                                                              !
       OUT OF                min.                        OUT OF
      SERVICE                                           SERVICE
                                      Black
      DO NOT USE                      lettering        DO NOT USE
  Plant:                                           Reason:
  Date:
  Time:
  Name:                               Yellow
                                      background
        50mm min.


        Front                                                Back


As the primary purpose of an out of service tag is to warn other persons that the
plant is unfit for use, the top of the tag shall carry the standard hazard - warning
symbol of a black exclamation mark inside a black triangle on a yellow background
(see AS 1319 - 1994 Table 2.1 and Section 2.3.3). The symbol shall be on both
sides.

Under the symbol, the tag shall carry the warning “Out of service”, and the
instruction “Do not use”. The warning and instruction shall be on both sides.

Tags shall have spaces for the person using the tag to enter the plant reference, the
reason for attaching the tag, the date and time of attaching the tag, and his or her
name.

Note: Tags are commercially available, but the designs do not necessarily conform
to AS 1319 - 1994.

Note: Some currently used out of service tags carry the standard hazard - danger
symbol of the word “Danger” in a red oval in a black rectangle. This symbol is for
use on signs warning of a life-threatening hazard (see AS 1319 - 1994 Clause
2.1(b)(i)). If the plant poses a life-threatening hazard without being put to use, then
an out of service procedure is not appropriate, and other measures need to be taken
to secure the plant and keep persons away from it.




                                                                           Page 9 of 11
5 ACCOUNTABILITIES AND COMPETENCIES


5.1    Accountabilities

All workers shall be responsible for attaching out of service tags to any plant they
find that is not safe or serviceable.

Any worker repairing, maintaining, inspecting or testing plant shall be responsible for
ensuring that the plant is in safe and serviceable condition before removing out of
service tags.


5.2    Competencies

All workers shall be familiar with and understand the purpose of out of service
procedures. Training in the out of service procedures used at the site shall be
included in general induction training.

Workers carrying out repairs, maintenance, inspections or tests shall be competent
to do so.



6 DEFINITIONS

Dissipation:        Release and discharge of energy stored or contained in
                    plant.

Isolation:          Disconnection or separation of plant or part of plant from
                    power supplies and other sources of energy.

May:                Indicates that a statement is discretionary.

Must:               Indicates that a statement is mandatory in all cases and is
                    an obligation imposed by the Mining and Quarrying Safety
                    and Health legislation.

Plant:              Machinery, equipment, appliance, pressure vessel,
                    implement, tool, personal protective equipment, or a
                    component of plant and a fitting, connection, accessory or
                    adjunct to plant.

Procedure:          Set of directions for a job (set of related tasks) for use by
                    the persons or group involved. May include standard work
                    instructions for some of the tasks forming part of the job.

Process:            Series of actions to achieve an objective.

Restraint:          Means to prevent energy contained in plant from acting, or
                    to prevent plant from moving.


                                                                           Page 10 of 11
Risk:              The risk of injury or illness to a person arising out of a
                   hazard, measured in terms of consequences and likelihood.

Risk,              Risk that is within acceptable limits and as low as
acceptable level   reasonably practicable.
of:
Shall:             Indicates that the statement is mandatory for the purposes
                   of this Guidance Note.

Should:            Indicates that the statement is a recommendation.

Standard work      Concise set of directions for a task, for use in the field by an
instruction:       individual or small group of persons.

Worker:            Any person who carries out work at a mine.




7 REFERENCES
AS 1319 – 1994 Safety signs for the occupational environment.




                                         ***




                                                                           Page 11 of 11

				
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