Document 3NYnbxpXqDXDd41kQ4Vemo3mn

SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT PLAINTIFF'S EXHIBIT a MON-278 PURPOSE BESZ9 To define the procedure necessary to prevent personnel injury because of inadvertent operation of electrical/mechanical machinery while inspection or repair work is in progress. POLICY All machinery shall be shutdown and locked in the "Off" posi tion by the owning department prior to turn over for inspection or repair work. This "first lock" is the primary "first-lineof-defense" while work is in progress. This lock is to remain in place until all work is complete. Each individual group performing work upon the machinery must also lock out the equipment. This lock is the "second-lineof-defense" and is primarily for the protection of the inspec tion or repair group. Both lockouts must be positive and shall prevent operation of the machinery. Symbolic lockouts will not be considered as an adherence to this policy, i.e., car seals, tags, tape, etc. Should the case arise where normal lockout is not possible because of system or equipment design, the machinery shall be isolated by such means as necessary to positively prevent operation (blinds, electrical disconnect, valve removal, etc.) This policy defines the minimum requirement for personnel and equipment safety and may be enlarged upon by request of any individual having doubts as to the integrity of the secured machinery. DEFINITIONS "MACHINERY" as used in this procedure means any mechanical device subject to being controlled through or powered by remote energy sources such as, but not necessarily exclusive to, steam and electricity. "GROUP" as used herein shall be considered as a collection of those individuals performing a common task of inspection or repair. By way of example, these may be insulators, fitters. Mechanical Maintenance, I&E Maintenance, Production, etc. 6113 17030 LQ01582 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT fCont'd) RESPONSIBILITIES 1. The "Owning Department" is responsible for,preventing accidental operation or energization of equipment during repair work, through effective use and enforcement of this lockout procedure. 2. The person performing inspction or repair work is responsible for "protecting himself" by verifying that the "owning depart ment" has correctly locked out the equipment to be repaired. He shall then apply his personal lock as the second-line-ofdefense. 3. The Maintenance Department is responsible for instructing con tractors in the use of the lockout procedure and enforcing its implementation. 4. Each "owning department" will provide an adequate number of locks, coded to identify the department. The "lockout" locks will all be coded alike within the same department and key control will be the responsibility of the owning department. 5. The Maintenance Department will provide each technician (or contractor) a lock, individually keyed for each lock. Maintenan ce supervision will have a sub-master key to fit all lockout locks. This sub-master will be used only in strict accordance with this procedure. BASIC LOCKOUT PROCEDURE The basic lockout procedure can be defined as having five discrete steps. STEP 1 The "owning department" will prepare the "machinery" for repair work and apply their department lock at the points designed to prevent "machinery" operation. STEP 2 The "group" or individual performing repair work will verify Step 1, above, and then apply his individual lock on top of the owning department's lock. STEP 3 Representatives from the owning department and the group performing the repair work will then jointly test the lockout by attempting to start or energize the "machinery" or open the valve, whichever is appropriate. 6113 17031 LC01383 ORIGINAL 3 /14/ 63),R.E REVISED / / .GuilliairjaEVIEWED4yi /yj By__________ PAGE 2 OF By R. E. Gu il 1 i am;; ATTACHMENT 5 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-018 CHOCOLATE BAYOU PLANT ac MACHINERY AND ELECTRICAL LOCKOUT (Cont'd) STEP 4 - The "group" or individual performing repair work will personally retain his key until his job is complete or until the end of his work shift. The individual removing this lock is responsible for assuring that all work by his "group" has stopped, before lock removal. Equipment turnover will occur upon completion of all maintenance repair work, at which time Maintenance will notify the owning department that the work is complete. The "owning department" will verify that all work is complete by visual inspection of the "machinery", and then remove the department lock. At this time, the "machinery" is ready for normal check out and startup. SPECIAL REQUIREMENTS 1. In some instances, equipment or machinery may be capable of moving itself even though all energy sources have been locked out. This is a common occurrence on fan blades which rotate when powered by the wind and can also be a problem with large flywheels or partially disassembled equipment that roll over because of gravity. Maintenance supervision is responsible for identfying the machinery where this potential exists, and commun icating the existance of this hazard to the personnel performing the repair work. The group performing the inspection or repair work. The group performing the inspection or repair shall apply any special mechanical stops, blocks, chains, etc. , necessary to prevent accidental machinery movement. 2. Special consideration may be necessary for certain vessel entry or repair work done within large compressors or confined fan areas. It should be remembered that this procedure speaks to minimum requirements and any party involved with the repair may request whatever action is reasonably necessary to assure him of his safety while performing the work. 3. Certain systems require special steps to be added to the lockout procedure. These are systems having more than one source of energy, systems having certain types of process interlocks, etc. In these cases, the owning department is responsible for identifying these special systems, and communicating special lockout requirements. These special requirements may consist of special locking hardware, multiple locking, special test. _____ procedure for verifying lockout, etc.. 6113 17032 EC015S4 SAFETY PROCEDURE MANUAL MONSANTO COMPANY ~ SP-018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT (Cont'd) 4. In special instances where lock removal by the group performing the repair could place the equipment or other groups in jeopardy t$e immediate supervisor of the group in question may elect to maintain the lockoout. . When this is done, a danger tag (See Attachment #1) shall be attached to the lock and this tag shall be signed and dated by that supervisor. Removal of this lock shall be done only by the party who installed it, and on offhours would require the Night Supervisor to call the individual who signed the tag before authorizing lock removal. If the signee cannot be reached, the Night Supervisor will contact appropriate department supervision^for assistance. DEFINITIONS AND INTERPRETATIONS 1. The lockout procedure is intended primarily to prevent injury to personnel working on equipment, and the owning department is not required to lock the equpiment until just prior to re leasing it to Maintenance for repairs. However, a secondary feature of lockout is to prevent damage to equipment resulting from operating it while it is in disrepair, and owning depart ments are encouraged to lockout equipment as soon as pratical. 2. The lockout procedure is not intended to provide repair job status communications. Each group involved in repair and oper ation of equipment must maintain normal and complete communication regarding job start, progress, breaks in schedule, need for testing, job completion, etc. 3. At times a lock will be inadvertently left on a piece of equip ment after repair work is complete. In these cases the foreman of the group leaving the lock in place will be called to verify job completion, and to remove the lock. Should this occur on off-hours, the Night Supervisor shall make the decision of lock removal and communicate the omission to supervision in the department involved. 4. Although electrical personnel are trained in the technique of working on live electric circuits, wherever possible they should follow the lockout procedure and work energized circuits only as a last resort. However, when trained personnel are working on energized circuits, and following prescribed techniques and safety procedures, it is not considered a violation of the lock out procedure. 5. A lockout may be removed for testing and adjusting equipment, checking motor winding, relays, belt tracking, etc. The Main tenance Foreman and the Production Shift Foreman shall jointly agree to lock removal, and shall communicate to all personnel BG01585 ORIGINAL /. / REVISED / / By_________ PAGE 4 OF 5 ISSUE 3 A4/63 ByR.E.GuilliangEVIEWED4/l /II ByR.E.Guilliamii ATTACHMENT 6113 17033 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP-018 CHOCOLATE BAYOU PLANT ""IX ^ MACHINERY AND ELECTRICAL LOCKOUT (Cont'd) involved, the exact nature, extent, and timing of the testing. All locks will be reinstalled immediately upon completion of tests. Joint testing of the lockout by Production and Main tenance is required after the locks have been reinstalled. 6. Lockout of control pushbutton circuits is not acceptable. 7. Electrical systems of 32 volts and below do not require lock out for protection from electrical shock. AUTHOR: R. E. Guillams APPROVED BY W. H. Collier APPROVED BY: G.E. Davenport ORIGINAL ISSUE 6113 17034 EG01586 3/14/6 3ByR. E . Guilliar REVISED / / By PAGE 5 OF 5 REVIEWED y 1/77 ByR.E.Guilliams ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY WMI SP-M8 CHOCOLATE BAYOU PLANT MONSANTO CHOCOLATE BAYOU l MONSANTO CHbCOLATE BAYOU DO HOT REMOVE THIS TAG EQUIPMENT LOCKED OUT: EQUIPMENT ISOLATED: Signed. Pew Mce-m* ' cr DO NOT OPERATE SrE TAG REMOVAL SHALL ^by authorized personnel ONLY. SEE PLANT PROCEDURES D0912 arid D0923. PREVENT INJURY -THIN K! IV CIl (Rev. tin) >* *,TI * ORIGINAL ISSUE 6113 17035 3^4/4 REVISED / / hi63_ByR.E.Guillian gEVIEWED4./l EG01587 By PAGE 1 OF 1 By R.E.Guilliamis ATTACHMENT#! SAFETY, PROCEDURE MANUAL MONSANTO COMPANY __ SP- 018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT PURPOSE To define the procedure necessary to prevent personnel injury and equipment damage because of inadvertent operation of electrical/mechanical machinery while inspection or repair work is in progress. POLICY All machinery shall be shutdown and locked in the "Off" position by the owning department prior to turn over for inspection or repair work. This "first lock" is the primary "first-line-of-defense; while work is in progress. This lock is to remain in place until all work is complete. Each individual group performing work upon the machinery must also lock out the equipment. This lock is the "second-line-of-defense" and is primarily for the protection of the inspection or repair group. Both lock outs must be positive and shall prevent operation of the machinery. Symbolic lock outs will not be considered as an adherence to this policy, i.e., car seals, tags, tape, etc. Should the case arise where normal lockout is not possible because of system or equipment design, the machinery shall be isolated by such means as necessary to positively prevent operation (blinds, electrical disconnect, yalve removal, etc.) Lighting panels containing molded case breakers in the range of 110 to 240 volts * can only be locked out by placing a specially prepared yellow strip of tape with adhesive backing on the breaker switch in the off position to prevent inadvertent movement. All lighting panel breakers above 240 volts will adhere to the third paragraph. See attachment #1 page 2 of 2. This policy defines the minimum requirement for personnel and equipment safety and may be enlarged upon by request of any individual having doubts as to the integrity of the secured machinery. DEFINITIONS "Machinery" as used in this procedure means any mechanical device subject to being controlled through or powered by remote energy sources such as, but not necessarily exclusive to, steam and electricity. * "Lighting Panel" as used in this procedure, refer to those lighting panels located in buildings and other non-classified areas which do not have lockout provision. "Group" as used herein shall be considered as a collection of those individuals performing a common task of inspection or repair. By way of example, these may be insulators, fitters. Mechanical Maintenance, I&E Maintenance, Production, etc. 6113 17036 Note Change EGG1588 ORIGINAL ISSUE 1/14/ REVISED 6/2l/7a By -T.M. rh-MHc PAGE 1 OF 5 jgByR. E. GuilliamsREVElWES /0/81 By C.R.Muirrell ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP 018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT (Cont'd) RESPONSIBILITIES 1. The "Owning Department" is responsible for preventing accidental operation or energization of equipment during repair work, through effective use and enforcement of this lockout procedure. 2. The person performing inspection or repair work is responsible for "protecting himself" by verifying that the "owning department" has correctly locked out the equipment to be repaired. He shall then apply his personal lock as the secondline-of defense. 3. The Maintenance Department is responsible for instructing contractors in the use of the lockout procedure and enforcing its implementation. 4. Each "owning department" will provide am adequate number of locks, coded to identify the department. The "lockout" locks will all be coded alike * within the same department and key control will be the responsibility of the owning department. 5. The Maintenance Department will provide each technician (or contractor) a lock, individually keyed for each lock. Mainteancne supervision will have a sub master key to fit all lockout locks. This sub-master will be used only in strict accordance with this procedure. BASIC LOCKOUT PROCEDURE The basic lockout procedure cam be defined as having five discrete steps. Step 1 The "owning department" will prepare the "machinery"* for repair work and apply their department lock at the points designed to prevent "machinery" operation. Step 2 The "group" or individual performing repair work will verify Step 1, above, and then apply his individual lock on top of the owning de partment's lock. Step 3 Representatives from the owning department and the group performing the repair work will then jointly test the lockout by attempting to start or energize the "machinery" or open the valve, whichever is appropriate. Step 4 ORIGINAL ISSUE The "group" or individual performing repair work will personally retain his key until his job is__complete or until the end of his work shift. The individual removing this lock is responsible for assuring that all work by his "group" has stopped, before lock removal. 6113 17037 EG01589 3/l4/463 By REVISED 6/ 2X 78By J.N. Childs R.E. Guillia" ^EVIEWED8 /20/ 81 ByC.R. Murre 11 PAGE 2 OF ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP 018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT (Cont.d) Step 5 - Equipment turnover will occur upon completion of all maintenance - % repair work, at which time Maintenance will notify the owning depart ment that the work is complete. The "owning department" will verify that all work is complete by visual inspection of the "machinery", and then remove the department lock. At this time, the "machinery" is ready for normal check out and startup. SPECIAL REQUIREMENTS 1. In some instances, equipment or machinery may be capable of moving itself even though all energy sources have been locked out. This is a common occurrence on fan blades which rotate when powered by the wind and can also be a problem with large flywheels or partially disassembled equipment that roll over be cause of gravity. Maintenence supervision is responsible for identifying the machinery where this potential exists, and communicating the existence of this hazard to the personnel performing the repair work. The group performing the inspection or repair shall apply any special mechanical stops, blocks, chains, etc., necessary to prevent accidental machinery movement. 2. Special consideration may be necessary for certain vessel entry or repair work done within large compressors or confined fan areas. It should be remembered that this procedure speaks to minimum requirements and any party involved with the repair may request whatever action is reasonably necessary to assure him of his safety while performing the work. 3. Certain systems require special steps to be added to the lockout procedure. These are systems having more than one source of energy, systems having certain types of process interlocks, etc. In these cases, the owning department is responsible for identifying these special systems, and communicating special lockout requirements. These special requirements may consist of special locking hardware, multiple locking, special test procedure for verifying lockout, etc... 4. In special instances where lock removal by the group performing the repair could place the equipment or other groups in jeopardy the immediate super visor bdE the group doing the repair may elect to maintain the lockout. When * this is done, a caution tag (See Attachment #1) shall be attached to the lock and this tag shall be signed and dated by that supervisor. Removal of this lock shall be done only by the party who installed it, and on off-hours would require the Night Supervisor to call the individual who signed the tag before authorizing lock removal. If,the signee cannot be reached, the Night Supervisor will contact appropriate department supervision for assistance. *Note Change 6113 17038 EG01590 ORIGINAL ISSUE 3/l4/ 63gy R.E. REVISED Guilliams - 6/21/78 ByJ.N. Childs REVIEWED 8/2? 81 By C.R.Murrell PAGE 3 OF ATTACHMENT 5 SAFETY PROCEDURE MANUAL MONSANTO COMPANY SP" 018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT (Cont'd) DEFINITIONS AND INTERPRETATIONS 1. The lockout procedure is intended primarily to prevent injury to personnel . working on equipment, and the owning department is not required to lock the equipment until just prior to releasing it to Maintenance for repairs. However, a secondary feature of lockout is to prevent damage to equipment resulting from operating it while it is in disrepair, and owning departments are en couraged to lock out equipment as soon as practical. 2. The lockout procedure is not intended to provide repair job status communi cations. Each group involved in repair and operation of equipment must maintain normal and complete communciation regarding job start, progress, breaks in schedule, need for testing, job completion, etc. 3. At times a lock will be inadvertently left on a piece of equipment after re pair work is complete. In these cases the foreman of the group leaving the lock in place will be called to verify job conpletion, and to remove the lock. Should this occur on off-hours, the Night Supervisor shall make the decision of lock removal and coinmunicate the omission to supervision in the department involved. - 4. Although electrical personnel are trained in the'technique of working on live electric circuits, where- ever possible they should follow the lockout procedure and work energized circuits only as a last resort. However, when trained personnel are working on energized circuits, and following prescribed techniques and safety procedures, it is not considered a violation of the lock out procedure. 5. A lockout may be removed for testing and adjusting equipment, checking motor winding, relays, belt tracking,etc. The Maintenance Foreman and the Production Shift Foreman shall jointly agree to lock removal, and shall communicate to all personnel involved, the exact nature, extent,and timing of the testing. All locks will be reinstalled immediately upon completion of tests. Joint testing of the lockout by Production and Maintenance is required after the locks have been reinstalled. 6. Lockout of control pushbutton circuits is not.acceptable. 7. Electrical systems of 32 volts and below do not require lockout for protection from electrical shock. 6113 17039 E001G91 ORIGINAL ISSUE / REVISED 6/21/ 78By j.n. Childs 3 14/563 By R.E. GuilliasijrREVEIWED8/2Q/81 By C.R.Murrell PAGE 4 OF ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY ^ SP- 018 CHOCOLATE BAYOU PLANT MACHINERY AND ELECTRICAL LOCKOUT (Cont.d) C>Approved by: X-J O / J OR IOINAI // 6113 17040 ,, ,,............... jREViSED~6/2y By j. N; ChjXdT PAGE 5 OF 5 Guillian|^EVE|WED a^cy&l ^ C.R. Murrell ATTACHMENT SAFETY PROCEDURE MANUAL MONSANTO COMPANY $P- 018 CHOCOLATE BAYOU PLANT DO NOT REMOVE THIS TAG EQUIPMENT LOCKED OUT: EQUIPMENT ISOLATED: MONSANTO CHOCOLATE BAYOU DO NOT OPERATE ACCIDENTAL OPERATION OF THIS DEVICE CAN CAUSE INJURY OR DAMAGE. TAG REMOVAL SHALL BE BY AUTHORIZED PERSONNEL ONLY. SEE PLANT PROCEDURES SP-016 and SP-018. ORIGINAL ISSUE 6113 17041 BQ01593 REVISED 6/21/78 Byj.N. Childs Guilliam r REVIEWED8/2CK 81 ByC.R.Murrell PAGE 1 OF 2 ATTACHMENT #1 SAFETY PROCEDURE MANUAL MONSANTO COMPANY LIGHTING EANEL LOCKOUT TAPE SP- oia CHOCOLATE BAYOU PLANT - -- Red Letters f Yellow Background LECTR1CAL LOCKOUT TO BE REMOVED ONLY BY liiowjmes / ------ PATE SP-OI8a SP-016. REV. 5/78. Black Letters ORIGINAL ISSUE 6113 17042 EG01594