RCES Lock Out Tag Out.pdf

Reedy Creek Energy Services

Operations Division 320, Energy Production

Lockout / Tagout (LOTO) Program

Purpose:

These procedures have been implemented within RCES Energy Production for the protection of personnel, equipment and the environment. Operating procedures are contained in the respective Departmental Standard Operating Procedures. Maintenance procedures are contained in applicable technical manuals.

This program does NOT supersede the requirements of the “Walt Disney World Lock-Out/Tag-out Program”, nor of the Occupational Safety and Health Administration (OSHA) “Control of Hazardous Energy (lockout/tagout)” 29 CFR1910.147, but enhances the application..

References:

(1) Walt Disney Parks and Resorts – Worldwide Safety “Lockout Tagout (LOTO) Safety Program – The

Control of Hazardous Energy – PRG-193950, Revision 0, September 25, 2017.

(2) Occupational Safety and Health Administration (OSHA) “The Control of Hazardous Energy

(lockout/tagout)” 29CFR 1910.147.

Appendices:

(1) LOTO sheet 1 – Lockout / Tagout Record Sheet

(2) LOTO sheet 2 – Lockout / Tagout Sign on Sheet

(3) LOTO sheet 3 – Group Leader Transfer Log

(4) Greater Than 1KV equipment practices

(5) HVAC Procedural Policies

(6) Removal of Lock Form

Scope:

This program applies to all Reedy Creek Energy Services Cast Members who service and maintain equipment and systems under the cognizance of the Division 320 Energy Production where LOTO is applied.

This program also applies to contractors and representatives of organizations external to Reedy Creek Energy Services, who service and maintain plant equipment and systems where LOTO is applied. Any Disney Cast Members or contractors, or others using this procedure must have training in basic LOTO including the recognition of hazardous energy sources.

Definitions:

• On Screen Operator – The operator on duty in the Control Room

• Control Room – The room associated with remote control of the plant systems

• RCES – Reedy Creek Energy Services

• CEP – Central Energy Plant

• ECEP – Epcot Central Energy Plant

• NSCEP – North Studios Central Energy Plant

• SSCEP – South Studios Central Energy Plant

• COGEN – Cogeneration Plant consisting of the power generation systems

• CHOT – Contemporary Hotel Chiller Plant

• Working Foreman – The on-shift operator responsible for shift operations

• Group Leader – A Level 2 Authorized Person or higher trained individual, who initiates group LOTO and is accountable as the primary contact throughout the entire process, unless their responsibility is passed on to another Group Leader.

• Department 321 – The CEP operators, mechanics

• Department 321H – Division 320 HVAC Mechanics

• Department 323 – The ECEP/SCEP operators and mechanics.

• Plant Supervisor – anyone of the several Operations Service Managers who has cognizant responsibility during their assigned shift(s).

• WDPR – Walt Disney Parks and Resorts

Roles and Responsibilities:

• Level 1 – Affected Worker o Affected workers are those whose job requires them to operate or use a machine or equipment on which service or maintenance is performed under LOTO by a level 2 Authorized Cast Member, and others whose job requires them to work in proximity to the machine or equipment under

LOTO.

o An Affected Cast Member must be familiar with LOTO and be able to recognize equipment under

LOTO.

o Affected Cast Members are responsible for the following:

Applying their lock and tag when they are potentially exposed to hazardous energy and only after a Level 2 Authorized Cast Member has performed LOTO and applied the first lock.

Complete WDPR Level 1 User Safety Training.

Recognize when LOTO is being used.

Understand the purpose and use of the LOTO procedures.

Understand the importance of not tampering or removing any LOTO devices and not starting up equipment that has been locked or tagged out.

Comply with the requirements of this program as appropriate.

• Level 2 – Authorized Cast Member o Authorized Cast Members are those, through knowledge, experience, and training, are able to perform LOTO on specific machines, equipment, or systems in order to perform service or maintenance.

o Authorized Cast Members are responsible for the following:

Understanding the type and magnitude of the hazardous energy sources associated with machinery or equipment on which they will perform, servicing or maintenance.

Understanding the LOTO process, including the methods and means to isolate and control relevant energy sources on a particular piece of equipment.

Implementing shutdown and LOTO procedures when performing service or maintenance on machines, equipment, or systems to control the release of hazardous energy.

Taking the lead and applying the first lock and tag when performing LOTO and when assisting other Cast Members who are not trained to perform LOTO on specific machines, equipment, or systems. When in this role, their lock must be the last lock removed, unless their responsibility has been handed off to at least another Level 2 Authorized Cast Member.

Verifying proper care of LOTO equipment under their control.

Recognizing and understanding all applicable hazardous energy sources including understanding that certain machines, equipment, and systems may have more than one energy source that needs to be controlled via LOTO.

• Level 2 Authorized cast members, who are not familiar with specific machines, equipment, systems, or the associated procedure for locking them out, must be assisted by another Level 2 – Authorized cast member, or higher level trained, who has the LOTO procedural knowledge and experience with the equipment involved to shut down the equipment and isolate energy.

• Level 3 – Responsible Person o A Level 3 Responsible Person is a designated cast member, typically a leader, with sufficient knowledge and training to provide field guidance on and enforcement of the LOTO safety program.

o Responsible Persons are responsible for the following:

Leads and guides Level 2 Authorized cast members Verifying that Level 2 Authorized cast members in their area understand their responsibilities under the LOTO safety program, by conducting periodic audits of their LOTO activities.

Coordinating appropriate training for cast members with LOTO safety responsibilities.

Participating in the investigation of any incidents and near misses that might occur related to LOTO hazards in their area.

• Contractors o All contractors performing service or maintenance on machines, equipment, or systems shall conduct activities in accordance with reference (2) and are required to:

Follow the RCES LOTO program as a Level 1 – Affected Worker.

Have personnel that are properly trained in the LOTO process.

Provide timely notification and coordinate with the line of business (LOB) that contracted those regarding when LOTO will be required and will it will be implemented.

Training: In accordance with reference (1).

Procedure:

To ensure consistency of the LOTO procedure, the following will be adhered to:

1. When it is determined that a LOTO is required, a Level 2 Authorized Cast Member will be assigned to implement the LOTO.

2. If the LOTO energy control procedures involve a piece of equipment that uses greater than 1KV, the qualified operator implementing the LOTO will ensure the additional required switching steps of Appendix 4 have been completed.

3. Authorized Cast Members are to use the LOTO procedures developed and available electronically at the plant or modify one to establish a zero energy state which addresses the specific work task to be performed.

4. The Authorized Cast Member is responsible to ensure the LOTO effectively isolates the equipment for the work to be performed and shall ensure it includes the steps necessary to validate zero energy state

(ZES).

5. All LOTO Tags will have the following information:

a. Unique LOTO Identification Number (in lieu of the /name of person installing tag)

b. Lock Number (Serial # on unique key)

c. Device the tag is attached to

d. Required Position

e. Date tag applied

6. The keys from these individual locks will be placed in a Group LOTO Box. The associated Group LOTO box shift continuity lock will be applied and the key will be placed in the departmental key cabinet where all Group LOTO box shift continuity locks and keys will be maintained. Keys may be maintained in RCES vehicles for short-term and remote LOTOs.

7. All LOTO’s will be verified ZEV for the appropriate hazardous energies expected. (For example:

Mechanical, Electrical, Thermal, Chemical, Pressure, or Stored/Potential Energy). This will be signed by the Authorized Cast Member hanging the LOTO as they either test the zero energy state themselves (Mechanical), or by a qualified technician or contractor checking the zero energy state for electrical systems (electrical).

8. Once the system is verified at ZEV, RCES cast members, outside contractors, or others performing the work will be offered an opportunity to verify the system ZEV and the boundaries. They will sign in the appropriate block on Sheet 2, accepting and verifying the LOTO is adequate for the scope of work being performed and place their RED personal LOTO lock identifying the person performing the work on the Group Lock Box. Workers who are Non RCES cast members will use their company designated personal lock and tag that will provide name and contact information.

9. A Level 2 Authorized Cast Member must be signed on to Sheet 3 as the Group Leader in order for work to be performed under the LOTO. The Group Leader is the go to person if any there are any questions about the LOTO or the LOTO needs to be modified. The Group Leader is considered a system expert for the system / equipment under the LOTO. The Group Leader will be the Working Foreman (WF) if work is expected to take less than 1 shift, or the Plant Service Manager. If the Group Leader is the WF, and the work continues past the current Group Leader's shift, a new Group Leader from the oncoming shift will have to relieve the current Group Leader for work to continue. This will be annotated on Sheet 3 of the LOTO. A Group Leader is not needed if no work is being performed.

10. If work on the equipment is determined to need additional tags at any time during the work, those tags will be filled in on Sheet 1 and listed as Tag Numbers Added/Removed, the Reason for Change, and sign as Verified and Accepted By.

11. Personal locks on group LOTO boxes must be removed at the end of each shift

12. After the work is completed or at the end of each shift, each person who accepted the LOTO will sign the

“Sign OFF” block on the sheet they previously signed, indicate if their work is complete, and remove their personal lock from the Group Lock Box.

13. Once all work is completed on the piece of equipment, all locks removed from the associated Group Lock boxes, and all “Signed Off” blocks from Sheet 2 are verified signed; the Authorized Cast member on shift may then sign the Final Removal Ordered By block on Sheet 1 and the LOTO will be removed. When the LOTO is removed, each device will be positioned consistent with expected standby conditions unless another LOTO is in effect on that piece of equipment.

14. When partial removal of the LOTO is required for testing purposes, the person or Cast Member requesting the test shall verify all work on that equipment is in a state that can support the test without causing damage to equipment or injury to personal. Once verified the test can be performed safely, all work on that system or equipment stops and all personnel working on the equipment will remove their locks from the group lock box of the LOTO. An Authorized Cast Member shall determine what tags are necessary to be remove to safely test the equipment and fill in Sheet 1 indicating what tags are to be removed and the reason for their removal and sign as Verified and Accepted By.

15. In the event that a LOTO lock and tag must be removed in the absence of the person that accepted the LOTO, ensure the following are adhered to and documented on the Removal of Lock Form in Appendix 6:

a. Every means must be used to locate the person

b. The Director, or above, has been notified and approved the removal.

c. The onsite leader has determined that it is safe to re-energize the affected equipment or machine.

d. The onsite leader or a Level 2 Authorized designee shall notify any operators, users, and other affected personnel that the equipment or machine is being re-energized.

e. The onsite leader or a Level 2 Authorized designee removes the lock and tag.

f. Management shall contact the person and notify them that their lock and tag was removed prior to their next work shift.

Note 1

The RCES HVAC maintenance department Cast Members, are authorized to use modifications to the above procedure in accordance with Appendix 5.

Note 2

Prior to commencing work, all Cast Members & others must ensure an active LOTO is in place on a piece of equipment or system. In no way does this remove the responsibility on the person performing work to, sign onto the LOTO, place their personal LOTO Lock & Tag on the Group Lock Box, and verify the equipment or system having work performed on it is in a zero energy state.

Appendix 1

Sheet 1

Reedy Creek Energy Services, Inc

LOCKOUT / TAGOUT RECORD SHEET

Plant/Are a

LOTO

Number

Group Lock Box Number Maximo Number

1 2 3 4

Equipment / System to be tagged Written By:

5 7 Reason for Lock Out Tag Out Checked By:

6 8 Group Leader No. Tags Issued Date / Time Zero Energy State Verified By: (Mechanical) Date / Time

9 10 11/ 12 13/ Final Removal Ordered By Date / Time Zero Energy State Verified By: (Electrical) Date / Time

16 17/ 14 15/

Date Time Tag Numbers Added/Removed Reason for Change Verified And Accepted By

26 27 28 29 30

Item Tagged Tagged Released

Tag Lock (Execute the following operations in the Required Hanger 2nd Check Removal Date

No. No. following order) Position Initials Initials Position Initials Remove d

1 18 19 20 21 22 23 24 25

Sheet 1 of the LOTO sheet will be filled out as follows:

1. Plant - CEP, CoGen, CHOT, ECEP, LBV Gate Station, or Building 5700 service lateral as appropriate.

2. LOTO Number - Next sequential number from the LOTO Index.

3. Group Lock Box Number – Group Lock Box number assigned to this LOTO

4. Maximo Number – Maximo work order number assigned to this work

5. Equipment / System to be tagged – equipment / component that will be LOTO.

6. Reason for LOTO – why is the equipment being LOTO.

7. Written by – signature of person that wrote this LOTO.

Dwyer, Richard S.

8. Checked by – signature of person performing the second check of the written boundaries

9. Group Leader – Person responsible for this LOTO when initiated

10. Number of Tags Issued – how many tags are associated with the original LOTO

11. Date & Time – enter date and time the Group Leader authorized the hanging of the LOTO

12. Zero Energy State (ZEV) Verified by (Mechanical) – Signature of the Qualified Operator who either verified ZEV or observed ZEV being checked by a qualified technician.

13. Date & Time – date and time zero mechanical energy was verified

14. Zero Energy State Verified by (Electrical) – Signature of the Qualified Operator who either verified

ZEV or observed ZEV being checked by a qualified technician.

15. Date & Time – date and time zero electrical energy was verified

16. Final removal Ordered by – signature of person authorizing the LOTO to be removed

17. Date & Time – date and time the removal order was authorized

18. Lock No. – LOTO lock number associated with this LOTO point

19. Item Tagged – description of the LOTO point / location

20. Required position – list the position the LOTO point is to be in for LOTO

21. Hanger Initials – initials of person hanging this LOTO point

22. 2nd check Initials – initials of person checking this LOTO point is LOTO correctly

23. Removal Position – position LOTO point is to be in once LOTO is removed

24. Initials – initials of person removing and positioning LOTO point

25. Date Removed – date this LOTO point was cleared

26. Date – date that a LOTO point was added or removed

27. Time – time that a LOTO point was added or removed

28. Tag Numbers Added / Removed – enter LOTO tag numbers added or removed

29. Reason for Change – reason for adding or removing these tags

30. Verified and Accepted by – signature of person verifying the LOTO points and accepting them

NOTE: Locks, Tags and locking devices shall be used to isolate sources of energy within the normal boundaries of the scope of the repair. It is permissible to use tags without locks, in accordance with Reference

(1) Chapter 4.0.

Appendix 2

Sheet 2

Sheet 2 of the LOTO sheet will be filled out as follows:

1. Plant - CEP, CoGen, CHOT, ECEP, LBV Gate Station, or Building 5700 service lateral as appropriate (Same as Sheet 1)

2. LOTO Identification Number - Next sequential number from the LOTO Index (Same as Sheet 1)

3. Maximo Number – Maximo work order number assigned to this work (Same as Sheet 1)

4. Date on – date worker starts work under this LOTO

5. Time on – time worker starts work under this LOTO

6. Dept / Company – RCES department or company worker is doing work for

7. Verified and Accepted by - Signature of worker after reviewing the LOTO to verify that it meets the needs of the work to be done and prior to commencing work and hanging lock on Group Lock Box of the person performing work under the LOTO. If requested, the equipment will be recertified for the Authorized person performing the work. This cast member must be Authorized to work under LOTO.

An Outside contractor must be qualified under their company LOTO procedure.

8. Date off - date worker stops work under this LOTO

9. Time off - time worker stops work under this LOTO

10. Sign OFF - Signature of worker after each shift or end of job and remove lock from Group Lock Box

11. Work Complete – worker circles whether the work is complete or not when signing off and removing lock from Group Lock Box

Plant LOTO Identif ication Number Maximo Number

Date On Time On Dept / Company Verif ied And Accepted By 4 5 6 7

Date Off Time Off Sign OFF 11 8 9 10

Date On Time On Dept / Company Verif ied And Accepted By

Date Off Time Off Sign OFF

Date On Time On Dept / Company Verif ied And Accepted By

Date Off Time Off Sign OFF

Reedy Creek Energy Services, Inc

LOCKOUT / TAGOUT SIGN ON SHEET

2 3

(legibly ci rcle one)

When signing off:

Is the work complete?

YES NO

When signing off:

Is the work complete?

(legibly ci rcle one) YES NO When signing off:

Is the work complete?

(legibly ci rcle one) YES NO

Appendix 3

Sheet 3

Sheet 3 of the LOTO sheet will be filled out as follows:

1. Plant - CEP, CoGen, CHOT, ECEP, LBV Gate Station, or Building 5700 service lateral as appropriate (Same as Sheet 1)

2. LOTO Identification Number - Next sequential number from the LOTO Index (Same as Sheet 1)

3. Maximo Number – Maximo work order number assigned to this work (Same as Sheet 1)

4. Accept:

a. Date – date Group Leader signs on as Group Leader for this LOTO

b. Time - time Group Leader signs on as Group Leader for this LOTO

c. Name – name of Group Leader

d. Signature – signature of Group Leader

5. Release:

a. Date – date Group Leader signs off as Group Leader for this LOTO

b. Time - time Group Leader signs off as Group Leader for this LOTO

c. Name – name of Group Leader

d. Signature – signature of Group Leader

Plant LOTO Identif ication Number Maximo Number

1 2 3 Accept 4 Release 5 Date Time Name Signature Date Time Name Signature

4a 4b 4c 4d 5a 5b 5c 5d

Group Leader Transfer Log

Appendix 4

Removal of Lock Form