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Suzlon Wind Energy Corporation
Corporate EHS Program
Page 1 of 83 Createdby Gordon McCalister
TABLE OF CONTENTS
 Safety Orientation (Pending Completion)
 Training Requirements
 SWECO Drug and Alcohol Policy
 Lock Out Tag Out (LOTO) Program
 Injury/Accident Reporting and Procedures
 Weather Restrictions
Suzlon Wind Energy Corporation
Corporate EHS Program
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ORIENTATIONFOR NEWLY HIRED EMPLOYEES
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Corporate EHS Program
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OVERVIEW
The SWECO Safety Orientation has been developed to provide initial and/or annual
refresher training to all SWECO employees, and employees with new job assignments.
This format is designed to provide the training information required in a terminology that
is easy to follow, thus helping to reduce needles accidents and wasted time in training.
Please not that there may be additional training, or refresher training required to perform
certain jobs within SWECO.
Teaching Time for this Program
While this training can be delivered according to special needs, it is a SWECO
requirement that this training be delivered to the employee in a one (1) day/shift format.
To run this safety orientation over a longer period of time may expose the employee to
hazardous situations. For any deviation from this program you must contact the Corporate
EHS Manager or the VP of construction for approval.
Learning Objectives
1. Identify SWECO/OSHA/CLIENT general safety rules and procedures.
2. Discuss Hazard Communication Requirements (MSDS), Impact of an accident on
the employee, the family, and the Company.
3. Identify various fall hazards, means of fall prevention, and when and were fall
protection is required.
4. Understanding the proper use of Ladders.
5. Recognize various electrical hazards on the job site and know ones limitation by
training and experience.
6. Understand the proper use of hand and power tools.
7. Identify the hazards of working in or near an excavation.
8. Discuss and sign the SWECO Drug and Alcohol Policy.
9. Participate in testing program if applicable.
10. Discuss the hazards and identify confined spaces.
11. Explain the different signs and barricades on a job site.
12. Identify the hazards of material handling and the procedures to abate these
hazards.
13. Describe and discuss proper rigging procedures.
14. Describe the proper use of every day clothing and specialized PPE.
15. Discuss mobile equipment and the requirements to operate it.
16. Discuss any special training or procedures for individual job descriptions or
projects.
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Corporate EHS Program
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Fall Hazards and Types of Protection
A. Fall Hazards
B. Ladders
C. Floor, Wall, and Stairway Openings
Electrical Hazards
A. Electrical Hazards
B. Electrical Power Systems
C. Hand and Power Tool Safety
Trenching Hazards/Heavy Equipment
A. Excavations
B. Emergency Response
C. Heavy Equipment
D. Crane Safety
E. Signs and Barricades
Struck By/Material Handling
A. Material Handling
B. Personal Protective Equipment
C. Rigging
Construction Health
A. Hazard Communication (Right to Know)
B. Housekeeping
C. Hearing Preservation
Topic
This information covered in this section is reflected in the SWECO employee handbook.
However, additional training is required, for example (confined space). Please notice that
the test to show proficiency is mandatory.
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Corporate EHS Program
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Other Topics Site/Specific Hazards
A. Respiratory Protection (Breathing)
B. Confined Space Entry
C. Lockout/Tagout
D. Fire Protection and Prevention
E. Welding and Cutting Hazards
F. Process safety management
G. Permits
H. Steel Erection
I. Concrete Work
J. Hot Weather Precautions
K. Cold Weather Precautions
L. Basic Rules of Safety
M. Summary
1. Summarize orientation
2. Answer questions
N. Test
Employees must score at least 80 percent on the test.
Note: The SWECO safety CD has several power points presentations covering all
the subjects mentioned above. The site supervisor shall ensure that each employee
received training if the hazards associated with his or her job change. If you don’t
have the required presentation or video/DVD, you must call the SWECO safety
office for immediate assistance.
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Corporate EHS Program
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.
SS
INTRODUCTION TO SWECO/OSHA/SAFETY
SuggestedEquipment and Materials
Copy of OSHA CFR 1926
Copy of OSHA poster
SWECO/site written safety program
Overhead projector and screen
White board/chalkboard
Markers/chalk
Copies of the test
Subjects
SWECO/ OSHA/Client
Accidents vs. Incidents
Impact of Accidents
Site Specific rules
Give an overview of this orientation
1. Take attendance and perform other administrative tasks.
2. Outline briefly the topics to be covered. Explain to the employees that they must
pass the Course Examination with a grade of at least 80 percent.
 Make sure to cover site specifics emergency procedures.
OSHA
1. Give a brief overview of OSHA. Explain to trainees refers both to the
Occupational Safety and Health Act passed by Congress in 1970 and to the
Occupational Safety and Health Administration who enforces these regulations.
2. Show trainees the OSHA poster that is required to be displayed in all workplaces.
3. Tell employees where the poster is located in their workplace.
3. 4. Explain the Employees’ Rights detailed on the OSHA poster.
Accidents vs. Incidents
1. Describe what an accident is.
2. Describe what an incident is.
3. Discussion
 Have participants list the various causes of accidents (unsafe acts and unsafe
conditions).
 Discuss the Accident Study Ratio transparency.
 Discuss the role of the employees in recognizing hazards and reporting them.
 Discuss the specific procedures for reporting hazards on their job or project.
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Impact of Accidents
1. Lecture
 Explain the actual cost of an accident.
 Explain the hidden cost of an accident.
FALL HAZARDS AND
TYPES OF PROTECTION
SuggestedEquipment and Materials
OSHA CFR 1926
SWECO/site written safety program
Examples of fall protection harnesses
Ladder
Examples of signs and covers for holes and openings
Overhead projector and screen
White board/chalkboard
Markers/chalk
Items to cover
Fall Hazards
Ladders
Scaffolding
Floor, Wall, and Stairway Openings
Fall Hazards
1. Explain that falling is the leading cause of death in construction. These deaths and
injuries occur because of falls from ladders, scaffolds, and other equipment. Fall
protection available includes:
 Personal fall protection system
 Guardrails
 Nets
2. Demonstrate the proper use of a harness, lanyards, and proper tie-off points. If time
permits, have employees try on harnesses and demonstrate the proper use as well.
3. Discuss when fall protection is needed.
 SWECO Six-foot rule or client/site specific rule (the most strict of the two will
apply)
 Lanyard (dual?) requirements
 Equipment inspections (monthly documented)
4. Have employees list and discuss the possible areas and situations that would require
the use of one of the fall protection systems.
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Ladders
Lecture
 Describe how to determine the load limits.
 Describe the need to use a ladder as intended by the manufacturer.
 Describe how to inspect a ladder. Demonstrate the 3-point method of climbing a
ladder in the classroom or outside of it. If time permits, let employees try as
well.
3. Discussion
 Have employees list the various causes of accidents using ladders.
 Discuss the proper angle a straight or extension ladder should be when erected.
 Discuss the specific procedures for reporting damaged ladders on their job or
project.
Scaffolding
Explain the following points. Scaffolding shall:
 Have solid foundation/support.
 Be plumb.
 Be fully braced.
 Use tag to report unsafe situation.
 Be inspected prior to use.
 Have safe access.
 Have guardrails and toeboards at 10 feet. (SWECO requires toe boards on all
scaffolds. For any deviation contact the SWECO Corporate EHS Manager)
1. Explain the role of the competent person.
2. Have the employees identify their competent person for scaffolding on their site.
3. If time permits, take the trainees to an area on the job site with scaffolding and ask
them to identify its “safety features” (bracing, guardrails, etc.)
Floor, Wall, and Stairway Openings
1. Explain the dangers of unguarded floor, wall, and stairway openings and the
employees’ responsibilities to make sure they are adequately guarded.
2. Show the employees examples of warning signs and covers for openings. If time
permits, show them places on the job site where guards and temporary covers
protect workers from openings.
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ELECRICAL HAZARDS
SuggestedEquipment and Materials
OSHA CFR 1926
SWECO/site written safety program
Examples of ground-fault circuit interrupters (GFCIs)
Examples of fall protection harnesses
Examples of double insulated tools
Overhead projector and screen
White board/chalkboard
Markers/chalk
Items to cover
Electrical Hazards
Electrical Power Systems
Hand and Power Tool Safety
Electrical Hazards
1. Explain that electrocution is one of the top four leading causes of death in
construction.
2. List examples of causes of electrical accidents.
3. Talk about the General rules for working around power lines.
Electrical Power Systems
1. List the types of electrical protection and explain how they work.
 Show the difference between a double-insulated tool and a grounded tool.
 Discuss SWECO assured grounding program.
 Demonstrate the proper use of a ground-fault circuit interrupters (GFCI).
2. Discuss the importance of daily inspection of equipment and tools.
Hand and Power Tool Safety
Discuss the importance of:
 Using the right tool for the job
 Care for tools
1. General precautions for power tools
 Never carry by the cord
 Disconnect tools not in use
 Never use legs as cutting surfaces
 Wear proper personal protective equipment
 Specialty tools (powder actuated, etc.)
 Special hazards
 Special requirements to operate
2. Have employees list the most commonly misused hand tools.
3. Discuss injuries from tools that have happened to family or friends.
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TRENCHING HAZARDS/HEAVY EQUIPMENT
SuggestedEquipment and Materials
Copy of OSHA CFR 1926
SWECO/site written safety program
Examples of signs, tags, and barricades
Overhead projector and screen
White board/chalkboard
Markers/chalk
Items to cover:
Excavations
Emergency Response
Heavy Equipment
Crane Safety
Signs and Barricades
Excavations (if SWECO employees will not be working around excavations you don’t have
to cover this section but if an employee is transferred at a later time and he/she will be
working near excavations you will need cover the hazards associated with excavations)
Working in or around excavations is one of the most dangerous jobs in the construction
industry. It is estimated that cave-ins claim 80 to 100 construction workers’ lives every
year.
1. Discuss the causes of cave-in, such as weather, vibrations, and movement of
buildings near excavations.
2. Outline the procedures to follow prior to start digging and what rules must be
followed.
3. Describe the competent person's role in excavations.
4. Explain the types of protective systems, such as sloping/benching, shoring, and
shields.
5. Explain the four-foot rule. (At depths of four feet, exits such as a ladder or ramp
must be provided every 25 feet.)
6. Explain the five-foot rule. (At depths of five feet and greater, the excavation must
be sloped or shored. A protective system must be used. If more than 20’ a PE
approval is required)
7. Explain the difference in soil classifications.
8. Have participants identify their competent person for excavation.
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Emerge
ncy
Response
Every operation that includes trenching should have emergency response procedures in
place, and rescue equipment ready, in case an accident occurs.
1. Go over the following critical concerns with the employees. Remind them of the
importance to have a plan in place in case of emergency.
 Who provides rescue and first aid? Where are the emergency phone numbers
listed? Who will notify the authorities and rescue personnel?
 Who will meet, advise, and direct rescue personnel at the job site?
 What emergency response equipment will be available on the job site? Where
will it be kept, and who is trained to use it?
 Neveruse heavy equipment in a rescue.
 Neverendanger yourself in a rescue attempt.
Heavy Equipment
1. Only authorized, trained personnel should operate vehicles and mobile equipment.
Certain equipment requires operators to be trained and certified. (SWECO requires
a test).
2. Discuss the SWECO requirements to operate each piece of equipment, such as
certification or site requirements
3. Discuss safe behavior for ground personnel working near heavy equipment and for
heavy equipment operators working near ground personnel.
4. Discuss the importance of stability control when operating heavy equipment or near
heavy equipment.
5. Have participants list the various types of equipment being used on the job site
Crane Safety
1. Only authorized, trained personnel shall operate cranes.
2. Discuss when conducting crane inspections, cranes must be in good working order
to be used on the job site.
3. Talk about safety procedures crane operators should follow.
Signs and Barricades
1. Outline the various types of signs employees are likely to see on the construction
site. Show examples.
2. Outline the types of tags employees are likely to see on the construction site. Show
examples.
3. Explain the types and uses of barricades. Show examples.
4. Demonstrate the proper procedures for using out of service tags on the job site.
5. If time permits, take the employees for a walk around the job site to identify the
various types of signs, tags, and barriers they see. Can they spot any places where
there should be a sign, tag, or barrier?
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STRUCK BY/MATERIAL HANDLING
SuggestedEquipment and Materials
OSHA CFR 1926
SWECO site written safety program
Examples of personal protective equipment
Overhead projector and screen
White board/chalkboard
Markers/chalk
Material to cover
Material Handling
Personal Protective Equipment
Rigging
Material Handling
Manual material lifting is the principal source of compensative work injuries in the
United States. In 1980 alone, about one million workers suffered back injuries in the
workplace, three-quarters of which were caused by lifting.
1. Discuss material handling by hand and the correct and incorrect ways to do it,
including:
 The risk to health from unskilled lifting
 The effects of lifting on the body
 Developing an awareness of your body's limits
 Recognition of physical factors that contribute to an accident
 Handling skill and safe lifting posture and procedures
 Handling aids
2. Discuss considerations when handling materials with machines, such as a dolly or
forklift.
3. Have participants identify proper pre-lift considerations.
Personal Protective Equipment
Personal protective equipment (PPE), properly used and kept in good condition, saves
lives and reduces injury and illness among employees. PPE includes: equipment for eyes,
face, head, arms, and legs; protective clothing; respiratory devices; and protective shields
and barriers.
1. Explain to the employees the importance of using PPE.
2. Discuss the kinds of PPE available and when and where to use what kinds.
3. Discuss trade-specific PPE.
4. Show the employees examples of PPE, such different kinds of eyewear, hard
hats, and gloves.
5. Identify the PPE required on the jobsite.
6. Discuss the procedures for replacing equipment in poor
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condition.
7. Review SWECO and jobsite rules on PPE.
Rigging
Moving large, heavy loads is crucial to today's manufacturing and construction industries.
Much technology, careful training, and extensive workplace precautions have been
developed for these operations. There are significant safety issues to be considered, both
for the operators of the diverse "lifting" devices and for workers in proximity to them.
1. Underscore that qualified personnel shall be involved in a lift. A qualified
signalman must be used, and the work must be properly supervised.
2. Safe methods and procedures must be observed in the lift at all times.
3. Know the rated capacity of the sling.
4. Know the condition of all the slings, shackles, hooks, and other lifting equipment.
5. Use eyebolts carefully.
6. Stay clear of suspended loads.
7. Keep the load balanced.
8. Don't jerk the load.
9. Maintain control and always use a tag line.
10. Watch the vertical angle.
11. Have each employee demonstrate the hand signals used. If time permits, divide
the trainees into pairs and have them signal to each other.
CONSTRUCTION HEALTH
SuggestedEquipment and Materials
OSHA CFR 1926
SWECO site written safety program
Overhead projector and screen
White board/chalkboard
Markers/chalk
Sample material safety data sheets (MSDS)
Examples of hazard labeling signs
Items to cover
Hazard Communication
Housekeeping
Hearing Preservation
Construction Ergonomics
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Hazard Communication:
1. Explain what hazard communication (HAZCOM) is and why it should be
important to all SWECO employees.
2. Tell the trainees what must be labeled.
3. Show the trainees how to read HAZCOM labels.
4. Pass out examples of hazard labeling signs for the employees to become familiar
with.
5. Explain what material safety data sheets (MSDS) are and where they are located
on the job site. If time permits, show the employees where the MSDS sheets are
located.
6. Show the employees how to read MSDS sheets.
7. Pass out examples of MSDS sheets to the employees.
8. Have participants identify on an MSDS the areas of concern:
 Name of the chemical
 Health hazards
 First aid/medical information
 Personal protective equipment required
Housekeeping:
Management and employees should recognize good housekeeping as a vital tool for
production and safety. Good housekeeping reduces operating costs, increases production,
opens aisles to permit faster safe movement of materials and employees, lowers accident
rates, reduces fire hazards, and raises employee morale.
1. Have the employees brainstorm about the benefits of good housekeeping around
the job site. Afterwards, fill in any benefits they may have missed.
2. List some of the many ways a job site is kept orderly, such as disposing of trash
promptly, putting away tools and equipment properly, and keeping walkways and
stairways free of debris and tripping obstacles.
Hearing Conservation
1. Hearing protection should be worn any time noise is too loud to understand a
normal conversation.
2. Ask your supervisor about hearing protection requirements at your job site.
3. Plain cotton is not an acceptable protective device.
4. Have participant discuss the long-term impact of noise on hearing.
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Construction Ergonomics
Ergonomics is the science of fitting the job to the worker. Often musculoskeletal
disorders (MSDS) can be prevented by simple and inexpensive changes in the workplace.
Adjusting the height of working surfaces, varying tasks for workers, and encouraging
short rest breaks can reduce risks. Reducing the size of the items workers must lift or
providing lifting equipment also may aid workers. The longer the time the worker must
maintain a fixed or awkward posture, exert force, repeat the same movements, experience
vibration, or handle heavy items, the greater the chance that such a disorder will occur.
1. Discuss the following critical concerns and how they can hurt your body:
 Frequency of the action or work cycle
 Awkward postures required to perform the task
 Forceful exertions required by the task
 Workplace conditions that may affect the hazard presented by a task
 Tools or clothing used on the job which may affect the hazard presented by
the task
Additional safety topics
SuggestedEquipment and Materials
OSHA CFR 1926
SWECO/site written safety program
TV/VCR (optional)
Respiratory Protection (Breathing)
Confined Space Entry
Lockout/Tagout
Fire Protection and Prevention
Welding and Cutting Hazards
Asbestos and lead Awareness
Permits
Steel Erection
Concrete Work
Hot Weather Precautions
Cold Weather Precautions
Test (Mandatory)
Respiratory Protection (Breathing)
Optional equipment: examples of respiratory equipment
1. Talk about the situations when respiratory equipment is mandatory.
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2. Discuss the necessity of being trained to use a respirator and receiving approval
from your supervisor before entering an area where a respirator is needed.
3. Show the employees examples of respiratory equipment.
4. Discuss the importance of maintaining, regularly inspecting,
and storing respiratory equipment properly.
Confined Space Entry
1. Define “confined space” and “permit-required confined space.” Make sure
employees understand the difference.
2. List and discuss some of the hazards associated with confined space, such as
atmospheric, mechanical, entrapment, and engulfment.
Underline the necessity of further training after this course before trainees should enter a
confined space. (All SWECO employees must receive the confined space training prior to
entering one).
Lockout/Tagout
Optional materials: SWECO lockout/Tagout procedures from the SWECO/site written
safety program
1. Define “Lockout/Tagout” for the employees. Tell them what kinds of equipment
must be locked-out/tagged-out for repair.
2. Talk to the trainees about SWECO- or site-specific Lockout/Tagout procedures.
Are they familiar with company policies? If the site specific policies are in
writing, you may want to pass around a few of the booklets.
3. Go over the General guidelines of “to do’s” and “don’t do’s” from the course
booklet.
Fire Protection and Prevention
Optional materials and equipment: different size fire extinguishers
1. Ask employees if they know where the fire extinguishers should be located on the
job site.
2. Show them the label on several different size fire extinguishers. Point out how
they differ as to the size fire the extinguisher can put out and what kinds of fires
the extinguishing compound can put out.
3. Discuss how to handle combustible materials at the job site.
4. Discuss the dangers of refueling portable power equipment while running or hot...
5. Talk about the proper storage of flammable liquids and materials.
Welding and Cutting Hazards
1. Discuss the safe way of handling welding leads and burning hoses.
2. Talk about the importance of daily inspections of all welding equipment.
3. Discuss the importance of flashback arresting valves and the safest way to install
them.
4. Discuss the safety provisions for electric arc welding outline in the course book.
5. Discuss the safety provisions for gas welding outline in the
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SWECO employee handbook.
Asbestos Awareness
1. Talk about why special training is so important when handling asbestos or lead,
including the many health risks.
2. List the numbers of places where old asbestos and lead may be found (see
additional package).
Permits
1. Talk about the necessity of permits for the jobsite. What can happen if the proper
permits are not secured before beginning a job?
2. Discuss the different types of work permits.
Steel Erection
1. Follow all rules and regulations governing fall protection during steel erection.
(new revised OSHA standard )
2. Discuss the safe way for connectors to work together.
3. Talk about the importance of safe crane and lifting practices.
Concrete Work (if applicable to SWECO employees on the jobsite)
1. Discuss safe ways to work with concrete. This primarily focuses on concrete
placement, such as safe shorting and reinforcing steel.
2. Emphasize the importance of avoiding skin contact with concrete.
Hot Weather Precautions
1. Outline the symptoms and first aid for the following:
 Heat cramps
 Heat exhaustion
 Heat stroke
2. Have the employees discuss precautions to avoid heat-related ailments, such as
drinking lots of fluids, trying to stay in the shade, and dressing appropriately.
Cold Weather Precautions
1. List the symptoms of hypothermia, frostbite, and overexposure.
2. Discuss how to avoid hypothermia, such as:
 Dressing in layers
 Keeping dry
 Using a buddy system
SWECO Drug & Alcohol policy
 The instructor will provide a copy of SWECO drug & alcohol policy to the
employee/applicant who must sign the consent form (last page).
Employee safety handbook
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Employees must sign the last page of this book (existing employees are not required to
sign this page when assigned to a new location unless changes have been made to the
employee safety handbook.
Test – Mandatory
1. Distribute copies of the test to all employees and then start the test.
2. Be sure to collect all copies of the test when completed. Review the test with the
employees to make sure that every employee knows the correct answer.
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TRAINING REQUIREMENTS
Required Training
1. All employees shall receive new hire orientation.
2. Operators of any powered equipment must receive training, take and pass a
written test and show proficiency prior to operating any equipment. Some
equipment also requires a physical under federal standard.
3. This would include but not be limited to:
 Forklifts
 Payloader with forks
 Backhoe/trackhoe
 JLG/Man lift
 Crane/Overhead Gantry
 Spider basket or similar
 Elevator
 Nail guns
 Air or electric tuggers
4. All SWECO field employees shall receive 10 Hr OSHA training with in 1 year of
employment.
5. Field Leads and Construction Managers shall receive OSHA 30 Hr courses with
in 1 year of employment.
6. Refresher training is required every 2 years for OSHA courses.
7. All employees shall receive site specific orientations.
8. High/Low Voltage training for effected personnel.
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DRUG AND ALCOHOL PROGRAM
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DRUG and ALCOHOL PROGRAM
Purpose
Dependency on alcohol and /or drugs can interfere with an employee’s health and job
performance, and may pose serious safety, health or security risks not only for the user
but also to those who work with the user. It is the obligation and intent of Suzlon Wind
Energy to maintain a safe, healthful, and secure work environment for all its employees,
and to protect company property and operations. Suzlon Wind Energy has established the
following policy regarding prescription medications, illegal drugs or paraphernalia,
alcoholic beverages, contraband, weapons, stolen property, or site specific unauthorized
items.
General
Company/Client Premises
The term “Company/Client Premises” includes all property, facilities, land, building,
structure, installations, and vehicles whether owned, leased, used, or parked on site. This
may also include other work locations and/or sites or to and from those locations while in
the course and scope of Suzlon Wind Energy employment.
Use, Possession, or Sale of Drugs or Alcohol
1. Illegal Drugs:
 Using, selling, manufacturing, purchasing, transferring, dispensing,
distributing, or possessing illegal drugs by any employee while in a Suzlon
Wind Energy facility, on a jobsite, or while performing Suzlon Wind
Energy business is strictly prohibited.
2. Prescription and /or Legal Drugs
 An employee that is required to take prescription medication or over the
counter medication that may affect the safety of them selves, co-workers,
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or members of the public, the employees performance, or the security and
safe operation Suzlon Wind Energy property or facilities, employees shall:
1. Notify his/her Suzlon Wind Energy Supervisor prior to
starting use of prescribed medication on the job.
2. Each prescription shall be in the employee’s name and
prescribed by a licensed medical practitioner.
3. Said prescription shall be no older than one year.
4. Employees shall partake of the medication as prescribed.
The employee may continue to work unless management determines that
use of the medication poses a risk.
Disciplinary Action
1. Violation of any part of this policy WILL result in the immediate termination of
employment.
2. All Suzlon Wind Energy employees will be required to sign an acknowledgment
and consent form prior to employment, or at the time of assignment to a job site to
attest their understanding of this policy.
3. If during a testing procedure an employee:
 Refuses a test
 Leaves the testing area
 Exceeds three hours with out a sample
His/hers employment will be terminated.
Drug and Alcohol Screening
1. Suzlon Wind Energy will most commonly use a urinalysis for drug and alcohol
screening, but are not limited to this process alone. Due to municipal laws and
possible client requirements, screening may be one or more of the following:
 Urinalysis, Blood test, Saliva, Breath, Hair Follicle
2. Testing may be announced or unannounced prior to the testing date and shall be
performed as a witnessed sample collection.
3. A drug and/or alcohol test may be requested by a prudent field supervisor when
an employee shows cause in his/hers mannerisms, or physical appearance.
4. A drug and alcohol test shall be performed post accident, post injury, (This would
include a major first aid or a doctor’s visit but not a minor first aid, i.e. a Band-
Aid) or when drugs or paraphernalia is located.
Searches
 Suzlon Wind Energy reserves the right to conduct unannounced searches for
illegal drugs, alcohol, paraphernalia, firearms, explosives, company equipment or
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tools, at/or in offices, facilities, job sites, vehicles, person, and clothing. These
searches do not have to be based on reasonable suspicion.
 The employee’s field supervisor has the right to conduct on-the-spot search and
inspection of employees and their personal effects as described in the policy if a
supervisor has a reasonable suspicion that employees are in direct violation of any
part of this policy.
 A search and/or inspection as defined in the policy may also include requiring
employees to submit to a drug and/or alcohol test. This may be required under the
following conditions:
1. Annual employee physical examinations (such as required for a DOT
license) or to comply with client requirements.
2. Part of an overall search and inspection of an employees work area at a
site location.
3. When an employees supervisor has reasonable suspicion that an employee
is under the affects of drugs or alcohol.
4. When an employee is arrested for a drug related crime.
5. Post accident or injury requiring a physician’s visit.
6. Submissions to such searches are conditions of employment and
continuing employment. Refusal to submit will result in immediate
termination of employment.
Definitions
For purposes of this policy, the following definitions apply:
1. Alcohol—any beverage that may legally or illegally sold and consumed and has
alcohol content of three percent or more by volume.
2. Illegal Drugs—any drug which is not legally obtainable or which is legally
obtainable but has not been legally obtained. (This would include prescription
medications not in the recipient’s name.) Illegal drugs are those under the US
Federal Controlled Substance Act as drugs with a high potential for abuse and are
classified as follows:
3. 0piates and opiate derivatives (i.e. heroin, codeine, morphine, lodnum)
 hallucinogenic substances ( i.e. marijuana, LSD, phencyclidine, peyote)
 depressants (i.e. methaqualone, barbiturates)
 stimulants (amphetamines, methamphetamines)
 coca leaf derivatives (i.e. cocaine, “crack”, “crank”)
 also included are look alike drugs, designer drugs and drug paraphernalia
4. Controlled Substance—schedule I through V of section202 of the controlled
substance act (21 USC 812), and as further defined in regulations at 21 CFR
1308.11-1308.15.
5. Conviction—a finding of guilt. (Including a plea of nolo contender) or imposition
of sentence, or both, by any judicial body duly charged with the responsibility to
determine violations of the federal state or local criminal drug statutes.
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6. Criminal Drug Statute—a federal or non federal, criminal statute involving the
manufacture, distribution, dispensing, possession, or use of any controlled
substance.
7. Under the influence—means that an employee is affected by drugs or alcohol in
any detectable manner. The symptoms of influence are not confined to those
consistent with misbehavior, or to obvious impairment of physical or mental
abilities such as slurred speech or difficulty in maintaining balance.
Acknowledgment and Consent Form
 Suzlon Wind Energy applicants/employees are required to sign the
acknowledgment and consent form—drug and alcohol testing as a condition of
employment and continued employment if assigned to perform services on a
Suzlon Wind Energy project. Included in the consent form is the agreement to
submit to periodic unannounced (random) testing during the course of their
employment. Refusal to cooperate with or submit to such testing will result in
immediate termination of employment. The employee’s signature, affixed to this
form is acknowledgment that this information was made available before
employment or as acceptance of a position with Suzlon Wind Energy on a jobsite
or office environment and has agreed to testing under this policy.
Testing Procedures
 Suzlon Wind Energy will arrange for all drug and alcohol testing. This will be
conducted on site when qualified personnel are present. When on site testing is
not possible arrangements will be made to have either third party testing on site or
the employee will travel to an offsite facility.
 Upon notification that a drug and/or alcohol test is to be performed, the employee
will be offered this policy and the consent form will be signed by the employee.
After signing the consent form testing will proceed. If the employee refuses to
sign the consent form or comply with any other portion of this policy the
employees employment will be terminated.
 The chain of custody document will be completed. The donor copy will be given
to the employee after the sample is provided and then the respective copies will be
sent to the laboratory, and Chicago corporate office.
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Standards of Testing
 The standard for test will initially be via enzyme multiplied immunoassay
technique (EMIT), and where positive followed by a more precise test, the gas
chromatograph and mass spectrometry (GC/MS). The minimum substance tested
shall be those included in the SAMSA (NIDA) (National Institute of Drug Abuse)
Panel 10 plus alcohol unless stated otherwise by a client contract.
 Cutoff levels will be those established by the federal Department of
Transportation (DOT) as set forth in 49 CFR part 40 unless stated otherwise in a
client contract.
Specimen Collection/Laboratory
 Collection shall be conducted by a Suzlon Wind Energy designated person or a
qualified agency in compliance with the guidelines established by the US
Department of Health and Human Services, set forth in 53 fed. Reg. 11970.
KROLL laboratories as a SAMSA (NIDA) facility will be Suzlon Wind Energy’s
laboratory of choice. If for some reason another facility is to be used the
Corporate Environmental Health and Safety (EHS) manager should be consulted
prior to its use.
Record Keeping and Confidentiality
 The request to submit to drug or alcohol testing is to be done discretely. Any
resulting allegations of drug policy violations will be kept highly confidential.
Disclosures will be made only to those with a “need to know” basis.
 All records pertaining to drug or alcohol testing will be kept in the corporate
office or on a secure file of the server, and will be released on a “need to know”
basis.
Positive Results
 In the event of a positive drug or alcohol test:
1. The applicant will not be hired until a clear screening has been acquired.
2. The employee will be removed from site or office, and suspended with
pay until review by the MRO. If however this positive result is due to a
prescribed medication it will be reviewed by a Medical Review Officer
(MRO) assigned by KROLL Laboratories, and verified by Suzlon Wind
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Energy’s corporate EHS and HR managers to ensure that the prescribed
medication does not pose a threat to operations.
3. If an employee fails a drug test he/she may request (at a Suzlon Wind
Energy approved site) a second test if done the same day as notification of
the “positive test”.
4. After a positive result has been confirmed and it was not due to a legally
prescribed medication, the employee will not be eligible for employment
for sixty (60) days. Additionally this person will need to successfully
complete a recognized drug or alcohol rehabilitation program that is not
less than fourteen (14) days in length prior to reemployment.
5. When reemployment has begun the employee will be subject to monthly
random testing for a period of one (1) year. Unemployed periods will not
be inclusive for the one (1) year time period.
6. If a second confirmed (positive) drug or alcohol test occurs the employee
will be permanently ineligible for employment.
Random Selection and Frequency
 Random testing shall be conducted at least quarterly but is not limited to this time
frame.
 Random testing may include randomly selecting a job site or office and testing
100% of the employees at that site, or it may be a 10% randomly picked through
out the US operations.
 All Suzlon Wind Energy employees are subject to random testing and this policy.
 Random selection will be done using either an employee’s social security number,
or their employee number.
Notification Procedure
At the time of random drug and/or alcohol testing, the following steps shall be taken:
 Personnel will be selected randomly, or it shall be a 100 percent (100 %) testing.
 The Suzlon Wind Energy supervisor will notify the selected employees privately
and escort them to the collection site.
 If an employee refuses to submit to the testing, the supervisor will explain to the
employee that employment will be terminated immediately unless he/she submits
to the procedure. This shall be done in an effort for the employee to reconsider.
Suzlon Wind Energy supervisors are not to attempt to use force in seeking
compliance.
 When Human Resources and the Drug Screening Administrators receive the
results, the site supervisor will be notified in the event of positive results.
Questions regarding drug screening should be directed to the Environmental Health and
Safety manager, or the Human Resources manager.
Chemical Screening Notification
A pre-employment drug screening is part of Suzlon Wind Energy’s overall pre- employment
procedures that enable our company to evaluate your eligibility for employment. One of the
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requirements for consideration of employment and/or continued employment is satisfactorily
passing a URINE DRUGSCREEN TEST. Please read the following instruction carefully.
NOTICE TO APPLICANTS/EMPLOYEES:
Suzlon Wind Energy has a policy that prohibits the possession and/or use of illegal and
unauthorized drugs or paraphernalia, and periodically searches and performs both urine screening
and breath analysis of employees as an enforcement measure in providing a safe working
environment. A positive drug/alcohol screening will remove you from consideration for
employment with Suzlon Wind Energy or terminate your employment.
Acknowledgements
 My signature below certifies that I understand I will be given an opportunity to make
written disclosure to the Medical review officer (MRO) of any over the counter or
prescription medication that I am currently taking or have recently taken, as well as any
other information relevant to the reliability of or explanation for, a positive drug result.
 My signature below certifies that I have read or had read to me, and understand the
Suzlon Wind Energy policy on unauthorized and illegal drugs or alcohol, and I
acknowledge that violating this policy will result in termination of employment
(EMPLOYEE) and or denied employment (APLICANT). I also understand that Suzlon
Wind Energy employees are subject to random testing and post accident testing for
injuries or illnesses that are job related.
 My signature below certifies that I authorize the testing agency to provide the results of
my test to Suzlon Wind Energy and further agree to hold Suzlon Wind Energy, the
testing agency or company, its agents,directors, officers, and employees harmless from
any and all liability in connection with the testing for drugs and/or alcohol content.
 My signature below certifies that I understand that any positive result will preclude or
terminate any offer of employment with Suzlon Wind Energy.
______________________________________
Applicant/Employee Name (Printed)
______________________________________ _____________________
Applicant/employee Signature Date
______________________________________
Suzlon Wind Energy Witness Name (Printed)
______________________________________ _____________________
Suzlon Wind Energy Witness Signature Date
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LOCK OUT TAG OUT PROGRAM
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SECTION ONE
Lockout/Tag out Procedure
1. All potential energy sources shall have a LOTO applied until the competent
person confirms removal is safe.
2. Installation and maintenance must be carried out by a qualified person.
3. Insuring that this LOTO is applied is the responsibility of the construction
manager.
4. Application and maintenance may be allocated at the Construction Managers
judgment.
5. Notifications shall be given to all effected people on site in writing.
6. A site roster will be kept identifying those persons for other contractors that have
the authority to give the all clear for there company.
7. No LOTO may be removed with out the signature of the authorized person of
each contractor.
8. LOCKOUT / TAGOUT (LOTO)
9. Changes may only be made to this document by the SWECO EHS department
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WARNING
There shall be no exceptions allowed or deviations from the prescribed LOTO procedure
contained within this document at any time.
Any person who operates a valve, switch, or Energy Isolating Device to which a lock or
danger tag is attached will be subject to disciplinary action up to and including immediate
termination.
Any person who removes a lock or danger tag from an Energy Isolating Device that is part
of an Active LOTO will be subject to disciplinary action up to and including immediate
termination.
Prepared By: Gordon McCalister
Approved By: Daniel Skinner/Gordon McCalister
Date Approved: 12-19-06
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Purpose
The purpose of the Lockout/Tagout (LOTO) program is to ensure that all persons
performing service and/or maintenance of machines and equipment during all
phases of a Site Project (construction, pre-commissioning, commissioning, testing
or servicing) are fully protected from unexpected energization, startup or the
uncontrolled release of energy, which could cause injury to those persons and/or
equipment. All work on energized systems shall follow the procedures described
herein.
Scope
The overall scope of this procedure is to ensure compliance with 29 CFR -
1910.147; Control of Hazardous Energy (Lockout/Tagout) and Subpart S,
1910.333 Selection and Use of Work Practices (Electrical Safety Related Work
Practices). Guidance provided by OSHA directive STD 1-7.3 for Group
Lockout/Tagout for work done on complex equipment (Appendix C) was also
used in the development of this program. Due to the complexity of activities,
which take place during power plant construction and commissioning, the length
of time and number of Lockout/Tagouts performed the use of a work permit
system (LOTO form) in addition to Lockout/Tagout is necessary. This system
provides centralized control over LOTO while providing an equivalent level of
personnel safety to individual Lockout/Tagout. This program shall be modified
accordingly in the event that local government or client LOTO regulations are
more stringent.
This procedure contains specific information relating to the following:
LOTO rules and Regulations
LOTO Definitions
The execution of a system/equipment LOTO
Special LOTO clearance procedure
System/equipment testing under LOTO
Employee LOTO training requirements
Employee responsibilities regarding the LOTO program and procedures
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Responsibility
The responsibilities listed below pertain to the administration of the
Lockout/Tagout (LOTO) program.
SWECO Construction/Site Manager
 Has overall responsibility for site safety for all SWECO Activities and
Subcontractors.
 Will order the review and issuance of revised LOTO procedures.
 Will assign the responsibility for weekly LOTO inspections of the LOTO
log and procedures.
 Will order stoppage of all work performed in an unsafe manner
SWECO Commissioning Manager/Designee
 Is responsible for establishing and implementing the LOTO program.
 Is responsible for the periodic review and revision of the LOTO
procedures as directed.
 Is responsible for training site personnel and contract employees in the
rules and regulations contained within these procedures.
 Is responsible for conducting weekly audits of the LOTO log and
reporting to the Site Manager the results of the audit.
Primary Authorized Employee
LOTO Administrator
System Authorized
Employee
Lead Authorized
Employee
System Authorized
Employee
System Authorized
Employee
Lead Authorized
Employee
Lead Authorized
Employee
Lead Authorized
Employee
Lead Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
Authorized
Employee
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 Will order stoppage of all work performed in an unsafe manner
 The Commissioning Manager may act as the Primary Authorized
Employee and/or the LOTO Administrator depending upon site
conditions.
Primary Authorized Employee
The Primary Authorized Employee shall be knowledgeable in all plant systems,
and trained in the practice of Lockout / Tag out (LOTO). The Primary
Authorized Employee is responsible for, authorization of all LOTO’s. The
Primary Authorized Employee shall be the central focal point for the
coordination of all work and test activities, during plant commissioning, that
require a LOTO. The Primary Authorized Employee may also act as a System
Authorized Employee for those plant systems that they are responsible for.
Responsible for the following under the LOTO program:
 Fully understanding the work to be done and authorization of the
protection required to make the system/equipment safe to work on
 Ensure contractor and site personnel compliance with the LOTO rules
and regulations
 Review of the Active LOTO’s each shift
 Notification of Site Management of any LOTO violations
 Stoppage of all work performed in an unsafe manner
System Authorized Employee
A System Authorized Employee shall be knowledgeable in the specific plant
systems that they have responsibility for. The System Authorized Employee may
lock out and tag out only the systems and equipment that have been assigned to
them. A System Authorized Employee is trained in the practice of
Lockout/Tagout (LOTO). The System Authorized Employee is designated by the
Primary Authorized Employee as qualified to physically operate all necessary
devices to isolate the equipment or system and to attach all locking devices and
tags. The System Authorized Employee shall ensure that all Affected Employees
are notified of servicing or maintenance activities within their respective areas
or on equipment under their scope of control/operation.
The System Authorized Employee and Authorized Employee may be the same
person when the System Authorized Employee‘s duties also include performing
maintenance or service on a machine or equipment.
A list of System Authorized Employees, and the equipment/systems assigned to
them, shall be listed on the Designation of LOTO Responsibilities form
(Attachment D) kept in the LOTO Logbook.
Responsible for the following under the LOTO program:
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 Fully understanding the work to be done and implementing the required
protection to make the system/equipment safe to work on
 Ensuring that all Affected Employees have been notified of the intent to
perform service or maintenance activities on or around his/her equipment
or system(s)
 Ensuring system/equipment isolation and the placement of locks and tags
per the respective LOTO Clearance Form (Attachment A)
 Notifying the Primary Authorized Employee, Authorized Employee(s)
and the Affected Employee(s) when protection is in effect.
 Notifying the Primary Authorized Employee of any LOTO violations
 Ensuring that he/she complies with the LOTO rules and regulations
 Ensuring that all personnel working within the Authorized Employee(s),
LOTO comply with all LOTO rules and regulations
 Promptly informing the Primary Authorized Employee of work
completion
 Ensuring that the system/equipment has been returned to a state of
operational readiness (e.g. all guards and safety devices are installed
prior to the completion of work activities)
 Stopping all work performed in an unsafe manner
LOTO Administrator
The LOTO Administrator shall be responsible for maintenance of LOTO
documentation including, the LOTO index, active and inactive LOTO Forms.
The LOTO Administrator shall monitor active LOTO’s for compliance with this
procedure. The LOTO Administrator may only place locks and tags under the
direct supervision of the Primary Authorized Employee or the System Authorized
Employee for that system unless they have been deemed qualified by the
Primary Authorized Employee and given the authorization to do so. The LOTO
Administrator is trained in the principals of Lockout/Tagout.
Responsible for the following under the LOTO program:
 Administration of the LOTO Log
 Ensuring that LOTO’s are issued in accordance with LOTO Procedure
 Ensuring contractor and site personnel compliance with the LOTO rules
and regulations
 Reviewing Active LOTO’s each shift
 Notifying Site Management of any LOTO violations
 Stopping all work performed in an unsafe manner
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Lead Authorized Employee
The Lead Authorized Employee is the authorized employee who oversees or
leads a group of servicing/maintenance workers (e.g. mill wrights, pipe fitters,
electricians) known as Authorized Employees. Lead Authorized Employee’s
may request the LOTO of machinery or equipment in order to perform servicing
or maintenance on that machine or equipment. Lead Authorized Employee’s are
trained in the practice of Lockout/Tagout (LOTO).
Responsible for the following under the LOTO program:
 Contacting the System Authorized Employee and requesting a LOTO for
the respective system/equipment he/she is to work on
 Providing the System Authorized Employee with all pertinent information
regarding the work activities to be accomplished under the LOTO
 Ensure that all Authorized Employees sign in and out on the Authorized
Employees Form at the beginning and end of each work shift
 Fully understanding the work to be done
 Notifying all Affected Employees of the intent to perform servicing or
maintenance activities on or around his/her equipment or system(s)
 Reviewing the System/equipment isolation and the placement of locks
and tags per the respective LOTO Clearance Form
 Notifying the System Authorized Employee of any LOTO violations
 Ensuring that he/she complies with the LOTO rules and regulations
 Ensuring that all personnel working within the Authorized Employee(s),
LOTO complies with all LOTO rules and regulations
 Promptly informing the System Authorized Employee of work
completion
 Ensuring that the system/equipment has been returned to a state of
operational readiness (e.g. all guards and safety devices are installed
prior to the completion of work activities)
 Stopping all work performed in an unsafe manner
Authorized Employees
An Authorized Employee is trained in the practice of Lockout/Tagout (LOTO).
An Authorized Employee is an employee who perform servicing or maintenance
on that machine or equipment under the supervision of a Lead Authorized
Person.
Responsible for the following under the LOTO program:
 Sign in and out on the Authorized Employees Form at the beginning and
end of each work shift
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 Fully understanding the work to be done
 Notifying all Affected Employees/Contractors of the intent to perform
servicing or maintenance activities on or around his/her equipment or
system(s)
 Reviewing the System/equipment isolation and the placement of locks
and tags per the respective LOTO Form
 Ensuring that he/she complies with the LOTO rules and regulations
 Ensuring that all personnel working within the Authorized Employee(s),
LOTO complies with all LOTO rules and regulations
 Promptly informing the System Authorized Employee of work
completion
 Ensuring that the system/equipment has been returned to a state of
operational readiness (e.g. all guards and safety devices are installed
prior to the completion of work activities)
 Stopping all work performed in an unsafe manner
Affected Employee
An Affected Employee is an employee whose job requires him/her to operate or
use a machine or equipment on which servicing or maintenance is being
performed under lockout/Tagout, or whose job requires him/her to work in an
area in which such servicing or maintenance is being performed. Any site
personnel who even work in the General vicinity of equipment or systems under
LOTO must be trained as an Affected Employee. This Training is the
responsibility of the individual companies and not SWECO’s.
Responsible for the following under the LOTO program:
 Being aware of work being performed on or around his/her affected
equipment/systems and signify his/her understanding and compliance by
signing on to the LOTO in the appropriate space provided.
 Understanding precautions to be taken while work is being performed by
the Authorized Employee(s)
 Notifying the Primary Authorized Employee of any LOTO violations
 Ensuring that he/she complies with the LOTO rules and regulations
 Ensuring that all personnel working within the Authorized Employee(s),
LOTO comply with all LOTO rules and regulations
 Stopping all work performed in an unsafe manner
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Definitions
Lockout/Tagout(LOTO)
The placement of a lockout device and associated tags on an energy isolating
device in accordance with an established procedure for ensuring that the
equipment being controlled by the energy isolating device, cannot be operated
until the lockout device and associated tags are removed.
LOTO Clearance Form
The LOTO Clearance Form is utilized for recording equipment/system specific
LOTO information. The LOTO Form also details the individuals authorized to
work on the specific equipment, work/testing to be performed, and the required
isolation boundaries established to make the equipment/system safe to work on.
This form acts as a Work Permit for the activities requiring LOTO.
LOTO Boundary
The safe limits of a given Lockout/Tagout as determined by the controls
required for the equipment and systems to be worked on. The Boundary, which
includes all Energy Isolation Devices for that system, machine or equipment; is
established and documented prior to each specific Lockout/Tagout.
General LOTO lock
A key lock that is not assigned to an individual employee as an Individual
LOTO Lock. This lock has only one key and master keys are not available. This
lock may be used to lock out individual energy-isolating devices or energy
sources when group or complex group LOTO is used. This lock may be left on
for durations of greater than one shift. This lock is unique within Project Site
Facility and is to be used only for LOTO
Lockout Devices
A Lockout device is a device that is utilized for attaching a lock, to an energy-
isolating device. Examples of Lockout Devices are as follows:
 Chain – utilized for preventing the movement of a valve when applied
with a lock
 Six hole lock clip – utilized for preventing the movement of an electrical
breaker or switch when applied with a lock
Transition Lock
A key lock for which multiple keys may be available and is used on equipment
or processes when they are not actively being serviced. Key control or access
must be limited to a small, closely controlled group of authorized individuals.
This lock must used in combination with a Transition tag “Caution do not
Operate” to indicate an unsafe to operate condition. This lock must not be used
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as an Individual LOTO Lock and may never be used on equipment that is being
actively serviced.
Transition Tag
Transition tags (must be yellow in color) are used to indicate that a machine,
equipment, process or circuit is out of service or inoperable, but no one is
actively working on the system. Transition tags are not to be used in place of red
tags and are not required with complex LOTO’s where SWECO controls the
first on last off. No activity to the machine, equipment, process and circuit may
occur when a transition tag is placed. Transition tags are not to be used as
General "out of service" tags and may only be applied by Authorized
Employees.
Transition Lock and Tag use
Transition locks and tags are required when a single individual has removed his
Lockout Tagout device because of shift change and SWECO does not have a
boundary lock applied to the clearance.
Tag out Devices
A Tag out Device is a 3” X 6”, red with white lettering, printed plastic tag, with
the words “DANSWECOR DO NOT OPERATE” printed in black on both
sides, and with spaces provided for the System Authorized Employee to write
the specific LOTO information as it applies to the system/equipment being
isolated.
Energy Isolating Devices
A mechanical device that physically prevents the transmission or release of
energy, including but not limited to the following:
 A manually operated electrical circuit breaker
 A disconnect switch
 A manually operated switch, by which the conductors of a circuit can be
disconnected from all ungrounded supply conductors; and in addition, no
pole can be operated independently
 A slide gate
 A blind flange
 A manual valve
 A block – (a device so configured as to prevent movement of the affected
component)
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 Any similar device used to block or isolate energy
WARNING:
The term does not include a push button, selector switch, and other
devices.
Energy Source
A resource that produces power, or has the potential to produce power, in forms
of electricity, flow, pressure or movement]
Energized
Energized is the state of being connected to an energy source or containing
residual or stored energy.
Servicing and/or Maintenance
Servicing and maintenance are workplace activities such as constructing,
installing, setting up, adjusting, inspecting, modifying and maintaining and/or
servicing equipment.
These activities include lubrication, cleaning or un-jamming of equipment and
making adjustment or tool changes where the employees may be exposed to the
unexpected energization or startup of the equipment or release of hazardous
energy.
Alternative Methods
Methods developed for work other than servicing and/or maintenance of
equipment. The methods guide personnel, utilizing the safest procedures for
tasks not requiring LOTO. Methods are developed based on risk assessment of
the machine, equipment, process and circuit
Capable of Being LockedOut
An energy isolating device will be considered capable of being locked out either
if it is designed with a hasp or other attachment or integral part to which or
through which a lock can be affixed or if it has a locking, mechanism built into
it.
Other energy isolating devices will also be considered to be capable of being
locked out, if lockout can be achieved without the need to dismantle, rebuild or
replace the energy isolating device or permanently alter its energy control
capability.
Active LOTO
A LOTO procedure is considered active under the following conditions:
 Locks and tags have been applied to the energy isolation devices and…
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 Authorized Employees are signed on to the LOTO or…
 The LOTO has not been “Cleared” by the Primary Authorized Employee
Inactive LOTO
A LOTO procedure is considered inactive under the following conditions:
 Authorized Employee(s) have signed off of LOTO and…
 The LOTO has been “Cleared” by the Primary Authorized Employee
and…
 All locks and tags have been removed by the System Authorized
Employee and…
 The system/equipment has been returned to a “Ready for Service” state
and…
 The affected LOTO Clearance Form (with all removed tags attached) has
been filed in the Inactive Section of the LOTO book
Double Tagged
Double tagged refers to having two separate LOTO’s in effect for a single
system or defined LOTO isolation boundary. There is no limit as to the number
of LOTO’s that can be applied to a single system or equipment.
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LOTO Standards and Rules
General Requirements for LOTO
Performing maintenance or servicing tasks covered by this program while the
equipment or process is energized is prohibited, unless the following apply:
 the Risk Assessment (RA) documents the necessity of working energized;
 the RA is approved by both operations leadership and EHS;
 the RA establishes the alternative procedures to be used;
 authorized employees who will perform the task have been trained on the
alternative procedures;
 Other training required by regulation has been completed.”]
Note
Sample and Template of Risk Assessment for
Alternative Methods are given in Attachment I of this
document
Locks
All SWECO supplied locks utilized in the isolation of plant equipment will be of
the single key, “non-keyed alike” variety. Each lock and key set will be
identified with a unique number and shall be unique in color from any other
locks used at the site.
Energy Isolating Devices
Electrical breakers and switches shall never be locked in the ON or CLOSED
position.
Operation of Energy IsolationDevices
Under no circumstances shall, any device, fitted with a lock and danger tag be
operated regardless of the circumstances.
WARNING
Any person who operates a valve, switch, or Energy Isolating Device to
which a lock or danger tag is attached will be subject to disciplinary
action up to and including immediate termination.
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Removalof Locks and Tags
Under no circumstances shall the Boundary Locks and Tags or Authorized
Employee(s) locks and tags be removed from an Energy Isolating Device that is
part of an active LOTO.
WARNING
Any person who removes a lock or danger tag from an Energy
Isolating Device that is part of an Active LOTO will be subject to
disciplinary action up to and including immediate termination.
DangerTags
All Danger Tags shall be affixed to the energy isolation devices with nylon “tie-
wrap.” The System Authorized Employee shall ensure that all Danger tags are
clearly visible to all personnel. The tags shall be Red (or Red and White) and
state “Danger-Do Not Operate” in black lettering. These tags shall only be used
for the protection of personnel under this Lockout/Tagout procedure. All
Danger Tags shall be properly filled out and shall include the following
information:
 LOTO Index Number (e.g. 00 - 0010)
 Tag Sequence Number (e.g. 1 of 3)
 Description of energy isolation device (e.g. Feed water Pump Suction
Valve)
 Position of energy isolation device (e.g. open or closed)
 Name of person installing the tag
LOTO Boundaries
Two (2) Valve Protection
When possible, a minimum of, two (2) -valve protections shall be utilized in order to
establish safe working conditions under the LOTO Program.
Grounding Straps
When working on electrical transformers and switch gear, 600 volts and greater,
grounding straps shall be utilized to safely route stray currents to ground. Danger
Tags shall be applied to all grounds straps
Residual Energy
Prior to the affected system/equipment is being locked, tagged and isolated the
System Authorized Employee shall:
 Drain, Vent, Bleed, Discharge and otherwise certify the removal of all
residual energy from within the LOTO Boundaries prior to the
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commencement of work activities and ensure that systems remains
drained, vented, discharged and de-energized throughout the work.
 Test the operation of all remote operated controls for the affected
system/equipment to ensure that there is no alternate source of energy
supplying the affected system/equipment prior to the commencement of
work activities This is accomplished by trying to start the component from
the DCS, MKV, MCC, and/or local control switch.
 Test circuit elements and electrical parts of equipment that Authorized
Employees will be exposed to during performance of the work, to ensure that
parts are de-energized. Testing shall be done using appropriate test and
personal protective equipment. Testing shall be documented on the LOTO form.
LOTO Documentation
A LOTO Log book shall be established for the site. The Logbook shall be
maintained by the Primary Authorized Employee and shall become part of the
site safety archive files.
Auditing of LOTO Program
On a weekly basis, inspections of the LOTO Program shall be conducted. The
LOTO Administrator or Primary Authorized Employee or management
representative trained as an Authorized Employee shall perform these
inspections. The Weekly Lockout/Tagout Inspection Form (Attachment H)
shall documenting the inspection findings, results and, as appropriate, corrective
actions taken to correct LOTO program deficiencies. Copies of these inspection
forms shall be retained in the LOTO Logbook.
In addition, detailed audits of the LOTO program by SWECO EHS staff shall be
conducted on at least an annual basis. The audit shall include a review of
responsibilities under the program and related procedures. Written
documentation of findings and corrective actions shall be made and retained.
Tagout
In the event that equipment cannot be locked out then Tagout procedures shall
be followed. Tagout alone shall only be utilized if it is infeasible to apply an
energy isolation device or when working under Customer LOTO procedures,
which do not allow the application of locks. The Tagout procedures shall be
applied in a rigorous manner to ensure personnel protection that is as protective
as Lockout/Tagout.
LOTO Clearance Completion
 The words “Tagout Only” and the reason why shall be stated at the top
of the LOTO Clearance.
 All spaces shall be completed except for Lock Number. Date Lock and
Tags Applied/Removed shall refer to date Tags Applied/Removed
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Application of Tags
 Tags shall be attached at the same or as close as possible to the
location where locks would have been applied.
 The System Authorized Employee shall apply boundary tags in the
same manner as Boundary lock and tag application.
 Authorized Employee tags shall be applied after the boundary tags
have been placed and de-energization of the system has been verified.
Secondary Means of Protection
Secondary means of protection shall be utilized to ensure protection of
personnel. Secondary means shall be appropriate to the system being tagged
out and may include:
 Removal of an isolating circuit element
 Application of grounding devices
 Blocking of control switches
 Opening of an extra disconnecting device
 Removal of valve handles
Training
All Affected Employees shall be notified that a Tagout system is being utilized
and that tags are not to be removed, or altered in any fashion.
Removal of Tags
Removal of tags shall follow the LOTO deactivation procedure described
below. All other procedures described in this plan shall apply to Tag only
operations.
LOTO Procedures
The following procedure shall be utilized for isolating and making safe,
equipment, or systems that are to be worked on. This procedure is to be followed
as it is presented here. There shall be no exceptions or deviation from the
SWECO LOTO procedure at any time.
LOTO Activation Procedure
The LOTO procedure may require the involvement of at least five (5)
individuals anytime a LOTO is issued:
The Lead Authorized Employee, Authorized Employee, System Authorized
Employee, LOTO Administrator and the Primary Authorized Employee. (Note:
there may be occasions when the System Authorized Employee and the
Authorized Employee doing the work is the same individual.)
Certain circumstances, such as employees working in the immediate area as
equipment under LOTO, may require the notification and signature of Affected
Employees.
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Step 1 (LOTO Activation Request)
The Lead Authorized Employee shall request, from the System Authorized
Employee a LOTO Clearance for the respective system/equipment that he/she is
planning to work on.
The Lead Authorized Employee shall provide the System Authorized Employee as
much detail as possible, concerning the work to be accomplished i.e...
 The type work/repair to be conducted
 Is hot work required?
 Does the work involve entry into a confined space?
 Does the work require lifting heavy loads?
 Will the work interfere or present a hazard to employees adjacent to the
proposed work activities? If so, have they been notified and properly
briefed?
 Will hazardous materials be generated because of the work activities?
 Will hazardous materials be utilized in the performance of the work
activities?
Once satisfied with the information provided by the Lead Authorized Employee,
and having discussed the work activities with the Affected Employee(s), and
making certain that the work can be performed in a manner consistent with the
SWECO site safety policy and procedures, the System Authorized Employee shall
initiate the activation of a LOTO for the respective System/Equipment.
NOTE
Only the Primary Authorized Employee can Authorize and sign for the
activation of a LOTO.
Step 2 (Isolation Boundary Review)
The System Authorized Employee shall review the associated Piping and
Instrument Diagrams (Pit’s) and Electrical and Instrument Diagrams (Enid’s) to
determine the proper procedure for making the system/equipment safe to work on.
This information will be reviewed with the Primary Authorized Employee prior to
LOTO Clearance Form Completion.
Step 3 (LOTO Clearance Form Completion)
The LOTO Administrator shall then obtain the next available LOTO index
number from the LOTO Index Sheet (Attachment F). He/she will fill out the
clearance form and assign the clearance number. He/she will also log the
clearance number in the clearance logbook
All energy isolation devices that are required to be, opened and/or closed, to
affect a safe work area shall be listed on the LOTO Clearance Form in the
sequence in which they will be isolated.
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The Primary Authorized Employee shall review the completed LOTO and sign off
on the form.
Step 4 (System/Equipment Isolation and Verification)
The System Authorized Employee, responsible for the equipment covered by that
LOTO, or LOTO Administrator under the direct supervision of the System
Authorized Employee, shall physically isolate the system/equipment in the
sequence in which they are listed on the LOTO Form. The application of these
Locks and Tags make up the LOTO boundary.
 All breakers shall be de-energized (opened), locked with a padlock and the
appropriate danger tag affixed
 All valves shall be closed and the appropriate danger tagged affixed
 All residual energy shall be dissipated by venting, draining, grounding or by
any other suitable and safe means
 Test the operation of all remote operated controls for the affected
system/equipment to ensure that there is no alternate source of energy
supplying the affected system/equipment before the commencement of work
activities.
As each system/equipment is physically isolated, tested/verified, and danger tags
and locks are applied; the System Authorized Employee shall initial and date each
respective energy isolation devices location on the LOTO Form. This important
step serves as the verification step.
The Primary Authorized Employee or LOTO Administrator shall then
retain the LOTO Lock key(s).
Any Affected Employee(s) shall be notified, by their supervisor, of the work to be
performed on or around his/her equipment or system. The Primary Authorized
Employee shall confirm that the notification has taken place prior to proceeding
with the work.
Step 5 (System/Equipment Isolation Verification)
The Lead Authorized Employee shall then review the placement of all danger tags
and the position of all energy isolation devices.
Authorized Employees shall be provided the opportunity to witness the
verification that all sources of energy have been isolated.
When the Authorized Employee(s) is (are) satisfied that the system/equipment is
safe for the commencement of work activities he/she (they) shall sign-on to the
Authorized Employee Sign-In Sheet (Attachment E).
At this time any Lead Authorized Employee Locks and Tags may be placed over
the Boundary Locks and Tags. Lead Authorized Employee Locks and Tags may
either be placed directly onto the Boundary Lockout device or a Lockbox
depending upon the complexity of the particular job. When a lockbox is used for
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group lockout/Tagout the Lead Authorized Employee shall place their lock and tag
on boundary lockout device. After the Lead Authorized Employee is satisfied that
all is in order, they shall sign onto the LOTO Clearance Form (Attachment A)
At this point, the contractor may elect to either allow their Authorized Employees
signatures on the Authorized Employee Sign-In Sheet (Attachment E) to serve as
their LOTO control device, or the contractor can use their own lock box system
with the Lead Authorized Employees key secured within the lock box and the
Authorized Employees locks and tags placed over the key.
For complex LOTO’s multiple Authorized Employee Sign-In Sheets may be used.
For example a separate Authorized Employee Sign-In Sheet may be used for each
crew, with the crew’s Lead Authorized Employee signing onto the Main LOTO
Clearance Form. Then, this Lead Authorized Employee will take the separate
Authorized Employee Sign-In Sheet back to the job trailer or contractor assembly
area and have each Authorized Employee under their control and supervision, sign
onto the form, as well as signing off from the form at the end of the work day.
This form will be maintained by the Lead Authorized Employee throughout the
workday and returned to the LOTO Administrator at the end of the workday. This
tiered approach is useful in managing complex LOTO’s involving multiple pieces
of equipment.
NOTE:
If additional Authorized Employees are required to work within the
established LOTO boundaries AFTER the LOTO has been authorized, then
the above steps must be repeated.
LOTO De-Activation (Clearance) Procedure
Before lockout devices are removed and energy is restored to the equipment or
system, the following actions shall be taken: Note this procedure may be applied
to an entire LOTO or to a single piece of equipment under a LOTO.
 A common practice at many sites is apply locks and tags to individual un-
energized circuits as they are installed within the Substation/PEECC
and/or MCC. This practice provides an additional level of employee
protection to prevent unexpected energization of equipment as power is
brought into the PEECC and MCC. As the project commences, these
circuits are energized and the locks and tags removed. SWECO and
Contractor personnel working within these areas need to be continuously
informed and notified as conditions within the PEECC or MCC change as
circuits become energized. There are various methods available for
accomplishing the notification. One option is to affix a red notification
tag (non LOTO tag) alerting employees that the equipment has been
energized. LOTO Tags may not be used for this purpose. An example of
an appropriate tag is provided;
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Step 1 (LOTO De-activation Request)
The Lead Authorized Employee(s) shall inform the System Authorized Employee
that all work has been completed; the system/equipment has been 100% re-
assembled and is now ready for energization (and/or testing if applicable).
The Lead Authorized Employee(s) shall submit the completed Authorized
Employee Sign-In Sheet and then sign off the LOTO Clearance Form and remove
all Lead Authorized Employee Locks and Tags, which have been placed.
If separate Authorized Employee Sign-In Sheets were used each Lead Authorized
Employee shall ensure that all individuals working under them have signed off on
the form. Once this has been done the supervisor shall sign off on the Main
LOTO Clearance Form.
NOTE
Only the Primary Authorized Employee, can Authorize and sign for the
De-activation of a LOTO.
Step 2 (System/Equipment Inspection)
The System Authorized Employee or his designee shall inspect the
system/equipment to ensure that non-essential items have been removed from the
area and that the system/equipment components are intact.
The work area shall be checked to be sure that all employees have been safely
positioned or removed.
If testing is required, refer to the "Equipment/System Testing Procedure".
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Step 3 (LOTO Locks and Danger Tag Removal)
The System Authorized Employee shall remove all boundary locks and danger
tags. The LOTO Form shall be referenced to ensure that all energy isolation
devices listed on the LOTO Form are properly removed.
The Primary Authorized Employee, or LOTO Administrator, shall verify receipt
of all locks and danger tags by signing the LOTO Released by section of the
LOTO Form.
Step 4 (Transfer LOTO to the Inactive Section)
The LOTO Administrator places the released LOTO form in the inactive section
of the LOTO book and designates the LOTO as Inactive in the LOTO Index.
Shift Change Procedure
This procedure shall be followed whenever work activities take place under a
single LOTO on more than one shift.
Note: Clearances covering activities that will be taking place on only one
shift do not have to transfer the Clearance as long as the Lead Authorized
Employee(s) and System Authorized Employee do not change. For Example:
First shift activities that will continue the next day and no work under that
LOTO will take place on the second shift.
Step 1 (Transfer by System Authorized Employees)
The System Authorized Employees for both second and first shift shall review the
LOTO and sign-off on the LOTO Clearance Form. The System Authorized
Employee who initiated the LOTO will review the work activities and placement
of energy isolation devices with his counterpart. The System Authorized Employee
who did not initiate the LOTO shall then sign onto the LOTO Form certifying that
they have reviewed the LOTO and taken responsibility for ensuring that the
LOTO is implemented properly on their shift.
Step 2 (Lead Authorized Employee(s) Removed from Clearance)
Lead Authorized Employee(s) shall inform the System Authorized Employee as to
the status of work completion. At the end of the shift, all Authorized
Employee(s) shall sign off the LOTO Clearance Form and remove all Lead
Authorized Employee Locks and Tags, which have been placed or complete a
key transfer.
Step 3 (New Lead Authorized Employee(s) Added to Clearance)
The New Lead Authorized Employee(s) shall then review the placement of all
locks and danger tags and the position of all energy isolation devices. During the
walk down they shall be provided with the opportunity to witness verification that
systems have been de-energized.
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When the New Lead Authorized Employee(s) is (are) satisfied that the
system/equipment is safe for the commencement of work activities he/she (they)
shall sign-on to the LOTO Form.
At this time New Lead Authorized Employee Locks and Tags may be placed over
the Boundary Locks and Tags or a key transfer can take place. Lead Authorized
Employee Locks and Tags may either be placed directly onto the Boundary
Lockout device or a Lockbox depending upon the complexity and type of LOTO
method used for the particular job.
Step 4 (Closing LOTO)
The System Authorized Employees for each shift shall review the status of the
work and any changes to the Active LOTO.
Once work under the LOTO has been completed then both the first and second
shift System Authorized Employees shall sign off on the LOTO. Both System
Authorized Employees have to sign off before the LOTO can be released.
Testing
Either one of the System Authorized Employees who have signed onto the LOTO
may temporarily release the LOTO for testing. All testing shall be done in
accordance with the procedures outlined in Section 6.5 of these procedures. Once
testing is complete the LOTO shall be returned to its pretest status.
SpecialLOTO Clearance Procedure
This special clearance procedure is only to be used in the un-likely event that a
system/equipment LOTO is required to be de-activated (cleared) and the System
Authorized Employee or any of the Authorized Employee(s) cannot be located to
provide the necessary authorization and signature to allow the system/equipment
to be returned to service.
Examples of when this special clearance procedure can be used includes, but is
not limited to, the following scenarios:
 The Authorized Employee(s) are no longer employed by the company or have
been re-assigned to another work place. (e.g. sub-contractor)
 The work was completed by Authorized Employee(s) on a different shift, and the
Authorized Employee(s) of the previous shift will not return until the following
(morning/evening), and it is imperative that the system be returned to service at
once.
 The Authorized Employee(s) forgot to sign-off the LOTO upon completion of work
activities and is not able to be contacted. (e.g. sub-contractor)
Step 1 (Contact of Authorized Employee(s))
The Primary Authorized Employee shall utilize all means to contact the
Authorized Employee(s) (at home if necessary) and request a release of the
LOTO.
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If unable to contact Authorized Employee(s,) the Authorized Employee(s)
supervisor shall be contacted
If unable to contact the Authorized Employee(s) supervisor then a member of SWECO
Site management (e.g. Site Manager or Commissioning Manager) shall be utilized to
authorize the clearance of the affected LOTO. This should be done only after an intense
search of the affected area.Step 2 (Review of the System/Equipment)
The System Authorized Employee shall walk down the affected system/equipment,
and shall be accompanied by at least one of the following personnel:
 Primary Authorized Employee
 The Lead Authorized Employee
 A member of the SWECO management team
Those personnel walking down and reviewing the system/equipment shall verify
and agree that all work is complete and the system/equipment is ready to return to
service.
Step 3 (Release of the LOTO)
The Lead Authorized Employee’s supervisor or a member of the SWECO
management team will then print and sign his/her own name on the appropriate
line of the LOTO Form. A notation shall be made on the form that the LOTO was
released under alternative procedures.
The LOTO will be released in accordance with Section 6.2.3
NOTE:
The Authorized Employee(s) shall be notified by their supervisor of the
removal of the LOTO upon their return to work. The System Authorized
Employee shall ensure that this has been done. The Authorized
Employee(s) shall note on the Inactive LOTO Clearance that they have been
informed that the LOTO was closed under alternative procedures.
In the event that the Authorized Employee(s) will not be returning to the
site, a notation shall be made on the Inactive LOTO Clearance by the LOTO
Administrator.
System/Equipment Testing
Periodically, during the performance of maintenance activities, testing of
equipment is required for the purpose of; making “On-line” adjustments of
components, “bumping” of motors for rotation checks, recording various
operating parameters, or testing the operation of a component, prior to the
cessation of all work activities.
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This procedure has been provided for this purpose only. It is not to be utilized as
a “shortcut” to prevent the entire clearance and re-issuance of a LOTO should
the repair turn out not to be effective.
The following steps shall be taken to test equipment/systems under an active
LOTO clearance procedure:
Step 1 (Request to Test System/Equipment)
The Lead Authorized Employee(s) shall contact the System Authorized
Employee and request approval to conduct a test on the system/equipment. The
Lead Authorized Employee(s) shall provide the System Authorized Employee
with the following information:
 Type of test to be conducted
 Systems/Equipment being tested
 List of personnel to be involved in the test procedure
 Safety precautions to be observed
 A notation shall be made on the LOTO Form (Step 2) under work
to be performed describing the test including the date of testing
Step 2 (Review of Test Procedure)
The System Authorized Employee shall review the information provided
by the Lead Authorized Employee concerning the test procedure.
He/she will then walk down the system/equipment in order to verify that
the test will be able to be accomplished in a safe manner and offers no
hidden hazards or dangers to site personnel or equipment.
The System Authorized Employee shall notify the Primary Authorized
Employee of the testing procedures and the systems that will be affected.
Step 3 (Approval of Test Activities)
Upon approval of the test by the Primary Authorized Employee, the
following actions shall be taken:
 All work on the affected system/equipment shall cease
 All Affected Employee(s) shall be notified of the test
The System Authorized Employee shall be the individual who is directing
the test sequence of events and maintaining radio contact with the control
room and other test personnel.
Step 4 (Removal of Locks and Danger Tags)
 Only the energy isolation devices affected by the test shall have their
locks and danger tags removed
 Lead Authorized Employee(s) shall remove their locks and tags from
the energy isolation devices affected by the test.
 Sign off on the LOTO Clearance Form.
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 System Authorized Employees shall remove the boundary locks and
tags off of the energy isolation devices affected by the test.
 On the LOTO Clearance Form the affected energy isolation devices
shall be dated and initialed as returned to service.
 The energy isolation devices are to be aligned to the position(s)
required for the test procedure
 The LOTO Form is to remain in the Active Section of the LOTO Log
Step 5 (Notification of Plant Personnel)
If the situation warrants, all plant personnel shall be notified of the test
procedure and the precautions to be observed. (e.g., all non-essential
personnel are to stay clear of the area)
Step 6 (Performance of Test)
The test shall be accomplished with strict adherence to all SWECO site
safety procedures.
Step 7 (Test Complete – No Further Work Required)
After the test is complete and no further work is required, the LOTO shall
be closed in accordance with Section 6.2.
Step 8 (Test Complete – Further Work Required)
If further work is required after the test is complete, the following actions
shall be taken:
 The System Authorized Employee shall re-attach the
system/equipment locks and danger tags and verify that the energy
isolation devices have been returned to their respective LOTO
positions as detailed on the LOTO Form.
 Each energy isolation device shall be reentered on the LOTO
Form, including signature and date confirming that the Locks and
Tags have been reapplied, not just resigned.
 All residual energy shall be dissipated by venting, draining,
grounding or by any other suitable and safe means.
 Test the operation of all remote operated controls for the affected
system/equipment to ensure that there is no alternate source of
energy supplying the affected system/equipment before the
commencement of work activities.
 The Lead Authorized Employee(s) shall review the application of
tags, locks and energy isolation devices lockout / Tagout positions
and shall sign back on to the LOTO Form and reapply Locks and
Tags.
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The system/equipment has been returned to the pre-test status under the
LOTO procedure and is now considered safe to resume maintenance
activities.
LOTO Training
SWECO Site Management shall ensure that training has been provided to all
personnel (SWECO, SWECO Contract, Contractor, and Customer) involved with
the Lockout/Tagout program. An individual(s) knowledgeable in the application
of Lockout/Tagout and this procedure and Qualified by SWECO as a LOTO
trainer shall conduct training. Contact your LOTO administrator or EHS Manager
if you have questions.
The purpose of this training is to provide the employees with the knowledge and
skills required for the safe application, and removal of energy controls.
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Demonstration of Training
The site operations shall conduct an annual demonstration of the effectiveness of
the training that is conducted for each authorized individual. The demonstration
shall be done in such a way as to ensure that authorized individuals demonstrate
the following:
 Knowledge of the program;
 Recognition and understanding of hazardous energy types;
 Use of appropriate hazardous energy control procedures.
Authorized individuals who do not demonstrate an adequate level of knowledge
or use of appropriate hazardous energy control procedures shall be retrained.
The following job classifications will attend the SWECO lead demonstration
training:
 Primary Authorized Employee
 System Authorized Employee
 Lead Authorized Employee
For remote or distributed field service work forces, demonstration that is observed
and verified by another authorized employee may not be feasible each year. In
these situations, simulation demonstrations may be acceptable. At a minimum,
there must be a live person-to-person demonstration following the authorized
employee’s initial training session. In these situations, the site/operation must also
have a random auditing process in place. This process should ensure that a
reasonable number of authorized employees are checked for demonstration each
year. At a minimum, live person-to-person demonstrations must occur every three
years.
NOTE:
It is the responsibility of the Contractor and Customer Safety Departments
to ensure that all non-supervisory employees and associated Vendors are
properly trained in LOTO in accordance to local regulatory requirements
prior to commencement of work activities on the Project Site.
Retraining shall be conducted whenever a periodic inspection reveals that there
are deviations from or inadequacies in an employee’s knowledge or use of energy
control procedures.
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 56 6/6/2022
G. McCalister
Retraining shall also be provided for all authorized and affected employees
whenever there is a change in job assignments, a change in machines, equipment
or processes that present a new hazard.
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 57 6/6/2022
G. McCalister
ATTACHMENT A
LOTO CLEARANCEFORM
STEP 1 – REQUIRED - LIST APPROPRIATE CLEARANCE NUMBER (S)
STEP 2
LOTO Requested By
Print Lead Authorized Employees (S)
Names
WORK TO BE PERFORMED (DESCRIPTION OF WORK)
STEP 3 -
Tag
No.
Lock
No.
DEVICE OR EQUIPMENT ISOLATED
(LIST AFFECTED EQUIPMENT)
POSITION
(e.g. OPEN,
CLOSED,
OFF, ON)
DATE Lock
and Tags
Applied
INITIAL
DATE
Lock and
Tag
Removed
INITIAL
1
2
3
4
Additional EquipmentIsolated ____ yes ____ no. If yes, attachAdditional Equipment IsolationForm(s).
STEP 4
STEP 5
Additional LeadAuthorized Employees ____ yes ____ no. If yes, attach Additional Lead AuthorizedEmployee
Form(s).
STEP 6–
LOTO APPROVED BY (SIGNATURE OF Primary Authorized Employee) - TIME DATE
STEP 7 –
LOTO RELEASED BY (SIGNATURE OF Primary Authorized Employee -) TIM E DATE
LOTO CLEARANCE NUMBER CONFINED SPACE ENTRY REQUIRED? HOT WORK REQUIRED?
NAME (PRINT and SIGN NAMES) TIME DATE
LOTO Verified System Authorized Employee -
LOTO Verified System Authorized Employee -
LOTO ISSUED TO
(SIGNATURE OF LEAD AUTHORIZED
EMPLOYEE (S)
TIME DATE
LOTO RELEASED BY
(SIGNATURE OF LEAD AUTHORIZED
EMPLOYEE (S)
TIM E DATE
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 58 6/6/2022
G. McCalister
ATTACHMENT B
ADDITIONAL EQUIPMENTISOLATION FORM
Page ______
LOTO CLEARANCE NUMBER DESCRIPTION OF WORK ACTIVITY
Tag
No.
Lock
No.
DEVICE OR EQUIPMENT ISOLATED
(LIST AFFECTED EQUIPMENT)
POSITION
(Eg. OPEN,
CLOSED, OFF,
ON)
DATE Lock
and Tags
Applied
INITIAL DATE Lock
and Tag
Removed
INITIAL
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 59 6/6/2022
G. McCalister
ATTACHMENT C
ADDITIONAL AUTHORIZED EMPLOYEEFORM
Page ______
LOTO CLEARANCE NUMBER SUPERVISOR
DESCRIPTION OF WORK ACTIVITY:
LOTO ISSUED TO
(SIGNATURE OF AUTHORIZED EMPLOYEE (S) TIME DATE
LOTO RELEASED BY
(SIGNATURE OF AUTHORIZED
EMPLOYEE (S)
TIM E DATE
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 60 6/6/2022
G. McCalister
ATTACHMENT D
DESIGNATION OF LOTO RESPONSIBILITIES
CONSTRUCTION MANAGER:
Name Representing Shift
COMMISSIONING/STARTUPMANAGER:
Name Representing Shift
PRIMARY AUTHORIZED EMPLOYEE:
Name Representing Shift
LOTO ADMINISTRATOR:
Name Representing Hang Locks
(yes/no)
Systems Shift
COMPANY LOCK DESCRIPTION
Company Name Color of Lock
NOTE: I certify that theabove designated LOTO Administrator(s) posses thespecific equipment knowledge to hang
locks and tags on the system(s) designated without direct supervision from a Primary or a Principal Authorized
Employee.
(Signature of Commissioning/EHS Manager and date)
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 61 6/6/2022
G. McCalister
ATTACHMENT D (Page 2)
DESIGNATION OF LOTO RESPONSIBILITIES
SYSTEM AUTHORIZED EMPLOYEES:
Name Equipment/System Representing Shift
LEAD AUTHORIZED EMPLOYEE (S):
Name Representing Shift
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 62 6/6/2022
G. McCalister
ATTACHMENT E
AUTHORIZED EMPLOYEE SIGN-IN SHEET
AUTHORIZED EMPLOYEE (S):
Name Representing Time On Time Off
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 63 6/6/2022
G. McCalister
Suzlon Wind Energy Corporation
Corporate EHS Program
Rev. 1 Page 64 6/6/2022
G. McCalister
ATTACHMENT F
LOTO INDEX
Site Name: ___________________________
LOTO
Number
Equipment System Authorized Employee Date
Opened
Date Closed Comments
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
Corporate EHS Program - Working Copy.doc
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Corporate EHS Program - Working Copy.doc
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Corporate EHS Program - Working Copy.doc

  • 1. Suzlon Wind Energy Corporation Corporate EHS Program Page 1 of 83 Createdby Gordon McCalister TABLE OF CONTENTS  Safety Orientation (Pending Completion)  Training Requirements  SWECO Drug and Alcohol Policy  Lock Out Tag Out (LOTO) Program  Injury/Accident Reporting and Procedures  Weather Restrictions
  • 2. Suzlon Wind Energy Corporation Corporate EHS Program Page 2 of 83 Createdby Gordon McCalister ORIENTATIONFOR NEWLY HIRED EMPLOYEES
  • 3. Suzlon Wind Energy Corporation Corporate EHS Program Page 3 of 83 Createdby Gordon McCalister OVERVIEW The SWECO Safety Orientation has been developed to provide initial and/or annual refresher training to all SWECO employees, and employees with new job assignments. This format is designed to provide the training information required in a terminology that is easy to follow, thus helping to reduce needles accidents and wasted time in training. Please not that there may be additional training, or refresher training required to perform certain jobs within SWECO. Teaching Time for this Program While this training can be delivered according to special needs, it is a SWECO requirement that this training be delivered to the employee in a one (1) day/shift format. To run this safety orientation over a longer period of time may expose the employee to hazardous situations. For any deviation from this program you must contact the Corporate EHS Manager or the VP of construction for approval. Learning Objectives 1. Identify SWECO/OSHA/CLIENT general safety rules and procedures. 2. Discuss Hazard Communication Requirements (MSDS), Impact of an accident on the employee, the family, and the Company. 3. Identify various fall hazards, means of fall prevention, and when and were fall protection is required. 4. Understanding the proper use of Ladders. 5. Recognize various electrical hazards on the job site and know ones limitation by training and experience. 6. Understand the proper use of hand and power tools. 7. Identify the hazards of working in or near an excavation. 8. Discuss and sign the SWECO Drug and Alcohol Policy. 9. Participate in testing program if applicable. 10. Discuss the hazards and identify confined spaces. 11. Explain the different signs and barricades on a job site. 12. Identify the hazards of material handling and the procedures to abate these hazards. 13. Describe and discuss proper rigging procedures. 14. Describe the proper use of every day clothing and specialized PPE. 15. Discuss mobile equipment and the requirements to operate it. 16. Discuss any special training or procedures for individual job descriptions or projects.
  • 4. Suzlon Wind Energy Corporation Corporate EHS Program Page 4 of 83 Createdby Gordon McCalister Fall Hazards and Types of Protection A. Fall Hazards B. Ladders C. Floor, Wall, and Stairway Openings Electrical Hazards A. Electrical Hazards B. Electrical Power Systems C. Hand and Power Tool Safety Trenching Hazards/Heavy Equipment A. Excavations B. Emergency Response C. Heavy Equipment D. Crane Safety E. Signs and Barricades Struck By/Material Handling A. Material Handling B. Personal Protective Equipment C. Rigging Construction Health A. Hazard Communication (Right to Know) B. Housekeeping C. Hearing Preservation Topic This information covered in this section is reflected in the SWECO employee handbook. However, additional training is required, for example (confined space). Please notice that the test to show proficiency is mandatory.
  • 5. Suzlon Wind Energy Corporation Corporate EHS Program Page 5 of 83 Createdby Gordon McCalister Other Topics Site/Specific Hazards A. Respiratory Protection (Breathing) B. Confined Space Entry C. Lockout/Tagout D. Fire Protection and Prevention E. Welding and Cutting Hazards F. Process safety management G. Permits H. Steel Erection I. Concrete Work J. Hot Weather Precautions K. Cold Weather Precautions L. Basic Rules of Safety M. Summary 1. Summarize orientation 2. Answer questions N. Test Employees must score at least 80 percent on the test. Note: The SWECO safety CD has several power points presentations covering all the subjects mentioned above. The site supervisor shall ensure that each employee received training if the hazards associated with his or her job change. If you don’t have the required presentation or video/DVD, you must call the SWECO safety office for immediate assistance.
  • 6. Suzlon Wind Energy Corporation Corporate EHS Program Page 6 of 83 Createdby Gordon McCalister . SS INTRODUCTION TO SWECO/OSHA/SAFETY SuggestedEquipment and Materials Copy of OSHA CFR 1926 Copy of OSHA poster SWECO/site written safety program Overhead projector and screen White board/chalkboard Markers/chalk Copies of the test Subjects SWECO/ OSHA/Client Accidents vs. Incidents Impact of Accidents Site Specific rules Give an overview of this orientation 1. Take attendance and perform other administrative tasks. 2. Outline briefly the topics to be covered. Explain to the employees that they must pass the Course Examination with a grade of at least 80 percent.  Make sure to cover site specifics emergency procedures. OSHA 1. Give a brief overview of OSHA. Explain to trainees refers both to the Occupational Safety and Health Act passed by Congress in 1970 and to the Occupational Safety and Health Administration who enforces these regulations. 2. Show trainees the OSHA poster that is required to be displayed in all workplaces. 3. Tell employees where the poster is located in their workplace. 3. 4. Explain the Employees’ Rights detailed on the OSHA poster. Accidents vs. Incidents 1. Describe what an accident is. 2. Describe what an incident is. 3. Discussion  Have participants list the various causes of accidents (unsafe acts and unsafe conditions).  Discuss the Accident Study Ratio transparency.  Discuss the role of the employees in recognizing hazards and reporting them.  Discuss the specific procedures for reporting hazards on their job or project.
  • 7. Suzlon Wind Energy Corporation Corporate EHS Program Page 7 of 83 Createdby Gordon McCalister Impact of Accidents 1. Lecture  Explain the actual cost of an accident.  Explain the hidden cost of an accident. FALL HAZARDS AND TYPES OF PROTECTION SuggestedEquipment and Materials OSHA CFR 1926 SWECO/site written safety program Examples of fall protection harnesses Ladder Examples of signs and covers for holes and openings Overhead projector and screen White board/chalkboard Markers/chalk Items to cover Fall Hazards Ladders Scaffolding Floor, Wall, and Stairway Openings Fall Hazards 1. Explain that falling is the leading cause of death in construction. These deaths and injuries occur because of falls from ladders, scaffolds, and other equipment. Fall protection available includes:  Personal fall protection system  Guardrails  Nets 2. Demonstrate the proper use of a harness, lanyards, and proper tie-off points. If time permits, have employees try on harnesses and demonstrate the proper use as well. 3. Discuss when fall protection is needed.  SWECO Six-foot rule or client/site specific rule (the most strict of the two will apply)  Lanyard (dual?) requirements  Equipment inspections (monthly documented) 4. Have employees list and discuss the possible areas and situations that would require the use of one of the fall protection systems.
  • 8. Suzlon Wind Energy Corporation Corporate EHS Program Page 8 of 83 Createdby Gordon McCalister Ladders Lecture  Describe how to determine the load limits.  Describe the need to use a ladder as intended by the manufacturer.  Describe how to inspect a ladder. Demonstrate the 3-point method of climbing a ladder in the classroom or outside of it. If time permits, let employees try as well. 3. Discussion  Have employees list the various causes of accidents using ladders.  Discuss the proper angle a straight or extension ladder should be when erected.  Discuss the specific procedures for reporting damaged ladders on their job or project. Scaffolding Explain the following points. Scaffolding shall:  Have solid foundation/support.  Be plumb.  Be fully braced.  Use tag to report unsafe situation.  Be inspected prior to use.  Have safe access.  Have guardrails and toeboards at 10 feet. (SWECO requires toe boards on all scaffolds. For any deviation contact the SWECO Corporate EHS Manager) 1. Explain the role of the competent person. 2. Have the employees identify their competent person for scaffolding on their site. 3. If time permits, take the trainees to an area on the job site with scaffolding and ask them to identify its “safety features” (bracing, guardrails, etc.) Floor, Wall, and Stairway Openings 1. Explain the dangers of unguarded floor, wall, and stairway openings and the employees’ responsibilities to make sure they are adequately guarded. 2. Show the employees examples of warning signs and covers for openings. If time permits, show them places on the job site where guards and temporary covers protect workers from openings.
  • 9. Suzlon Wind Energy Corporation Corporate EHS Program Page 9 of 83 Createdby Gordon McCalister ELECRICAL HAZARDS SuggestedEquipment and Materials OSHA CFR 1926 SWECO/site written safety program Examples of ground-fault circuit interrupters (GFCIs) Examples of fall protection harnesses Examples of double insulated tools Overhead projector and screen White board/chalkboard Markers/chalk Items to cover Electrical Hazards Electrical Power Systems Hand and Power Tool Safety Electrical Hazards 1. Explain that electrocution is one of the top four leading causes of death in construction. 2. List examples of causes of electrical accidents. 3. Talk about the General rules for working around power lines. Electrical Power Systems 1. List the types of electrical protection and explain how they work.  Show the difference between a double-insulated tool and a grounded tool.  Discuss SWECO assured grounding program.  Demonstrate the proper use of a ground-fault circuit interrupters (GFCI). 2. Discuss the importance of daily inspection of equipment and tools. Hand and Power Tool Safety Discuss the importance of:  Using the right tool for the job  Care for tools 1. General precautions for power tools  Never carry by the cord  Disconnect tools not in use  Never use legs as cutting surfaces  Wear proper personal protective equipment  Specialty tools (powder actuated, etc.)  Special hazards  Special requirements to operate 2. Have employees list the most commonly misused hand tools. 3. Discuss injuries from tools that have happened to family or friends.
  • 10. Suzlon Wind Energy Corporation Corporate EHS Program Page 10 of 83 Createdby Gordon McCalister TRENCHING HAZARDS/HEAVY EQUIPMENT SuggestedEquipment and Materials Copy of OSHA CFR 1926 SWECO/site written safety program Examples of signs, tags, and barricades Overhead projector and screen White board/chalkboard Markers/chalk Items to cover: Excavations Emergency Response Heavy Equipment Crane Safety Signs and Barricades Excavations (if SWECO employees will not be working around excavations you don’t have to cover this section but if an employee is transferred at a later time and he/she will be working near excavations you will need cover the hazards associated with excavations) Working in or around excavations is one of the most dangerous jobs in the construction industry. It is estimated that cave-ins claim 80 to 100 construction workers’ lives every year. 1. Discuss the causes of cave-in, such as weather, vibrations, and movement of buildings near excavations. 2. Outline the procedures to follow prior to start digging and what rules must be followed. 3. Describe the competent person's role in excavations. 4. Explain the types of protective systems, such as sloping/benching, shoring, and shields. 5. Explain the four-foot rule. (At depths of four feet, exits such as a ladder or ramp must be provided every 25 feet.) 6. Explain the five-foot rule. (At depths of five feet and greater, the excavation must be sloped or shored. A protective system must be used. If more than 20’ a PE approval is required) 7. Explain the difference in soil classifications. 8. Have participants identify their competent person for excavation.
  • 11. Suzlon Wind Energy Corporation Corporate EHS Program Page 11 of 83 Createdby Gordon McCalister Emerge ncy Response Every operation that includes trenching should have emergency response procedures in place, and rescue equipment ready, in case an accident occurs. 1. Go over the following critical concerns with the employees. Remind them of the importance to have a plan in place in case of emergency.  Who provides rescue and first aid? Where are the emergency phone numbers listed? Who will notify the authorities and rescue personnel?  Who will meet, advise, and direct rescue personnel at the job site?  What emergency response equipment will be available on the job site? Where will it be kept, and who is trained to use it?  Neveruse heavy equipment in a rescue.  Neverendanger yourself in a rescue attempt. Heavy Equipment 1. Only authorized, trained personnel should operate vehicles and mobile equipment. Certain equipment requires operators to be trained and certified. (SWECO requires a test). 2. Discuss the SWECO requirements to operate each piece of equipment, such as certification or site requirements 3. Discuss safe behavior for ground personnel working near heavy equipment and for heavy equipment operators working near ground personnel. 4. Discuss the importance of stability control when operating heavy equipment or near heavy equipment. 5. Have participants list the various types of equipment being used on the job site Crane Safety 1. Only authorized, trained personnel shall operate cranes. 2. Discuss when conducting crane inspections, cranes must be in good working order to be used on the job site. 3. Talk about safety procedures crane operators should follow. Signs and Barricades 1. Outline the various types of signs employees are likely to see on the construction site. Show examples. 2. Outline the types of tags employees are likely to see on the construction site. Show examples. 3. Explain the types and uses of barricades. Show examples. 4. Demonstrate the proper procedures for using out of service tags on the job site. 5. If time permits, take the employees for a walk around the job site to identify the various types of signs, tags, and barriers they see. Can they spot any places where there should be a sign, tag, or barrier?
  • 12. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 12 6/6/2022 G. McCalister STRUCK BY/MATERIAL HANDLING SuggestedEquipment and Materials OSHA CFR 1926 SWECO site written safety program Examples of personal protective equipment Overhead projector and screen White board/chalkboard Markers/chalk Material to cover Material Handling Personal Protective Equipment Rigging Material Handling Manual material lifting is the principal source of compensative work injuries in the United States. In 1980 alone, about one million workers suffered back injuries in the workplace, three-quarters of which were caused by lifting. 1. Discuss material handling by hand and the correct and incorrect ways to do it, including:  The risk to health from unskilled lifting  The effects of lifting on the body  Developing an awareness of your body's limits  Recognition of physical factors that contribute to an accident  Handling skill and safe lifting posture and procedures  Handling aids 2. Discuss considerations when handling materials with machines, such as a dolly or forklift. 3. Have participants identify proper pre-lift considerations. Personal Protective Equipment Personal protective equipment (PPE), properly used and kept in good condition, saves lives and reduces injury and illness among employees. PPE includes: equipment for eyes, face, head, arms, and legs; protective clothing; respiratory devices; and protective shields and barriers. 1. Explain to the employees the importance of using PPE. 2. Discuss the kinds of PPE available and when and where to use what kinds. 3. Discuss trade-specific PPE. 4. Show the employees examples of PPE, such different kinds of eyewear, hard hats, and gloves. 5. Identify the PPE required on the jobsite. 6. Discuss the procedures for replacing equipment in poor
  • 13. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 13 6/6/2022 G. McCalister condition. 7. Review SWECO and jobsite rules on PPE. Rigging Moving large, heavy loads is crucial to today's manufacturing and construction industries. Much technology, careful training, and extensive workplace precautions have been developed for these operations. There are significant safety issues to be considered, both for the operators of the diverse "lifting" devices and for workers in proximity to them. 1. Underscore that qualified personnel shall be involved in a lift. A qualified signalman must be used, and the work must be properly supervised. 2. Safe methods and procedures must be observed in the lift at all times. 3. Know the rated capacity of the sling. 4. Know the condition of all the slings, shackles, hooks, and other lifting equipment. 5. Use eyebolts carefully. 6. Stay clear of suspended loads. 7. Keep the load balanced. 8. Don't jerk the load. 9. Maintain control and always use a tag line. 10. Watch the vertical angle. 11. Have each employee demonstrate the hand signals used. If time permits, divide the trainees into pairs and have them signal to each other. CONSTRUCTION HEALTH SuggestedEquipment and Materials OSHA CFR 1926 SWECO site written safety program Overhead projector and screen White board/chalkboard Markers/chalk Sample material safety data sheets (MSDS) Examples of hazard labeling signs Items to cover Hazard Communication Housekeeping Hearing Preservation Construction Ergonomics
  • 14. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 14 6/6/2022 G. McCalister Hazard Communication: 1. Explain what hazard communication (HAZCOM) is and why it should be important to all SWECO employees. 2. Tell the trainees what must be labeled. 3. Show the trainees how to read HAZCOM labels. 4. Pass out examples of hazard labeling signs for the employees to become familiar with. 5. Explain what material safety data sheets (MSDS) are and where they are located on the job site. If time permits, show the employees where the MSDS sheets are located. 6. Show the employees how to read MSDS sheets. 7. Pass out examples of MSDS sheets to the employees. 8. Have participants identify on an MSDS the areas of concern:  Name of the chemical  Health hazards  First aid/medical information  Personal protective equipment required Housekeeping: Management and employees should recognize good housekeeping as a vital tool for production and safety. Good housekeeping reduces operating costs, increases production, opens aisles to permit faster safe movement of materials and employees, lowers accident rates, reduces fire hazards, and raises employee morale. 1. Have the employees brainstorm about the benefits of good housekeeping around the job site. Afterwards, fill in any benefits they may have missed. 2. List some of the many ways a job site is kept orderly, such as disposing of trash promptly, putting away tools and equipment properly, and keeping walkways and stairways free of debris and tripping obstacles. Hearing Conservation 1. Hearing protection should be worn any time noise is too loud to understand a normal conversation. 2. Ask your supervisor about hearing protection requirements at your job site. 3. Plain cotton is not an acceptable protective device. 4. Have participant discuss the long-term impact of noise on hearing.
  • 15. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 15 6/6/2022 G. McCalister Construction Ergonomics Ergonomics is the science of fitting the job to the worker. Often musculoskeletal disorders (MSDS) can be prevented by simple and inexpensive changes in the workplace. Adjusting the height of working surfaces, varying tasks for workers, and encouraging short rest breaks can reduce risks. Reducing the size of the items workers must lift or providing lifting equipment also may aid workers. The longer the time the worker must maintain a fixed or awkward posture, exert force, repeat the same movements, experience vibration, or handle heavy items, the greater the chance that such a disorder will occur. 1. Discuss the following critical concerns and how they can hurt your body:  Frequency of the action or work cycle  Awkward postures required to perform the task  Forceful exertions required by the task  Workplace conditions that may affect the hazard presented by a task  Tools or clothing used on the job which may affect the hazard presented by the task Additional safety topics SuggestedEquipment and Materials OSHA CFR 1926 SWECO/site written safety program TV/VCR (optional) Respiratory Protection (Breathing) Confined Space Entry Lockout/Tagout Fire Protection and Prevention Welding and Cutting Hazards Asbestos and lead Awareness Permits Steel Erection Concrete Work Hot Weather Precautions Cold Weather Precautions Test (Mandatory) Respiratory Protection (Breathing) Optional equipment: examples of respiratory equipment 1. Talk about the situations when respiratory equipment is mandatory.
  • 16. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 16 6/6/2022 G. McCalister 2. Discuss the necessity of being trained to use a respirator and receiving approval from your supervisor before entering an area where a respirator is needed. 3. Show the employees examples of respiratory equipment. 4. Discuss the importance of maintaining, regularly inspecting, and storing respiratory equipment properly. Confined Space Entry 1. Define “confined space” and “permit-required confined space.” Make sure employees understand the difference. 2. List and discuss some of the hazards associated with confined space, such as atmospheric, mechanical, entrapment, and engulfment. Underline the necessity of further training after this course before trainees should enter a confined space. (All SWECO employees must receive the confined space training prior to entering one). Lockout/Tagout Optional materials: SWECO lockout/Tagout procedures from the SWECO/site written safety program 1. Define “Lockout/Tagout” for the employees. Tell them what kinds of equipment must be locked-out/tagged-out for repair. 2. Talk to the trainees about SWECO- or site-specific Lockout/Tagout procedures. Are they familiar with company policies? If the site specific policies are in writing, you may want to pass around a few of the booklets. 3. Go over the General guidelines of “to do’s” and “don’t do’s” from the course booklet. Fire Protection and Prevention Optional materials and equipment: different size fire extinguishers 1. Ask employees if they know where the fire extinguishers should be located on the job site. 2. Show them the label on several different size fire extinguishers. Point out how they differ as to the size fire the extinguisher can put out and what kinds of fires the extinguishing compound can put out. 3. Discuss how to handle combustible materials at the job site. 4. Discuss the dangers of refueling portable power equipment while running or hot... 5. Talk about the proper storage of flammable liquids and materials. Welding and Cutting Hazards 1. Discuss the safe way of handling welding leads and burning hoses. 2. Talk about the importance of daily inspections of all welding equipment. 3. Discuss the importance of flashback arresting valves and the safest way to install them. 4. Discuss the safety provisions for electric arc welding outline in the course book. 5. Discuss the safety provisions for gas welding outline in the
  • 17. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 17 6/6/2022 G. McCalister SWECO employee handbook. Asbestos Awareness 1. Talk about why special training is so important when handling asbestos or lead, including the many health risks. 2. List the numbers of places where old asbestos and lead may be found (see additional package). Permits 1. Talk about the necessity of permits for the jobsite. What can happen if the proper permits are not secured before beginning a job? 2. Discuss the different types of work permits. Steel Erection 1. Follow all rules and regulations governing fall protection during steel erection. (new revised OSHA standard ) 2. Discuss the safe way for connectors to work together. 3. Talk about the importance of safe crane and lifting practices. Concrete Work (if applicable to SWECO employees on the jobsite) 1. Discuss safe ways to work with concrete. This primarily focuses on concrete placement, such as safe shorting and reinforcing steel. 2. Emphasize the importance of avoiding skin contact with concrete. Hot Weather Precautions 1. Outline the symptoms and first aid for the following:  Heat cramps  Heat exhaustion  Heat stroke 2. Have the employees discuss precautions to avoid heat-related ailments, such as drinking lots of fluids, trying to stay in the shade, and dressing appropriately. Cold Weather Precautions 1. List the symptoms of hypothermia, frostbite, and overexposure. 2. Discuss how to avoid hypothermia, such as:  Dressing in layers  Keeping dry  Using a buddy system SWECO Drug & Alcohol policy  The instructor will provide a copy of SWECO drug & alcohol policy to the employee/applicant who must sign the consent form (last page). Employee safety handbook
  • 18. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 18 6/6/2022 G. McCalister Employees must sign the last page of this book (existing employees are not required to sign this page when assigned to a new location unless changes have been made to the employee safety handbook. Test – Mandatory 1. Distribute copies of the test to all employees and then start the test. 2. Be sure to collect all copies of the test when completed. Review the test with the employees to make sure that every employee knows the correct answer.
  • 19. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 19 6/6/2022 G. McCalister TRAINING REQUIREMENTS Required Training 1. All employees shall receive new hire orientation. 2. Operators of any powered equipment must receive training, take and pass a written test and show proficiency prior to operating any equipment. Some equipment also requires a physical under federal standard. 3. This would include but not be limited to:  Forklifts  Payloader with forks  Backhoe/trackhoe  JLG/Man lift  Crane/Overhead Gantry  Spider basket or similar  Elevator  Nail guns  Air or electric tuggers 4. All SWECO field employees shall receive 10 Hr OSHA training with in 1 year of employment. 5. Field Leads and Construction Managers shall receive OSHA 30 Hr courses with in 1 year of employment. 6. Refresher training is required every 2 years for OSHA courses. 7. All employees shall receive site specific orientations. 8. High/Low Voltage training for effected personnel.
  • 20. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 20 6/6/2022 G. McCalister DRUG AND ALCOHOL PROGRAM
  • 21. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 21 6/6/2022 G. McCalister DRUG and ALCOHOL PROGRAM Purpose Dependency on alcohol and /or drugs can interfere with an employee’s health and job performance, and may pose serious safety, health or security risks not only for the user but also to those who work with the user. It is the obligation and intent of Suzlon Wind Energy to maintain a safe, healthful, and secure work environment for all its employees, and to protect company property and operations. Suzlon Wind Energy has established the following policy regarding prescription medications, illegal drugs or paraphernalia, alcoholic beverages, contraband, weapons, stolen property, or site specific unauthorized items. General Company/Client Premises The term “Company/Client Premises” includes all property, facilities, land, building, structure, installations, and vehicles whether owned, leased, used, or parked on site. This may also include other work locations and/or sites or to and from those locations while in the course and scope of Suzlon Wind Energy employment. Use, Possession, or Sale of Drugs or Alcohol 1. Illegal Drugs:  Using, selling, manufacturing, purchasing, transferring, dispensing, distributing, or possessing illegal drugs by any employee while in a Suzlon Wind Energy facility, on a jobsite, or while performing Suzlon Wind Energy business is strictly prohibited. 2. Prescription and /or Legal Drugs  An employee that is required to take prescription medication or over the counter medication that may affect the safety of them selves, co-workers,
  • 22. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 22 6/6/2022 G. McCalister or members of the public, the employees performance, or the security and safe operation Suzlon Wind Energy property or facilities, employees shall: 1. Notify his/her Suzlon Wind Energy Supervisor prior to starting use of prescribed medication on the job. 2. Each prescription shall be in the employee’s name and prescribed by a licensed medical practitioner. 3. Said prescription shall be no older than one year. 4. Employees shall partake of the medication as prescribed. The employee may continue to work unless management determines that use of the medication poses a risk. Disciplinary Action 1. Violation of any part of this policy WILL result in the immediate termination of employment. 2. All Suzlon Wind Energy employees will be required to sign an acknowledgment and consent form prior to employment, or at the time of assignment to a job site to attest their understanding of this policy. 3. If during a testing procedure an employee:  Refuses a test  Leaves the testing area  Exceeds three hours with out a sample His/hers employment will be terminated. Drug and Alcohol Screening 1. Suzlon Wind Energy will most commonly use a urinalysis for drug and alcohol screening, but are not limited to this process alone. Due to municipal laws and possible client requirements, screening may be one or more of the following:  Urinalysis, Blood test, Saliva, Breath, Hair Follicle 2. Testing may be announced or unannounced prior to the testing date and shall be performed as a witnessed sample collection. 3. A drug and/or alcohol test may be requested by a prudent field supervisor when an employee shows cause in his/hers mannerisms, or physical appearance. 4. A drug and alcohol test shall be performed post accident, post injury, (This would include a major first aid or a doctor’s visit but not a minor first aid, i.e. a Band- Aid) or when drugs or paraphernalia is located. Searches  Suzlon Wind Energy reserves the right to conduct unannounced searches for illegal drugs, alcohol, paraphernalia, firearms, explosives, company equipment or
  • 23. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 23 6/6/2022 G. McCalister tools, at/or in offices, facilities, job sites, vehicles, person, and clothing. These searches do not have to be based on reasonable suspicion.  The employee’s field supervisor has the right to conduct on-the-spot search and inspection of employees and their personal effects as described in the policy if a supervisor has a reasonable suspicion that employees are in direct violation of any part of this policy.  A search and/or inspection as defined in the policy may also include requiring employees to submit to a drug and/or alcohol test. This may be required under the following conditions: 1. Annual employee physical examinations (such as required for a DOT license) or to comply with client requirements. 2. Part of an overall search and inspection of an employees work area at a site location. 3. When an employees supervisor has reasonable suspicion that an employee is under the affects of drugs or alcohol. 4. When an employee is arrested for a drug related crime. 5. Post accident or injury requiring a physician’s visit. 6. Submissions to such searches are conditions of employment and continuing employment. Refusal to submit will result in immediate termination of employment. Definitions For purposes of this policy, the following definitions apply: 1. Alcohol—any beverage that may legally or illegally sold and consumed and has alcohol content of three percent or more by volume. 2. Illegal Drugs—any drug which is not legally obtainable or which is legally obtainable but has not been legally obtained. (This would include prescription medications not in the recipient’s name.) Illegal drugs are those under the US Federal Controlled Substance Act as drugs with a high potential for abuse and are classified as follows: 3. 0piates and opiate derivatives (i.e. heroin, codeine, morphine, lodnum)  hallucinogenic substances ( i.e. marijuana, LSD, phencyclidine, peyote)  depressants (i.e. methaqualone, barbiturates)  stimulants (amphetamines, methamphetamines)  coca leaf derivatives (i.e. cocaine, “crack”, “crank”)  also included are look alike drugs, designer drugs and drug paraphernalia 4. Controlled Substance—schedule I through V of section202 of the controlled substance act (21 USC 812), and as further defined in regulations at 21 CFR 1308.11-1308.15. 5. Conviction—a finding of guilt. (Including a plea of nolo contender) or imposition of sentence, or both, by any judicial body duly charged with the responsibility to determine violations of the federal state or local criminal drug statutes.
  • 24. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 24 6/6/2022 G. McCalister 6. Criminal Drug Statute—a federal or non federal, criminal statute involving the manufacture, distribution, dispensing, possession, or use of any controlled substance. 7. Under the influence—means that an employee is affected by drugs or alcohol in any detectable manner. The symptoms of influence are not confined to those consistent with misbehavior, or to obvious impairment of physical or mental abilities such as slurred speech or difficulty in maintaining balance. Acknowledgment and Consent Form  Suzlon Wind Energy applicants/employees are required to sign the acknowledgment and consent form—drug and alcohol testing as a condition of employment and continued employment if assigned to perform services on a Suzlon Wind Energy project. Included in the consent form is the agreement to submit to periodic unannounced (random) testing during the course of their employment. Refusal to cooperate with or submit to such testing will result in immediate termination of employment. The employee’s signature, affixed to this form is acknowledgment that this information was made available before employment or as acceptance of a position with Suzlon Wind Energy on a jobsite or office environment and has agreed to testing under this policy. Testing Procedures  Suzlon Wind Energy will arrange for all drug and alcohol testing. This will be conducted on site when qualified personnel are present. When on site testing is not possible arrangements will be made to have either third party testing on site or the employee will travel to an offsite facility.  Upon notification that a drug and/or alcohol test is to be performed, the employee will be offered this policy and the consent form will be signed by the employee. After signing the consent form testing will proceed. If the employee refuses to sign the consent form or comply with any other portion of this policy the employees employment will be terminated.  The chain of custody document will be completed. The donor copy will be given to the employee after the sample is provided and then the respective copies will be sent to the laboratory, and Chicago corporate office.
  • 25. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 25 6/6/2022 G. McCalister Standards of Testing  The standard for test will initially be via enzyme multiplied immunoassay technique (EMIT), and where positive followed by a more precise test, the gas chromatograph and mass spectrometry (GC/MS). The minimum substance tested shall be those included in the SAMSA (NIDA) (National Institute of Drug Abuse) Panel 10 plus alcohol unless stated otherwise by a client contract.  Cutoff levels will be those established by the federal Department of Transportation (DOT) as set forth in 49 CFR part 40 unless stated otherwise in a client contract. Specimen Collection/Laboratory  Collection shall be conducted by a Suzlon Wind Energy designated person or a qualified agency in compliance with the guidelines established by the US Department of Health and Human Services, set forth in 53 fed. Reg. 11970. KROLL laboratories as a SAMSA (NIDA) facility will be Suzlon Wind Energy’s laboratory of choice. If for some reason another facility is to be used the Corporate Environmental Health and Safety (EHS) manager should be consulted prior to its use. Record Keeping and Confidentiality  The request to submit to drug or alcohol testing is to be done discretely. Any resulting allegations of drug policy violations will be kept highly confidential. Disclosures will be made only to those with a “need to know” basis.  All records pertaining to drug or alcohol testing will be kept in the corporate office or on a secure file of the server, and will be released on a “need to know” basis. Positive Results  In the event of a positive drug or alcohol test: 1. The applicant will not be hired until a clear screening has been acquired. 2. The employee will be removed from site or office, and suspended with pay until review by the MRO. If however this positive result is due to a prescribed medication it will be reviewed by a Medical Review Officer (MRO) assigned by KROLL Laboratories, and verified by Suzlon Wind
  • 26. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 26 6/6/2022 G. McCalister Energy’s corporate EHS and HR managers to ensure that the prescribed medication does not pose a threat to operations. 3. If an employee fails a drug test he/she may request (at a Suzlon Wind Energy approved site) a second test if done the same day as notification of the “positive test”. 4. After a positive result has been confirmed and it was not due to a legally prescribed medication, the employee will not be eligible for employment for sixty (60) days. Additionally this person will need to successfully complete a recognized drug or alcohol rehabilitation program that is not less than fourteen (14) days in length prior to reemployment. 5. When reemployment has begun the employee will be subject to monthly random testing for a period of one (1) year. Unemployed periods will not be inclusive for the one (1) year time period. 6. If a second confirmed (positive) drug or alcohol test occurs the employee will be permanently ineligible for employment. Random Selection and Frequency  Random testing shall be conducted at least quarterly but is not limited to this time frame.  Random testing may include randomly selecting a job site or office and testing 100% of the employees at that site, or it may be a 10% randomly picked through out the US operations.  All Suzlon Wind Energy employees are subject to random testing and this policy.  Random selection will be done using either an employee’s social security number, or their employee number. Notification Procedure At the time of random drug and/or alcohol testing, the following steps shall be taken:  Personnel will be selected randomly, or it shall be a 100 percent (100 %) testing.  The Suzlon Wind Energy supervisor will notify the selected employees privately and escort them to the collection site.  If an employee refuses to submit to the testing, the supervisor will explain to the employee that employment will be terminated immediately unless he/she submits to the procedure. This shall be done in an effort for the employee to reconsider. Suzlon Wind Energy supervisors are not to attempt to use force in seeking compliance.  When Human Resources and the Drug Screening Administrators receive the results, the site supervisor will be notified in the event of positive results. Questions regarding drug screening should be directed to the Environmental Health and Safety manager, or the Human Resources manager. Chemical Screening Notification A pre-employment drug screening is part of Suzlon Wind Energy’s overall pre- employment procedures that enable our company to evaluate your eligibility for employment. One of the
  • 27. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 27 6/6/2022 G. McCalister requirements for consideration of employment and/or continued employment is satisfactorily passing a URINE DRUGSCREEN TEST. Please read the following instruction carefully. NOTICE TO APPLICANTS/EMPLOYEES: Suzlon Wind Energy has a policy that prohibits the possession and/or use of illegal and unauthorized drugs or paraphernalia, and periodically searches and performs both urine screening and breath analysis of employees as an enforcement measure in providing a safe working environment. A positive drug/alcohol screening will remove you from consideration for employment with Suzlon Wind Energy or terminate your employment. Acknowledgements  My signature below certifies that I understand I will be given an opportunity to make written disclosure to the Medical review officer (MRO) of any over the counter or prescription medication that I am currently taking or have recently taken, as well as any other information relevant to the reliability of or explanation for, a positive drug result.  My signature below certifies that I have read or had read to me, and understand the Suzlon Wind Energy policy on unauthorized and illegal drugs or alcohol, and I acknowledge that violating this policy will result in termination of employment (EMPLOYEE) and or denied employment (APLICANT). I also understand that Suzlon Wind Energy employees are subject to random testing and post accident testing for injuries or illnesses that are job related.  My signature below certifies that I authorize the testing agency to provide the results of my test to Suzlon Wind Energy and further agree to hold Suzlon Wind Energy, the testing agency or company, its agents,directors, officers, and employees harmless from any and all liability in connection with the testing for drugs and/or alcohol content.  My signature below certifies that I understand that any positive result will preclude or terminate any offer of employment with Suzlon Wind Energy. ______________________________________ Applicant/Employee Name (Printed) ______________________________________ _____________________ Applicant/employee Signature Date ______________________________________ Suzlon Wind Energy Witness Name (Printed) ______________________________________ _____________________ Suzlon Wind Energy Witness Signature Date
  • 28. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 28 6/6/2022 G. McCalister LOCK OUT TAG OUT PROGRAM
  • 29. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 29 6/6/2022 G. McCalister SECTION ONE Lockout/Tag out Procedure 1. All potential energy sources shall have a LOTO applied until the competent person confirms removal is safe. 2. Installation and maintenance must be carried out by a qualified person. 3. Insuring that this LOTO is applied is the responsibility of the construction manager. 4. Application and maintenance may be allocated at the Construction Managers judgment. 5. Notifications shall be given to all effected people on site in writing. 6. A site roster will be kept identifying those persons for other contractors that have the authority to give the all clear for there company. 7. No LOTO may be removed with out the signature of the authorized person of each contractor. 8. LOCKOUT / TAGOUT (LOTO) 9. Changes may only be made to this document by the SWECO EHS department
  • 30. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 30 6/6/2022 G. McCalister WARNING There shall be no exceptions allowed or deviations from the prescribed LOTO procedure contained within this document at any time. Any person who operates a valve, switch, or Energy Isolating Device to which a lock or danger tag is attached will be subject to disciplinary action up to and including immediate termination. Any person who removes a lock or danger tag from an Energy Isolating Device that is part of an Active LOTO will be subject to disciplinary action up to and including immediate termination. Prepared By: Gordon McCalister Approved By: Daniel Skinner/Gordon McCalister Date Approved: 12-19-06
  • 31. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 31 6/6/2022 G. McCalister Purpose The purpose of the Lockout/Tagout (LOTO) program is to ensure that all persons performing service and/or maintenance of machines and equipment during all phases of a Site Project (construction, pre-commissioning, commissioning, testing or servicing) are fully protected from unexpected energization, startup or the uncontrolled release of energy, which could cause injury to those persons and/or equipment. All work on energized systems shall follow the procedures described herein. Scope The overall scope of this procedure is to ensure compliance with 29 CFR - 1910.147; Control of Hazardous Energy (Lockout/Tagout) and Subpart S, 1910.333 Selection and Use of Work Practices (Electrical Safety Related Work Practices). Guidance provided by OSHA directive STD 1-7.3 for Group Lockout/Tagout for work done on complex equipment (Appendix C) was also used in the development of this program. Due to the complexity of activities, which take place during power plant construction and commissioning, the length of time and number of Lockout/Tagouts performed the use of a work permit system (LOTO form) in addition to Lockout/Tagout is necessary. This system provides centralized control over LOTO while providing an equivalent level of personnel safety to individual Lockout/Tagout. This program shall be modified accordingly in the event that local government or client LOTO regulations are more stringent. This procedure contains specific information relating to the following: LOTO rules and Regulations LOTO Definitions The execution of a system/equipment LOTO Special LOTO clearance procedure System/equipment testing under LOTO Employee LOTO training requirements Employee responsibilities regarding the LOTO program and procedures
  • 32. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 32 6/6/2022 G. McCalister Responsibility The responsibilities listed below pertain to the administration of the Lockout/Tagout (LOTO) program. SWECO Construction/Site Manager  Has overall responsibility for site safety for all SWECO Activities and Subcontractors.  Will order the review and issuance of revised LOTO procedures.  Will assign the responsibility for weekly LOTO inspections of the LOTO log and procedures.  Will order stoppage of all work performed in an unsafe manner SWECO Commissioning Manager/Designee  Is responsible for establishing and implementing the LOTO program.  Is responsible for the periodic review and revision of the LOTO procedures as directed.  Is responsible for training site personnel and contract employees in the rules and regulations contained within these procedures.  Is responsible for conducting weekly audits of the LOTO log and reporting to the Site Manager the results of the audit. Primary Authorized Employee LOTO Administrator System Authorized Employee Lead Authorized Employee System Authorized Employee System Authorized Employee Lead Authorized Employee Lead Authorized Employee Lead Authorized Employee Lead Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee Authorized Employee
  • 33. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 33 6/6/2022 G. McCalister  Will order stoppage of all work performed in an unsafe manner  The Commissioning Manager may act as the Primary Authorized Employee and/or the LOTO Administrator depending upon site conditions. Primary Authorized Employee The Primary Authorized Employee shall be knowledgeable in all plant systems, and trained in the practice of Lockout / Tag out (LOTO). The Primary Authorized Employee is responsible for, authorization of all LOTO’s. The Primary Authorized Employee shall be the central focal point for the coordination of all work and test activities, during plant commissioning, that require a LOTO. The Primary Authorized Employee may also act as a System Authorized Employee for those plant systems that they are responsible for. Responsible for the following under the LOTO program:  Fully understanding the work to be done and authorization of the protection required to make the system/equipment safe to work on  Ensure contractor and site personnel compliance with the LOTO rules and regulations  Review of the Active LOTO’s each shift  Notification of Site Management of any LOTO violations  Stoppage of all work performed in an unsafe manner System Authorized Employee A System Authorized Employee shall be knowledgeable in the specific plant systems that they have responsibility for. The System Authorized Employee may lock out and tag out only the systems and equipment that have been assigned to them. A System Authorized Employee is trained in the practice of Lockout/Tagout (LOTO). The System Authorized Employee is designated by the Primary Authorized Employee as qualified to physically operate all necessary devices to isolate the equipment or system and to attach all locking devices and tags. The System Authorized Employee shall ensure that all Affected Employees are notified of servicing or maintenance activities within their respective areas or on equipment under their scope of control/operation. The System Authorized Employee and Authorized Employee may be the same person when the System Authorized Employee‘s duties also include performing maintenance or service on a machine or equipment. A list of System Authorized Employees, and the equipment/systems assigned to them, shall be listed on the Designation of LOTO Responsibilities form (Attachment D) kept in the LOTO Logbook. Responsible for the following under the LOTO program:
  • 34. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 34 6/6/2022 G. McCalister  Fully understanding the work to be done and implementing the required protection to make the system/equipment safe to work on  Ensuring that all Affected Employees have been notified of the intent to perform service or maintenance activities on or around his/her equipment or system(s)  Ensuring system/equipment isolation and the placement of locks and tags per the respective LOTO Clearance Form (Attachment A)  Notifying the Primary Authorized Employee, Authorized Employee(s) and the Affected Employee(s) when protection is in effect.  Notifying the Primary Authorized Employee of any LOTO violations  Ensuring that he/she complies with the LOTO rules and regulations  Ensuring that all personnel working within the Authorized Employee(s), LOTO comply with all LOTO rules and regulations  Promptly informing the Primary Authorized Employee of work completion  Ensuring that the system/equipment has been returned to a state of operational readiness (e.g. all guards and safety devices are installed prior to the completion of work activities)  Stopping all work performed in an unsafe manner LOTO Administrator The LOTO Administrator shall be responsible for maintenance of LOTO documentation including, the LOTO index, active and inactive LOTO Forms. The LOTO Administrator shall monitor active LOTO’s for compliance with this procedure. The LOTO Administrator may only place locks and tags under the direct supervision of the Primary Authorized Employee or the System Authorized Employee for that system unless they have been deemed qualified by the Primary Authorized Employee and given the authorization to do so. The LOTO Administrator is trained in the principals of Lockout/Tagout. Responsible for the following under the LOTO program:  Administration of the LOTO Log  Ensuring that LOTO’s are issued in accordance with LOTO Procedure  Ensuring contractor and site personnel compliance with the LOTO rules and regulations  Reviewing Active LOTO’s each shift  Notifying Site Management of any LOTO violations  Stopping all work performed in an unsafe manner
  • 35. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 35 6/6/2022 G. McCalister Lead Authorized Employee The Lead Authorized Employee is the authorized employee who oversees or leads a group of servicing/maintenance workers (e.g. mill wrights, pipe fitters, electricians) known as Authorized Employees. Lead Authorized Employee’s may request the LOTO of machinery or equipment in order to perform servicing or maintenance on that machine or equipment. Lead Authorized Employee’s are trained in the practice of Lockout/Tagout (LOTO). Responsible for the following under the LOTO program:  Contacting the System Authorized Employee and requesting a LOTO for the respective system/equipment he/she is to work on  Providing the System Authorized Employee with all pertinent information regarding the work activities to be accomplished under the LOTO  Ensure that all Authorized Employees sign in and out on the Authorized Employees Form at the beginning and end of each work shift  Fully understanding the work to be done  Notifying all Affected Employees of the intent to perform servicing or maintenance activities on or around his/her equipment or system(s)  Reviewing the System/equipment isolation and the placement of locks and tags per the respective LOTO Clearance Form  Notifying the System Authorized Employee of any LOTO violations  Ensuring that he/she complies with the LOTO rules and regulations  Ensuring that all personnel working within the Authorized Employee(s), LOTO complies with all LOTO rules and regulations  Promptly informing the System Authorized Employee of work completion  Ensuring that the system/equipment has been returned to a state of operational readiness (e.g. all guards and safety devices are installed prior to the completion of work activities)  Stopping all work performed in an unsafe manner Authorized Employees An Authorized Employee is trained in the practice of Lockout/Tagout (LOTO). An Authorized Employee is an employee who perform servicing or maintenance on that machine or equipment under the supervision of a Lead Authorized Person. Responsible for the following under the LOTO program:  Sign in and out on the Authorized Employees Form at the beginning and end of each work shift
  • 36. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 36 6/6/2022 G. McCalister  Fully understanding the work to be done  Notifying all Affected Employees/Contractors of the intent to perform servicing or maintenance activities on or around his/her equipment or system(s)  Reviewing the System/equipment isolation and the placement of locks and tags per the respective LOTO Form  Ensuring that he/she complies with the LOTO rules and regulations  Ensuring that all personnel working within the Authorized Employee(s), LOTO complies with all LOTO rules and regulations  Promptly informing the System Authorized Employee of work completion  Ensuring that the system/equipment has been returned to a state of operational readiness (e.g. all guards and safety devices are installed prior to the completion of work activities)  Stopping all work performed in an unsafe manner Affected Employee An Affected Employee is an employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout/Tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed. Any site personnel who even work in the General vicinity of equipment or systems under LOTO must be trained as an Affected Employee. This Training is the responsibility of the individual companies and not SWECO’s. Responsible for the following under the LOTO program:  Being aware of work being performed on or around his/her affected equipment/systems and signify his/her understanding and compliance by signing on to the LOTO in the appropriate space provided.  Understanding precautions to be taken while work is being performed by the Authorized Employee(s)  Notifying the Primary Authorized Employee of any LOTO violations  Ensuring that he/she complies with the LOTO rules and regulations  Ensuring that all personnel working within the Authorized Employee(s), LOTO comply with all LOTO rules and regulations  Stopping all work performed in an unsafe manner
  • 37. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 37 6/6/2022 G. McCalister Definitions Lockout/Tagout(LOTO) The placement of a lockout device and associated tags on an energy isolating device in accordance with an established procedure for ensuring that the equipment being controlled by the energy isolating device, cannot be operated until the lockout device and associated tags are removed. LOTO Clearance Form The LOTO Clearance Form is utilized for recording equipment/system specific LOTO information. The LOTO Form also details the individuals authorized to work on the specific equipment, work/testing to be performed, and the required isolation boundaries established to make the equipment/system safe to work on. This form acts as a Work Permit for the activities requiring LOTO. LOTO Boundary The safe limits of a given Lockout/Tagout as determined by the controls required for the equipment and systems to be worked on. The Boundary, which includes all Energy Isolation Devices for that system, machine or equipment; is established and documented prior to each specific Lockout/Tagout. General LOTO lock A key lock that is not assigned to an individual employee as an Individual LOTO Lock. This lock has only one key and master keys are not available. This lock may be used to lock out individual energy-isolating devices or energy sources when group or complex group LOTO is used. This lock may be left on for durations of greater than one shift. This lock is unique within Project Site Facility and is to be used only for LOTO Lockout Devices A Lockout device is a device that is utilized for attaching a lock, to an energy- isolating device. Examples of Lockout Devices are as follows:  Chain – utilized for preventing the movement of a valve when applied with a lock  Six hole lock clip – utilized for preventing the movement of an electrical breaker or switch when applied with a lock Transition Lock A key lock for which multiple keys may be available and is used on equipment or processes when they are not actively being serviced. Key control or access must be limited to a small, closely controlled group of authorized individuals. This lock must used in combination with a Transition tag “Caution do not Operate” to indicate an unsafe to operate condition. This lock must not be used
  • 38. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 38 6/6/2022 G. McCalister as an Individual LOTO Lock and may never be used on equipment that is being actively serviced. Transition Tag Transition tags (must be yellow in color) are used to indicate that a machine, equipment, process or circuit is out of service or inoperable, but no one is actively working on the system. Transition tags are not to be used in place of red tags and are not required with complex LOTO’s where SWECO controls the first on last off. No activity to the machine, equipment, process and circuit may occur when a transition tag is placed. Transition tags are not to be used as General "out of service" tags and may only be applied by Authorized Employees. Transition Lock and Tag use Transition locks and tags are required when a single individual has removed his Lockout Tagout device because of shift change and SWECO does not have a boundary lock applied to the clearance. Tag out Devices A Tag out Device is a 3” X 6”, red with white lettering, printed plastic tag, with the words “DANSWECOR DO NOT OPERATE” printed in black on both sides, and with spaces provided for the System Authorized Employee to write the specific LOTO information as it applies to the system/equipment being isolated. Energy Isolating Devices A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following:  A manually operated electrical circuit breaker  A disconnect switch  A manually operated switch, by which the conductors of a circuit can be disconnected from all ungrounded supply conductors; and in addition, no pole can be operated independently  A slide gate  A blind flange  A manual valve  A block – (a device so configured as to prevent movement of the affected component)
  • 39. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 39 6/6/2022 G. McCalister  Any similar device used to block or isolate energy WARNING: The term does not include a push button, selector switch, and other devices. Energy Source A resource that produces power, or has the potential to produce power, in forms of electricity, flow, pressure or movement] Energized Energized is the state of being connected to an energy source or containing residual or stored energy. Servicing and/or Maintenance Servicing and maintenance are workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying and maintaining and/or servicing equipment. These activities include lubrication, cleaning or un-jamming of equipment and making adjustment or tool changes where the employees may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy. Alternative Methods Methods developed for work other than servicing and/or maintenance of equipment. The methods guide personnel, utilizing the safest procedures for tasks not requiring LOTO. Methods are developed based on risk assessment of the machine, equipment, process and circuit Capable of Being LockedOut An energy isolating device will be considered capable of being locked out either if it is designed with a hasp or other attachment or integral part to which or through which a lock can be affixed or if it has a locking, mechanism built into it. Other energy isolating devices will also be considered to be capable of being locked out, if lockout can be achieved without the need to dismantle, rebuild or replace the energy isolating device or permanently alter its energy control capability. Active LOTO A LOTO procedure is considered active under the following conditions:  Locks and tags have been applied to the energy isolation devices and…
  • 40. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 40 6/6/2022 G. McCalister  Authorized Employees are signed on to the LOTO or…  The LOTO has not been “Cleared” by the Primary Authorized Employee Inactive LOTO A LOTO procedure is considered inactive under the following conditions:  Authorized Employee(s) have signed off of LOTO and…  The LOTO has been “Cleared” by the Primary Authorized Employee and…  All locks and tags have been removed by the System Authorized Employee and…  The system/equipment has been returned to a “Ready for Service” state and…  The affected LOTO Clearance Form (with all removed tags attached) has been filed in the Inactive Section of the LOTO book Double Tagged Double tagged refers to having two separate LOTO’s in effect for a single system or defined LOTO isolation boundary. There is no limit as to the number of LOTO’s that can be applied to a single system or equipment.
  • 41. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 41 6/6/2022 G. McCalister LOTO Standards and Rules General Requirements for LOTO Performing maintenance or servicing tasks covered by this program while the equipment or process is energized is prohibited, unless the following apply:  the Risk Assessment (RA) documents the necessity of working energized;  the RA is approved by both operations leadership and EHS;  the RA establishes the alternative procedures to be used;  authorized employees who will perform the task have been trained on the alternative procedures;  Other training required by regulation has been completed.”] Note Sample and Template of Risk Assessment for Alternative Methods are given in Attachment I of this document Locks All SWECO supplied locks utilized in the isolation of plant equipment will be of the single key, “non-keyed alike” variety. Each lock and key set will be identified with a unique number and shall be unique in color from any other locks used at the site. Energy Isolating Devices Electrical breakers and switches shall never be locked in the ON or CLOSED position. Operation of Energy IsolationDevices Under no circumstances shall, any device, fitted with a lock and danger tag be operated regardless of the circumstances. WARNING Any person who operates a valve, switch, or Energy Isolating Device to which a lock or danger tag is attached will be subject to disciplinary action up to and including immediate termination.
  • 42. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 42 6/6/2022 G. McCalister Removalof Locks and Tags Under no circumstances shall the Boundary Locks and Tags or Authorized Employee(s) locks and tags be removed from an Energy Isolating Device that is part of an active LOTO. WARNING Any person who removes a lock or danger tag from an Energy Isolating Device that is part of an Active LOTO will be subject to disciplinary action up to and including immediate termination. DangerTags All Danger Tags shall be affixed to the energy isolation devices with nylon “tie- wrap.” The System Authorized Employee shall ensure that all Danger tags are clearly visible to all personnel. The tags shall be Red (or Red and White) and state “Danger-Do Not Operate” in black lettering. These tags shall only be used for the protection of personnel under this Lockout/Tagout procedure. All Danger Tags shall be properly filled out and shall include the following information:  LOTO Index Number (e.g. 00 - 0010)  Tag Sequence Number (e.g. 1 of 3)  Description of energy isolation device (e.g. Feed water Pump Suction Valve)  Position of energy isolation device (e.g. open or closed)  Name of person installing the tag LOTO Boundaries Two (2) Valve Protection When possible, a minimum of, two (2) -valve protections shall be utilized in order to establish safe working conditions under the LOTO Program. Grounding Straps When working on electrical transformers and switch gear, 600 volts and greater, grounding straps shall be utilized to safely route stray currents to ground. Danger Tags shall be applied to all grounds straps Residual Energy Prior to the affected system/equipment is being locked, tagged and isolated the System Authorized Employee shall:  Drain, Vent, Bleed, Discharge and otherwise certify the removal of all residual energy from within the LOTO Boundaries prior to the
  • 43. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 43 6/6/2022 G. McCalister commencement of work activities and ensure that systems remains drained, vented, discharged and de-energized throughout the work.  Test the operation of all remote operated controls for the affected system/equipment to ensure that there is no alternate source of energy supplying the affected system/equipment prior to the commencement of work activities This is accomplished by trying to start the component from the DCS, MKV, MCC, and/or local control switch.  Test circuit elements and electrical parts of equipment that Authorized Employees will be exposed to during performance of the work, to ensure that parts are de-energized. Testing shall be done using appropriate test and personal protective equipment. Testing shall be documented on the LOTO form. LOTO Documentation A LOTO Log book shall be established for the site. The Logbook shall be maintained by the Primary Authorized Employee and shall become part of the site safety archive files. Auditing of LOTO Program On a weekly basis, inspections of the LOTO Program shall be conducted. The LOTO Administrator or Primary Authorized Employee or management representative trained as an Authorized Employee shall perform these inspections. The Weekly Lockout/Tagout Inspection Form (Attachment H) shall documenting the inspection findings, results and, as appropriate, corrective actions taken to correct LOTO program deficiencies. Copies of these inspection forms shall be retained in the LOTO Logbook. In addition, detailed audits of the LOTO program by SWECO EHS staff shall be conducted on at least an annual basis. The audit shall include a review of responsibilities under the program and related procedures. Written documentation of findings and corrective actions shall be made and retained. Tagout In the event that equipment cannot be locked out then Tagout procedures shall be followed. Tagout alone shall only be utilized if it is infeasible to apply an energy isolation device or when working under Customer LOTO procedures, which do not allow the application of locks. The Tagout procedures shall be applied in a rigorous manner to ensure personnel protection that is as protective as Lockout/Tagout. LOTO Clearance Completion  The words “Tagout Only” and the reason why shall be stated at the top of the LOTO Clearance.  All spaces shall be completed except for Lock Number. Date Lock and Tags Applied/Removed shall refer to date Tags Applied/Removed
  • 44. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 44 6/6/2022 G. McCalister Application of Tags  Tags shall be attached at the same or as close as possible to the location where locks would have been applied.  The System Authorized Employee shall apply boundary tags in the same manner as Boundary lock and tag application.  Authorized Employee tags shall be applied after the boundary tags have been placed and de-energization of the system has been verified. Secondary Means of Protection Secondary means of protection shall be utilized to ensure protection of personnel. Secondary means shall be appropriate to the system being tagged out and may include:  Removal of an isolating circuit element  Application of grounding devices  Blocking of control switches  Opening of an extra disconnecting device  Removal of valve handles Training All Affected Employees shall be notified that a Tagout system is being utilized and that tags are not to be removed, or altered in any fashion. Removal of Tags Removal of tags shall follow the LOTO deactivation procedure described below. All other procedures described in this plan shall apply to Tag only operations. LOTO Procedures The following procedure shall be utilized for isolating and making safe, equipment, or systems that are to be worked on. This procedure is to be followed as it is presented here. There shall be no exceptions or deviation from the SWECO LOTO procedure at any time. LOTO Activation Procedure The LOTO procedure may require the involvement of at least five (5) individuals anytime a LOTO is issued: The Lead Authorized Employee, Authorized Employee, System Authorized Employee, LOTO Administrator and the Primary Authorized Employee. (Note: there may be occasions when the System Authorized Employee and the Authorized Employee doing the work is the same individual.) Certain circumstances, such as employees working in the immediate area as equipment under LOTO, may require the notification and signature of Affected Employees.
  • 45. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 45 6/6/2022 G. McCalister Step 1 (LOTO Activation Request) The Lead Authorized Employee shall request, from the System Authorized Employee a LOTO Clearance for the respective system/equipment that he/she is planning to work on. The Lead Authorized Employee shall provide the System Authorized Employee as much detail as possible, concerning the work to be accomplished i.e...  The type work/repair to be conducted  Is hot work required?  Does the work involve entry into a confined space?  Does the work require lifting heavy loads?  Will the work interfere or present a hazard to employees adjacent to the proposed work activities? If so, have they been notified and properly briefed?  Will hazardous materials be generated because of the work activities?  Will hazardous materials be utilized in the performance of the work activities? Once satisfied with the information provided by the Lead Authorized Employee, and having discussed the work activities with the Affected Employee(s), and making certain that the work can be performed in a manner consistent with the SWECO site safety policy and procedures, the System Authorized Employee shall initiate the activation of a LOTO for the respective System/Equipment. NOTE Only the Primary Authorized Employee can Authorize and sign for the activation of a LOTO. Step 2 (Isolation Boundary Review) The System Authorized Employee shall review the associated Piping and Instrument Diagrams (Pit’s) and Electrical and Instrument Diagrams (Enid’s) to determine the proper procedure for making the system/equipment safe to work on. This information will be reviewed with the Primary Authorized Employee prior to LOTO Clearance Form Completion. Step 3 (LOTO Clearance Form Completion) The LOTO Administrator shall then obtain the next available LOTO index number from the LOTO Index Sheet (Attachment F). He/she will fill out the clearance form and assign the clearance number. He/she will also log the clearance number in the clearance logbook All energy isolation devices that are required to be, opened and/or closed, to affect a safe work area shall be listed on the LOTO Clearance Form in the sequence in which they will be isolated.
  • 46. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 46 6/6/2022 G. McCalister The Primary Authorized Employee shall review the completed LOTO and sign off on the form. Step 4 (System/Equipment Isolation and Verification) The System Authorized Employee, responsible for the equipment covered by that LOTO, or LOTO Administrator under the direct supervision of the System Authorized Employee, shall physically isolate the system/equipment in the sequence in which they are listed on the LOTO Form. The application of these Locks and Tags make up the LOTO boundary.  All breakers shall be de-energized (opened), locked with a padlock and the appropriate danger tag affixed  All valves shall be closed and the appropriate danger tagged affixed  All residual energy shall be dissipated by venting, draining, grounding or by any other suitable and safe means  Test the operation of all remote operated controls for the affected system/equipment to ensure that there is no alternate source of energy supplying the affected system/equipment before the commencement of work activities. As each system/equipment is physically isolated, tested/verified, and danger tags and locks are applied; the System Authorized Employee shall initial and date each respective energy isolation devices location on the LOTO Form. This important step serves as the verification step. The Primary Authorized Employee or LOTO Administrator shall then retain the LOTO Lock key(s). Any Affected Employee(s) shall be notified, by their supervisor, of the work to be performed on or around his/her equipment or system. The Primary Authorized Employee shall confirm that the notification has taken place prior to proceeding with the work. Step 5 (System/Equipment Isolation Verification) The Lead Authorized Employee shall then review the placement of all danger tags and the position of all energy isolation devices. Authorized Employees shall be provided the opportunity to witness the verification that all sources of energy have been isolated. When the Authorized Employee(s) is (are) satisfied that the system/equipment is safe for the commencement of work activities he/she (they) shall sign-on to the Authorized Employee Sign-In Sheet (Attachment E). At this time any Lead Authorized Employee Locks and Tags may be placed over the Boundary Locks and Tags. Lead Authorized Employee Locks and Tags may either be placed directly onto the Boundary Lockout device or a Lockbox depending upon the complexity of the particular job. When a lockbox is used for
  • 47. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 47 6/6/2022 G. McCalister group lockout/Tagout the Lead Authorized Employee shall place their lock and tag on boundary lockout device. After the Lead Authorized Employee is satisfied that all is in order, they shall sign onto the LOTO Clearance Form (Attachment A) At this point, the contractor may elect to either allow their Authorized Employees signatures on the Authorized Employee Sign-In Sheet (Attachment E) to serve as their LOTO control device, or the contractor can use their own lock box system with the Lead Authorized Employees key secured within the lock box and the Authorized Employees locks and tags placed over the key. For complex LOTO’s multiple Authorized Employee Sign-In Sheets may be used. For example a separate Authorized Employee Sign-In Sheet may be used for each crew, with the crew’s Lead Authorized Employee signing onto the Main LOTO Clearance Form. Then, this Lead Authorized Employee will take the separate Authorized Employee Sign-In Sheet back to the job trailer or contractor assembly area and have each Authorized Employee under their control and supervision, sign onto the form, as well as signing off from the form at the end of the work day. This form will be maintained by the Lead Authorized Employee throughout the workday and returned to the LOTO Administrator at the end of the workday. This tiered approach is useful in managing complex LOTO’s involving multiple pieces of equipment. NOTE: If additional Authorized Employees are required to work within the established LOTO boundaries AFTER the LOTO has been authorized, then the above steps must be repeated. LOTO De-Activation (Clearance) Procedure Before lockout devices are removed and energy is restored to the equipment or system, the following actions shall be taken: Note this procedure may be applied to an entire LOTO or to a single piece of equipment under a LOTO.  A common practice at many sites is apply locks and tags to individual un- energized circuits as they are installed within the Substation/PEECC and/or MCC. This practice provides an additional level of employee protection to prevent unexpected energization of equipment as power is brought into the PEECC and MCC. As the project commences, these circuits are energized and the locks and tags removed. SWECO and Contractor personnel working within these areas need to be continuously informed and notified as conditions within the PEECC or MCC change as circuits become energized. There are various methods available for accomplishing the notification. One option is to affix a red notification tag (non LOTO tag) alerting employees that the equipment has been energized. LOTO Tags may not be used for this purpose. An example of an appropriate tag is provided;
  • 48. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 48 6/6/2022 G. McCalister Step 1 (LOTO De-activation Request) The Lead Authorized Employee(s) shall inform the System Authorized Employee that all work has been completed; the system/equipment has been 100% re- assembled and is now ready for energization (and/or testing if applicable). The Lead Authorized Employee(s) shall submit the completed Authorized Employee Sign-In Sheet and then sign off the LOTO Clearance Form and remove all Lead Authorized Employee Locks and Tags, which have been placed. If separate Authorized Employee Sign-In Sheets were used each Lead Authorized Employee shall ensure that all individuals working under them have signed off on the form. Once this has been done the supervisor shall sign off on the Main LOTO Clearance Form. NOTE Only the Primary Authorized Employee, can Authorize and sign for the De-activation of a LOTO. Step 2 (System/Equipment Inspection) The System Authorized Employee or his designee shall inspect the system/equipment to ensure that non-essential items have been removed from the area and that the system/equipment components are intact. The work area shall be checked to be sure that all employees have been safely positioned or removed. If testing is required, refer to the "Equipment/System Testing Procedure".
  • 49. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 49 6/6/2022 G. McCalister Step 3 (LOTO Locks and Danger Tag Removal) The System Authorized Employee shall remove all boundary locks and danger tags. The LOTO Form shall be referenced to ensure that all energy isolation devices listed on the LOTO Form are properly removed. The Primary Authorized Employee, or LOTO Administrator, shall verify receipt of all locks and danger tags by signing the LOTO Released by section of the LOTO Form. Step 4 (Transfer LOTO to the Inactive Section) The LOTO Administrator places the released LOTO form in the inactive section of the LOTO book and designates the LOTO as Inactive in the LOTO Index. Shift Change Procedure This procedure shall be followed whenever work activities take place under a single LOTO on more than one shift. Note: Clearances covering activities that will be taking place on only one shift do not have to transfer the Clearance as long as the Lead Authorized Employee(s) and System Authorized Employee do not change. For Example: First shift activities that will continue the next day and no work under that LOTO will take place on the second shift. Step 1 (Transfer by System Authorized Employees) The System Authorized Employees for both second and first shift shall review the LOTO and sign-off on the LOTO Clearance Form. The System Authorized Employee who initiated the LOTO will review the work activities and placement of energy isolation devices with his counterpart. The System Authorized Employee who did not initiate the LOTO shall then sign onto the LOTO Form certifying that they have reviewed the LOTO and taken responsibility for ensuring that the LOTO is implemented properly on their shift. Step 2 (Lead Authorized Employee(s) Removed from Clearance) Lead Authorized Employee(s) shall inform the System Authorized Employee as to the status of work completion. At the end of the shift, all Authorized Employee(s) shall sign off the LOTO Clearance Form and remove all Lead Authorized Employee Locks and Tags, which have been placed or complete a key transfer. Step 3 (New Lead Authorized Employee(s) Added to Clearance) The New Lead Authorized Employee(s) shall then review the placement of all locks and danger tags and the position of all energy isolation devices. During the walk down they shall be provided with the opportunity to witness verification that systems have been de-energized.
  • 50. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 50 6/6/2022 G. McCalister When the New Lead Authorized Employee(s) is (are) satisfied that the system/equipment is safe for the commencement of work activities he/she (they) shall sign-on to the LOTO Form. At this time New Lead Authorized Employee Locks and Tags may be placed over the Boundary Locks and Tags or a key transfer can take place. Lead Authorized Employee Locks and Tags may either be placed directly onto the Boundary Lockout device or a Lockbox depending upon the complexity and type of LOTO method used for the particular job. Step 4 (Closing LOTO) The System Authorized Employees for each shift shall review the status of the work and any changes to the Active LOTO. Once work under the LOTO has been completed then both the first and second shift System Authorized Employees shall sign off on the LOTO. Both System Authorized Employees have to sign off before the LOTO can be released. Testing Either one of the System Authorized Employees who have signed onto the LOTO may temporarily release the LOTO for testing. All testing shall be done in accordance with the procedures outlined in Section 6.5 of these procedures. Once testing is complete the LOTO shall be returned to its pretest status. SpecialLOTO Clearance Procedure This special clearance procedure is only to be used in the un-likely event that a system/equipment LOTO is required to be de-activated (cleared) and the System Authorized Employee or any of the Authorized Employee(s) cannot be located to provide the necessary authorization and signature to allow the system/equipment to be returned to service. Examples of when this special clearance procedure can be used includes, but is not limited to, the following scenarios:  The Authorized Employee(s) are no longer employed by the company or have been re-assigned to another work place. (e.g. sub-contractor)  The work was completed by Authorized Employee(s) on a different shift, and the Authorized Employee(s) of the previous shift will not return until the following (morning/evening), and it is imperative that the system be returned to service at once.  The Authorized Employee(s) forgot to sign-off the LOTO upon completion of work activities and is not able to be contacted. (e.g. sub-contractor) Step 1 (Contact of Authorized Employee(s)) The Primary Authorized Employee shall utilize all means to contact the Authorized Employee(s) (at home if necessary) and request a release of the LOTO.
  • 51. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 51 6/6/2022 G. McCalister If unable to contact Authorized Employee(s,) the Authorized Employee(s) supervisor shall be contacted If unable to contact the Authorized Employee(s) supervisor then a member of SWECO Site management (e.g. Site Manager or Commissioning Manager) shall be utilized to authorize the clearance of the affected LOTO. This should be done only after an intense search of the affected area.Step 2 (Review of the System/Equipment) The System Authorized Employee shall walk down the affected system/equipment, and shall be accompanied by at least one of the following personnel:  Primary Authorized Employee  The Lead Authorized Employee  A member of the SWECO management team Those personnel walking down and reviewing the system/equipment shall verify and agree that all work is complete and the system/equipment is ready to return to service. Step 3 (Release of the LOTO) The Lead Authorized Employee’s supervisor or a member of the SWECO management team will then print and sign his/her own name on the appropriate line of the LOTO Form. A notation shall be made on the form that the LOTO was released under alternative procedures. The LOTO will be released in accordance with Section 6.2.3 NOTE: The Authorized Employee(s) shall be notified by their supervisor of the removal of the LOTO upon their return to work. The System Authorized Employee shall ensure that this has been done. The Authorized Employee(s) shall note on the Inactive LOTO Clearance that they have been informed that the LOTO was closed under alternative procedures. In the event that the Authorized Employee(s) will not be returning to the site, a notation shall be made on the Inactive LOTO Clearance by the LOTO Administrator. System/Equipment Testing Periodically, during the performance of maintenance activities, testing of equipment is required for the purpose of; making “On-line” adjustments of components, “bumping” of motors for rotation checks, recording various operating parameters, or testing the operation of a component, prior to the cessation of all work activities.
  • 52. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 52 6/6/2022 G. McCalister This procedure has been provided for this purpose only. It is not to be utilized as a “shortcut” to prevent the entire clearance and re-issuance of a LOTO should the repair turn out not to be effective. The following steps shall be taken to test equipment/systems under an active LOTO clearance procedure: Step 1 (Request to Test System/Equipment) The Lead Authorized Employee(s) shall contact the System Authorized Employee and request approval to conduct a test on the system/equipment. The Lead Authorized Employee(s) shall provide the System Authorized Employee with the following information:  Type of test to be conducted  Systems/Equipment being tested  List of personnel to be involved in the test procedure  Safety precautions to be observed  A notation shall be made on the LOTO Form (Step 2) under work to be performed describing the test including the date of testing Step 2 (Review of Test Procedure) The System Authorized Employee shall review the information provided by the Lead Authorized Employee concerning the test procedure. He/she will then walk down the system/equipment in order to verify that the test will be able to be accomplished in a safe manner and offers no hidden hazards or dangers to site personnel or equipment. The System Authorized Employee shall notify the Primary Authorized Employee of the testing procedures and the systems that will be affected. Step 3 (Approval of Test Activities) Upon approval of the test by the Primary Authorized Employee, the following actions shall be taken:  All work on the affected system/equipment shall cease  All Affected Employee(s) shall be notified of the test The System Authorized Employee shall be the individual who is directing the test sequence of events and maintaining radio contact with the control room and other test personnel. Step 4 (Removal of Locks and Danger Tags)  Only the energy isolation devices affected by the test shall have their locks and danger tags removed  Lead Authorized Employee(s) shall remove their locks and tags from the energy isolation devices affected by the test.  Sign off on the LOTO Clearance Form.
  • 53. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 53 6/6/2022 G. McCalister  System Authorized Employees shall remove the boundary locks and tags off of the energy isolation devices affected by the test.  On the LOTO Clearance Form the affected energy isolation devices shall be dated and initialed as returned to service.  The energy isolation devices are to be aligned to the position(s) required for the test procedure  The LOTO Form is to remain in the Active Section of the LOTO Log Step 5 (Notification of Plant Personnel) If the situation warrants, all plant personnel shall be notified of the test procedure and the precautions to be observed. (e.g., all non-essential personnel are to stay clear of the area) Step 6 (Performance of Test) The test shall be accomplished with strict adherence to all SWECO site safety procedures. Step 7 (Test Complete – No Further Work Required) After the test is complete and no further work is required, the LOTO shall be closed in accordance with Section 6.2. Step 8 (Test Complete – Further Work Required) If further work is required after the test is complete, the following actions shall be taken:  The System Authorized Employee shall re-attach the system/equipment locks and danger tags and verify that the energy isolation devices have been returned to their respective LOTO positions as detailed on the LOTO Form.  Each energy isolation device shall be reentered on the LOTO Form, including signature and date confirming that the Locks and Tags have been reapplied, not just resigned.  All residual energy shall be dissipated by venting, draining, grounding or by any other suitable and safe means.  Test the operation of all remote operated controls for the affected system/equipment to ensure that there is no alternate source of energy supplying the affected system/equipment before the commencement of work activities.  The Lead Authorized Employee(s) shall review the application of tags, locks and energy isolation devices lockout / Tagout positions and shall sign back on to the LOTO Form and reapply Locks and Tags.
  • 54. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 54 6/6/2022 G. McCalister The system/equipment has been returned to the pre-test status under the LOTO procedure and is now considered safe to resume maintenance activities. LOTO Training SWECO Site Management shall ensure that training has been provided to all personnel (SWECO, SWECO Contract, Contractor, and Customer) involved with the Lockout/Tagout program. An individual(s) knowledgeable in the application of Lockout/Tagout and this procedure and Qualified by SWECO as a LOTO trainer shall conduct training. Contact your LOTO administrator or EHS Manager if you have questions. The purpose of this training is to provide the employees with the knowledge and skills required for the safe application, and removal of energy controls.
  • 55. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 55 6/6/2022 G. McCalister Demonstration of Training The site operations shall conduct an annual demonstration of the effectiveness of the training that is conducted for each authorized individual. The demonstration shall be done in such a way as to ensure that authorized individuals demonstrate the following:  Knowledge of the program;  Recognition and understanding of hazardous energy types;  Use of appropriate hazardous energy control procedures. Authorized individuals who do not demonstrate an adequate level of knowledge or use of appropriate hazardous energy control procedures shall be retrained. The following job classifications will attend the SWECO lead demonstration training:  Primary Authorized Employee  System Authorized Employee  Lead Authorized Employee For remote or distributed field service work forces, demonstration that is observed and verified by another authorized employee may not be feasible each year. In these situations, simulation demonstrations may be acceptable. At a minimum, there must be a live person-to-person demonstration following the authorized employee’s initial training session. In these situations, the site/operation must also have a random auditing process in place. This process should ensure that a reasonable number of authorized employees are checked for demonstration each year. At a minimum, live person-to-person demonstrations must occur every three years. NOTE: It is the responsibility of the Contractor and Customer Safety Departments to ensure that all non-supervisory employees and associated Vendors are properly trained in LOTO in accordance to local regulatory requirements prior to commencement of work activities on the Project Site. Retraining shall be conducted whenever a periodic inspection reveals that there are deviations from or inadequacies in an employee’s knowledge or use of energy control procedures.
  • 56. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 56 6/6/2022 G. McCalister Retraining shall also be provided for all authorized and affected employees whenever there is a change in job assignments, a change in machines, equipment or processes that present a new hazard.
  • 57. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 57 6/6/2022 G. McCalister ATTACHMENT A LOTO CLEARANCEFORM STEP 1 – REQUIRED - LIST APPROPRIATE CLEARANCE NUMBER (S) STEP 2 LOTO Requested By Print Lead Authorized Employees (S) Names WORK TO BE PERFORMED (DESCRIPTION OF WORK) STEP 3 - Tag No. Lock No. DEVICE OR EQUIPMENT ISOLATED (LIST AFFECTED EQUIPMENT) POSITION (e.g. OPEN, CLOSED, OFF, ON) DATE Lock and Tags Applied INITIAL DATE Lock and Tag Removed INITIAL 1 2 3 4 Additional EquipmentIsolated ____ yes ____ no. If yes, attachAdditional Equipment IsolationForm(s). STEP 4 STEP 5 Additional LeadAuthorized Employees ____ yes ____ no. If yes, attach Additional Lead AuthorizedEmployee Form(s). STEP 6– LOTO APPROVED BY (SIGNATURE OF Primary Authorized Employee) - TIME DATE STEP 7 – LOTO RELEASED BY (SIGNATURE OF Primary Authorized Employee -) TIM E DATE LOTO CLEARANCE NUMBER CONFINED SPACE ENTRY REQUIRED? HOT WORK REQUIRED? NAME (PRINT and SIGN NAMES) TIME DATE LOTO Verified System Authorized Employee - LOTO Verified System Authorized Employee - LOTO ISSUED TO (SIGNATURE OF LEAD AUTHORIZED EMPLOYEE (S) TIME DATE LOTO RELEASED BY (SIGNATURE OF LEAD AUTHORIZED EMPLOYEE (S) TIM E DATE
  • 58. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 58 6/6/2022 G. McCalister ATTACHMENT B ADDITIONAL EQUIPMENTISOLATION FORM Page ______ LOTO CLEARANCE NUMBER DESCRIPTION OF WORK ACTIVITY Tag No. Lock No. DEVICE OR EQUIPMENT ISOLATED (LIST AFFECTED EQUIPMENT) POSITION (Eg. OPEN, CLOSED, OFF, ON) DATE Lock and Tags Applied INITIAL DATE Lock and Tag Removed INITIAL
  • 59. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 59 6/6/2022 G. McCalister ATTACHMENT C ADDITIONAL AUTHORIZED EMPLOYEEFORM Page ______ LOTO CLEARANCE NUMBER SUPERVISOR DESCRIPTION OF WORK ACTIVITY: LOTO ISSUED TO (SIGNATURE OF AUTHORIZED EMPLOYEE (S) TIME DATE LOTO RELEASED BY (SIGNATURE OF AUTHORIZED EMPLOYEE (S) TIM E DATE
  • 60. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 60 6/6/2022 G. McCalister ATTACHMENT D DESIGNATION OF LOTO RESPONSIBILITIES CONSTRUCTION MANAGER: Name Representing Shift COMMISSIONING/STARTUPMANAGER: Name Representing Shift PRIMARY AUTHORIZED EMPLOYEE: Name Representing Shift LOTO ADMINISTRATOR: Name Representing Hang Locks (yes/no) Systems Shift COMPANY LOCK DESCRIPTION Company Name Color of Lock NOTE: I certify that theabove designated LOTO Administrator(s) posses thespecific equipment knowledge to hang locks and tags on the system(s) designated without direct supervision from a Primary or a Principal Authorized Employee. (Signature of Commissioning/EHS Manager and date)
  • 61. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 61 6/6/2022 G. McCalister ATTACHMENT D (Page 2) DESIGNATION OF LOTO RESPONSIBILITIES SYSTEM AUTHORIZED EMPLOYEES: Name Equipment/System Representing Shift LEAD AUTHORIZED EMPLOYEE (S): Name Representing Shift
  • 62. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 62 6/6/2022 G. McCalister ATTACHMENT E AUTHORIZED EMPLOYEE SIGN-IN SHEET AUTHORIZED EMPLOYEE (S): Name Representing Time On Time Off
  • 63. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 63 6/6/2022 G. McCalister
  • 64. Suzlon Wind Energy Corporation Corporate EHS Program Rev. 1 Page 64 6/6/2022 G. McCalister ATTACHMENT F LOTO INDEX Site Name: ___________________________ LOTO Number Equipment System Authorized Employee Date Opened Date Closed Comments