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Practical guide

MANUFACTURING ACTIVITIESOPERATORS INTERVENINGON PRODUCTION MACHINES

Rev. 00 - NOVEMBER 2019 / EN

GM-GR-HSE-455

This booklet is aimed at operators and managers using automated production machine during manufacturing activities* within the Group.

Some brief physical interventions carried out by operators on production machines, such as loosening, unblocking, cleaning, adjusting or changing out a tool, can be necessary. They are specific interventions that are performed within a strict framework.

In compliance with Golden Rule no. 7, this type of intervention on powered systems that are not fully isolated, can be performed only in the frame of a documented specific authorization.

The aim of the present document is to give a reminder of all the risks posed by this type of intervention and clarify the conditions of the specific authorization.

N.B. The search for failures, maintenance interventions, and interventions on electrical installations are not addressed in this document. The machine is to be completely isolated from all power sources before this type of intervention takes place.

* Activities to produce goods and equipment, such as manufacturing packaging for lubricants, packing lubricants, filling LPG cylinders, making batteries, fabricating rubber parts and elastomers, or certain polymer production activities including packaging chains.

INTRODUCTION

WHAT IS THE SUBJECT OF THIS BOOKLET AND WHO IS IT AIMED AT?

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Follow the isolation plan and supervision instructions attached to the work permit.

Check all isolations, locks and tags before performing any work and remove them before restarting operations.

Begin any work until you have checked that all energy and fluid sources have been isolated, unless you are specifically authorized to do so.

YOU MUST:

YOU MUST NOT:

GOLDEN RULE 7

POWERED SYSTEMS

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THE RISKS POSED BY MACHINES

The machines used in manufacturing activities have moving parts that present risks of cuts, entanglement and crushing, particularly for the fingers and hands.

COMPRESSED AIR

ELECTRICITY

MECHANICAL INERTIA

CHEMICALS

MACHINES USE VARIOUS ENERGIES

AND PRODUCTS THAT CAN ALSO

REPRESENT HAZARDSOTHER GAS OR LIQUID

HEAT

or

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1 person injured: hand fracture.

On a packaging machine, the operator was wiping a rotating part using a cloth held in one hand, while using the control switch to set the part in motion with the other hand. The cloth got caught, pulling the operator’s hand and trapping it between two mechanical parts. The “step-by-step” manual operating mode was for the exclusive use of the maintenance team for adjusting machine settings, and was not meant to be used in this case.

1 person injured: chemical burns to the face.

While an operator was cleaning the electrolyte filling sensor with a brush, electrolyte spurted out and splashed him in the face. The filling system had not been stopped beforehand, and the brush activated the automatic filling system. The operator suffered facial burns.

SIGNIFICANT EVENTS THAT OCCURRED IN THE GROUP

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Lubricant packaging

Battery manufacturing

Polymer manufacturing

One person injured: finger crushed.

Following the accumulation of solid resin on a pinion of the head of a pellet mill, an operator manually removed a piece of resin while the machine was still running. His finger got caught and was crushed between the transmission and the pinion.

1 severe injury: amputation of several fingers on one hand.

After the protective housing of a press was closed, the machine stopped before reaching the end of its cycle because a cylinder was not in the right position (sensor detection problem). Trying to solve the problem, the operator slipped his arm inside the housing and moved the sensor. The press immediately resumed its automatic cycle and the operator’s hand was crushed.

Auto parts manufacturing

MACHINE SAFETY SYSTEMS

Risk prevention starts as soon as the machine is designed by taking into account the environment in which it will be installed, and the safety of its user and third parties. The machine complies with the applicable safety standards (e.g. Directive 2006/42/EC).

Safety devices are introduced in the design stage to prevent risks whatever the machine is used for, particularly in the case of specific interventions. They are not meant to be modified or circumvented.

Any modification to the machine or its safety systems requires a prior risk assessment performed by competent personnel (cf. Golden Rule 11: Change management).

Emergency shutdown functions and safety barriers (light barriers, limit switch, etc.)

are fully functional and tested at regular intervals.

The tests are formalized and recorded.

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UPSTREAM OF THE INTERVENTION

Brief physical interventions such as those mentioned on page 2, carried out by operators on production machines, can only be done by authorized personnel and in specific, predefined, assessed and documented cases. They are specific interventions.

In compliance with Golden Rule no. 7, this type of intervention on powered systems that are not fully isolated, can be performed only in the frame of a documented specific authorization.

This specific authorization is sometimes known as an accreditation.

On site, before these specific interventions are considered, it is necessary to follow the steps detailed on the page opposite, which, among other things, list the conditions for a specific authorization.

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FOR MANAGEMENT

Promote the practice of safety pauses to assess the situation, or even take time for safety talks before these specific interventions.

As these interventions are specific, introduce a system for counting and reporting them in order to rapidly identify any unusual increase in frequency.

Best practices

See page 10

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List the interventions performed on non-fully isolated machines

Formalize the list of interventions performed.

Run a risk assessment on these interventions and define the associated preventive measures.

Formalize the operating procedures of these interventions.

Provide regular training to the people having to perform these interventions.

Formalize an authorization from the site manager (or his/her delegate) for these people, and make a list of those authorized to intervene.

Can these interventions be avoided or done away with? (eliminate the risk at the source)

Implement measures for avoiding or doing away with these interventions.

If these interventions cannot be done away with, they can be performed only in the frame of a documented specific authorization. The following actions are required:

YES

NO

Organization and training

Equipment

Check that the buttons, valves and contacts of the machine mentioned in the operating procedures are clearly labeled to give their exact function.

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FOR OPERATORS

PERFORMING THE INTERVENTION

Before the intervention, I pause and run a last-minute check:

I am trained and authorized to perform this specific intervention on the machine concerned.I know the operating procedure for performing the operation. If I’m not sure, I do not intervene and I seek assistance.

I make sure I have the appropriate Personal Protective Equipment (PPE) and tools.I check whether signage or marking is stipulated in the operating procedure and if it is, I put it in place.

I secure the equipment or the equipment part before any intervention.

I respect the operating procedure of the intervention and I stop the machine unless otherwise specified in the document.

During the intervention:

I am careful and I keep my body away from areas with moving parts or parts likely to start moving.

I flag up any anomalies or hazardous situations and I stop the intervention. (e.g. inapplicable operating procedure, unforeseen event not covered in the operating procedure, damaged equipment, etc.).

I wear the PPE and use the tools stipulated in the operating procedure.

I am not authorizedto perform the intervention

I do not intervene and I seek assistance (depending on my organization: contact point,

line manager, team manager, maintenance, etc.)

=

IMPORTANT:� Protective housings and devices are there to prevent

accidents. I do not modify them, I do not remove them without authorization, I do not try to get round them.

� �Emergency shutdown functions and safety barriers are in place to respond to emergency situations. I do not activate them to intervene on the machine, unless stipulated in the procedure.

� �I flag up any anomaly or unauthorized modification of a safety device.

Keep away from hazardous areas:

Whatever the intervention, do not position yourself or put your hands between moving parts or parts likely to start moving.

More information on energy isolation in the Golden Rule no. 7 - Work on powered systems guide (GM-GR-HSE-454)

Go to the HSE Toolbox www.toolbox-hse.total.com

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total.com

HSE DivisionTOTAL S.A.2, place Jean Millier - La Défense 692078 Paris - La Défense Cedex - FrancePhone: +33 (0)1 47 44 45 46Share capital: € 6,340,193,800Nanterre Trade Register 542 051 180

Total is a major energy player that produces and markets fuels, natural gas, and low-carbon energies. Our 100,000 employees are committed to better energy that is safer, cleaner, more efficient, more innovative and accessible to as many people as possible. With operations in more than 130 countries, our ambition is to become the responsible energy major.

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