Transcript Fatality Prevention Standard in Indiana Harbor (FCA

RS# 5 Maintenance
Draft date: Oct 5, 2011 Rev 1
Corporate Health and Safety
ArcelorMittal
Summary
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General subjects regarding Maintenance
Definitions and terms
FPA Questions
Maintenance tasks on or near Railways
Maintenance tasks on Rail Equipment
1
General subjects regarding Maintenance
• Maintenance tasks (both on rails and vehicles)
have a high level of risk.
• When operating with heavy vehicles moving
heavy loads, accidents do not give a second
opportunity.
• Besides, most of the maintenance task on rail
devices may be affected by risks other critical
risks:
– Isolation (Golden Rule 3)
– Working at height (Golden Rule 2)
– Confined spaces, when working in
maintenance pits, rail scales (Golden Rule 4)
– Lifting equipment (Golden Rule 5)
2
Definitions and terms
•
Lineside
You are on the lineside if:
– you are between the railway boundary fence and the area called on or near the
line, and
– you can be seen by the driver of an approaching train.
You are not on the lineside if:
– you are on a platform (loading bay, station,..).
– You are not on or near the line if you are crossing the line at a level crossing.
• On or near the line
You are on or near the line if you are:
– within 3 meters (10 feet) of a line and there is no
permanent fence or structure between you and
the line
– on the line itself.
You are not on or near the line if:
– you are on a platform unless you are carrying
out engineering or technical work within 1.25
meters (4 feet) of the platform edge.
3
Definitions and terms
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•
•
•
Isolation
– Physical process to block the possibility of a rolling stock to enter a certain part of
the railway track.
Train Approach Warning (TWA)
– The form of track protection that a watchman/lookout provides, for warning track
workers when a train is approaching
Individual Train Detection (ITD)
– The form of track protection that can be performed when there´s and only worker
performing basic tasks.
Derailment
– A derailment is an accident on a railway in which a rail vehicle, or part or all of a
train, leaves the tracks on which it is travelling, with consequent damage and in
many cases injury and/or death.
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FPA questions - Maintenance
• Level 3 – Question 1 [L3 - Q1]
Are all the legally required periodical verifications identified? Are they performed by
trained and authorized people? Are the results of those controlsformalized?2. Does
the plant know and understand the ArcelorMittal standard for Rail Safety and
distributed the information to the personnel concerned?
Recommendations and good examples !
•
•
Braking system Maintenance regulations
change among countries, and its
application is not compulsory for internal
traffic. Anyway, the Legal requirements
could be a good starting point in order to
establish a safe Maintenance system
Air tanks should be inspected and
certified regularly.
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FPA questions - Maintenance
• Level 3 – Question 2 [L3 - Q2]
Is the responsible person for rail activities always informed prior any work when
isolation is necessary by the supervisor or his designee? Is a HIRA always performed
before starting any work? Is a safety plan defined on the basis of the HIRA including
the necessary safety actions to protect workers from rail traffic movements? Are
formalized audits regularly performed to check compliance with the safety plan
(particularly concerning the isolation procedure respect)? 3.
Recommendations and good examples !
•
A Work permission, job briefing and a safety coordinator for
every maintenance task performed on/near the rail will
reduce risk ALARP.
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Maintenance Tasks on Railways
1. People accreditation and PPE´s
2. Track Protection
2.1 Working Limits isolation
2.2 TAW – Train Approaching Warning
2.3 ITD – Individual Train Detection
3. Job Briefing
4. Communication
5. Maintenance and Equipment inspections
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1. People Accreditation & PPE´s
AM Standard Rail Safety 004
• They must be trained and competent
• They must know and follow Standard Operation – AM Safety 004 – Rail Safety
• They must use approved protection equipment for the respective job
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1. People Acreditation & PPE´s
Personal Protective Equipment; L1Q13
• The used PPE may vary and must be the outcome of a HIRA.
• Approved protection equipment must be used for the respective jobs.
• Requirements are e.g.;
– Safety boots (high ankle boots where necessary!)
– Safety glasses
– Hard hat / helmet
– High visibility clothing’s
– Gloves
– Hearing protection
– The means of communication
11
2. Track Protection (L1Q8, L1Q9)
•
Level 1 – Question 8
Have safety rules been written for situations when duties require people to go on the lineside?
The lineside within the area between the rail boundary fencing and the point that is called “on or
near the line”. Have those rules been written on the basis of a HIRA? Do those rules ensure the
concerned people are protected from rail movements?
•
Level 1 – Question 9
Is it forbidden to walk on tracks? Have safety rules been written for situations when duties require
people to go on or near the line (on or within 3 meters / 10 feet of a railway track)? Have those
rules been written on the basis of a HIRA? Do those rules ensure the concerned people are
protected from rail movements by track isolation using derail or switch locks?
Recommendations and good examples !
• By track protection, there are two different
situation:
– Working/going on the lineside (>3 m of a line).
– Track protection (<3 m of a line; on or near de line).
There may be three possibilities to prevent workers
from being struck by a moving equipment
(explained later on).
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2. Track Protection Working on the lineside (> 3m of a line)
L1Q8, L1Q9
• Going on the lineside (> 3m of a line);
– You must wear the correct high-visibility clothing issued to you by your employer.
– You must use an authorized access point, if provided, to get onto the operational
railway.
– You must use authorized walking routes if they are provided.
– You must raise one arm above your head to acknowledge the driver of any
approaching train who sounds the warning horn.
– Keep in mind when on or about tracks is to expect movement in either direction on
any track at any time!
– You must have a min. distance of 3 m/ 10 feet from standing cars or other
equipment when you cross any track.
• Working on the lineside;
– Any work done on the lineside must not affect or go within the area called on or
near the line.
• Using a road vehicle on the lineside;
– If you are using a road vehicle, you must not allow it to enter the area called on or
near the line unless it’s isolated.
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2. Track Protection Working on or near the Line
(< 3m of a line; L1Q8, L1Q9)
• Prior to beginning work where railroad track isolation is necessary, or to prevent
unwanted car movement into an area, the supervisor, or designee, must notify those
responsible for rail operations to alert them of the work to be performed.
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2. Track Protection Working on or near the
Line (< 3m of a line; L1Q8, L1Q9)
• Track protection is a way to prevent
roadway workers from being struck by a
moving train or other equipment. Track
protection works in two ways, either by
keeping:
– Trains away from roadway workers
– Roadway workers away from trains
• The employee-in-charge has established
boundaries for a section of track for a
specified period of time and trains can
move through these boundaries only with
permission from the employee-in-charge.
Type
Works By Keeping
1. Working Limits
Isolation
2. Train Approaching
Warning (TAW)
Trains away from
roadway workers
Roadway workers
away from trains
3. Individual Train
Detection (ITD)
Roadway workers
away from trains
• TAW (where isolation is not possible) requires
that certain conditions be met and that there
is a qualified watchman/lookout available.
• ITD (temporary access, routine inspections,
minor corrections) and TAW ; allows a track
• Track within the Working Limits is made
worker to gain temporary access to tracks
inaccessible by use of switches, derails, or
where Working Limits have not been
other devices used to prevent traffic. L1Q9
established. It can be used only when a
number of conditions have been met.
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2.1 Isolation of the track; L1Q8, L1Q9
Trains away from roadway/ track workers
• Working Limits; Track within the Working Limits is made inaccessible by use of switches,
derails, or other devices used to prevent traffic.
• Unless specifically allowed within your company instructions, you must consider the following as
types of work that will affect the safety of the line (Work that needs the line to be isolated!):
– Carrying heavy or awkward equipment or materials across or along the line.
– Work that will affect the condition of the track.
– Digging a hole or stacking material or equipment close to the line or near the edge of a platform.
– Placing a hand trolley on the line.
– Using plant within 3 meters/10 feet of the line.
– Using a road vehicle within 3 meters/10 feet of the line.
– Using a crane or other lifting equipment that will foul the line.
– Attaching anything to a railway structure, such as a bridge, a station roof or building, a signal
post or gantry, or electrical equipment.
– Using a ladder, unless secured so that it cannot fall towards the line.
– Using scaffolding or a climbing tower, unless secured so that it cannot fall or move towards the
line.
– Felling or trimming trees.
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2.1 Isolation of the track; L1Q8, L1Q9
Trains away from roadway/ track workers
• May there be any equipment (locomotive, wagon, or any other rolling stock)
inside the protected area, do not forget to wedge properly!
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2.2. Train Approaching Warning (TAW);
Roadway workers away from trains
• The form of track protection that a watchman/lookout provides is called Train
Approach Warning. It relies on the watchman/lookout being able to see and/or hear
trains. It may be used when isolation of the track is not possible
• Identification; You must wear the correct high-visibility clothing issued to you by your
employer. Lookouts and site-wardens must wear visual recognizable defined clothing's
e.g. armlets, badges or an specific color helmet.
• To act as a Watchman/Lookout or a site warden you must be trained and competent.
• You must:
– make sure your mobile phone is switched off
– stay alert and carefully watch the group
– not leave your post
• You must not:
– take part in the actual work
– carry out any other duties
– allow yourself to be distracted
– act as a lookout site warden if you cannot stay alert.
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2.2 TAW - Watchman/Lookout; L2Q2
• Train Approach Warning can be used only when all of the following conditions are
met:
– Isolation of a line is not possible
– Person has been qualified as a watchman/lookout by successfully completing
this training and has knowledge of the area’s physical characteristics and train
operations.
– Roadway/ track workers are performing routine inspections or minor repairs that
do not affect the safe movement of trains.
– No equipment is fouling the track.
– Person is able to see the approach of a train, engine, or other railroad equipment
approaching at maximum speed authorized and can move to and be in
PREDETERMINED place of safety not less than 15 seconds before the train,
engine, or other railroad equipment would arrive.
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2.2 TAW Watchman/lookout duties; L2Q2
• Watch for approaching trains or on-track equipment.
• Provide sufficient warning to employees that a train or other moving equipment is
approaching.
• When you see a train approaching on any of the lines concerned, you must wave your
chequered flag above your head as a warning. If there is more than one site lookout,
each must acknowledge your warning.
• You must give the warning using one of the following methods:
– Whistle or air horn
– Flags or lantern or fusee / touch depending of the visibility
• Identify a place of safety that workers can reach at least 15 seconds before a train
moving at maximum speed authorized can reach the worker’s location.
• You must stop any work, acknowledge the warning and move to the position of safety
immediately the lookout gives the warning.
• If someone does not acknowledge or move to the position of safety when the lookout
gives the warning, the lookout will give an urgent warning. This urgent warning is a
series of short sharp blasts on the whistle or horn.
• You must not leave the position of safety until all workers are in position of safety.
• Lookout must never be distracted. Do not wear anything that makes you less able to
see or hear approaching trains.
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2.3 ITD and individual working alone;
Roadway workers away from trains
• The only occasion when you can go on or near the line not isolated without a
watchman/lookout, is when you are walking alone.
• You must wear the correct high-visibility clothing issued to you by your employer.
• Make sure you have a suitable lamp with you if you will be on or near the line during
darkness, poor visibility or if you are to enter a tunnel.
– Before you go on or near the line alone, consider:
• the maximum speed
• the direction from which trains normally approach
• the location of any area where you must not go while
• trains are running any location with limited clearances.
• Patrolling, examining or inspecting
• You can patrol, examine or inspect an open line if you are sure you will be able
to look up often enough (at least every 5 seconds) to see any train approaching
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2.3 ITD and individual working alone
•
•
Lone worker MUST conduct job briefings with their supervisor and then the person
responsible for train activities MUST be informed.
Individual Train Detection, or ITD, can be used only if all the following six
conditions are met:
1. Person must be trained and competent.
2. Person is performing routine inspections or minor repairs and not fouling the
track with work equipment.
3. Person is working on a track outside control points, interlocking, or hump yard
facility.
4. Person is able to see the approach of a train, engine, or other railroad equipment
approaching at maximum speed authorized and can move to and be in
predetermined place of safety not less than 15 seconds before the train, engine,
or other railroad equipment would arrive.
5. No power-operated tools or roadway maintenance machines are being used that
impair the hearing of the lone worker.
6. No other physical conditions (light, fog, noise, etc.) exist that impair the vision or
hearing of the lone worker.
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2.3 ITD and individual working alone
• While walking alone
– Any items you carry while walking must not affect your ability to walk safely or to
see or hear and acknowledge approaching trains.
– You must use authorised walking routes if they are provided.
– Do not wear anything that makes you less able to see or hear approaching trains.
– Do not allow yourself to be distracted by anyone or anything.
– If you have to cross the line, you must not step on rails or sleepers or between
movable parts of points.
– Keep a good lookout for approaching trains. Make sure you look up at least every
5 seconds so that you can reach a position of safety and be in it no less than 15
seconds before an approaching train arrives.
• When a train approaches
– When a train approaches you must immediately move to a position of safety or, if
already in a position of safety, stay there.
– If the driver sounds the warning horn, raise one arm above your head to show you
have heard the warning.
– You must stay in your position of safety until the train has passed clear or you are
certain you will not be put in danger by that train or any other train.
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3. Job Briefing
• Job Briefing is a communication tool required before any on-track safety job or task
begins and any time the works conditions changes. A risk assessment should be
performed before this job briefing by the employee-in-charge. Repetitive works
should have safe work instructions.
• Job briefing should have a documental
support, with written duties and
responsibilities
• Job briefing should be done BEFORE
starting the job from a safe location
• It should be done under safe conditions
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3. Job Briefing
1. Identifies the employee-in-charge of on-track safety. Discusses the job and the sequence of the
steps required.
2. Points out the potential hazards. Explains the type of track protection that has boon established
for jobs that foul the track (HIRA).
3. Directs participants to check the equipment and tools to be used.
4. Reviews the protective equipment required.
5. Makes sure everyone, at a minimum, can answer questions applicable to the job, such as:
– Who is the employee-in-charge of on-track safety? What type of track protection do I have
on the track I’m working? Is this type of track protection appropriate for the work I’m doing?
Will I foul the track with personnel? With machinery? If using a lookout, what is the sight
distance? Is it sufficient?
– Will other machines or people be involved? How?
– What type of track protection do I have, if any, on adjacent tracks? How will I be warned
when trains pass on adjacent tracks? Can I continue to work when trains are passing on
adjacent tracks?
– When clearing the track, where is my “place of safety”?
– What are the track limits of my track protection?
– What is the time limit, if any, of my track protection? Do I have the correct time now?
– Do I understand everything and feel confident that I’m adequately protected against trains
and on-track requirement?
6. Follows up as necessary to ensure compliance.
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3. Job Briefing
• On any job that includes work equipment, make sure job briefing includes discussion of on-track
safety, such as:
– Reminder about the blind spots of the equipment. A good rule of thumb is that if the
roadway worker cannot see the eyes of the operator, the operator cannot see him.
– Discussion of the danger (red) zone around any equipment.
• Roadway workers must not enter a machine’s red zone without first communicating with
the operator.
• Conversely, an operator must not allow the machine to approach workers closer than e.g.
3 meters/10 feet without first communicating with them.
– Review of the spacing requirements between machines and between the machine and
workers.
– Reminder of the signal used for reverse movement of equipment or any other special
movement and the designated employee to give these signals to the operator.
– Review of any factor, such as weather, visibility, or track condition, that might impact
stopping capabilities of the work equipment.
– Review whether track protection exists on adjacent tracks in situations where booms or
arms can foul adjacent tracks.
– Review of engine numbers of scheduled trains passing through or by Working Limits.
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4. Communication
• You must not use communications equipment if it may cause a distraction or affect
safety.
• Make sure you are in a position of safety before using mobile communications
equipment.
• Before beginning work, the method of communication between each operator and
other roadway workers must be established.
• Whether radios or hand signals are used depends on work site circumstances, but
communications must be clear.
• Employees involved in the movement of rail equipment must follow AM Standard on
mobile phones (AM ST 301).
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5. Maintenance and equipment inspections L2Q6
• Are all the lines, points, level-crossings, signalling and rolling stock listed? Is there a
planning for regular inspections and maintenance on lines, points, ballasts, levelcrossings, signalling and rolling stock? Is the planning followed? Are the results of
those inspections formalized?
Recommendations and good examples !
• Rail equipment including track, switches and trestles must be
maintained in a safe condition.
• Identify inspections steps and develop inspection process
for the following:
– identify and apply the steps to be taken in inspecting the
equipment
– develop and implement a plan for equipment inspection
appropriate for the equipment being used
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5. Maintenance and equipment inspections; L2Q6
• Derailments can be caused by poor housekeeping, weather conditions, poor track
maintenance, worn train car wheels, damaged switch, going too fast or careless train
operation.
• Pay attention to winter/extreme conditions, when
maintenance task on switches (and other critical
parts) should be increased
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5. Maintenance and equipment inspections; L3Q1
• Level 3 – Question 1
Are all the legally required periodical verifications identified? Are they performed by
trained and authorized people? Are the results of those controlsformalized?2. Does
the plant know and understand the ArcelorMittal standard for Rail Safety and
distributed the information to the personnel concerned?
Recommendations and good examples !
• There must be a program of regular legally required- and other inspection and preventive
maintenance to ensure equipment is in good working order, in order o ensure that people
and assets are properly preserved. Legal requirements should be taken into account
(despite there may not apply to internal traffic) and could be a good reference to establish
the Maintenance plans
• Authorized persons conducting audits, observations, being trained, or trouble shooting for
maintenance may be permitted to ride on the equipment after receiving permission from the
competent operator. No unauthorized person is allowed to ride on cars or locomotives.
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Maintenance Tasks on Rail Equipment
1. People acreditation & PPE´s
2. Maintenance Tasks on the general purpose railway
3. Maintenance Tasks in the Workshop
1. Wedging
2. Workshop track protection
3. Lifting equipment
4. Working in pits
4. Maintenance Plans
5. Maintenance Derailment & Re Railing
1. Derailments
2. Re-railing
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1. People Acreditation & PPE´s
AM Standard Rail Safety 004
• They must be trained and competent
• They must know and follow Standard Operation – AM Safety 004 – Rail Safety
• They must use approved protection equipment for the respective job
32
1. People Acreditation & PPE´s
Personal Protective Equipment; L1Q13
• The used PPE may vary and must be the outcome of a HIRA.
• Approved protection equipment must be used for the respective jobs.
• Requirements are e.g.;
– Safety boots (high ankle boots where necessary!)
– Safety glasses
– Hard hat / helmet
– High visibility clothing’s
– Gloves
– Hearing protection
– The means of communication
33
2. Maintenance Tasks on the general purpose railway
• When any maintenance task is needed on equipment, the
priority should be to have this task done in the workshop, due to
the fact that this environment is better known by workers, all
tools and needed equipments are in the same area
• Nevertheless, when it is not possible (e.g. due to a major
breakdown), maintenance task must be done on the railway out
of the workshop. In this case, the same conditions as railway
maintenance tasks apply:
–Job briefing
–Track protection.
–Wedging of both maintained & near equipment
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3. Maintenance Tasks in Workshops
• Maintenance works in the vehicles workshop are affected by many others risks, being
the ones with the AM Standards the most dangerous:
– Confined spaces (Golden Rule 4)
– Lifting equipment (Golden Rule 5)
– Isolation (Golden Rule 3)
– Working at height (Golden Rule 2)
– Hot work (cutting and welding)
• People performing maintenance in the workshop, must be then trained and competent
on all these topics.
• Service tracks who enter a workshop will depend on the responsibility of the
department others external service tracks fall under the responsibility of the railway
service.
• Entering / Exiting workshop;
– Crews pulling or setting cars in and out of a building must come to a stop before
entering.
– A crew member must enter the workshop ahead of the train to see that track is
clear of obstructions and personnel in or near cars are warned of the trains
approach.
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3.1 Wedging in Workshops
• May there be any equipment (locomotive, wagon, or any
other rolling stock) inside the protected area, do not forget
to wedge it properly
– Locomotives
– Wagons
– Mounted axes
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3.2 Workshops Track Protection
• Changes driving to workshops must be isolated according to internal instructions, in
order to avoid other vehicles to enter the maintenance tasks zone without notice.
• Isolation must be performed by people in-charge of the workshop.
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3.3 Lifting equipment
• Slings, chains, hooks, lifting devices, and every other device hanging/suporting a load
are to be considered under this Standard (AMS 007) and Golden Rule (Number 5)
• Lifting equipment should be in good condition, and checked:
– before each use
– Monthly, keeping a register
– yearly by a specialized service (internal or external)
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3.4 Working in pits
• Maintenance pits should meet legal requirements (current voltage, lights, number of
exits, air renewal, etc)
• In some cases, it can even be considered as a confined space!
• Pits must also have a protection agains falling from heights, by means of railings, life
lines, coverings etc.
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4. Maintenance Plans
• AM Standard Rail Safety 004
• There must be a procedure for inspections to
establish that equipment is in good working
order before operating. This inspection must
encompass all equipment highlighted in a risk
assessment.
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5.1 Maintenance - derailment
• There are several main causes of derailment: broken or misaligned rails, excessive speed, faults
in the train and its wheels, and collisions with obstructions on the track. Derailment can also
occur as a secondary effect in the aftermath of a collision between two or more trains. Trap
points protect main lines from runaway vehicles by deliberately derailing them to bring them to a
stop. Flangeless wheels make it easier for a locomotive to negotiate curves, but make them
more prone to derailment. Rerailing a train after it has derailed is not an easy task, and often
requires the use of large rail-mounted cranes.
• Rail breakages
• Rail breaks at rail joints
• Manufacturing defects in rail
• Wheel burn-related rail breaks
• Wheelflat-related rail breaks
• Cold weather-related rail breaks
• Cold weather and switch points
• Misaligned railroad tracks
• Excessive speed derailments
• Slow speed derailments
• Uneven loading
• Train "stringlining" on sharp reverse curves
• Poor train handling
• Rolling stock design
• Obstacles
• Housekeeping
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5.2 Maintenance – re-railing
•
•
•
•
Re-railing
Is the process used to place wagons or
engines back on the tracks and repair
damage from the incident. Since engines and
wagons are quite heavy, up to 300 tons, even
a slight derailment can be difficult to rectify.
Serious derailments where the cars are
completely removed from the normal track
alignment will likely incur track damage, and
vehicles may have to be removed by rail
mounted cranes. Contracting companies
specializing in derailment recovery exists
some countries, and railroads often rely on
external contractors for disaster recovery.
If rolling stock rolls down an embankment as
a result of a derailment, a locomotive and
cable can sometimes be used to haul those
vehicles back to the top again.
Special precautions must be taken to avoid
overhead power lines, utilities and
underground lines and gas pipes
Special precautions must be taken when
using jacks, cranes complete with lifting plans
and HIRA
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