INDUSTRIAL RAIL SAMPLE SAFETY MANAGEMENT SYSTEM (For Provincially Regulated Railways) Update: May 2011 Revision 20110531 Industrial Railway SMS Page 1 NFORMATION The following sample safety management system has been provided to allow provincially regulated industrial railways to operate in accordance with the Railway (Alberta) Act by creating a program that meets the minimum regulatory requirements in the Province of Alberta. Many thanks to the AFPA Health and Safety Committee for its commitment and assistance in generating this document for industry! NOTICE TO READERS Every effort has been made to ensure that the information in this document is accurate at the time of preparation. However, this document is intended to serve only as a guide and cannot replace first-hand information such as specific legislation. This document has been prepared by the Alberta Forest Products Association closely following a template first developed by the Carrier Services Section of Alberta Transportation for another purpose. This template is intended to represent a sample safety management system for the operation of a provincially regulated industrial rail. Provincially regulated railways are those that operate in accordance with the Railway (Alberta) Act. “Industrial railway” means a railway that: transports only goods or commodities that are manufactured, refined or otherwise produced, processed or handled by the person who operates the railway or on whose behalf the railway is operated, and is operated wholly or in part within the confines of the industrial site on which goods or commodities are manufactured, refined or otherwise produced, processed or handled, and is not operated for the purposes of transporting goods or commodities for a toll or a fee or of being a common carrier. This document should be altered to address the compliance and operational needs of a specific industrial railway. This sample document, by itself, should NOT be used or accepted as meeting regulatory requirement unless it has been appropriately modified and implemented. Corrections, comments and suggestions can be submitted to Alberta Forest Products Association at any time by contacting us at 780.452.2841 or by email to cvonsass@albertaforestproducts.ca. The items included in this document are considered to be the minimum items required by law. You may include additional policies to these minimum requirements in your programs. The responsibility is still on the industrial railway to ensure that its programs meet the requirements of the law. To assist you in meeting the requirements, the following web sites may help when developing your programs and/or training. You are required to implement your program, evaluate it periodically and update your program as necessary. For more information on rail safety, training, etc. view the Alberta Transportation “Rail Safety Web Site” on the internet at: http://www.transportation.alberta.ca/521.htm. For more information on Regulatory Requirements consult the following legislation: Railway (Alberta) Act; Railway Regulations AR 177/2002 Alberta Industrial Railway Regulation. Alberta regulations are available from the Queens Printer at 780-427-4952 or on their website: www.qp.gov.ab.ca. SAMPLE SAFETY MANAGEMENT SYSTEM for Provincially Regulated Railways (Industrial Railway) NFORMATION The following sample safety management system has been created in order to provide industrial railways with a sample program that meets the minimum regulatory requirements in the Province of Alberta. Industrial Railway Name: ______________________________________________ Safety Management System For Provincially Regulated Railways (Industrial Railway) Prepared by: ________________________________________ Effective Date: _________________________________________ Revision 20110531 Industrial Railway SMS Page 1 TABLE OF CONTENTS SECTION A – SAFETY POLICY .................................................................................................................. 4 Policy ............................................................................................................................................................ 4 Safety Targets ............................................................................................................................................. 4 Sample Safety Initiatives ............................................................................................................................ 4 SECTION B – ORGANIZATION CHART ..................................................................................................... 6 Roles and Responsibilities ........................................................................................................................ 6 Mill Manager ............................................................................................................................................. 6 Production Manager ................................................................................................................................. 6 Mill Superintendent ................................................................................................................................... 6 Supervisors (Machine / Shift / Transportation) ......................................................................................... 7 Clerks ........................................................................................................................................................ 7 Area Employees........................................................................................................................................ 7 SECTION C – EMPLOYEE AND MANAGEMENT INVOLVEMENT ........................................................... 8 SECTION D – RISK CONTROL ................................................................................................................... 9 Hazard Assessment and Control ............................................................................................................... 9 SECTION E – COMPLIANCE..................................................................................................................... 12 Compliance Monitoring ............................................................................................................................ 12 Proposed Schedule ................................................................................................................................... 12 SECTION F – TRAINING ............................................................................................................................ 14 Training ...................................................................................................................................................... 14 Training Requirements ............................................................................................................................. 14 Training Outline ......................................................................................................................................... 15 SECTION G – INSPECTIONS .................................................................................................................... 16 Inspection Types ....................................................................................................................................... 16 Track Inspections .................................................................................................................................... 16 Railcar Mover Inspection ........................................................................................................................ 16 Locomotive Inspection ............................................................................................................................ 16 Railway Freight Car Inspections ............................................................................................................. 16 Inspection Records ................................................................................................................................... 16 Sample Industrial Railway Track inspection ........................................................................................... 17 Sample Track inspection Report............................................................................................................. 18 Sample Railcar Mover (RCM) Inspection ............................................................................................... 19 Sample Locomotive Inspection ............................................................................................................... 20 SECTION H – INCIDENT INVESTIGATION .............................................................................................. 21 SECTION I – EMERGENCY PROCEDURES ............................................................................................ 22 Rail Safety Contacts ............................................................................................................................... 22 SECTION J – RECORDS ........................................................................................................................... 23 SECTION K – GENERAL OPERATING PROCEDURES (GOI) ................................................................ 24 1. Yard Operations................................................................................................................................ 24 1.1 Scope of Operations ......................................................................................................................... 24 Revision 20110531 Industrial Railway SMS Page 2 1.2 Joint Operations with Canadian National Railway (CNR) ................................................................ 25 1.3 Access and Slope of Track ............................................................................................................... 25 1.4 Maximum Speeds ............................................................................................................................. 25 1.5 Restricted Clearances ...................................................................................................................... 25 1.6 Hand brakes ..................................................................................................................................... 25 1.7 Ice or Material on Track, Switches and Flangeways ........................................................................ 25 1.8 Cars Spotted for Loading .................................................................................................................. 25 1.9 Obstructions ...................................................................................................................................... 26 1.10 Use of Rail Car Mover Bell and Horn, if applicable ........................................................................ 26 1.11 Moving Equipment .......................................................................................................................... 26 2. Industrial Railway Operating Rules (IROR) Application ............................................................... 26 2.1 Applicable Industrial Railway Operating Rules ................................................................................. 26 3. Safety Rules ...................................................................................................................................... 27 3.1 Personal Protective Equipment Policy .............................................................................................. 27 3.2 Pre-Job Communication ................................................................................................................... 28 3.3 Crossing through Rail Equipment ..................................................................................................... 28 3.4 On or About Track and Equipment ................................................................................................... 28 3.5 Mounting / Dismounting Standing Equipment .................................................................................. 28 3.6 Red Zone – Protection against Moving Equipment .......................................................................... 29 4. Engine Operation.............................................................................................................................. 29 4.1 Rail Car Mover (RCM) ...................................................................................................................... 29 4.2 Locomotive........................................................................................................................................ 31 4.3 Securing Equipment ......................................................................................................................... 33 4.4 Coupling and Uncoupling Equipment ............................................................................................... 35 5. Emergency Telephone Numbers .................................................................................................... 36 SECTION L – MEDICALS .......................................................................................................................... 37 SECTION M – MAINTENANCE.................................................................................................................. 38 SECTION N – SAFETY PERFORMANCE ASSESSMENT ....................................................................... 39 AMENDMENT RECORD ............................................................................................................................ 40 Revision 20110531 Industrial Railway SMS Page 3 SECTION A – SAFETY POLICY Policy Industrial Railway Name will operate in a safe manner ensuring the safety of people and equipment and to be in compliance with the industrial railway rules and regulations as required by the Railway (Alberta) Act. See also site safety policy attached – next page. Attach or copy company safety policy - next page. Safety Targets Our aim is to improve the health and safety performance of this organization on an ongoing basis. Management and employees at all levels of the company will work together to make this happen. Performance Targets Initiatives 2009 2010 2011 2012 Employees injuries* Disabling injuries Minor injuries Rail Equipment Incidents Yard derailments Yard collisions Other (please specify) *related to train operations Sample Safety Initiatives Person Responsible Initiative Complete manager inspections once per month Verify implementation of initiatives resulting from incident reports Provide industrial rail training to designated employees Conduct safety/tailgate meetings at frequency specified in the company SMS Provide safety advisory bulletins to employees Revision 20110531 Industrial Railway SMS Target Maintain zero incident target No repeat of similar incidents Maintain zero incident target Page 4 INDUSTRIAL RAILWAY NAME SAMPLE SAFETY POLICY Industrial Railway Name is committed to the health and safety of our employees and the public, where they are impacted by our operations (if applicable). To fulfill this commitment, all of us must make health and safety an integral part of our lives. We must take personal responsibility for our actions and adhere to safety policies, rules and regulations at all times. The Company is committed to provide the leadership, organization, training, and resources needed to maintain a healthy and safe working environment. All employees must make a personal commitment to safety and perform their work in a manner that will prevent accidents to themselves, their fellow workers and the public. No job on our Railway will ever be so important that we can’t take the time to do it safely. Signature Name of Signatory Position of Signatory Date Transport Canada Sample Rail Safety Policy Revision 20110531 Industrial Railway SMS Page 5 SECTION B – ORGANIZATION CHART Organization Chart Identify clear authorities, responsibilities and accountabilities for safety at all levels in the railway company here or in responsibilities section below. Mill Manager Overall responsibility for the safe operation of the site Production Manager Superintendent Warehouse Supervisor Roles and Responsibilities Mill Manager Overall responsibility for the safe operation of the site. Overall responsibility for the SMS. Production Manager Responsible for the safe operation of the site – including rail and other. Mill Superintendent Responsible for the safe operation of the site – including rail. Revision 20110531 Industrial Railway SMS Page 6 Supervisors (Machine / Shift / Transportation) Machine Reports to Mill Superintendent Day supervisor for the mill Responsible for training including rail. Responsible for pre-use inspection management on engine. Shift Transportation Clerks Area Employees Warehouse Other Include (where applicable): training, mentoring, safety meetings, track inspections, signals inspections, incident investigation, engine inspection, and so on. Revision 20110531 Industrial Railway SMS Page 7 SECTION C – EMPLOYEE AND MANAGEMENT INVOLVEMENT The SMS Plan will be reviewed on an annual basis, and revised as required. Transportation clerks / or could be the Health and Safety Committee members will be involved in this review. Participation may include but is not limited to the following activities: conducting workplace inspections, proficiency tests, accident and incident investigations, risk assessments; hazard identification, reporting and resolving; implementing and monitoring corrective actions; communicating safety programs, policies and procedures to employees; and providing input on employees’ complaint resolution, etc. Changes to the SMS will be reviewed with all applicable employees at department safety meetings. Major changes to the rail system will involve input and participation by the effected employees. Rail car mover/locomotive pre-use inspections will be kept on file indicate where inspection documents will be filed here. All track inspection reports and maintenance reports will be kept on file indicate where inspection documents will be files here. A copy of the current Industrial Rail Operating Authority Renewal Application will be kept of file indicate where inspection documents will be files here. The SMS will be maintained in the indicate where the SMS document will be located for ease of reference. Revision 20110531 Industrial Railway SMS Page 8 SECTION D – RISK CONTROL Hazard Assessment and Control Industrial Railway Name has completed a Hazard Assessment of its existing railway operations which is attached to this document. See following pages. Subsequent assessments will be conducted when new equipment is acquired or changes to the operation are implemented. Identification, reporting and mitigation of hazards is the responsibility of all employees working with management. This may be through participation in committees, teams, safety representatives, projects, pre-planning, safety meetings, etc. Employees are to report imminent dangers to their supervisor immediately. Definition Section 13(a) of the Act defines imminent danger as ".....any conditions or practices in any place of employment which are such that a danger exists which could reasonably be expected to cause death or serious physical harm immediately or before the imminence of such danger can be eliminated through the enforcement procedures otherwise provided by this Act." Revision 20110531 Industrial Railway SMS Page 9 Industrial Railway Name Risk Assessment and Control Risk Area Identified Hazards Control Methods Train / Equipment Operations Derailments Collisions Human reliability (alertness, ability to use equipment and follow procedures) Unintended movements (runaways) Missed or misunderstood communications Failure to follow rules or procedures Failure to see/obey signals Equipment, Infrastructure and Facilities Contractors Revision 20110531 uniform, coordinated development and implementation of operating rules and procedures periodic review and revision of operating rules and procedures training programs monitoring of employees and supervisors rules violation monitoring Equipment failures leading to collisions, derailments and/or employee injuries Unsafe equipment Safety appliances Infrastructure failures Rail failures (broken, spread) Track condition (ties, ballast, cross level, spirals, tight rail) areas of recent work Slope failures Washouts Flooding Impact of significant changes to operations (type of service, speed, frequency, weight) Unsafe facilities inspection and maintenance standards and procedures, including cycles, record-keeping procedures, and corrective action and implementation monitoring procedures modification review and approval process for capital expenditures relevant safety policies, requirements and standards communicated to contractors through orientation facility inspection procedures, including a hazard identification and elimination process, cycles, recordkeeping procedures, and corrective action and implementation tracking procedures Failure to understand or follow company rules and procedures Failure to provide or use safety equipment Failure to coordinate activities with company personnel/train operations Failure to use specified materials, equipment or procedures Industrial Railway SMS a process to ensure that contractors are trained in the organization’s safety procedures and are familiar with safety equipment requirements and their safety responsibilities ensuring that safety requirements are included in contractors’ statements of work and competency requirements selection, control and performance review of contractors, taking into account contractor ability to meet safety requirements and follow safety procedures Page 10 Employees Safety Deaths Injuries Incidents (near misses) Fitness for duty Unsafe conditions not identified or corrected Failure to identify, provide or use safety equipment Hazardous materials in workplace taking action when contractors do not comply with the organization’s safety procedures an employee safety program and health controls that meet the requirements of the Canada Labour Code (Part II) a process for feedback on risk control actions, safety performance and safety audit results to employees formal job briefings safety awareness and promotion programs a workplace hazardous materials program meeting the Workplace Hazardous Materials Information System (WHIMIS) requirements safety training, particularly with respect to new equipment, processes and procedures a recognition and rewards system that recognizes the right behaviors and safe working practices Emergencies Derailments Chemical spills emergency preparedness and response plan Vandalism, Terrorism and Sabotage Risk to employees and operations from deliberate malicious acts Objects on right-of-way Misaligned switches Thrown objects Runaway equipment Sabotaged equipment Bomb/sabotage threats identification of risks (threat assessments) and development of security plans and procedures (with the appropriate confidentiality) staff training and familiarity with security risks and procedures security exercises links with security agencies Revision 20110531 Industrial Railway SMS Page 11 SECTION E – COMPLIANCE Compliance Monitoring Compliance to regulations, general operating instructions, SMS, records, and training will be monitored through formal, informal and pre-operation inspections. The frequency of formal inspections by designated employees to monitor compliance and identify areas of non-conformance is as follows: Proposed Schedule Managers / Supervisors / Workers Frequency Monitoring Compliance to: Regulations / GOI / SMS / Records / Training Verification of Compliance to Regulations Source Industrial Rail Regulatory Requirements consulted for currency in the following legislation: Monitoring Frequency Annually Railway (Alberta) Act; Railway Regulations AR 177/2002 Alberta Industrial Railway Regulation. Alberta Transportation website at: http://www.transportation.alberta.ca/521.htm Queens Printer website at: www.qp.gov.ab.ca Revision 20110531 Industrial Railway SMS Page 12 Requirement Track Inspections Engine Safety Inspections Engine Pre-Use Inspections Freight Car Inspection Industrial Railway Operating Authority Renewal Application Employee Training Records Retention Current Company SMS Demonstration of Compliance Task Inspect track for defects Frequency Monthly or before movement Position Responsible Transp. supervisor (if used less than 1/month) RCM – Inspected to ensure safe operation As per Manufacturer’s specifications. Transp. supervisor Locomotive – Safety Inspection placing engine in-service. Records retained for min. 92 days RCM - pre-use inspection Intervals of < 45 days Locomotive Inspector (designated by railway operator) RCM operator or designated, competent employee Locomotive operator or designated, competent employee Employees directly involved with movement of cars Transp. supervisor Locomotive - pre-use inspection Informal, visual inspection for observable defects When placed in service or undergone a layover of more than 8 hours When placed in service or undergone a layover of more than 8 hours Prior to loading and following movement Maintained on-file Training employees for competency RCM Maintenance Locomotive Maintenance Track Inspection Training (including Safety Critical) - kept on file Medical Assessment Maintained Safety Management System Pre-Duty & Competency review every 3 yrs Maintained for min. 3 yrs Maintained for min. 1 year Maintained for min. 3 year See exception letter attached Reviewed annually and revised as required Supervisor Transp. supervisor Transp. supervisor Supervisor Industrial railway operator A checklist and a reporting system are used. Revision 20110531 Industrial Railway SMS Page 13 SECTION F – TRAINING Training Employees of Industrial Railway Name are trained in accordance with the railway employee qualification rules. Industrial Railway Name utilizes competent in-house trainers to train employees involved in railway operations. Training is conducted using internally developed competency based training material. This material consist of classroom or computer based training (CBT) instruction with quizzes, field tours and exercises, field mentoring and sign off by trainer and supervisor, as appropriate. All training records are maintained for a min. 3 year period in the employee file in identify specific location here. Any persons that are granted access to Industrial Railway Name‘s property, to work in any capacity in the railway operation, have appropriate skills and training and are adequately supervised to ensure that they comply with the SMS requirements and general operating instructions as they pertain to their roles while on site. Training Requirements All employees directly or indirectly involved in the movement of rail equipment will be provided with training that includes: 1. Industrial Railways Operating (IROR) Rules a. Including: Railway Radio Communications, Signals, Operation of Movement 2. General Operating Instructions 3. Railcar Securement 4. Inspections Choose an item. operators will be provided with additional training to include: Engine a. Pre-Inspection Criteria, Airbrake Systems, Operation and Practical In-Field Component See also training outline – over. Employees, qualified to work in a rail related capacity will undergo a competency evaluation at intervals of not more than 3 years. Revision 20110531 Industrial Railway SMS Page 14 Training Outline Description: Industrial Rail training developed to provide health and safety orientation, work-related instruction and on-the-job training opportunities to promote and verify employee competency. Objectives: At the end of the training participants will: be familiar with company health and safety requirements respecting rail operation; develop an understanding of the specific rules and procedures for the work area; have the specialized training needed to effectively operate, as applicable; be able to perform job tasks competently and safely. Topics to be covered during training include: Web Course Responsibilities Operation of movements Derails Communication Switching Hand brakes Air brakes Shoving Coupling/uncoupling Core rail safety rules Engine operation Communication Hands-On Engine Classification Air brake system Equipment handling Rail Car Type PPE Pre-job communication Freight car inspection Red zone Coupling/uncoupling freight Switching Derails Hand brake system Hand Radio Audible warning Headlight Blue flag Fixed signal Engine Start-up Operation Evaluations: Competency verification conducted at intervals of not more than 3 years. Revision 20110531 Industrial Railway SMS Page 15 SECTION G – INSPECTIONS Industrial Railway Name conducts regular equipment and site inspections of its joint operation with Canadian National Railway (CNR). Trackage for Industrial Railway Name is located at indicate mile location here of CNR, indicate location here. Inspection Types Track Inspections Industrial Railway Name maintains the track through monthly inspections (with a minimum 20 day interval from the last inspection) and minor repairs by identify track maintenance company here. Any major track work is conducted by identify track maintenance company here. Rail maintenance (track work) is protected in accordance with IROR Rule 12. Railcar Mover Inspection Pre-use inspections are conducted by Industrial Railway Name to ensure rail car movers placed or continued in service are free from safety defects. Locomotive Inspection Pre-use inspections are conducted by Industrial Railway Name to ensure locomotives placed or continued in service are free from safety defects. Safety inspections are conducted at intervals of no greater than 45 days by identify third party inspector or other here. Railway Freight Car Inspections ‘Walk-around’ visual freight car inspections are conducted by designated employees on all cars, for hazards that could pose a risk to employees accessing the car prior to and following movement. Freight car inspections look for: car body leaning or listing to the side car body sagging downward object dragging below the car body door insecurely attached object extending from the side of the car body that could pose a risk to persons conducting the switch or others in the areas brake functioning improperly See also sample inspection forms – following pages. Inspection Records Inspection and maintenance records are maintained in the appropriate equipment files. Revision 20110531 Industrial Railway SMS Page 16 Sample Industrial Railway Track inspection Monthly Track Inspection For: Track Number: Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Day of Inspection Inspector Initials Gauge X-Level Rail Condition Ballast Condition Spikes – any missing? Bolts Missing – loose? Splice Bars – present? / tight? Surface Condition Alignment Turnouts Crossings Signs Month Exceptions Revision 20110531 Remedial Action Taken Industrial Railway SMS Initials Date yy/mm/dd Page 17 Sample Track inspection Report Date: YY MM DD Company: Location: Track Inspected: Track Inspected: Track Inspected: Track Inspected: Track Inspected: Inspection Type: Item Location Accompanied By Revision 20110531 Class of Track SCHEDULED SPECIAL (TSR minimum) Specify reason: Description of Exception or Condition Inspector (please print) Industrial Railway SMS HY-RAIL WALKING Remedial Action Taken TRAIN Date Corrected yy/mm/dd Signature of Inspector Page 18 Sample Railcar Mover (RCM) Inspection Railcar Mover’s Pre- Departure Inspection Report [Done when rail car mover is placed in service or when a layover of more than 8 hours has occurred .] Check any Defective Item and Give Details under “Remarks” Month Day Year Unit No.: Odometer Reading: Action Start: End: Sunday Monday Tuesday Wednesday Thursday Friday Saturday PRE USE PRE USE PRE USE PRE USE PRE USE PRE USE PRE USE BRAKE SYSTEMS HAND BRAKE HEADLIGHTS OSCILLATING LAMP(S) RUNNING GEAR ANY APPARENT SAFETY HAZARDS S – SATISFACTORY N – NEED NOT BE CORRECTED C – DEFECTS CORRECTED RAILCAR MOVER OPERATOR’S INITIALS Remarks Operator’s Name: Revision 20110531 Signature: Industrial Railway SMS Page 19 Sample Locomotive Inspection Locomotive Pre- Use Inspection Report [Done when rail car mover is placed in service or when a layover of more than 8 hours has occurred.] Check any Defective Item and Give Details under “Remarks” Month Day Year Unit No.: Odometer Reading: Action Start: End: Sunday Monday Tuesday Wednesday Thursday Friday Saturday PRE USE PRE USE PRE USE PRE USE PRE USE PRE USE PRE USE BRAKE SYSTEMS HAND BRAKE HEADLIGHTS, BELL, WHISTLE OR OTHER AUDIBLE WARNING DEVICE FLAGGING EQUIPMENT - SUPPLIED ANY APPARENT SAFETY HAZARDS S – SATISFACTORY N – NEED NOT BE CORRECTED C – DEFECTS CORRECTED LOCOMOTIVE OPERATOR’S INITIALS Remarks Operator’s Name: Revision 20110531 Signature: Industrial Railway SMS Page 20 SECTION H – INCIDENT INVESTIGATION Industrial Railway Name is required to report accidents / incidents to the Railway Administrator as per the Railway (Alberta) Act, Part 3 section 38(1) and Railway Regulations AR 177/2002 Part 3 section 35(1). The following incident types are reportable: main-track collision or derailments highway grade crossing collisions accidents involving a trespasser, employee or passenger fire or explosion involving railway property collision between rolling stock and an object non-main-track collision or derailments collision involving a track unit collision between rolling stock and an abandoned vehicle and; incidents involving dangerous goods - require an immediate report under the Transportation of Dangerous Goods Regulations Immediately after an accident, Industrial Railway Name will verbally report the details to the Co-ordination and Information Center (CIC). Their 24 hour toll free number is 1-800272-9600 or 780-422-9600. Communication will be through list position of person responsible here. A written report, outlining the details of any reportable incident, will be forwarded to the Railway Administrator using the Industrial Railway Incident Report within 30 days of the incident occurring. The report will be completed and forwarded to the Railway Administrator by list position of person responsible here. The Provincial Industrial Railway Reporting Form is available at the following link: http://www.transportation.alberta.ca/Railway_Incident_Report_July_03_2009.pdf. The following incident types will not be reported to the Railway Administrator: minor injuries not involving lost time or a visit to a physician, and minor equipment damage such as paint scrapes. Records of any incident investigations will be maintained as per company policy. Indicate policy used here. Revision 20110531 Industrial Railway SMS Page 21 SECTION I – EMERGENCY PROCEDURES In the event of a medical or environmental emergency, the Industrial Railway Name site Emergency Response plan would be activated to deal with the situation quickly, safely and effectively. See plan attached or reference where the plan can be found. Rail Safety Contacts Dangerous goods and rail incidents must be reported to: The Alberta Transportation Coordination and Information Center (CIC) by calling 1800- 272-9600. The CIC is operational 24 hours a day seven days a week. For rail technical information: 1. call the Rail Safety Officer at 780-427-7572 or toll free at 310-0000 and at the prompt dial 780-427-7572, or 2. send email to Knut Ohm, Rail Safety Officer, Knut.Ohm@gov.ab.ca or 3. send a note to the general mailbox at Alberta Rail Safety Main Floor, Twin Atria Building Alberta Transportation 4999 - 98 Avenue Edmonton, AB T6B 2X3, or 4. send a fax to 780-989-7238. Revision 20110531 Industrial Railway SMS Page 22 SECTION J – RECORDS All records pertaining to rail operations including: Inspection reports (track and engine), Railway incident reports, Railway maintenance reports Operating authority and renewals Hazard Assessments Employee Fit for Duty Declarations [See exception letter attached], and Training records are maintained by Industrial Railway Name. Record Track Inspection Engine Inspection Incident Investigations Maintenance Operating Authority/Renewals Training Rail System Audits Revision 20110531 Method of Access Paper format Paper format Paper format Paper format Paper format Electronic Paper format Industrial Railway SMS Location Indicate file location Indicate file location Indicate file location Indicate file location Indicate file location Indicate file location Indicate file location Page 23 SECTION K – GENERAL OPERATING PROCEDURES (GOI) Every employee in any service connected with rail car movements and protection of track work and track units shall be subject to and conversant with the Alberta Industrial Railway Regulations Rules, general operating instructions and all operating procedures pertaining to the employee’s occupation. All employees will have access to the Alberta Industrial Railway Regulations Rules and GOI while on duty. Note: The GOI may be organized as a separate document. 1. Yard Operations Diagram of Rail Operation at Industrial Railway Name (Include: crossings, derail locations, switches, structures, etc.) 1.1 Scope of Operations Industrial Railway Name operates a railway yard at its mill in location here for the purpose of receiving empty cars to be loaded for shipping product to customers. Employees are responsible for Choose an item. rail cars which are then secured for CNR pick-up. If the facility is unloading chemical cars also, please indicate process used here. Revision 20110531 Industrial Railway SMS Page 24 1.2 Joint Operations with Canadian National Railway (CNR) Please outline track location here. Industrial Railway Name maintains the track from indicate location to the mill site here. Monthly track inspection and minor repairs are contracted to indicate company responsible here. Any major track work is handled by indicate company responsible here. Rail maintenance (track work) shall be protected in accordance with IROR Rule 12. CNR personnel are required to activate the flashing amber warning lights provided, when they come on the mill site to move equipment. All Industrial Railway Name, rail side activities must cease, including working on or around rail cars, when CNR is present. 1.3 Access and Slope of Track Please provide details here. 1.4 Maximum Speeds Industrial Railway Name trackage speed limit is ...................................................15 km/h 1.5 Restricted Clearances Employees are prohibited from riding on the side and the roof of moving equipment when passing side and/or overhead restrictions. Any company specific restrictions should be listed here. 1.6 Hand brakes Hand brakes will be applied on all rail cars left standing unattended. Air brakes must not be used in place of hand brakes to secure unattended rail cars. 1.7 Ice or Material on Track, Switches and Flangeways When a movement is required to move cars on a track where gravel, snow or ice conditions are present, precautions must be taken to avoid derailment. The affected track and/or switches must be cleared of these conditions. When ice/snow may impede switch points to close properly when operated by a wheel flange, the switch must be manually lined before a trailing move is commenced over the switch. Movements operating in a facing point direction must observe the position of the points in addition to the target indication before proceeding. Flangeways must be kept clear of ice or buildup of material that could cause wheel lift, especially with empty cars. 1.8 Cars Spotted for Loading Empty cars spotted for loading must be secured with handbrakes as follows: Minimum Hand Brake Application # of Cars # of Hand Brakes Required 1-2 1 3-19 2 20-29 3 30-39 4 *These are guidelines only; more than the specified # may be needed. Empty cars spotted for loading must also be protected with a blue signal (i.e. blue flag/blue equipment sign/blue light). Revision 20110531 Industrial Railway SMS Page 25 1.9 Obstructions Indicate any site obstructions here. 1.10 Use of Rail Car Mover Bell and Horn, if applicable Use the RCM bell when passing any movement standing on an adjacent track. The RCM Air Horn Signals One blast confirm ‘Three – Point Protection’ in effect Two blasts move forward Three blasts move backward 1.11 Moving Equipment When equipment is shoved by an engine or is headed by an unmanned remotely controlled engine, a worker must be on the leading piece of equipment or on the ground in a position to observe the track to be used and to give signals or instructions necessary to control the move. Exception: A worker need not be so positioned when the portion of the track to be used is “known to be clear”. Where a railway track and a public road share the same roadbed and there is no fence or other barrier between them, moving rail cars not headed by an engine or when headed by a remotely controlled engine must be protected by a worker on the leading car or on the ground in a position to warn persons standing on, or crossing, or about to cross the track. 2. Industrial Railway Operating Rules (IROR) Application Employees connected with rail car movements and protection of track work and track units at Industrial Rail Name must: Understand, comply and have access to the Industrial Rail Name rules, general operating instructions and all company-specific rail operating procedures while on duty. Notify Industrial Rail Name of any condition that may affect the safe movement of an engine or rail car. Seek help if unable to control a harmful or dangerous condition. Complete a competency-based review every 3 years. Ask for help from their supervisor if in doubt as to the meaning of any rule or instruction. 2.1 Applicable Industrial Railway Operating Rules Schedule 1 – IROR 1. General Notice 2. General Rules 3. Definitions Signals Rules 4. Hand signals Revision 20110531 Industrial Railway SMS Page 26 5. Engine bell 6. Engine bell failure 7. Headlight 8. Blue signal protector 9. Signal imperfectly displayed 10. Fixed signal recognition and compliance 11. Emergency protection Protection of Impassable or Speed-restricted Track 12. Protection of track work on non-main track 13. Mounting of signals Operation of Movements 15. Starting a movement 16. Stopping clear of fouling point 17. Protection against extraordinary conditions 18. Emergency stop protection 21. Hand-operated switches 23. Derails 24. Speed on industrial railway track 25. Crew responsibilities 26. Securing equipment 27. Coupling to equipment 28. Fouling other tracks 29. Shoving equipment Radio 30. Reliability tests 31. Continuous monitoring 32. Radio terms 33. Radio or hand signals 34. Switching by radio 35. Positive identification 36. Content of radio communications 37. Verification procedures 38. Avoiding distraction 39. Emergency communication procedures 3. Safety Rules 3.1 Personal Protective Equipment Policy Employees must comply with the company’s personal protective equipment policy. Revision 20110531 Industrial Railway SMS Page 27 3.2 Pre-Job Communication 3.2.1 Job Briefing Procedure: Conduct a job briefing at/near the work site, at a location free of distractions, before work begins and when task conditions change. Include all affected individuals including team members and outside parties or contractors. Verify understanding of job expectations before work begins. Plan the work to be done, who does what and identify any potential hazards. Talk it through using questions to communicate specifically who does what, where, when, how and why. Break complex jobs down into manageable portions. Implement the plan; if the scope of work changes or a new task begins, take time to stop and re-brief everyone on the changes. Confirm that the work group is following the plan as discussed. 3.3 Crossing through Rail Equipment Employees must not: Cross through moving equipment. Cross under couplers or underneath cars unless duties require and protection against movement has been provided. Step on the coupler or uncoupling lever. Place hands, feet, or other parts of the body on the sliding sill or between the coupler horn and end sill of the car. 3.4 On or About Track and Equipment When working around track and equipment, employees must: Look in both directions for approaching rail movements while approaching or crossing tracks. Exercise extreme caution when entering or crossing between uncoupled equipment that is separated by less than 15 m (approximately one car length). Not sit or step on: rail, frogs, switches, or connecting rods unless duties require and proper protection has been received. Not walk between the rails of, or foul the track except when duties require. Not position yourself between any structure and standing or moving equipment without sufficient clearance to avoid injury. Not occupy the top of railcars unless duties require. Not sit or lie underneath standing equipment unless duties require and proper protection has been provided. Not sit or stand on car mover handrails or steps. Watch for tripping and other hazards. 3.5 Mounting / Dismounting Standing Equipment When getting on or off equipment, employees must: Face the equipment and use side ladders, sill steps, and grab irons provided. Not step or jump from car to car. Revision 20110531 Industrial Railway SMS Page 28 Not step on the sliding center sill or cushioned under frame device of any car. Keep off couplers and their components. Not entrain or detrain equipment: When carrying items that would prevent a secure handhold or proper balance. In areas of poor footing or restricted clearance. Maintain 3-point contact. 3.6 Red Zone – Protection against Moving Equipment Before entering the “Red Zone”, employees must advise the RCM operator. The RCM operator must provide “Red Zone Protection” as follows: 1. Confirm full application of the rail car mover parking brake. 2. Place rail car mover transmission selector in neutral. 3. Leave the accelerator in idle position. If the request to enter the “Red Zone” is given by radio, employees must respond by radio “Red Zone in effect.” If the request to enter the “Red Zone” is given by hand signal, employees must respond with one short blast of the horn. After confirmation is received from the RCM operator, the employee may enter the “Red Zone”. After clearing the “Red Zone,” employees must cancel the protection received. Slack adjustment should be monitored if hand brakes are being released. Employees must not go between the uncoupled RCM and cars when clearance between them is less than 15 m (about 1 car length). 4. Engine Operation 4.1 Rail Car Mover (RCM) RCM Operators at Industrial Railway Name are classified “Safety Critical” as per the Alberta Industrial Railway Regulations. An employee occupying a safety critical position as defined through the Industrial Railway Regulations, must undergo a medical fitness for duty assessment before occupying the position. An exception from the requirement to have persons in safety critical positions (i.e. employees operating a RCM) undergo periodic medicals (as required under Schedule 10, Industrial Rail Legislation) was requested due to the low risk nature of the operations at Industrial Railway Name, and the effectiveness of the SMS to adequately manage the risks. See copy of Exception Letter attached. RCM operator responsibilities include: Being familiar with current information regarding the systems and mechanical procedures that apply to the RCM. Taking responsibility for the proper use of and handling of equipment in their care. Shutting down equipment when abnormal conditions arise such as noise, smoke or odour from the engine, electrical panel or other components; taking appropriate fire fighting action if necessary. Revision 20110531 Industrial Railway SMS Page 29 Periodically checking all gauges in the operating cab to verify normal operating standards are being maintained. 4.1.1 Inspection Standards Pre-use inspections are conducted by Industrial Railway Name to ensure rail car movers placed or continued in service are free from safety defects. Specifications for fluid levels & general maintenance issues are found in the supplier’s Operator Manual. RCM pre-start inspection requirements include the following: 1 Brake Systems Test the brake; include safety control systems. 2 Hand Brake Verify hand brake(s) are in working condition. 3 Headlights 4 Oscillating Lamps Verify that all lights are in working condition. 5 Running Gear Verify that running gear is free of safety defects. 6 Safety Control Equipment Verify that safety controls are functioning. 7 Any Apparent Safety Hazards Note any Identified hazards. 4.1.2 Start-Up Procedure After pre-start inspection, “start-up procedures” are performed as below and as per the general operating instructions at Industrial Railway Name. Confirm parking brake is set. Place transmission direction selector in neutral. Verify road wheels are up (when on rails). Verify road wheels are down (when off rails). Leave accelerator in idle position. Turn key switch to start position and hold firmly in this position. Note: If the engine fails to start within 5 seconds, release key and allow starting motor to cool at least 30 seconds before another attempt. If the engine fails to start after four attempts, an inspection should be made to determine the cause. When engine starts, release key and depress accelerator to attain the desired warm-up speed. Warm-up could take 5 minutes. Confirm oil pressure is between 5 psi & 25 psi depending on engine temperature. At idle and at normal operating temperature, range should be between 5 psi and 10 psi. Monitor air pressure indications: – air reservoir: 110-120 psi (normal) – Train air: 90 psi (normal). Confirm amp-meter indicates slight charge (+). Note: When engine has reached normal operating temperature (185° to 195°F), confirm transmission in neutral and check high engine RPM. RPM is governed at 3000 RPM. Check transmission temperature gauge is between 185° to 195°F. Maximum allowable temperature is 250°F. Check all audible warning devices, headlights, back-up warning alarm and beacon light for proper operation. Check operation of windshield wiper (if needed for weather conditions). Revision 20110531 Industrial Railway SMS Page 30 4.1.3Initial Movement Procedures The steps below must be followed in preparation for initial movement “on rail”. Confirm front & rear road wheels are in the ‘up’ position and remain there. Fasten seat belt (if applicable). Communicate travel intention and direction. Release parking brake. Position transmission selector in forward or reverse depending on desired direction. Select desired speed range (operate “on rail” in position 1 or 2). Depress the accelerator to begin movement. Note: On initial movement, verify brake operation. Spotter must check rail wheels during initial movement to verify they are properly seated on the rail and are not being forced off. When changing direction of travel, confirm RCM is brought to a complete stop before moving transmission direction selection lever. 4.1.4 Shutdown Procedures The steps below must be followed in preparation for shutting down the RCM. Place the transmission speed range selector to “1”. Place the transmission direction selector in neutral. Set the parking brake. Turn the ignition switch off. Move all electrical controls to their off positions. Close all windows. Report any malfunctions or maintenance issues. 4.2 Locomotive Locomotive Operators at Industrial Railway Name are classified “Safety Critical” as per the Alberta Industrial Railway Regulations. An employee occupying a safety critical position as defined through the Industrial Railway Regulations, must undergo a medical fitness for duty assessment before occupying the position. An exception from the requirement to have persons in safety critical positions (i.e. employees operating a locomotive) undergo periodic medicals (as required under Schedule 10, Industrial Rail Legislation) was requested due to the low risk nature of the operations at Industrial Railway Name, and the effectiveness of the SMS to adequately manage the risks. See copy of Exception Letter attached. Locomotive operator responsibilities include: Being familiar with current information regarding the systems and mechanical procedures that apply to the locomotive. Taking responsibility for proper use/handling of equipment in their care. Being observant to the locomotive’s gauges and indicators and to the area around the outside of the locomotive. Blowing the horn when approaching any area where people are likely to be near the tracks. Keeping headlights on while the locomotive is moving. Handling the throttle carefully; always starting slowly, moving the throttle gradually forward until the locomotive begins to move. Once at the desired Revision 20110531 Industrial Railway SMS Page 31 speed, reducing the throttle position until the locomotive remains at that speed. Shutting equipment down when abnormal conditions arise and taking appropriate fire fighting action in the event of fire. 4.2.1 Inspection Standards Pre-use inspections are conducted by Industrial Railway Name to ensure locomotives placed or continued in service are free from safety defects. Safety inspections are conducted at intervals of no greater than 45 days. Locomotive pre-start inspection requirements include the following: 1 Brake Systems Test the brake; include safety control systems. 2 Hand Brake Verify hand brake(s) are in working condition. 3 Headlights Verify that all lights are in working condition. 4 Bell/Whistle/Other Verify that audible warning devices are working. 5 Running Gear Verify that running gear is free of safety defects. 6 Flagging Equipment Verify that flagging equipment is fully supplied. 7 Any Apparent Safety Hazards Note any Identified hazards. 4.2.2 Start-Up Procedure After pre-start inspection, “start-up procedures” are performed as below and as per the general operating instructions at Industrial Railway Name unless they conflict with the decal* posted inside the cab of the locomotive (*decal instructions are complied with). Note: Diesel engines must not be started under any of the following conditions: hot engine and low lube oil indications are displayed at the same time; crankcase over pressure device is tripped; an indication of a governor shutdown (low lube oil) occurs two consecutive times. Locomotive Cab Place the isolation switch in the START position. Verify that the battery knife switch is closed. Reset any tripped circuit breakers and place the control/fuel pump switch to the ON position. Confirm that the fuses are properly positioned. Confirm throttle or MU shutdown button is not in the STOP position. Engine Room Reset engine protective devices that are tripped, except do not reset a crankcase over pressure device. Check engine lube oil, cooling water, air compressor lube oil levels: If any of the levels is at or below the LOW level, do not start the engine – mechanical repairs may be required. If all of the levels are above the LOW level, start the engine. Starting the Engine Prime the fuel system. Crank diesel engine until it starts, but not longer than 30 seconds. Revision 20110531 Industrial Railway SMS Page 32 Note: Hold the layshaft lever (if so equipped) at 1/3 travel – there may be a delay of up to 15 seconds before the engine begins to crank. If the diesel engine fails to start, repeat this procedure. If it does not start after a second attempt, mechanical repairs may be required. 4.2.3 Emergency Shutdown Procedures The steps below must be followed during an emergency shutdown of the locomotive. Place the isolation switch in the START position. Stop the engine by pressing the engine stop button. Open the radio circuit breaker. Open the battery knife switch. 4.2.4 Leaving the Locomotive Unattended Controls on the controlling locomotive when left unattended are positioned as follows: Independent Brake Cut in and in the FULL APPLICATION position Automatic Brake Cut in and in the: FULL SERVICE position, if the locomotive is coupled to railcars. RELEASE position, if the locomotive is not coupled to a train. Throttle In the IDLE position Reverse Lever Removed and stored Control/Fuel Pump Switch In the: ON position, if the engine is running. RELEASE position, if the engine is shut down. Generator Field Switch In the OFF position. Engine Run Switch In the OFF position. Isolation Switch In the ISOLATE position on all locomotives in the locomotive consist. Battery Knife Switch (on all locomotives in the consist) Is: CLOSED, if the engine is to be left running OPENED, after the diesel engine is manually shut-down and no mechanical system restart is planned. 4.3 Securing Equipment 4.3.1 Hand Brake Hand brakes must be applied on all cars left standing unattended and empty cars spotted for loading must be secured. Note: A rail car is considered unattended when no crew member is close enough to take safe and effective action to control its movement. Revision 20110531 Industrial Railway SMS Page 33 To prevent equipment from moving even when secured by a full application of the air brakes, the following chart will be used to determine the minimum number of hand brakes required. Minimum Hand Brake Application # of Cars # of Hand Brakes Required 1-2 1 3-19 2 20-29 3 30-39 4 *These are guidelines only; more than the specified # may be needed. Hand brakes must not be applied while equipment is being pulled or pushed. A car with a defective hand brake must never be left by itself. It must be coupled to another car with an effective hand brake. Brakes must be applied on each cut or block of cars consecutively. Whenever possible, cars should be secured located at the end of a downward sloping track first. After switching and when cars are left unattended, the required number of hand brakes should be applied. 4.3.2 Hand Brake Application Procedure When applying a hand brake, the following procedure is followed: Release the air brake or bleed off the brake cylinder. Do not attempt to bleed a car off with SERVICE brake applications in effect to avoid an undesired release of other cars. When an air brake application is required (i.e. heavy grades with heavy cars), it must be as light an application as possible to prevent movement while hand brakes are being applied. Fully apply the brake with your normal physical capability (force). Confirm braking surfaces are free of ice and snow during winter. Cars must be stationary; don’t apply hand brakes on a moving car. Do not use your feet. When releasing a hand brake, the following procedure is followed: Confirm the brake is FULLY RELEASED before moving car(s) to avoid damage to wheels. Note: hand brakes have the ability to provide far more brake shoe force than air brakes. Verify that the vertical rod and chain are slack. Note: Do not depend on brake shoes being clear of the wheels as on many cars, the hand brake applies on the “B” end only. Note: Do not release hand brakes from cars left standing on a grade until the air brake system has been fully charged, unless movement can be prevented with car mover brakes. Revision 20110531 Industrial Railway SMS Page 34 When testing hand brake effectiveness, the following should be noted: Equipment must never be left unattended without first conducting a PUSH or PULL TEST. Fully apply the hand brake and move the car, or cut of cars slightly to confirm the required minimum hand brake(s) application applies the necessary retarding force to prevent movement. Observe that the slack does not run out on cars as the equipment stops, i.e. when the car mover or cars coupled to the car mover stop, so do the secured car(s). It may be necessary to apply more hand brakes than required in the “Minimum Hand brake Application” table due to the many variables in the condition of the braking equipment. 4.3.3 Air brake Employees must be able to identify and explain the purpose of each major component of a freight car air brake system and how it works. Employees must never rely on emergency air brake applications to hold equipment stationary during switching unless there are at least 10 cars which are sufficiently charged with air AND a worker is close by to safely apply hand brakes if unintended movement occurs. Under winter conditions, air brakes should be applied at sufficient intervals to keep braking surfaces free of ice and snow. Brake equipment must be conditioned for service. 4.3.4 Air Brake Control Procedure Operation of the brake control lever causes the rail car brakes to apply provided that the brake pipe air hoses are coupled, angle cocks opened and the rail car reservoirs are sufficiently charged with air. Full Forward Position: Release (reservoirs charging and rail car air brakes released) First Detent: 10 psi reduction of brake pipe pressure Second Detent: 20 psi reduction of brake pipe pressure Third Detent: 30 psi reduction of brake pipe pressure Note: Standard train air pressure is 90 psi. engine ‘train air’ should be adjusted to this pressure for consistency with CNR standards. 4.4 Coupling and Uncoupling Equipment Prior to coupling to or moving equipment, employees must: Confirm equipment is properly secured. Notify all persons in or about the equipment. Vehicles and loading or unloading devices must be clear. Before coupling the brake pipe from a rail car mover to other equipment, condensation & foreign material must be blown from the brake pipe. Revision 20110531 Industrial Railway SMS Page 35 When coupling to equipment for any purpose, the coupling must be stretched to verify that it is secure. This is not required when flat switching where rail cars are intentionally let run free. To prevent by-pass couplers when coupling to equipment on other than tangent track, a stop must be made (not less than 2 m nor greater than 4 m) from the coupling, confirming couplers are properly aligned prior to coupling being made. 4.4.1 Coupling Procedures The maximum speed when coupling must not exceed 6 km/h. Each coupling must be tested to confirm proper coupling has been made. Only the hand may be used to operate the uncoupling lever. Employees must not attempt to adjust the coupler or knuckle of an approaching car. When connecting air hoses, one foot must be kept outside the rail! Coupler or components must not be adjusted with the feet. Feet must be kept clear of the knuckle in case it falls. After coupling, no car or cut of cars may be pushed or shoved until it is known that a proper coupling has been made. The slack must be taken or be seen to run out on all cars to be moved. Hand brakes must be applied as required. Whenever a car mover is uncoupled from equipment, the angle cock must be fully opened. 4.4.2 Adjusting a Misaligned Coupler To adjust a misaligned coupler, an employee must reach in and pull/push the yoke into alignment (i.e. aligned with the receiving coupler). 5. Emergency Telephone Numbers Canadian National Railway (for situations that create a hazard for their operations) CNR Customer Service Rep (24 hrs): 1-866-926-7245 Emergency Telephone # (CN Police): 1-800-465-9239 5 Alive Practice the following five basic safety principles when operating railway equipment: 1. Secure equipment before action is taken. 2. Protect personnel against moving equipment. 3. Discuss safety at the beginning of a job or when a work plan changes. 4. Communicate before action is taken. 5. Mentor less experienced personnel. Revision 20110531 Industrial Railway SMS Page 36 SECTION L – MEDICALS An employee occupying a safety critical position as defined through the Industrial Railway Regulations, must undergo a medical fitness for duty assessment before occupying the position. An exception from the requirement to have persons in safety critical positions (i.e. employees operating a Choose an item.) undergo periodic medicals (as required under Schedule 10, Industrial Rail Legislation) was requested due to the low risk nature of the operations at Industrial Railway Name, and the effectiveness of the SMS to adequately manage the risks. See copy of Exception Letter attached. Revision 20110531 Industrial Railway SMS Page 37 SECTION M – MAINTENANCE Industrial Railway Name and its employees ensure the proper and safe functioning of all Choose an item.and railcars. The focus is on early detection and preventative maintenance, which increases equipment reliability and safety. All brake equipment is maintained in a safe and serviceable condition as a minimum in accordance with legislation and manufacturers’ recommendations. Revision 20110531 Industrial Railway SMS Page 38 SECTION N – SAFETY PERFORMANCE ASSESSMENT Safety performance and processes are evaluated annually through the use of an audit process. Recommendations from the evaluation are drafted, initiated and/or implemented. Revision 20110531 Industrial Railway SMS Page 39 AMENDMENT RECORD No. Date Name Section Description Revised 1 2 3 4 5 6 7 8 9 10 Revision 20110531 Industrial Railway SMS Page 40