Project Safety ManagementProject Safety ManagementTool InstallTool Install

By: Tom Osteen, CSPBy: Tom Osteen, CSP

Benchmark Consulting Group, Benchmark Consulting Group, LLCLLC

Tool Install ManagementTool Install ManagementTool installations can consistently be completed in a Tool installations can consistently be completed in a safe and timely manner when a good plan is safe and timely manner when a good plan is developed and utilized.developed and utilized.

Pre-job Contractor MeetingsPre-job Contractor Meetings

Types of Tool InstallsTypes of Tool Installs

Common ESH Issues Associated With Tool InstallsCommon ESH Issues Associated With Tool Installs

Planning for the InstallPlanning for the Install

ESH Care-aboutsESH Care-abouts

Pre-Job Contractor MeetingsPre-Job Contractor MeetingsThe first step, after the contractor has been pre-The first step, after the contractor has been pre-qualified and selected, is to lay out the project qualified and selected, is to lay out the project expectations. Key communications are as follows:expectations. Key communications are as follows:

Existing facility hazardsExisting facility hazards

ESH and project expectationsESH and project expectations

Necessary submittalsNecessary submittals

Qualification of personnel Qualification of personnel

Chemical list requirements Chemical list requirements

Work Permit Process Work Permit Process

Types of Tool InstallsTypes of Tool InstallsThe second step is to understand the potential The second step is to understand the potential issues associated with each type of tool install issues associated with each type of tool install activity. Several major install categories are: activity. Several major install categories are:

New build-outNew build-out

Retrofitting existing equipmentRetrofitting existing equipment

Types of Tool InstallsTypes of Tool InstallsNew build-outNew build-out: : There are ESH issues associated There are ESH issues associated with each tool install phase: with each tool install phase:

DesignDesign

Lay-outLay-out

Tool move-insTool move-ins

InstallsInstalls

EnergizeEnergize

Types of Tool InstallsTypes of Tool InstallsEquipment retrofittingEquipment retrofitting: : There are unique ESH There are unique ESH issues associated with retrofit activities. issues associated with retrofit activities.

DesignDesign

Sequencing of demoSequencing of demo

Planning for decontamination proceduresPlanning for decontamination procedures

Waste disposalWaste disposal

Process tie-in’sProcess tie-in’s

RetrofitRetrofit

It has been said that doing a It has been said that doing a major tool retrofit project in a major tool retrofit project in a operational manufacturing operational manufacturing fab is fab is “a little like doing a “a little like doing a heart and lung transplant on heart and lung transplant on a patient while he is running a patient while he is running a marathon”a marathon”

Common ESH Issues Associated Common ESH Issues Associated With Tool InstallsWith Tool Installs

Chemical exposureChemical exposure

Decontamination of tools and equipmentDecontamination of tools and equipment

Risk of InterruptionsRisk of Interruptions

Fall Protection IssuesFall Protection Issues

Energized electrical IssuesEnergized electrical Issues

Extension Cord IssuesExtension Cord Issues

Planning for the InstallPlanning for the Install

Design of tools and their accoutrements:Design of tools and their accoutrements:

Fall protection or access (Implanters)Fall protection or access (Implanters)

Doors into areas (confined space issues)Doors into areas (confined space issues)

Material storage areasMaterial storage areas

SequencingSequencing

Electrical panels and when energizedElectrical panels and when energized

First start-up tools on common panelsFirst start-up tools on common panels

Waste drain tie-insWaste drain tie-ins

Other Planning issuesOther Planning issues

TrainingTraining

BadgingBadging

Construction accessConstruction access

Life Safety Tech to help with alarm issuesLife Safety Tech to help with alarm issues

Space ManagementSpace Management

Lock-out/Tag-out Procedures for controlling Lock-out/Tag-out Procedures for controlling laterals and panelslaterals and panels

Planning Issues (Continued)Planning Issues (Continued)

Dedicated electrical outletsDedicated electrical outlets

Chemical approval processChemical approval process

Marked exit corridors in the subfabMarked exit corridors in the subfab

Ladder Storage PlanLadder Storage Plan

ESH Care-AboutsESH Care-Abouts

Decon Sign-offsDecon Sign-offs

Tool move-ins - route of movement not to block Tool move-ins - route of movement not to block access ways or exitsaccess ways or exits

Proper BarricadingProper Barricading

Proper coordination with facility as to hazardous Proper coordination with facility as to hazardous activities in specific areasactivities in specific areas

Tool Sign-off ProtocolsTool Sign-off Protocols