1.2 Isolation, Lockout, Tagout

Isolation, Lockout / Tagout

1©SHE - Management Consultancy & Support Services

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Why do you think we have Isolation & LOTO Procedures?

• Protect People, Equipment and the

Environment.

• Positive isolation of hazardous energy

sources

• Defines responsibilities, task and work

location.

• Communication, documentation and

tracking.

• Operations, Mechanical and I&E -

Under multi-discipline control,

• Consistency in application


What do you get by following lockout/ Tagout/ Isolation Procedures?

• Accidents can be prevented by following the lockout/tagout procedures.

• These procedures ensure energy is shut-off to machinery or other equipment when it is being repaired, cleaned, or otherwise maintained.

• The main reason is to protect your health and Safety!!

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Equipment used in Lockout/ Tagout

• Locks

• Tags

• Cables

• Lockout board(s)

• Multi-Hole Hasp

• Tie wraps

• Blinds/Spades

• Blind Flanges

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Hasp is a fastener for a door or lid; a hinged metal strap that fits over a staple and is locked with a pin or padlock.

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Types of Lockout Devices

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http://drs.yahoo.com/S=96062883/K=lock+out+tag+out+photos/v=2/l=IVI/*-http:/www.cdc.gov/niosh/docs/2002-123/images/photo41.jpg

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Locks, Tags and Keys


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Locks, Keys and Tags

Completed Tag



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Definition of:• Isolation• Zero Energy• Personal lock holder• Employees• Affected• Other• Energized• Energy Source

Isolation: Process of “cutting off” plant and equipment from all energy sources,so that certain work can be carried out on the plant or machinery without therisk of injury from that energy source.

Zero Energy: When an equipment is shutdown, depressurized and devoid ofhazardous energy that could cause injury or harm to personnel

Personal lock holder: A person that has been trained in the lock out procedurebut will not perform the initial lock out and will only attach his/her lock to theappropriate lock out device in place.

Employees• Authorized

Person who uses lockout/ tagoutAffected

• Person who operates or uses machine where lockout/ tagout is being performed or

• Works in area Other

• All “other” employees

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Definitions Energized

Connected to energy source

Contains residual or stored energy;

Energy Source

Electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.

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Mechanical Energy Chemical EnergyThermal Energy

Most frequently, energy releases are manifestedas the unexpected movement of machinery.However, they also can involve….

….such things as thesudden release of achemical or the suddenrelease of steam.

This Often Occurs During…

Machine set-ups

Equipment servicing

Machine repairs

Unjamming

Workers get injured orkilled because they donot eliminate the sourcesof energy before startingto work on a piece ofequipment or machinery.

Sometimes the Presence of Energy is Obvious

Flywheels are spinning

Presses are cycling

Blades are rotating

Conveyors are moving

Drums are revolving

Sometimes it isn’t…

Residual pneumatic or hydraulic pressure

Stored gravitational energy

Stored mechanical energy

Stored electrical energy

Residual Pneumatic Pressure

Air Accumulator Tank

Stored Gravitational Energy

Large Counterweight

Stored Mechanical Energy

Spring Tension or Compression

Stored Electrical Energy

Capacitors

Simply turning off a machine or a piece of

equipment doesn’t guarantee your safety.

Energy Still Can Be Released By:

Cross-circuiting Wrong switching off of

feeders Reversed wiring Unblocking Component failure Leakage Repositioning Separation Actions of Others

The safest way to work on amachine or piece of equipment isto bring it to a Zero EnergyState.

You Do This By…

Shutting off all energy sources

Isolating the equipment from thoseenergy sources with energy isolatingdevices (EIDs)

Locking out the EIDs

Releasing any stored energy

Testing to make sure you have reached theZero Energy State


Preferred methods for isolating a gas, liquid or

vapor process stream are:

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Energy Control Program

Energy Control Procedures

Periodic Inspections

Employee Training


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Written ProceduresWritten procedures must include the following concerns :

• A statement of their intended use• Specific steps to be followed when shutting down,

isolating, blocking and securing machines or equipment.• Specific steps for placing, removing or transferring lockout

or tagout devices, including who is responsible for them. These steps must assure the continuity of protection and orderly transfer of lockout/tagout devices during shift and personnel changes.

• Must have specific steps for testing a machine or equipment to verify the effectiveness of the lockout or tagout devices before work is started.

Lockout/Tagout?

If energy isolating device cannot be locked out: Tagout

If energy isolating device can be locked out: Lockout or

Tagout - Attach at the same location as lockout

Provide equivalent level of safety as lockout


• Hazard Identification, Risk Assessment and Control

• Communication, Awareness and Training

• Design, Purchase, Fabrication, Installation and Commissioning

• Isolation and lockout process• Work Permit Process• Responsibilities• Maintenance• Emergency Controls• Audits

Procedure and Responsibilities


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Hazard Identification, Risk Assessment and Control

1. Hazardous Energy Survey – to identify hazardous energies associated with plant,

machinery and equipment

The Survey must record• The plant/ equipment/ machinery.• Its identification name or number, and location.• The different types of hazardous energies

associated with that plant and equipment.• Lockout and isolation points for key items of

equipment.


2. A documented Safe Working procedure shall be developedfor undertaking isolations:

3. The procedure must address:

• Definition of isolation points for each item of plant, machineryor equipment.

• Specification of the lockout mechanism/s to be used.• Consideration of the particular work to be performed on each

item of plant.• Definition of the steps required to isolate and lockout all energy

sources.• The method of testing (prior to commencement of work)

that the energy has been safely controlled.• Definition of the steps required to remove isolations and re-

energise the plant, machinery or equipment.• The shift change process or absence of the authorised person.• Lock and key control.


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3. All isolations shall be undertaken by means of formallockout. The following isolation cases may exist:

i) A single or multiple isolation carried out to protecta single person

ii) A single isolation carried out to protect multipleworkers:

iii) A multiple isolation carried out to protect multipleworkers:

4. Visitors must be supplied with a lock which will beattached after the Isolation Officer has applied theirlock.

5. The name of each person applying an isolation must berecorded at the point of isolation.


6. Where lockout cannot be achieved,then tags may be used as an interim measure.However the ability to lockout will be retrofitted to allplant and equipment.

7. For certain activities where isolation procedures are notavailable, job safety analysis/ task analysis shall beperformed to address the energy sources present and thetype of isolation required


Communication, Awareness & Training

• Ongoing awareness, information and instruction must beprovided by permit issuer on a regular basis to personnelwho install, construct, inspect and maintain equipmentand plant with a potential for hazardous energy release.

• Changes to isolation and lockout procedures must bedocumented subject to change management and theimplications must be communicated to persons who maybe affected by those changes through formal meetings,safety meetings, toolbox meetings.


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Communication, Awareness & Training

• A central training register shall be maintained providing a recordof those persons who have been trained by plant HR in lockoutand isolation.

• Plant OH&S coordinator shall train any person responsible foridentifying lockout points and applying the primary lock as anIsolation Officer.

• Plant OH&S coordinator shall train all persons involved inapplying personnel protection locks (personal lock holders) aspart of isolation, in those aspects of the isolation procedurerelevant to them.


Design, Purchase, Fabrication, Installation and Commissioning

Technical Head

• Consideration of the ability to lockout and isolate must beaddressed as part of the design or purchase processes fornew plant and equipment.

• Design or purchase specifications must be developed for allsystems plant and equipment which ensure thathazardous energy sources can be isolated and locked out.

• Purchasing specifications must ensure that local isolation ofplant and equipment is available.


Design, Purchase, Fabrication, Installation and Commissioning

Technical Head• Purchasing specifications must address isolation capability

for mobile plant and equipment

• Master locks purchased shall be identifiable and separate from personal locks

• Personal locks purchased shall be such that they can only be unlocked by the key that was issued with the lock.

• A formal commissioning process shall be applied to ensure that the plant/Equipment/ Machine has been inspected to confirm that it has the capacity to be isolated and locked out before being introduced into service.


Isolation & Lockout Process

A common series of steps have been established to provide aconsistent approach for conducting the isolation and lockout ofhazardous energy sources associated with plant and equipment.

This process is termed as the twelve steps to safe isolation andlockout. The diagram below summarises this process

ACCESS

EQUIPMENT

RESTORE

EQUIPMENT

1

2

3 4

5

6

7

8

9 10

11

12

Identify

Energy

Sources

Advise

Relevant

Parties

Isolate & Secure

Energy

(Master Lock)

Test

Isolation

Place Locks

or Permits

Commence

Work

Complete

Work

Check

Work

Clear

Area

Remove Personal

Locks & Then

Master Lock

Restore

Energy

Check

Operation

ACCESS

EQUIPMENT

RESTORE

EQUIPMENT

1

2

3 4

5

6

7

8

9 10

11

12

Identify

Energy

Sources

Advise

Relevant

Parties

Isolate & Secure

Energy

(Master Lock)

Test

Isolation

Place Locks

or Permits

Commence

Work

Complete

Work

Check

Work

Clear

Area

Remove Personal

Locks & Then

Master Lock

Restore

Energy

Check

Operation


STEP 1: Identify Hazardous Energy Sources

• Shutdown equipment and ensure it is cleaned / flushed / purged /drained prior to isolations

• Identify all hazardous energy sources

• Determine the type of isolation to be applied

• Determine if Permits are required and complete: i.e.o Confined Space Entryo Hot Worko Working At Heighto Excavationo High Voltage

• Identify hazards in work area and relevant controls prior to the workcommencing (e.g. clean and tidy up work area, remove trip hazards,provide barriers etc.


STEP 2: Advise Relevant Parties

• Notify all relevant personnel of the isolation and work to be

conducted

• Communicate hazards in work area and controls required prior to

work commencing

STEP 3: : Isolate Hazardous Energy Sources using Isolation Officer’s Lock

Isolate the hazardous energy sources required as per isolation type as per

the Isolation Matrix, including but limited to:

• Mechanical

• Hydraulic

• Pneumatic

• Electrical

• Radiation41©SHE - Management Consultancy & Support Services

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STEP 4: Test isolation (Zero Potential)

Test isolations to ensure energy source is effectively isolated, e.g.

• Checking for the presence of voltage for electrical isolations

• Attempting to start the equipment i.e. Local stop/start

• Check all stored energy has been secured or released i.e. choking,purging, bleeding pressure

STEP 5: Place Personal Danger Tags

1. Each person to work in, on or around isolated equipment to placePersonal Danger Tag on each isolation point prior to commencingwork.

2. No Personal Danger Tag is to be placed until the Out Of Service Taghas been put in place by the Isolation Officer

Note : All Personal Danger Tags to be removed at the completion ofthe required work and or prior to leaving the site.


STEP 6: Commence the Work

• Conduct required work.

• Monitor the work area for new/additional hazards

STEP 7: Complete the Work

• Check all required work and tasks have been completed.

• Check work is completed to required standard

• Ensure all personnel working in, on or around isolated equipment

have placed Personal Danger Tags on Isolation points


STEP 8: Clear the Work Area

• Ensure work area has been returned to safe operational standard e.g. guards and covers are replaced or refitted

• All equipment tools and material have been removed from the work area.

STEP 9: Check the Work Area

• Ensure all persons working on the affected plant or equipment have

left the work area.

STEP 10 : Remove Personal Danger Tags

• Each individual to remove their own Personal Danger Tag from each Isolation Point

Note: No person is to remove another persons Personal Danger Tag


STEP 11: Restore Energy

• Advise all relevant or affected parties of the intention to restore energy.• Ensure Personal Danger Tags are removed• Remove Out Of Service Tags and De-Isolate each isolation point• Communicate to relevant persons that the plant or equipment has been

returned to service.

STEP 12: Check Equipment is Operating Correctly

• Test equipment is operating normally.


Responsibilities Who Responsibilities

All Personnel • Comply with requirements of Isolation and LockoutProcedure.

• Report all breaches of Isolation and Tagging Procedure onIncident Report Form.

Isolation Officer • Ensure that all isolations are completed according torequirements of Isolation Matrix.

• Report all breaches of Isolation and Tagging Procedure onIncident Report Form.

Maintenance Manager • Ensure maintenance personnel comply with the Isolation and Lockout procedure.

OH&S Manager/ Coordinator

• Monitoring and audit the isolation and tagging procedure.

• Review and update the procedure as required.• Report all breaches of Isolation and Tagging Procedure on

Incident Report Form.

Plant Manager • Ensure all personnel are trained and understand the procedure and that relevant supporting equipment and materials (tags / permits) are available.


Responsibilities

Who Responsibilities

Production Manager • Ensure the Isolation and Lockout Procedure isimplemented.

Procurement Manager • Ensure that adequate supplies of tags and permits are instock.

Supervisors • Ensure the isolation and tagging procedure is followed by all personnel.

• Monitor workplace for hazards in work areas• Ensure that isolations are correct type and location as per

Isolation Matrix• Report all breaches of Isolation and Tagging Procedure on

Incident Report Form.


Work Permit Process• Work on the equipment which are required to be isolated and locked is only

permitted after obtaining a written authorisation in the form of a workpermit from a person nominated in writing.

• Permit shall be issued in quadruplicate with colour code as follows.o Pink – for Permit holder – to be displayed at work site.o Light green - for OH&S departmento White – for Permit issuer/CCR.o Yellow – isolation officer

• Permit issuer (department individual who requires the work to be carriedout) will obtain the signature of CCR in-charge (if applicable), request theIsolation officer to isolate the required energy.

• Isolation officer isolates the energies as per the checklist in the permit.

• After the permit is signed off by the isolation officer, the permit issuer handover the permit to Permit holder who signs off the permit.


Work Permit Process• After the completion of the work, the permit is forwarded by the Permit

Holder to the isolation officer for his signatures and restoring of the energy.

• After obtaining signatures of the isolation officer, permit holder shallhandover the permit to Permit issuer.

• Permit issuer will intimate the CCR in-charge and obtain his signatures onthe permit. (If applicable)

• Permit issuer will finally sign off the permit as an acceptance after checkingand verifying the completion of work and close the permit.

• Isolation officers and permit issuers shall be nominated by Unit head.

• The permit shall be issued for 8 hours which can be extendable up to 24hours after verifying the compliance to permit conditions. The extensioncan be done on the permit holders copy (pink copy). In case work extendingbeyond 24 hours new work permit shall be issued.


Work Permit Process

• In case of isolation of multiple energy sources, respective isolation officersshall isolate and sign off on the work permit.

• OH&S representative shall randomly check the compliance to the permitconditions and in case of the deviation from the procedure, shall suspendthe permit until the conditions are complied.

• Once the work is completed the permit holder will sign off the permit andreturn the same to the permit issuer/isolation officer. The permit issuer /isolation officer shall check for the completion of work and close thepermit.

• Permit issuer/isolation officer shall maintain the necessary permit records.


Responsibilities

Unit Head

• Establishing written procedures covering works involving Isolation and

lock out.

• Train personnel in the use of test equipment for ensuring isolation.

• Establishing emergency plans.

• Ensuring the personnel follow the same precautions and procedures laid

down for company employees.

• Ensuring Isolation and lock out survey is carried out.


Responsibilities

OH&S Department

• Assist Unit Head in establishing written procedures for works involving isolation

and lock out.

• Conducting training programmes for employees and contractor personnel.

• Assist in establishing emergency plans.

• Random check of the work permit conditions compliance.

Permit issuer

• Checking that all conditions of the Permit/s have been met prior to permit

authorisation.

• Fill up the relevant sections of the permit form

• Mandatory inspection of the work area and discussion of the scope of work

with the Permit Holder, prior to the issue of the Permit to Work

• Inspection and acceptance of the completed work.


Responsibilities

Isolation officer

• Ensure that the source of energy is isolated and master lock is applied. Put themaster tag

• Fill up the relevant sections of the permit form.• De-isolation shall be done


Responsibilities

Permit issuer

• Completing the scope of the work to be completed• Mandatory inspections of the work area and discussions detailing the scope of

work with the Isolation officer/Authorised Person, prior to the issue of thePermit to Work.

• Ensuring that all conditions and precautions specified on the Permit to Workhave been met prior to accepting the Permit to Work.

• Signing to accept the Permit/s to Work.• Ensuring that all persons working under a Permit to Work are aware and

understand the scope of work of the permit, the isolation, potential hazards,and that they adhere to special precautions associated with the Permit to Work.

• Certifying that the work is completed, the work area has been left clean andtidy and all maintenance equipment has been removed, prior to closing off thePermit to Work.

• Placing information notes on the back of the permits, collating the permits andreturning them to the Permit Issuer.


Maintenance

• Head maintenance shall develop a maintenance programme forensuring that all plant and equipment identified in the survey haslockable isolation points installed or a physical means to prevent ahazardous energy release, and that the location/method of isolation isin a useable state.

• Head maintenance must maintain all isolation and lockout testequipment according to manufacturer’s specifications


Emergency Controls

The Operations emergency medical response capabilities shall ensure thatthe Operation can respond and treat all potential injuries that may result fromfailure in applying isolation and lockout which might range from:

• Fractures, crush injuries, amputations

• Major bleeds

• Electrocutions, burns


Hazardous Energies Requiring Isolation

Hazardous Energies

Definition Examples

Electrical Electrical energy can be in the form of a livecircuit or as a residual current. Electricalenergy is classified as:

• High Voltage (exceeding 650V)• Low Voltage (not exceeding 650V)• Extremely Low Voltage (not

exceeding 32V)Electrical energy is considered hazardouswhere an electrical charge can cause injuryby passing through the body.

• Power lines• Distribution Boards• Extension cords• Power tools• Generated electrical

power, static sources, or electrical storage devices such as batteries

Thermal Thermal energy can be in the form of hot orcold temperatures. This becomes hazardouswhen the thermal energy exceeds thebodies’ ability to cope with the temperature.

• Steam, services at the power plant

• High or low temperatures resulting from mechanical work, radiation, chemical reaction or electrical resistance.



Hazardous Energies

Definition Examples

Chemical Chemical energy is considered hazardous when it contains properties that can cause injury or illness through contact by means of inhalation, absorption or digestion. Chemicals are normally classified as:

• Corrosive Explosive• Oxidizing• Flammable• Poisonous

• Diesel fuel lines• Acetylene manifold

Radiation Radiation or radioactive sources areconsidered hazardous when theyspontaneously emit enough energy to causechanges to the bodies’ molecular structure“damage organs”. Radiation can beclassified as ionizing and non- ionizing.

• UHF/VHF aerials • Density gauges• Geophysical logging

probes



Hazardous Energies

Definition Examples

Potential Potential energy is stored energy which may be released if controls fail.

• Pressure vessels• Pressurised lines• Springs

Gravitational Gravitational energy refers to thosecircumstances that are subject to theinfluence of gravity, i.e. if controls fail thenthe equipment may move because of theinfluence of gravity

• Clinker falling into silo• “Hang-up” on silo walls• Raised tray on truck

Mechanical Mechanical energy is considered hazardous when there is enough energy to cause physical harm to a person. Mechanical energy can be classified as:

• Gravitational (by virtue of position)

• Hydraulic• Stored (springs• Pneumatic

The moving parts of mechanical systems.

Truck: hydraulic systemTruck: Pneumatic brakes


Isolation and Lock out Permit

Permit No.ISSUER ________________Date: __________________ Time : ________________________Block / Department:____________________Location of Equipment: __________________________Execution department: ____________________________Equipment tag number :Equipment HAC code________________________________

Energy is defined as movement or the possibility of movement. Potential energy sources are:

Electrical / Mechanical / Hydraulic / Pneumatic /Thermal / Gravitational

Description of work to be carried out:----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Trained Persons who will undertake the work: 1. 2. 3.

4. 5. 6.

Isolation and Lock out PermitChecklist (To be filled by the isolation officer/ authorised person ) (Tick the correct)

Type of Energies YES NOT REQUIRED

Electrical Energy1. Area isolated by operating Moulded Case Circuit Breaker(MCCB)/

Air Circuit Breakers2. Isolated & Locked out Vacuum Circuit Breakers (VCB) /Load Break

Switches (LB switch)3. All related fuses removed & all possible back feeding supplies

have been disconnected4. Danger boards / warning tags displayed5. Related switch is effectively locked in isolation position, tested

and tagged.6. Discharging of capacitors done (if required)

Gravitational Energy1. Are chute in to crusher blocked2. Chute in to mill Blocked3. Securing dump body of dumper by providing suitable stopper.4. Secured Mast5. Falling Objects fence

Isolation and Lock out PermitChecklist (To be filled by the isolation officer/ authorised person ) (Tick the correct)

Type of Energies YES NOT REQUIRED

Hydraulic Energy1. Hydraulic Pumps Isolated.2. Residual Pressure released.3. Mechanical Stopper provided.

Pneumatic Energy1. Air supply stopped.2. Residual Air pressure Released.3. Connecting valves isolated by suitably blind

Thermal Energy1. Radiator or turbo charger cooled.2. Heat of rollers reduced.3. Mill temperature reduced.4. Blanketing/ damper isolation provided from heat source.5. Heat Resistant PPEs Provided.

Audits

• Plant OH&S shall perform audits once in six months to verify the

quality and effectiveness of the requirements set out in this procedure.

Audits shall be done to verify:

• quality of the equipment maintenance programme

• Compliance to the training, and awareness requirements.

• compliance to Isolation and Lockout permitting procedures

• Report shall be submitted to Unit Head and corrective action shall be

monitored.



Documents

1.2 Isolation, Lockout, Tagout