Safety Guideline:- Isolation and Lockout

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Topic : Safety Guideline

Isolation and Lockout

1. Context:Persons may suffer fatal or serious injury if they are exposed to hazardous energy sources.  One potential exposure occurs while undertaking inspection or maintenance work on plant and equipment.  Therefore it is necessary to ensure that energies are controlled while personnel are working in, or on, plant and equipment.

2. Purpose:

The purpose of this element is to ensure that the installation, construction, inspection and maintenance work performed on plant and equipment where there is potential for hazardous energy release, is only undertaken by competent and authorized persons after the equipment has been safely isolated, and locked such that the risk of fatalities is controlled.

3. Scope:

This element applies to the management of any activity where personnel may be required to interface directly or indirectly with sources of hazardous energy that have the potential to cause fatal or serious injury.  In particular this element applies to both fixed and mobile plant, machinery and equipment.  It applies to all personnel working on  sites and to visitors.

4.0 Element Requirements	Accountability
4.1 Hazard Identification Risk Assessment and Control
A survey must be undertaken to identify hazardous energies associated with plant,machines and equipment.  This survey must record: The plant / equipment / machine Identification name or number / HAC code and location Different types of hazardous energies associated with that plant and equipment. Isolation points for each hazardous energy (these may be local and/or remote)	Company Director
A documented process for undertaking isolation must be developed.  This process must address: Definition of isolation points for each item of plant, machinery or 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 isolation's and re-energize the plant, machine or equipment.	Company Director
Competent persons must be nominated as Isolation Officers for each type of equipment requiring isolation.	Company Director
All isolation's will be undertaken by means of formal lockout.  Lockout will occur through the application of a lock by the nominated Isolation Officer for the equipment, with subsequent application of locks by each person who will work on the equipment.  The following isolation cases may exist: A single or multiple isolation carried out to protect a single person:  In this case, the single person will apply his/her own lock(s) if he/she is trained as an Isolation Officer.  Otherwise an Isolation Officer must apply the first lock, and then the person requiring the isolation applies their own lock.  A single isolation carried out to protect multiple workers: In this case, the Isolation Officer will apply the first lock.  Other persons will then apply their own lock if they are trained as personal lock holders. A multiple isolation carried out to protect multiple workers: In this case, the Isolation Officer will apply locks and isolate multiple locations as required.  The Isolation Officer will then place the keys of the different isolation locks in a lockout box which he/she will then also lock.  Other persons will then apply their own lock and tag to the lockout box if they are trained as personal lock holders. Visitors must be supplied with a lock which will be attached after the Isolation Officer has applied their lock.	Company Director
The name of each person applying an isolation must recorded at the point of isolation.	Company Director
Where lockout cannot be achieved, then tags may be used for isolation as an interim measure.  However, the ability to lockout will be retrofitted to all plant and equipment.	Company Director
Any risk identified as having a potential to cause fatal incident must be controlled prior to carrying out any tasks.	Company Director
If a documented isolation procedure is not in place, then a job safety analysis must be carried out on tasks prior to commencement of work.  This job safety analysis will address the energy sources present and the nature and the type of isolation required.	Company Director
All documentation and records relating to surveys and risk assessments must be retained for the life of the equipment.	Company Director
When equipment is isolated for more than one shift, a record of the isolation will documented for communication to the incoming shift.	Company Director
Approval must be obtained to remove a lock placed by another person. (Note : such approval will only be sought in exceptional circumstances)	Plant Manager
4.2 Selection, Training, Competency and Authorization
The training and competency assessment system will ensure: Competency standards for persons undertaking surveys to identify hazardous energies associated with plant and equipment.  Competency standards for persons performing the functions of an Isolation Officer. Competency standards for persons performing the functions of personal lock holder. Training and formal competency assessments for the above personnel Authorization of the above personnel to isolate plant and place locks. Recording of all training undertaken and the results of competency assessment. A register of all persons authorized to carry out isolation's.	Company Director
All personnel who undertake surveys, perform JSA’s or any other risk assessments relating to isolation and lockout must be: Competent to undertake isolation and lockout Competent to undertake/facilitate JSA’s or risk assessments	Company Director
Any person responsible for identifying lockout points and applying the primary lock must be formally trained and competent as an Isolation Officer.	Company Director
All persons involved in applying personnel protection locks (personal lock holders) as part of an isolation must be trained in those aspects of the isolation procedure relevant to them.	Company Director
4.3 Communication and Awareness
Isolation and lockout awareness must be a component of general induction for all personnel.  Records of having received awareness training must be maintained.	Company Director
Changes to isolation and lockout safe work procedures must be documented subject to change management and implications communicated to persons who may be affected by the changes.  Copies of written safe work procedures or relevant job safety analysis must be made available in the work place to those persons who perform isolation's.	Company Director
Ongoing awareness information and instruction must be provided on a regular basis to personnel who install, construct, inspect and maintain equipment, and plant with a potential for hazardous energy release.  This awareness must specifically address: Critical aspects of isolation and lockout as summarized below: o    Reasons for isolation o    Types of energies needing to be isolated o    The difference between single isolation's and multiple isolation's o    The rules associated with isolation's Applicable safe work procedures	Company Director
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4.4 Design, Purchase, Fabrication, Installation and Commissioning
Consideration of the ability to lockout and isolate must be addressed as part of the design or purchase processes for new plant and equipment.	Company Director
Design or purchase specifications must be developed for all systems plant and equipment which ensure that hazardous energy sources can be isolated and locked out.	Company Director
Purchasing specifications must ensure that local isolation of plant and equipment is available.	Company Director
Purchasing specifications must address isolation capability for mobile plant and equipment.	Company Director
Purchasing specifications for locks must ensure the master series locks has series keys available.	Company Director
Personal locks are designed so that they can only be unlocked by the key that was issued with the lock.	Company Director
4.5 Work Method and Condition Control
Isolation requirements must be applied to all activities performed on sources of hazardous energy.  This will include application to fixed and mobile plant and equipment.	Company Director
Isolation requirements must also provide guidance on safe working methods for testing plant that has been isolated.	Company Director
Isolation requirements must distinguish between isolation methods and use of “Out of Service” tags.	Company Director
4.6 Maintenance
A maintenance programme must be in place for ensuring that all plant and equipment identified in the survey has lockable isolation points installed or a physical means to prevent a hazardous energy release, and that the location/method of isolation is in a usable state.  .	Company Director
All isolation and lockout equipment must be maintained in a “fit for purpose” condition.  This may include: Isolation points Switches Valves Dampers Flaps Circuit breakers Locks Keys, and Other multiple lockout devices.	Company Director
All isolation and lockout test equipment must be maintained according to manufacturer’s specifications.	Company Director
4.7 Emergency Controls
The site emergency response team and site emergency plan should address potential injuries that may result from failure in isolation systems.	Company Director
4.8 Monitoring, Inspections and Audits
Annual audits must be performed to verify the quality and effectiveness of the requirements set out in this element. As a minimum this will include : Schedules for audits Audit verification of: quality of the risk assessments performed quality of the equipment maintenance programme compliance to training, competency, and awareness requirements compliance to isolation and lockout  procedures Feedback and reporting requirements	Company Director
Inspection of all equipment used for isolation's  must be maintained in accordance with manufacturer’s recommendations and results recorded.	Company Director
Planned Job Observations must be performed by supervisors for the purpose of measuring compliance in regard of: Permit issuing procedures Safe working procedures Status of isolation records	Company Director
4.9 Reporting, Assessment and Corrective Actions
Processes must be in place for the reporting, assessment, and correction of hazards equipment isolation or procedures and must address: Actions required to stand down unsafe equipment, tag it, stop work Recording of actions taken to correct the hazard or defect Actions required to re-start the equipment	Company Director
Processes must also be in place to address actions that may arise from auditing of this particular fatality prevention element.	Company Director

 5. Glossary of Terms

Accountability	The person designated to ensure that the assigned requirement is implemented. This person is held liable and answerable to the level of compliance against the stated requirement.
Authorised	Permission granted by the relevant Manager or nominee to carry out specific tasks.
Competent Person	A person having appropriate knowledge, internal and/or external qualifications, skills, experience and capability to carry out specified tasks.  The combination of such attributes underlies critical aspects of their successful professional performance, and may be assessed against defined competency criteria.
Contractor	A firm or person employed under a contract to provide services in organisation  as distinct from a contract of employment.
Department Manager	The person nominated by organisation as Manager under the organizational structure, also the most senior position with a firm contracting work to organisation.
Hazardous Energy	These energy sources are one or more of; electricity, radiation, pneumatics, hydraulics, gases and liquids, chemical, gravity or any other energy source that has the potential to cause injury or damage.
Isolation	Where a de-energized energy source has been locked in accordance with the Isolation Procedures.  At organisation this is the only form of isolation that is accepted and is other wise known as Positive Isolation.
Must / Shall	Must  / shall is to be interpreted as mandatory.
Non compliance of Isolation	A situation or an occurrence where the organisation  Isolation Regulations or Safe Work Procedure for isolation has not or can not be followed.
Operational Experience	Is a person with a minimum of one years experience relating to the isolation and lockout regulations.
Personal Lock Holder	A person who has received training in the isolation, lockout and tagout procedure.
Isolation Officer	A person who has received advanced training in the isolation, lockout and tagout procedure. The person must have operational experience in the area he/she is working in.
Potential to cause a Fatality/ Risk of a fatality	A hazard that has been identified that if not properly controlled will contribute to a fatal incident.  This can be derived from previous fatal incident experience and / or having being identified by means of risk assessment as having a consequence for fatal injuries.
Risk Assessment	A risk assessment is the estimation of the level of risk associated with and identified hazard to determine the resources needed to control it.  Risk is measured in the terms of consequence and probability.
Safe Work Procedure for Isolation	Is the process of isolating plant or equipment from all energy sources so that work can be carried out on that plant or equipment, without risk of injury from the energy it self.  In the context of this element, a Safe Work Procedure of Isolation is one that has been compiled by the relevant operating department for specific jobs.  The procedures for working on or testing of “live” machinery must be approved by the appropriate Superintendents before implementation.

 

 

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