GFG Alliance Whyalla QP29.20 ISOLATION FOR …€¦ · GFG Alliance Whyalla ISOLATION FOR PERSONAL...

GFG Alliance Whyalla ISOLATION FOR PERSONAL

PROTECTION

QP29.20 Revision 15

Safety

Any PRINTED copies of this procedure are UNCONTROLLED Page: 1 of 13

1.0 PURPOSE Ensure isolation of energy source is carried out to prevent injury to personnel caused by:

The accidental or unexpected start-up of machinery or movement of materials during servicing, maintaining or any other interaction.

Contact with or exposure to hazardous energy. This procedure describes the minimum requirements for the control of potentially damaging energy (and substances) to provide personnel protection.

2.0 SCOPE Applies to all people working (where isolation is required for personal protection) on SIMEC Mining and Liberty OneSteel Steelwork’s sites. When personnel would be endangered by the unexpected start-up of machinery or

release of stored energy. When personnel are required to bypass any guard, interlock or other safety device. When personnel are required to place any part of their body into an area where work is

being performed. This procedure does not cover operations (e.g., hot-tap, fault finding electrical testing or calibration) where equipment shutdown is impossible, provided that special equipment and/or procedures are used that will ensure proven effective personal protection. This document covers responsibilities, training, procedures, audits, variations, non-conformance and hardware. The major components of the isolation system are that it is:

- planned - locked - verified, and - carried out by appropriately authorised personnel.

3.0 REFERENCES

GFG Alliance Australia Code of Practice - Isolation MM.29.04 Safety Management Systems Manual QP 02.03 Event Recorder / Audit Database and Issues Management QP 29.06 Incident Investigation and Reporting QP 29.11 Plant Safety Management and Inspections QP 29.13 Safety Risk Management QP 29.21 Warning Tag Regulations QP 29.28 Health and Safety Training WI 29.541 Management Review of Disciplinary Action Arising From Safety

Breaches FORM29.005 Variation Approval Form FORM29.006 Operational Access Approval Form FORM29.007 Isolation Code Variation Approval Form


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QP29.20 Revision 15

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4.0 DEFINITIONS

Affected Person Person whose job requires them to use or operate equipment which is isolated for personal protection or work in an area influenced by equipment which is isolated for personal protection

Authorised Personnel

A person authorised to undertake one of the following roles, Plant Owner, Planner, Isolation Leader or Isolating Person

Central Isolation Board

A board set up by an isolation leader to protect groups of people in an isolation. (Also known as a “group lock” board)

Complex Isolation An isolation where there are more than two energy sources or more than three isolators. Complex Isolations require a written isolation procedure and / or permit.

Energy All types of potentially hazardous energy including: electricity, heat, gas, pressurised fluids, steam, and chemicals. It may also be kinetic or potential energy, toxic, biological substances or radiation.

Energised Connected to an energy source or containing residual or stored energy.

Green Group Lock A lock (coloured green) used by an isolation leader to lock a central isolation board. An isolation leader may only remove this lock.

Hot Tap A procedure used in the repair, maintenance and servicing activities, which involve welding on a piece of equipment under pressure in order to install connections.

Individual Isolation A non-complex isolation where, following verification of the isolation, a multilock device and equipment lock are attached to the isolator to signify the isolation has been verified. The equipment lock has a label or tag attached that identifies the isolating person. Protected persons then lock each isolator by placing their personal lock(s) on the multilock device(s).

Isolated The condition into which equipment or plant is placed when all sources of potentially damaging energy are prevented or blocked by the operation and securing of isolating devices.

Isolator A device that physically prevents the transmission or release of potentially damaging energy. A central isolation board is an isolator when used under an approved group isolation procedure.

Isolation Checker A person who confirms that the Isolation Permit is completed and verified correctly, in situations deemed necessary by the Isolation Planner. The Isolation Checker is only responsible for checking the isolation and the verification process and not doing the physical isolation.


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QP29.20 Revision 15

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Isolation Committee

Representatives from Safety, Engineering, Procurement and Operating departments who, on behalf of the management team, act as the custodian of the Isolation and Warning Tag procedures. Their role is to; review isolation incidents, review, and where appropriate grant variations Constantly review, and where required, update the procedures.

Isolation Leader An isolating person who co-ordinates the isolation activities of isolating personnel. The person who applies the group lock to a central isolation board.

Isolation Permit Identifies the person who authorises the isolation permit, isolation leader, the person who locks the isolators and the person who verifies the effectiveness of the isolation. Any changes to an Isolation Permit must be re-authorised by the appropriate person.

Isolating Person A person assigned by the responsible manager to apply equipment locks to isolators.

Isolation Planner A person who plans and documents plant specific isolation procedures.

Locked Placement of a lock on an isolating device, in accordance with an established procedure, so that accidental or inadvertent operation of the equipment is prevented.

Multilock Device An accessory attached to an isolator, which permits the device to accept multiple locks. The presence of a multilock device signifies that the isolation has been verified. A multilock device is essential hardware for every isolation

Non-Complex Isolation

An isolation where there are no more than two energy sources or no more than three isolators. Non-complex Isolations do not require a written isolation procedure or permit. In some cases a procedure or permit may be used.

Operational Access

Operational Access refers to the day-to-day operation of machinery. It covers loading and unloading parts, adjustment, inspection, housekeeping and tool changes

Plant Owner A person designated responsible (by the responsible manager) for the plant area and equipment.

Protected Person A person who places their red personal lock on a multilock device or a central isolation board for personal protection.

Red Personal Lock A lock (coloured red) and identification used by a protected person for personal protection.

Responsible Manager

Person responsible for the planning, direction and control of personnel safety within a recognised production area.


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QP29.20 Revision 15

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Safety Breaches Disciplinary Committee

Two members of the Steelworks Management Team and a Human Resources Manager/Superintendent (plus Contractor Principal if Contractor employee involved).

Satellite Board A satellite board is joined to a main isolating board. A yellow equipment lock is placed on the isolating bar of the main board and its key is placed in the window of the satellite board. The main isolation is set up first and then the satellite board. The satellite board permit refers to the main board as the isolator on a line of the permit.

Securing Device A device used to allow the locking of an isolator where the isolating device cannot be directly locked. Securing devices include lockable valve covers, chains, wire ropes etc.

Verification Is the act of confirming that the isolation procedure as practiced achieves its objective i.e. protects personnel by blocking potentially damaging energy. An isolating person is responsible for any verification.

Yellow Equipment Lock

A lock (coloured yellow) with identification that is applied to equipment that is to be isolated. Yellow equipment locks must be attached to a multilock device after verification has occurred.

5.0 PROCEDURE 5.1 General

A hazard identification and evaluation survey shall be performed to identify all energy

sources and related exposures in the equipment, systems and machines. All equipment shall be locked to protect against accidental or inadvertent operation when

such operation could cause injury to personnel. Each person required to lock an isolator for personal protection shall place a lock on:

a) Each isolator locked with a multilock device and a yellow equipment lock. or b) A central isolation board which is locked with a green group lock.

All isolators shall be uniquely and permanently labelled to indicate their function for isolation purposes.

No person may affix or remove the personal lock of another person. New isolators shall have the capability to be locked in the safe position.


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5.2 Responsibilities The following are functional responsibilities, which shall exist for every isolation. All personnel: Be trained to recognise isolators. Not attempt to operate a locked isolator. Not remove any lock, tag or mechanism, other than their own. Only use locks and tags on specified equipment they are authorised to work on. First preference for labelling red or yellow locks, is a personally labelled lock

(encapsulated), second preference is the OneSteel purple identification tag; third preference is a personal identification tag e.g. (ASCO card).

Ensure that red personnel locks are clearly labelled with the person’s name and department number or if the employer is a contractor then the contractors’ name.

Yellow equipment locks identify the person or department who has placed the lock and in group isolation situations, the board number.

Ensure that during isolation, all keys are secured. Bring any isolation problems to the attention of their supervisor. Responsible Managers: Ensure that plant and equipment can be isolated safely and appropriately. Assign ownership (for isolation purposes) for all process, plant and equipment within

their area of control, this must be documented in a department register. The register must provide a list of current authorised persons.

Ensure that service providers and contractors are authorised to supervise the attachment of red personal locks and that this is documented in a department register.

Ensure personnel receive appropriate isolation training. Establish and sustain a departmental isolation system. Assign responsibility for the development, modification and authorisation of Isolation

Permits. Ensure that management controls (for locks and keys) are in place, which ensure that

individuals always have control over the potentially damaging energy. Audit and evaluate the application of isolation system in all areas within their jurisdiction.

The aim of the audit shall be to improve the system by correcting any deviations or inadequacies.

Plant Owner: Be aware of those working under an isolation. Grant permission for equipment to be isolated. Isolation Planner: Have a thorough knowledge of all energy sources associated with the equipment. Ensure a hazard analysis is conducted to determine the isolation requirements. Identify the relevant isolators. Identify the method to isolate all necessary energy sources. Identify the method of locking the isolators. Identify the method to verify the isolation. Ensure that all the necessary requirements are included in the Isolation Permit. Identify a situation where an Isolation Checker is required. Authorised and responsible for completing or altering the task list. Also refer to FAQ P32 Currently employed in the department at the time the isolation permit is generated. For emerging work or break in work another planner may plan the isolation provided that

they are authorised and deemed competent by the plant manager.


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Isolation Leader: Gain permission from the plant owner before isolating. Coordinate the activities of the isolating personnel. Ensure that all relevant isolators are locked and the isolation verified. Notify personnel that the isolation is ready for use and any other relevant matters. Isolating Personnel: Completely understand (knowledge and skills) equipment operational characteristics,

associated hazards and its isolation requirements and undertaken a practical on-the-job assessment.

Place isolators under their control in the safe position and lock with an equipment lock. Verify that the isolation is effective. For Non-Complex Isolations:- Provide sufficient locks and multilock devices. Ensure protected personnel comply with isolation procedures. For Complex Isolations:- Carry out the isolation in accordance with isolation Procedure/Permit. Initial Isolation Permit at the time of attaching equipment lock. Initial Isolation Permit at the time of verifying isolation. Protected Personnel: Follow established procedures Only place personal locks on isolators that are locked by the isolating person with an

equipment lock and a multilock device or the Central Isolation Board which is locked with a group lock.

Affected Personnel: Be able to identify personnel who are using isolation for personal protection. The department must ensure that only personnel listed on the isolation permit or task list

are able to supervise first time locking. Examples of authorised personnel who are able to supervise first time locking are the

isolation planner, isolation leader, and project controller or contractor supervisor. The department shall indicate, in the task list, which service providers or contractors are

able to supervise the first time locking of isolations. Service Providers and Contractors: Ensure that the attachment of their peoples red personal lock is supervised. If the

service providers attaching their red locks are Yellow or Green lock trained, there is no requirement to be supervised. If unsupervised, Service Providers must be yellow lock trained if they are placing their red locks on individual isolations and Green lock trained if they are placing their red locks on central isolation boards.

Contractor supervisor’s can supervise locking when trained to Isolation Leader level to supervise isolation boards and trained to yellow lock level for individual isolations and their names are listed on the isolation permit task list.

Use and enforce the isolation requirements. Whyalla Operations Management: Conduct periodic reviews of the application of isolation procedures across the site.


PROTECTION

QP29.20 Revision 15

Safety


5.3 Training Isolation training shall be listed as critical safety training for all personnel working on

Whyalla Steelworks sites. Isolation training shall be carried out at start of employment and periodically thereafter. Site specific training shall take place for job assignments, machines, equipment,

processes and procedures that present hazards to personnel or as deemed necessary by the responsible manager.

Retraining shall take place for changes to job assignment, machines, equipment, processes and procedures that present new hazards to personnel or as deemed necessary by the responsible manager.

Isolation training and assessment shall be knowledge based for theory components and competency based (knowledge and skill) for practical components.

Competency based assessment for isolating persons shall include an on-the-job assessment using the approved checklist.

Isolation training shall include purpose, function and restrictions of this isolation procedure.

Planners shall complete the competency assessment that is provided in the isolation code of practice to demonstrate competency. The plant equipment that the planner is responsible for isolating shall be utilised for this assessment.

Red Personal Lock Protected Personnel and Affected Personnel shall be red personal lock trained to:- Recognise that isolation is in place. Understand the importance of not interfering with isolated equipment. Understand the safety significance, purpose and use of this procedure. Understand the use of a Personal Red Lock and ensure that the key is kept secure

during isolations.

Yellow Equipment Lock Plant Owner, Isolation Planner, Isolation Leader and Isolating Person, performing Non-Complex Isolations shall be Yellow Equipment Lock trained to:-

Recognise potentially damaging energy sources. Use methods and means necessary to isolate and lock potentially damaging energy. Use methods to verify the effectiveness of the isolation. Confirm that a situation is a Non-Complex Isolation Recognise a situation that is a Complex Isolation, and that a Permit is needed. Understand the use of a Yellow Equipment Lock and a Multilock Device and ensure that

yellow equipment lock keys are kept secure during isolations.

Green Group Lock Plant Owner, Isolation Planner, Isolation Leader and Isolating Person and Isolation Checker shall be Green Group lock trained to :-

Recognise potentially damaging energy sources. Use methods and means necessary to isolate and lock potentially damaging energy. Use methods to verify the effectiveness of the isolation. Understand the procedure for completing Isolation Permits and setting up a Central

Isolation Board and ensure that green group lock keys are kept secured during isolations All green group lock keys shall be stored in designated labelled key cupboards or similar

controlled container for access by authorised persons only. All other personnel shall be instructed :- about this procedure. understand the importance of not interfering with isolated equipment.


PROTECTION

QP29.20 Revision 15

Safety


5.4 Isolation Procedures and Permits Isolation procedures and permits for personal protection shall be developed, documented and used for isolation of potentially damaging energy. The procedure and/or permit shall clearly state the scope, purpose, authorisation, rules, and techniques to be used for the isolation of potentially damaging energy. Attachment 1 outlines the necessary features of any isolation procedure. Written isolation procedures and/or permits are required for all complex isolations.

5.5 Isolation Practice 5.5.1 Group Isolation Practice

A written procedure and/or permit shall exist before group isolation can be used. Group isolation may be used if many persons are involved, the isolation is in place for

more than one shift, many isolation points are involved or as deemed necessary by the responsible manager.

The personnel setting up the isolation must be provided with the steps necessary to be protected from stored energy.

The permit shall reference the pertinent work procedures. When there is a sequence of isolations required to do a job safely a work procedure shall explain the stored energies and what personnel who are setting up the isolation must do to be safe when setting up the isolation. A greater level of detail should be included in the work procedure – generally more so than on the isolation permit. If any doubt exists then a safe system of work should be completed.

If a permit is one in a sequence then this must be clearly indicated. For example if isolating the counter balance on a conveyor is the second isolation of three for removing a conveyor belt.

An isolating person shall place the isolators in the safe position and lock them with equipment locks and central isolation board identification.

An isolating person shall verify that the isolation is effective. The yellow equipment lock will be attached to a multi-lock device to indicate that the

isolation has been verified. The completed Isolation Permit and Equipment List is displayed on the Central Isolation

Board. Where isolation boundaries cross normal access and egress areas the boundary of the

isolation must be marked. If this causes major difficulties then a diagram of the isolated area must be displayed at all access and egress points so that a person following normal practices could not unknowingly enter an area controlled by the isolation. The diagram must also be kept on the isolation board with the permit.

The keys of each equipment lock shall be placed in the central isolation board by the isolation leader affixing the group lock.

Green group lock keys shall be stored in designated labelled key cupboards or similar controlled container for access by authorised persons only.

Then and only then shall individuals lock the central isolation board with their personal lock.


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QP29.20 Revision 15

Safety


Satellite central isolation boards may be set up: the isolation leader shall lock the master central isolation board with an equipment

lock. the key of the equipment lock shall be placed in the satellite central isolation board

and locked by the isolation leader affixing a group lock. then and only then shall individuals lock the satellite central isolation board with their

personal locks. For more detail on Satellite Boards see Attachment 9, Section 5.

5.5.1.1 Use of an Isolation Checker

In some circumstances, due to the risk or nature of a particular isolation, it may be deemed necessary by the Isolation Planner to have an independent Isolation Checker. Where this is the case the requirements and responsibilities of the Isolation Checker must be documented in the isolation procedure and/or permit. Using checkers is optional however when utilised they must be appropriately trained (trained to the same level as the isolating person) and must check the process of verification. The isolation planner will decide if a checker should be used and will provide a permit with the appropriate sign-off box.

5.5.2 Individual Isolation Practice

An isolating person shall: Place the isolator in the safe position and lock with an equipment lock.

This step is to ensure that the person conducting the verification has control over the isolator. It also demonstrates to others that the isolation has not yet been verified for individual isolation.

If verification is immediate and visual, e.g. a knife switch or slip plate, then the multilock device may be fitted immediately.

When the lock prevents the verification step being carried out, the verification step can be carried out without the yellow equipment lock in place provided that the isolating person is in total control of the isolator during the verification step.

Verify the isolation is effective. Remove the equipment lock, fit a multilock device and lock with an equipment lock and

isolating person identification. Yellow equipment lock keys shall be stored in designated labelled key cupboards or

similar controlled container for access by authorised persons only. (When the isolation doesn’t progress beyond the current shift, the Isolating Person can keep the yellow lock keys secure without the need for the keys to be placed in a designated key cupboard).

Protected person lock each isolator with a personal lock on the multilock device, which has been locked with an equipment lock.

5.5.3 Contractor Yellow Equipment and Green Group locking

Contractors can isolate individual isolations and group isolations when: The contracting isolating personnel are trained, competency assessed and authorised by

the plant manager. The department keeps a register of authorised contractors and what plant the contractor

can isolate. The department shall keep a record of the contractor’s training assessment.


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5.6 Equipment Restoration Checklist The equipment lock list can be used to restore plant when the restoration of the plant equipment is in the reverse order. When the plant to be restored is not in the reverse order than an equipment restoration checklist must be used, see Attachment No. 12.

5.7 Removal of Locks An isolating person shall not remove any equipment lock from an isolator unless all

personal locks are first removed. An isolation leader shall not remove a group lock from a central isolation board unless all

other personal locks are first removed. Personnel shall only remove their own personal locks. Personal locks must be removed at the end of the person’s shift or if the requirement for

personal protection is no longer needed for the particular job/task. If a person is leaving the works they are required to remove their personal lock. NOTE: If removal of personal locks is required for other reasons, this shall be

communicated via the A.T.W. and toolbox meetings at the commencement of the job.

5.8 Shift and Personnel changes The continuity of personal protection must be ensured during shift or personnel changes. The following steps shall be observed if changeover of the isolation leader is required

using a group isolation procedure. The on-coming isolation leader shall be fully conversant with all aspects of the

isolation. The on-coming isolation leader receives custody of the group lock key from the off-

going isolation leader. The on-coming isolation leader shall satisfy themselves of the integrity of the

isolation. The on-coming isolation leader shall change the name in the isolation leaders position

on the central isolation board. 5.9 Emergency Removal of Locks 5.9.1 Red Personal Locks and Individual Yellow Equipment Locks

Where a person has failed to remove a personal lock or equipment lock the responsible manager may authorise the plant owner to remove the lock provided that all the following requirements are met: ensure that the plant is safe to operate. all practical efforts have been made to locate the individual and have them remove

their lock. all practical efforts have been made to contact the person to ensure that the person

could not return to the job and be endangered by the equipment being operated. The emergency removal check list in Attachment No. 4 must be completed before cutting off the lock.Where a person has lost the key to their personal lock

Identification of the person must be confirmed with the lock in question The emergency removal check list in Attachment No. 4 must be completed before

cutting off the lock.


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5.9.2 Green Group Locks If, for some reason, the Isolation Leader cannot be located to remove the group lock

from a Group Isolation Board, the responsible manager may authorise an isolating person to remove the green group lock provided the following requirements are met: ensure that the plant is safe to operate, all practical efforts have been made to locate the Isolation Leader and have them

remove the lock, ensure all red personal locks and/or yellow equipment locks have been removed from

the group isolation board. 5.9.3 Emergency Removal Of Locks Checklist

When emergency removal of a personal lock, equipment lock or group lock occurs the checklist in Attachment 4 should be completed as a record that the correct process has been followed and authorised. Follow-up actions should also be documented on this attachment.

5.10 Intermittent Operation

Intermittent or remote operations, which do not conform to the requirements of this procedure, shall be considered a variation (ref. 5.13)

5.11 Non-conformance Any non-conformance from this procedure shall be reported and investigated

immediately. The responsibility for the investigation rests with the responsible manager. Corrective action and incident investigation procedures shall be used.

Any disciplinary action taken for a breach of this procedure shall be referred to the responsible manager’s one-up supervisor (see WI 29.541).

All non-conformance’s are to be reported in writing to the Safety Breaches Disciplinary Committee.

5.12 Audit

Periodic audits shall be conducted (at least annually) to ensure that plant isolation practices comply with the requirements of this isolation procedure.

Personnel other than those using the procedure shall conduct audits. The aim of the audit shall be to correct any deviations or inadequacies identified.

A record of any audit shall be retained for seven years. The record shall identify the equipment on which the procedure was being used, the date of the audit, personnel included in the audit and the person performing the audit.

5.13 Variations

Any variations in the application of this procedure shall be formulated in consultation with the appropriate Safety Representative and committee.

Variations to the application of this procedure are only valid where submitted by a member of the Whyalla Operations management team and approved by the Isolation Committee.

Variations shall only apply to a particular procedure detailed in the variation. The Variation Procedure is detailed in Attachment 8.


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5.14 Hardware Isolation equipment shall be standardised (colour, shape, size, print, format) as specified in Attachment 2. Locks

Locks shall be substantial enough to prevent unauthorised removal. Shall be clearly identifiable as for personal protection only. Personal locks shall identify the person applying the lock.

Securing Devices

Devices used to allow the locking of isolators where the isolating device cannot be directly locked. Securing devices include lockable valve covers, chains, locks etc.

Central Isolation Boards

Equipment locks keys shall be captured and locked. Isolation permit shall be readable. Group lock shall activate the central isolation board. Equipment covered by the central isolation board shall be listed. The equipment locked list must be secured by the green group lock The permit shall identify the isolation leader who set up the isolation and the board

shall identify the position of the isolation leader eg. Maintenance Shift Supervisor. Central isolation board may be portable or fixed. Central isolation board shall be uniquely identified.

Isolation Permit

Identifies the isolation leader, the person who locks the isolation and the person who verifies the effectiveness of the isolation -refer Attachment 5.

Date of the isolation. Cross reference to the isolation procedure. Identify all isolators. Identifies the isolation planner. The permit can only be altered by an authorised

isolation planner.

5.15 Modification Control A modification control process shall be used if plant equipment is modified. Isolation practices shall be reviewed to ensure that isolation permits reflect any equipment modifications.

5.16 Intermittent Operation Form

An “Intermittent Operation” form may be used in situations when the plant is required to be frequently locked and unlocked eg Isolation practice for maintenance on kilns. Refer to Attachement 13.


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6.0 DOCUMENTATION Attachment 1 Necessary Requirements for an Isolation Procedure Attachment 2 Hardware Specification Attachment 3 Verification Attachment 4 Emergency Removal of Locks Checklist Attachment 5 Isolation Permit Attachment 6 A Basic Guide for Isolating Persons – Yellow and Green Locks Attachment 7 A Basic Guide for Using Red Personal Locks Attachment 8 Variation Procedure Attachment 9 QP 29.20 Guide Attachment 10 Lock Management Attachment 11 Isolation of Vehicle keys, Best Practice Attachment 12 Equipment restoration checklist Attachment 13 Intermittent Operations Form

Isolation for Personal Protection Attachment 1

QP 29.20/1 7/05/2014 Page 1 of 2

Necessary Requirements for an Isolation Procedure

ISOLATION: Note steps 1 – 11 shall be carried out by the person assigned by the responsible manager. 1. NOTIFY PLANT OWNER

Notify the plant owner (reason and duration). - the plant owner shall notify all affected personnel

2. HAZARD ANALYSIS - Identify type and magnitude of energy - Understand hazards of the energy - Know the methods of controlling the hazards. - Ensure the area of isolation is adequately defined or barricaded so accidental

entry will not occur.

3. COMPLEX ISOLATIONS For group or board isolations the procedure in 5.5.1 is followed to set up the board. In some departments an independent checker signs off when the correct isolator is

locked and after it has been verified. 4. MACHINE CONTROLS IN SAFE POSTION

Identify the type and location of every machine and its controls and their safe position. Place controls in their safe position.

5. ISOLATORS IN SAFE POSITION

Identify the type and location of every isolator and its safe position. Place the isolators in the safe position. Confirm that the correct isolator(s) have been identified and placed in the safe position.

6. IDENTIFY THE METHOD FOR SECURING ISOLATORS.

7. ATTACH EQUIPMENT LOCKS TO ISOLATION SECURING EQUIPMENT 8. IDENTIFY STORED ENERGIES AND DISSIPATE OR RESTRAIN

Identify the type of stored energy and the method of dissipation or restraint. Dissipate or restrain stored or residual energies.

9. VERIFY THAT ISOLATIONS ARE EFFECTIVE

Identify the methods of verification. Verify that the isolations are effective and if a permit is used sign off verification on the isolation permit.

10. MULTILOCK

Remove equipment lock and place multilock onto isolator then place the equipment lock onto the multilock. For complex isolations sign off on the permit that the equipment has been locked.

11. PERSONAL LOCK For individual isolation individuals place their personal lock onto the multilock. For group isolations Individuals place their personal lock onto an activated isolation board.


QP 29.20/1 7/05/2014 Page 2 of 2

RESTORATION:

Note the restoration shall be carried out by the person assign by the responsible manager.

1. Check machine or equipment for : - operational integrity (e.g., safety guards replaced) - removal of non-essential items.

2. Check work area (personal locks removed and personnel clear). 3. Verify controls in ‘Off’ or ‘Neutral’. 4. Remove equipment locks. 5. Place the isolators in the required position. 6. Notify plant owner.


QP 29.20/2 3/12/2010 page 1 of 2

Hardware Specification

Locks

Lock Type Material Number

Description

Personal 54001609 Padlock Safety Lockout -Red - keyed differently - Master Cat No 410

Group 55049015 Padlock Safety Lockout -Green - keyed differently - Master Cat No 410

Equipment 53145845 Padlock Safety Lockout -Yellow - keyed differently - Master Cat No 410

Equipment 55049016 Padlock Safety Lockout -Yellow - set of six(6) keyed alike - Master Cat No 410

Equipment 55049017 Padlock Safety Lockout -Yellow - set of twelve (12) keyed alike - Master Cat No 410

Equipment 55049018 Padlock Safety Lockout -Yellow - set of eighteen (18) keyed alike - Master Cat No 410

Equipment 55049019 Padlock Safety Lockout - Yellow - set of twenty four (24) keyed alike - Master Cat No 410

Equipment 55049020 Padlock Safety Lockout -Yellow - set of thirty (30) keyed alike - Master Cat No 410

Multilock Device

Material Number

52130419

Master multilock device - 25mm ID #420

Material Number

53145411

Master multilock device - 38mm ID #421


QP 29.20/2 3/12/2010 page 2 of 2


Material Number

55049340


Material Number

55049364

Portable Central Isolation Board

Identification Tags

Material Number

51666889

Identification Tags

Attachment 3

QP 29.20/3 10/06/2005 Page 1 of 1

VERIFICATION

Verification

Is the act of confirming that the isolation procedure as practised achieves its objective i.e. protects personnel. An isolating person shall be responsible for any verification.

The isolation shall be tested for zero state energy (specialised test equipment and qualified personnel

may be required), and/or tried (operate the normal controls (return all controls to the off or neutral position)).

If stored, residual or accumulated energy was present the isolating person shall ensure that all stored, residual or accumulated energy is dissipated or restrained

e.g. inspect each moving part to see if it is at rest. Where re-accumulation of stored energy is possible periodic or continuous verification is required to ensure that the energy level or intensity is not harmful.

Attachment 4

Emergency Removal Of Locks Checklist

QP 29.20/4 10/06/05 Page 1 of 1

Circle appropriate response

Personal Lock Yes / No

Details: .........................................................................................................................

Equipment Lock Yes / No

Details: .........................................................................................................................

Group Lock Yes / No

Details: .........................................................................................................................

Plant Assessed Safe To operate Yes / No

Details: .........................................................................................................................

All Reasonable Efforts Made To Locate key and/or Key Holder Yes / No

Details: .........................................................................................................................

.........................................................................................................................

All Personal and/or Equipment Locks Removed Yes / No (for Equipment or Group Lock Removal)

Details: ......................................................................................................................... Administered By: _____________________ ______________________ __ / __ / ____

Print Name Sign Date

(Plant Owner - Personal Locks) (Isolation Leader - Equipment or Group Locks) Authorised By: _______________________ ______________________ __ / __ / ____

(Responsible Manager) Print Name Sign Date

Follow-up Discussion:

Details: .........................................................................................................................

.........................................................................................................................

......................................................................................................................... (Lock Owner) _______________________ ______________________ __ / __ / ____


(Supervisor) ________________________ ______________________ __ / __ / ____


Isolation Permit No. ............................... QP 29.20/5 3/12/2010 Page 1 of 3

EQUIPMENT LIST

Date: Isolation Leader ............................... QP 29.20/5 3/12/2010 Page 2 of 3

Issued for Tasks Permit No........................

Work Order Number Description Work Group &

Supervisor of first time locking

Work Group:

Supervisor: Supervisor: Supervisor: Supervisor:

Work Group:


Work Group:


Work Group:


Work Group:


Work Group:


Work Group:


Work Group:


Work Group:


Date: Isolation Leader ............................... QP 29.20/5 3/12/2010 Page 3 of 3

Isolation Permit No

Prepared By Authorised By: Plant Owner: Equipment Description Revision No. Date of Job Duration

ISOLATOR METHOD of Name Identifier Location Securing Initial Verifying Initial

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Attachment 6

QP 29.20/6 7/05/2014 Page 1 of 3

A Basic Guide for Isolating Persons – Yellow & Green Locks

What is an Equipment Lock?

An Equipment Lock is a yellow lock that is attached to an Isolator. It identifies the Isolating Person or a Central Isolation Board.

Why use an Equipment Lock?

Use an Equipment Lock to secure an Isolator in the safe position and to prevent its accidental or inadvertent operation.

Who can use an Equipment Lock?

Only a person (Isolating Person) assigned by the Responsible Manager shall attach yellow Equipment Locks.

What is a Central Isolation Board?

It is a special purpose board with a place for -

An Isolation Leader’s name or position title

A receptacle and hook for Equipment Lock key(s)

A Green Group Lock.

Red Personal Locks.

A list of equipment.

An Isolation Permit.

When is a Central Isolation Board used?

If many persons are involved in the isolation.

If many isolation points are involved.

If the isolation is to be in place for more than one shift.

If the Responsible Manager deems it necessary.

How does the Central Isolation Board work?

An Isolating Person shall -

Use a written Isolation Permit.

Secure each Isolator with a yellow Equipment Lock.

Verify that the isolation is effective.

Place all the keys for each Equipment Lock in the place provided on the Central Isolation Board.

Attachment 6

QP 29.20/6 7/05/2014 Page 2 of 3

The Isolation Leader shall -

Ensure that all requirements of the isolation are completed.

Place the completed Permit in the place provided on the Central Isolation Board.

Place the Equipment Locks key(s) in the place provided on the Central Isolation Board and secure with a green Group Lock.

Print their name or position title on the Central Isolation Board.

Then and only then shall individuals attach their red Personal Lock to the Central Isolation Board.

What must be done before Personal Locks are used?

Gain permission from the Plant Owner.

Assess all hazards.

Stop the machine.

Place each Isolator in the safe position.

Confirm that each Isolator is locked in the safe position.

Secure each Isolator with a yellow Equipment Lock.

Dissipate or restrain any stored energy.

Verify that the isolation is effective.

Lock each isolating device with a Multilock Device and a yellow Equipment Lock.

Ensure that individuals can secure the isolation with a red Personal Lock.

What must be done before the equipment is returned to service?

Check that all persons are clear.

Check that all red Personal Locks have been removed from Isolator multi-lock devices or Central Isolation Board.

Check that all guards etc. are in place.

Check that all tools etc. have been removed.

Check that all controls are in the safe position.

Remove each Equipment Lock.

Notify the Plant Owner.

Remember

Never remove a yellow Equipment Lock if a red Personal Lock is still in use.

Attachment 6

QP 29.20/6 7/05/2014 Page 3 of 3

Attachment 7

QP 29.20/7 10/06/05 Page 1 of 1

A Basic Guide For Using Red Personal Locks - Level 1

What is a Personal Lock? A Personal Lock is a red lock marked “DANGER - Locked Out - Do Not Remove” and a person’s name on the other side. The Red Personal Lock is attached to a multilock device on an Isolator or Central Isolation Board. Why should you use a Red Personal Lock? Use a Red Personal Lock to protect yourself by stopping others accidentally or inadvertently operating equipment, which could injure you. When do you use your Red Personal Lock? Whenever you could be at risk by:

the operation or movement of equipment or materials. contact with or exposure to hazardous energy or substances.

How do you use your Red Personal Lock? Make sure that each Isolator is placed in the safe position and secured with a yellow Equipment Lock. Attach your Red Personal Lock to the multilock device on each Isolator or the Central Isolation Board, which is secured with a green Group Lock. What must be locked? All plant, machinery and equipment where isolation is required for your personal protection. REMEMBER Never attempt to bypass or operate a locked Isolator. Never try to start equipment that is isolated and locked. Never attach or remove another person’s Red Personal Lock. Never depend on someone else’s Red Personal Lock. Never lend your Red Personal Lock or key to anyone. Always attach your own Red Personal Lock. Report loss of your Red Personal Lock or key immediately.

If in doubt ask your supervisor. IT’S YOUR LOCK ! - YOUR LIFE !

Attachment 8

QP 29.20/8 3/08/2015 Page 1 of 1

Variation to the Code of Practice:

Approval is required from: Business Manager, 2 Isolation Committee members, Safety Manager and the General Manager

Must use the Code of Practice Variation Form (Refer FORM29.007) Requires a review every 2 years

Operational Access Approval (for use of non-positive isolations)

Approval is required from: Business Unit Manager, 2 Isolation Committee members and the Safety Manager

Must use the Operational Access Approval form (Refer FORM29.006) Requires a review every 2 years

ATTACHMENT 9

QP 29.20/9 7/05/2014 Page 1 of 21

GF

GGFG Alliance Whyalla

ISOLATION GUIDE

Frequently Asked Questions

of

Isolation For Personal Protection

QP 29.20

Attachment No. 9

QP 29.20/9 7/05/2014 Page 2 of 21

Liberty OneSteel Whyalla

ISOLATION FOR PERSONAL PROTECTION

IT’S YOUR LOCK - IT’S YOUR LIFE

This Guide contains frequently asked questions about Isolation. To ensure compliance to the requirements of QP 29.20 - Isolation for Personal Protection refer controlled (Intranet) document. Isolation of energy sources is carried out to prevent injury to personnel caused by:-

the accidental or unexpected start up of machinery or movement of materials during servicing, maintaining or other interaction

contact with or exposure to hazardous energy Energy sources include all types of potentially hazardous energy. This may include electricity, pressurised fluids, steam, chemicals, rotating or kinetic energy, potential energy, toxic or biological substances or radiation. TYPES OF ISOLATION There are two types of isolation

individual isolation group isolation

Some isolation information is common to both Individual and Group isolation, however there is specific information for each type of isolation MORE INFORMATION? The following information is to provide some understanding of why the various parts of isolation are used to protect you and others. Other information is also available in QP29.20 Isolation for Personal Protection QI13.30P Rolling Mill Isolation practices manual QP 29.13 Hazard Assessment QP 29.21 Warning Tag Regulations WI 31.103 Disciplinary Process for Safety Breaches by Contractors

Attachment No. 9

QP 29.20/9 7/05/2014 Page 3 of 21

CONTENTS

Section 1 Group and Individual isolation Section 2 Group Isolation Section 3 Individual Isolation Section 4 Isolation Planning Section 5 Setting up Satellite Boards Section 6 Changing the Isolation, Two Scenarios

It’s Your Lock - It’s Your Life Acknowledgment This booklet was created by the Rolling Mills with valuable input from all employees

Attachment No. 9

QP 29.20/9 7/05/2014 Page 4 of 21

SECTION 1 GROUP AND INDIVIDUAL INFORMATION What is the role of each of the following?

Plant Owner to be aware of those working under the isolation and grant permission for the

equipment to be isolated Isolation Planner plan the isolation have a thorough knowledge of all energy sources associated with the equipment ensure a hazard analysis is conducted to determine the isolation requirements identify the relevant isolators identify the method to isolate all necessary energy sources identify the method of locking the isolators identify the method to verify the isolation ensure all necessary requirements are included in the isolation permit Isolation Leader gain permission from the Plant Owner co-ordinate the activities of Isolating Personnel ensuring that all the relevant isolators are locked and the isolation is verified (ie all

securing and verifications are initialled by an Isolating Person) notify personnel that the isolation is ready for use and any other relevant matters Isolating Person completely understand (knowledge and skills) equipment operational characteristics,

associated hazards and its isolation requirements carry out the isolation in accordance to an isolation plan provide sufficient locks and multilock devices place isolators under their control in the safe position and lock with an equipment lock

(initial “securing” on the permit if a group isolation) verify that the isolation is effective (initial “verification” on the permit if a group isolation) ensure that protected personnel comply with isolation procedures What are each of the following used for?

Red lock personal lock for your protection Yellow lock equipment lock to secure an isolator Green lock group lock for central isolation board Multilock device highlights verification is complete for individual isolation, can be used when more than 1 equipment lock is required on the isolator for group isolation

Attachment No. 9

QP 29.20/9 7/05/2014 Page 5 of 21

Can I put my personal lock directly onto an isolator?

No! A personal lock must not be placed directly on to an isolator. You can only place your personal lock onto a Central Isolation Board locked with a group lock or an Isolator locked with a multilock device which has an equipment lock identifying the Isolating Person being used for Individual isolation

If the verification step (as specified in the permit) could not be done correctly, what

would you do? STOP the isolation, contact the appropriate specialist (mechanical or electrical) DO NOT continue until suitable solution is determined If the isolator I should use for an isolation does not work, what should I do? STOP the isolation, contact the appropriate specialist (mechanical or electrical) DO NOT continue until suitable solution is determined There are 2 types of training required to become an Isolation Leader or Isolating

Person, these are theory and practical What is the purpose of each? Theory training is to provide the understanding of the isolation procedures and

responsibilities Practical training - To demonstrate an understanding of the isolation procedures and

responsibilities. Site-specific training is required for a task/area to demonstrate a practical understanding of the energy sources and how to identify and control them

Competency will be assessed and approval to isolate based on a specific task/area will be given by the Plant owner.

When should I use Group isolation?

Group isolation may be used if many persons are involved the isolation is in place for more than one shift many isolation points are involved as deemed necessary by the responsible manager

Removal of locks.

An Isolating Person shall not remove any equipment locks from an isolator unless all Personal locks have been first removed

An Isolation Leader shall not remove a group lock from a central isolation board unless all other Personal locks are first removed

Personnel shall only remove their Personal lock

Attachment No. 9

QP 29.20/9 7/05/2014 Page 6 of 21

Emergency removal of locks Personal Locks

Where a person has failed to remove a personal lock, the Responsible Manager may authorise a plant owner to remove the lock, provided that ALL the following requirements are met all practical efforts have been made to contact the person to ensure that the person

could not return to the job and be endangered by the equipment being operated ensure that the plant is safe to operate

Group Locks

If, for some reason, the Isolation Leader cannot be located to remove the group lock from a Group Isolation Board, the responsible manager may authorise an isolating person to remove the green group lock provided the following requirements are met: ensure that the plant is safe to operate, all practical efforts have been made to locate the Isolation Leader and have them

remove the lock, ensure all red personal locks and/or yellow equipment locks have been removed from

the group isolation board.

Emergency Removal Of Locks Checklist When emergency removal of either a personal lock or group occurs the checklist in QP 29.20 Attachment 4 should be completed as a record that the correct process has been followed and authorised.

It’s Your Lock - It’s Your Life

Attachment No. 9

QP 29.20/9 7/05/2014 Page 7 of 21

SECTION 2 GROUP ISOLATION The major components of Group Isolation are

Central Isolation board (or satellite isolation board) Equipment locks - to secure the isolators Group lock - to secure the Equipment lock key/s in the Isolation board Isolation permit Equipment List Task List

The isolation procedure for Group isolation is:

The isolation will be planned by an Isolation Planner The Isolation Leader will be provided with the appropriate isolation permit for the task The Isolation Leader will gain permission from the Plant Owner The Isolation Leader will coordinate the isolation (ensure that all the isolators are

secured and verified by an Isolating Person) An Isolating Person shall place the isolator in the safe position, lock it with an equipment

lock and initial the isolation permit as secured (for that isolator) An Isolating Person shall verify that the isolation is effective and initial the isolation

permit as verified (for that isolator) Isolating Persons continue to secure and verify (initialling the permit as they go) until all

isolators on the permit have been secured and verified Note: during a group isolation there may be one or several Isolating Persons The Isolation Leader will check that the permit is complete by ensuring - the Plant Owner who granted permission is identified all isolators have been initialled as secured and verified by an Isolating Person the permit includes the Isolation Leader’s name the Date of Job is completed the Duration is completed the Equipment list identifies the equipment on the isolation permit which has been locked the Issued For Task List has been completed by the Isolation Planner The permit is placed on the isolation board along with the Equipment list and the Task list All the key/s of each equipment lock shall be placed in the central isolation board . The

key/s are captured and locked in the central isolation board by the Isolation Leader affixing a group lock and placing their name on the isolation board or position title

Then and only then shall individuals lock the central isolation board with their personal locks

The restoration procedure for Group isolation is

check machine or equipment for operational integrity (eg safety guards in place) removal of non-essential items ensure that all Personal locks have been removed from the isolation board check that all personnel are clear remove the Group lock to allow access to the equipment lock key/s verify that controls are in “off” or “neutral” remove equipment locks place the isolators in the appropriate position notify the Plant Owner

Attachment No. 9

QP 29.20/9 7/05/2014 Page 8 of 21

What is the purpose of an Isolation Permit? plan for isolation, what and how to isolate and verify identifies isolation leader and isolating persons acts as a checklist as each isolator is systematically isolated Can a permit be used twice? No, it can only be used once as each isolation requires the initialling for securing and

verification to be performed for that specific isolation What does the term verification mean to you? ensuring that the isolation is effective eg no pressurised fluid from valve VIP 6004 or zero volts

Who initials the permit (securing and verification)? the Isolating Person, this can be different for each act but good practice is for the Isolating

Person to do both securing and verification When is the Permit initialled (securing and verification)?

the Isolating Person must initial the permit as the isolation occurs. It is unacceptable to bulk initial the Isolation Permit at the completion of the entire permit

Why are Isolation permits initialled?

to indicate that the Isolating Person is satisfied that the isolation has been carried out correctly During a group isolation must there be two people present?

No, but in some circumstances it may be necessary to use two people. If isolating with two Isolating Persons who initials securing and who initials for the

verification?

The Isolating Person who secures initials as secured on the permit The Isolating Person who verifies initials as verified on the permit

Each permit has an area called “prepared by”

must this be signed? yes, if a permit is not signed it must not be used what does this mean? indicates that the isolation has been planned, all the necessary energy sources have

been identified, securing and verification methods are determined and that the isolation has been physically checked by “walking” through the permit

Attachment No. 9

QP 29.20/9 7/05/2014 Page 9 of 21

Each permit has an area called “authorised by”

must this be signed? yes, if a permit is not signed it must not be used what does this mean? that a person independent of the planner has ensured the planner has completed all the requirements of the permit and checked that the

verification technique is effective reviewed the completeness of equipment identified as necessary for the isolation for

the area/task all isolators are uniquely named and identified

What is the purpose of the equipment list? It is a summary of the equipment locked to allow protected persons to ensure they are

protected. How does the Equipment List relate to the Isolation Permit? This identifies the equipment locked for this specific isolation and must include exactly the

same equipment/isolators as the isolation permit The equipment list is generated from the permit. If ANY alterations to the number of isolators on

the permit then the equipment list must reflect this Why do you need to put the Date of Job on the isolation permit? To show that the permit relates to the current isolation Who can remove/strike out an isolator on a permit? An Isolation Planner may remove an isolator from a permit if they understand the implication of

doing this. This may require specific expertise and therefore electrical or mechanical specialists may be required for advice

What must be done to remove/strike out an isolator? A hazard assessment must be conducted to ensure that adequate controls ensure the safety of

all personnel, the isolator to be removed must be crossed out and initialled by the Isolation Planner, the equipment isolated list must be changed to reflect the modification

Attachment No. 9

QP 29.20/9 7/05/2014 Page 10 of 21

If I find an isolation permit on an activated board with the following scenarios, are they

breaches? And what should I do? an initial is not against one of the verifications Yes this is a breach. You should remove all people from the area immediately and notify

the supervisor It will be investigated as a high potential incident by the plant manager. If disciplinary action is required, the plant manager will consult with another manager to

review consistency of approach in disciplinary action taken. Refer to WI.31.103 for Safety Breaches Attachment 2 Flow chart.

an isolator which has no initials against securing and verification

Yes this is a breach and will be investigated as a high potential incident and referred to the isolation disciplinary committee. You should remove all people from the area, notify the supervisor

no Isolation Leaders name Yes this is a technical breach and will be investigated by the supervisor who will

determine the appropriate action no date Yes this is a technical breach and will be investigated by the supervisor who will

determine the appropriate action

Who locks the Isolation Board with the group lock?

The Isolation Leader is the only person who can lock or remove a group lock At the bottom of each page on the permit is a space for the Isolation Leaders name,

does this need to be signed?

Yes, all pages of the permit must be signed to indicate that the Isolation Leader is satisfied that all of the required isolators have been isolated by the Isolating Person/s (as indicated by the initials against securing and verification)

During an isolation can I be the Isolation Leader and Isolating Person?

Yes, during group isolation you may play more than one role. In some situations you may undertake all of the isolation roles

It is not uncommon for a person to be Plant Owner, Isolation leader, Isolating Person and a Protected Person during an isolation

What are the key steps in restoration

associated with the equipment Check that all guards are in place, check that all tools have been removed etc, controls are in the safe position

Attachment No. 9

QP 29.20/9 7/05/2014 Page 11 of 21

when de-activating the isolation board

Check that personnel are clear, red locks have been removed, remove equipment locks, return isolators to the appropriate position, notify the Plant Owner, remove all used permits and equipment lists from the isolation board

Who can remove equipment locks?

Only Isolating Persons can remove equipment locks What would you do in the following scenarios:

I am Isolation Leader and Isolating Person for a group isolation when I find that the isolator I wish to isolate is already locked (secured) and verified under another group isolation?

How can I make sure that the isolation is effective?

Securing: must resecure the isolator with equipment lock for your isolation verification: if verification can be conducted without restoring power then verify as

normal if verification cannot be conducted without restoring power then to get verification for your isolation you must contact the other Isolation Leader and get the Isolating Person to initial the verification on your permit

I am Isolation Leader and Isolating Person for a group isolation when I find that

the isolator I wish to isolate is already locked (secured) and verified under an individual isolation?

How can I make sure that the isolation is effective? Securing: must resecure the isolator with equipment lock for your isolation verification: if verification can be conducted without restoring power then verify as

normal if verification cannot be conducted without restoring power then to get verification for

your isolation you must contact the other Isolation Leader and get Isolating Person to initial the verification on your permit

I am Isolation Leader and Isolating Person for a group isolation when I find that

the isolator I wish to isolate is turned off? How can I make sure that the isolation is effective?


normal if verification cannot be conducted without restoring power then you must contact the

supervisor for the area to assist in determining why the isolator is off and then carry out the verification step as per the isolation permit

At the end of a shift if the Isolation Leader role changes to another person. What are

the key steps involved? The off-going and on -coming Isolation Leaders shall meet at the central isolation board The on-coming Isolation Leader shall be made fully conversant with all aspects of the isolation The on-coming Isolation Leader receives custody of the group lock key from the off-going Isolation Leader The on-coming Isolation Leader shall change the name in the Isolation Leaders position on the isolation board

Attachment No. 9

QP 29.20/9 7/05/2014 Page 12 of 21

When taking over an isolation must I physically walk around and check that all of the

Isolators are secured and verified?

No, the isolation system requires that all Isolation Leaders are competent and as such trust is required to ensure the process works

After you have successfully completed the theory and practical training, what role/s

can you be expected to undertake?

Protected person, Isolating Person and Isolation Leader for Group Isolation. Departments will determine task specific or area specific isolation which can be done depending on training (ie. clarify for area/department). Not all Isolating Persons will become Isolation Leaders. It is the discretion of the Plant Owner.


Attachment No. 9

QP 29.20/9 7/05/2014 Page 13 of 21

SECTION 3 INDIVIDUAL ISOLATION The major components of individual isolation are

multilock device - must be used for all individual isolations, verification must be completed before the multilock device is fitted

equipment lock/s - to secure the isolators and must identify the Isolating Person (an identification tag is the most common method)

identification tag - identifying the Isolating Person

Note: multilock devices can be used for both Group and Individual isolations, if the equipment lock identifies the Isolating Person, then the isolation will be Individual. If the equipment lock identifies the Central Isolation Board, then the isolation will be Group The isolation procedure for Individual isolation is

the isolation will be planned by an Isolation Planner the Isolating Person will gain permission from the Plant Owner the Isolating Person shall place the isolator in the safe position the Isolating Person shall verify that the isolation is effective

If the verification is remote from the isolator then: the Isolating Person shall place the isolator in the safe position the Isolating Person shall secure the isolator with an equipment lock the Isolating Person shall verify that the isolation is effective the Isolating Person shall remove the equipment lock the Isolating Person shall place a multilock device/s on the isolator/s the Isolating Person shall secure the isolator/s (after verification) by locking the

multilock device/s onto the isolator/s with an equipment lock/s which identifies the Isolating Person

The restoration procedure for Individual isolation is

check machine or equipment for operational integrity (eg safety guards in place) removal of non-essential items ensure that all Personal locks have been removed from the multilock device/s check that all personnel are clear verify that controls are in “off” or “neutral” remove equipment lock/s place the isolator/s in the appropriate position notify the Plant Owner

Why is an identification tag used on an equipment lock for Individual isolation? To identify the Isolating Person What are the 4 pieces of equipment I need to perform an individual isolation and

protect myself? Identification tag with Isolating Person written on it, equipment lock, multilock device and a

personal lock

Attachment No. 9

QP 29.20/9 7/05/2014 Page 14 of 21

What does the term verification mean to you? ensuring that the isolation is effective eg no pressurised fluid from valve VIP 6004 or zero volts What would you do in the following scenarios:

I am Isolating Person for an isolation when I find that the isolator I wish to isolate is already locked (secured) and verified under another group isolation?

How can I make sure that the isolation is effective?



other Isolation Leader/ Isolating Person and assure yourself that the verification has been completed

I am Isolating Person for an isolation when I find that the isolator I wish to

isolate is already locked (secured) and verified under an individual isolation? How can I make sure that the isolation is effective? Securing: must secure the isolator with equipment lock for your isolation verification: if verification can be conducted without restoring power then verify as


other Isolation Leader/ Isolating Person and assure yourself that the verification has been completed

I am Isolating Person for an isolation when I find that the isolator I wish to

isolate is turned off? How can I make sure that the isolation is effective?

Securing: must secure the isolator with equipment lock for your isolation verification: if verification can be conducted without restoring power then verify as


supervisor for the area to assist in determining why the isolator is off

I need another Isolating Person to individually isolate for me (I am an Isolating Person but not trained in this specific isolation), who takes responsibility for the equipment lock key/s?

An Isolating Person who is trained in the specific isolation must take responsibility for the equipment lock key/s

What is the definition of a complex isolation?

more than two (2) energy sources or or more than three (3) Isolators An Isolation Permit to use a Central Isolation Board or isolation documentation for an Individual Isolation

Attachment No. 9

QP 29.20/9 7/05/2014 Page 15 of 21

After you have successfully completed the theory and practical training what role/s

can you be expected to undertake?

Protected person and Isolating Person for Individual Isolation. The Plant Owner will determine task specific or area specific isolation, which can be done depending on training (ie. clarify for area/department).

As an Isolating Person, what training or documentation do I need to perform an

individual isolation?

Individual isolations must be conducted with a plan/written procedure unless the Isolating Person is an Isolation Planner or the Isolating Person has had specific training in Individual isolation for that specific task or piece of equipment

A number of plant areas use a written procedure, which looks like a permit for

individual isolation. Do you need to complete the details on the procedure?

No, the written procedure is used to ensure that all Isolating Persons performing the isolation use the correct method of securing and verification for the task being performed

If the task you are about to do is expected to take more than one shift, should the isolation be individual or group?

The isolation should be group isolation, individual isolation is generally used for simple isolations with an expected duration of less than one shift

What is required if an individual isolation is required across a change of shift?

The name of the Isolating Person is changed on the equipment lock.


Attachment No. 9

QP 29.20/9 7/05/2014 Page 16 of 21

SECTION 4 ISOLATION PLANNING Who can plan an isolation permit?

Only Isolation Planners can plan an isolation (either individual or group)

How can I be an Isolation Planner when I do not know everything about the plant and the process?

The Isolation Planners responsibility is to ensure that if any uncertainty exists they utilise all available resources. This may require the Isolation Planner to use other Isolation Planners with specific expertise

When planning an isolation do you plan the isolation to cover specific equipment or task/s Isolations are planned for task/s as all isolation is for the protection of people.

What would you do in the following scenarios?

I am an Isolation Planner with electrical expertise and the task I wish to do requires isolation of electrical energy sources and a hydraulic system?

As an Isolation Planner for electrical tasks I am competent to plan this part of the isolation but I would utilise an Isolation Planner for mechanical tasks to assist me in planning the hydraulic component of the isolation

As an Isolation Planner for mechanical isolations I wish to repair an oil leak on the

equipment that production personnel have group isolated and are cleaning?

As an Isolation Planner I must first determine if the current isolation is adequate. If this is true then I must contact the Isolation Leader of the group isolation discussing my requirements, place the task on the “Task List”, initial the task on the “Task List” and then place my personal lock on the isolation board

Why do you need to physically check a permit when generating a new permit?

The Isolation Planner must physically walk through the permit checking all of the isolators to ensure

* the correct name of the equipment/isolator is recorded on the permit * the isolator is uniquely identified * the securing method is correct and all isolation equipment is available * the verification methods are correct What is the purpose of the “Task List”?

To identify all of the tasks being conducted under the specific isolation Who can add a task to a “Task List”?

An Isolation Planner is the only person who can add a task to a “Task List”

Attachment No. 9

QP 29.20/9 7/05/2014 Page 17 of 21

What must be done to add a task to the “Task List”?

An Isolation Planner must assess the task to be performed and determine if the specific isolation is adequate. Once satisfied, the Isolation Planner can add the task to the “Task List” and initial the change

When planning an isolation, does the bleed valve need to be locked?

Yes, the bleed valve is locked to ensure that no pressure builds up in the system. If the bleed valve were not locked then it may be possible for pressure to build up (in some situations where accumulators are utilised) and thus cause a hazard

How does the isolator name (as identified on the isolator) relate to the permit?

The isolator name (first column in all permits) must be the same as what is written on the isolator for the equipment

How do you determine the method of securing for an isolation?

The method of securing must prevent accidental or inadvertent operation of the isolator. Methods of securing range considerably from chain, cable ties, purpose built devices to “off the shelf isolation devices”

How do you determine the method of verification for an isolation?

The verification step ensures that a “test” (verification) is carried out to ensure that the energy source is controlled. The energy must be dissipated of restrained. The method of verification is dependant upon task being performed complexity of system

I know that there is some standard terminology for securing and verification. Where

can I find this information?

In the Rolling Mills Isolation Practices manual QI13.30P for example, includes a number of examples of energy type, securing and verification terminology

Who can assess an Isolation Planner as competent?

Only the Responsible Manager or deputy. The Responsible Manager’s deputy is an “Authorised Person”

To perform a group isolation where no permit exists what are the key steps in Planning the isolation?

1. conduct a hazard analysis to determine the isolation requirements 2. identify the relevant isolators 3. identify the method to isolate all necessary energy sources 4. identify the method of locking the isolators 5. identify the method of verification 6. complete an isolation permit, including “Equipment list” and “Task list” 7. walk through the permit and physically check all information 8. when satisfied that the permit is correct sign off the “Prepared by” area 9. get an authorised person to sign off the “Authorised by” area

Attachment No. 9

QP 29.20/9 7/05/2014 Page 18 of 21

SECTION 5 SETTING UP SATELLITE BOARDS

There are three scenarios that indicate that a satellite board may be necessary: Too many Red Personal Locks for the Board If there are too many red personal locks for the isolation board a satellite board is set up to accommodate the extra personal locks. Convenience for Isolating Personnel There may be a long distance between the equipment being repaired and the main energy source. Satellite boards allow personnel who are working on plant equipment to place their personal red locks on a board that is conveniently close to the equipment they are repairing. Flexibility of Shutdown Planning

A satellite board may be set up to allow flexibility for shutdown planning. The plant may need to be sequentially deactivated or alternatively restored to service. The isolation permits and the equipment locked lists for the boards may share the same plant or different plant equipment. Who can set up a satellite isolation board?

If a permit exists, then an Isolation Leader can set up the satellite board If a permit does not exist, then the permit must be created by an Isolation Planner and then an Isolation Leader can set up the satellite board

What are the key steps involved in setting up a satellite board?

1. Isolation Planner to provide the Isolation Leader with the correct permit for the task 2. Isolation leader to place equipment lock/s onto central isolation board/boards required for

isolation (according to the permit). Verification of isolation is to ensure central isolation board is activated by checking that the group lock is correctly locked onto the board and correct documentation is present

3. All equipment lock keys to be placed in the satellite central isolation board 4. Isolation leader to activate satellite board by placing permit, equipment list and task list on

the board and securing the equipment key/s with the group lock. 5. Then and only then shall individuals lock the satellite central isolation board with their

personal locks.

EXAMPLE : If the task requires the equipment on boards RM101 and RM307 to be isolated, equipment locks are placed onto both RM101 and RM307. Satellite board POR-17 is activated and Personal locks are placed onto POR-17

Attachment No. 9

QP 29.20/9 7/05/2014 Page 19 of 21

CENTRAL ISOLATION BOARD EQUIPMENT ISOLATED

ISOLATION PERMIT

ISOLATION LEADER


ISOLATION PERMIT

ISOLATION LEADER


ISOLATION PERMIT

ISOLATION LEADER

SATELLITE CENTRAL ISOLATION BOARD POR-17

CENTRAL ISOLATION BOARD RM101

CENTRAL ISOLATION BOARD RM307

EQUIPMENT LOCK EQUIPMENT LOCK


Attachment No. 9

QP 29.20/9 7/05/2014 Page 20 of 21

SECTION 6

Scenario 1: The removal of isolation points from a group isolation board permit.

‘Person A’ performs the isolation as indicated on the group isolation board permit. Later, all work covered by one or more of the isolation points listed on the group isolation board permit is completed.

‘Person B’ is asked to de-lock that single isolation point, so that testing can begin on the associated equipment and to reactivate the group isolation board with the remaining isolation points.

What do you do?

Answer:

1. First assess if the integrity of the isolation is in tact by obtaining approval from the authorised planner and the isolating person. If a new permit is not required then the old permit may be used.

2. Protect people leaving the isolation area ensuring that the plant is left in a safe condition and remove their personal red locks from the group isolation board.

3. Remove the green group lock, the yellow equipment lock keys and the isolation permit from the board.

4. If the integrity of the isolation is in tact then accept that the isolation has been performed correctly because the previous isolation person and leader signed it off. Cross off that which is no longer applicable and initial the permit, the equipment locked out list and the restoration list.

5. Re-activate the board. Put a comment in the notes section that part of the original isolation has been removed and the reason it was removed.

What do you do if you decide a new permit is required?

Answer:

If a new permit is required and the isolation points are taken off the permit. What is required by ‘Person B’ to re-activate the group isolation board?

1. First assess if the integrity of the isolation is in tact by obtaining approval from the authorised planner and the isolating person.

2. Protected people leave the isolated area ensuring that the plant is left in a safe condition and remove their personal red lock from the group isolation board.


4. It is recommended that person B walks around to check each isolation point listed on the permit is correctly isolated as per the permit.

5. Sign both the verified and locked boxes. Remember that person B is signing a new permit and indicting that they are responsible for the integrity of the isolation.

6. Re-activate the board. Keep the old permit to prove that the verification process has been completed previously. Put a comment in the notes section to indicate that part of the original isolation has been removed and the reason it was removed.

You are not required to de-lock each isolation point, re-verify and re-lock each isolation point, however you should do so if you doubt the integrity of the original isolation. e.g. there has been an isolation breach in which equipment was not verified or locked correctly.

If person A is the same person signing the new permit then a walk around to check that the equipment isolated is in the correct position is not necessary.

Attachment No. 9

QP 29.20/9 7/05/2014 Page 21 of 21

Scenario 2: Movement of equipment listed on a group isolation board permit

‘Person A’ isolates as indicated on the group isolation board permit but ‘Person B’ is to move a piece of equipment that was previously isolated. The piece of equipment is to be moved as part of the work that is required.

Question? What do we do?

Answer:

1. The authorised planner and the isolating person should have given their prior approval. If it hasn’t been, approval must be obtained to ensure that the integrity of the isolation is still in tact.

2. Protected people leave the isolated area ensuring that the plant is left in a safe condition and remove their personal red lock from the group isolation board.


4. ‘Person B’ then removes the lock from the isolation point for that piece of equipment and then moves the equipment into the new position and then verifies and relocks as per the isolation permit.

5. Sign off on the same permit in the isolated and verified boxes and date the signature to indicate that it has been relocked and reverified.

6. Re-activate the board. Put a comment in the notes section to indicate that part of the original isolation has been removed and the reason it was removed.

Printing a new permit is not required; de-locking each isolation point and then reverifying and relocking is not required. Checking that the existing isolation points listed on the permit are in the correct position is also not required.

If a new permit is required, then keep the old permit to prove that the verification process has been completed previously. If eth authorised person is the same person who performed the original isolation and the integrity of the isolation has been established, then there is not need to de-lock verify and relock the isolation points.

If a new isolating person makes a new permit it is recommended that a walk around be performed to check that each isolation point listed on the permit is correctly isolated.

You are not required to de-lock each isolation point, re-verify and re-lock each isolation point, however you should do so if you doubt the integrity of the original isolation. e.g. there has been an isolation breach in which equipment was not verified or locked correctly.

Attachment No. 10

QP 29.20/10 3/12/2010 Page 1 of 1

Loss of Keys Personal Locks Destroy lock and replace. Equipment Locks Option 1 Destroy lock(s) and replace. Option 2 If a secured replacement key is available. Remove lock(s) from service and either; a) Quarantine locks for a period of no less than six months or until lost key is found. b) Exchange locks with another department, which is geographically separated from the original department. Group Locks Destroy lock and replace.

Attachment No. 11

QP 29.20/11 3/12/2010 Page 1of 1

RE: Isolation of Vehicle Ignition Switches

A safe system of work or isolation procedure must be implemented to isolate the vehicle ignition switch or key of any heavy vehicle that requires maintenance work in the Steelworks. This requirement excludes light vehicles such as cars and Ute. Here are some options to consider. Battery Isolation (Preferred Method) Option 1– Lockout Isolation of vehicle or equipment using Battery Isolation The isolation of equipment by battery isolation enables work to be undertaken on vehicles in a safe manner. The battery isolator is a manually operated key device that breaks the power supply from the batteries to the machines electrics. (Best Practice)

1. Turn battery isolator switch to the OFF position. 2. Remove key from the battery isolator and attach a yellow lock through the

isolator. 3. Verify the isolation by attempting to start machine.

Note: If machine is broken down, an appropriate testing device (eg multimeter) may be used to ensure contact between terminal of battery isolator and the machines electrical circuit has been broken.

4. Isolation confirmed. Remove yellow lock and attach multi-lock device, then attach “Identification Tag” and yellow lock to multi-lock device.

5. Equipment is now safe to attach personal lock(s). Option 2 - Securing Box

1) Vehicle ignition keys can be locked inside a securing box with a multilock, a yellow equipment lock and a red personal lock(s) attached.

2) These are put onto the drivers seat or attached to the vehicles steering wheel. Option 3 – Cover, Over Ignition Switch

1) Place a cover over the ignition switch (usually hinged) with a multilock, a yellow equipment lock and red personal lock(s) attached to isolate the vehicle.

2) The vehicle ignition key is kept in the driver’s pocket during the isolation. Option 4 – Safe System of Work

A safe system of work can be used to ensure that the vehicle ignition switch or key is unable to be accessed while work is occurring on the vehicle.

New Heavy Vehicles Any new heavy vehicles brought onto the plant must have a battery isolator.

Attachment No. 12

QP 29.20/12 27/11/2007 Page 1of 1

Board No.

Isolation Permit No.:

Restoration Check List

Item Name Identifier Location Restored Status

1

2

3

4

5

6

7

8

9

10

Attachment No. 13

QP 29.20/13 3/12/2010 Page 1of 1

INTERMITTENT OPERATION FORM

LOCKOUT BOARD: Permit Number: ______________________

NAME OF ISOLATOR IDENTIFIER

De - Locked Locked

Date Time Name Time Isolated / Init Verified / Init

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