2017 - Handout - Equipment Preparer - ENG - 07 - N°01

EQUIPMENT PREPARER
Ref : HS - 601 Permit To Work System & Risk Management System
2015_Handout_Equipment Preparer_ENG _07_n°01 1

EQUIPMENT PREPARER
Duration : 4 H EP,PC
Procedure available in P drive Switch off your mobile phone
Pass rate : 85% Appreciation sheet

Prerequisites
1. Plant Site Safety Induction (PSSI)
2. Permit Users
3. JSEA
4. Equipment Preparer
Warning
This document is a teaching tool to facilitate learning.

It is not a substitute for the validated procedure « Permit To Work
System ».
Compliance to the Permit to Work (PTW) applies to :

all employees,
contractors
and visitors to Ambatovy Sites .

Problematic
What might happen if…

Problematic
Best practices…

What’s this training for ?
To ensure all employees, planning or conducting any tasks are protected by:
 the identification of the hazards involved,
 by putting a safe work system in place to eliminate or control the risks associated
with the work scope.
To provide you, as an Equipment Preparer (EP) working under SWP, with the standards
that will enable you to perform isolation in a safe manner.

Objectives
At the end of this module and all related activities, each participant
will be able to :
 Explain how to control all hazardous energy that may affect a
work scope
 Describe the Equipment Preparer’s responsibilities while
working under a Safe Work Permit.
 Take part in the process of continuous improvement concerning
the Permit To Work.

Outline
I. Introduction to Isolation
II. Shared and specific Responsibilities
III. Isolation Procedure
IV. Particular cases

Field validation
Only Equipment Preparers are authorized to perform the different types

of Isolation.
They are required to have knowledge of the isolation requirements for
specific plants, equipment and systems and must therefore demonstrate
competency under direct supervision until deemed competent.
To become competent as an Equipment Preparer, you must

successfully complete:
the training final test (85% pass rate)
and the field validation of competency.
2015_Handout_Equipment Preparer_ENG _07_n°01

10
I
INTRODUCTION
TO ISOLATION

Introduction to isolation
Isolation is a physical removal of energy sources and substances, which

are potentially hazardous to any person performing work on the equipment
or being in the vicinity of the work performed.
Isolation is to ensure that all potentially hazardous energy sources

affecting an item of equipment are :
 removed
 or effectively contained
Isolation allows a safe access for any person performing work on the
equipment or being in the vicinity of work performed.

Introduction to isolation
Isolation is critical for any equipment representing hazardous energy sources that may
affect a work scope as well as the workers, such as:
 Equipment requiring electrical isolation
 Equipment requiring mechanical Isolation : inhibition of movement between equipment

parts in the work area (Rotating equipment, conveyor…)
 Process Isolation: isolation of various process substances (solids, liquids and gases) to
allow intrusive work.
 Nuclear Source Isolation
 Isolation of Fire and Emergency Protection System.

Introduction to Isolation
Only Equipment Preparers shall perform different types of Isolation.
 Only electrician can lock electric devices.
 Nuclear sources isolation are performed by competent and certified

Instrument Technicians (PCR) trained in nuclear safety.
 The FPS responsible (Fire Protection System) perform any protective

safety system isolation, with prior authorization of the area
Superintendent.

Documents
JSEA
Take 5
Certificates
Isolation List Testing and

PTW 2015_Handout_Equipment Preparer_ENG _07_n°01
Jogging form 15
II
Shared and Specific
Responsibilities

Actors involved
If a scope of work is subjects to SWP and shall be held by Maintenance team in
Operation area:
Operation Maintenance
Management Management
Operation Maintenance
Superintendent Superintendent
Area Permit Coordinator Equipment Permit

Supervisor Acceptor
Preparer
Permit
2015_Handout_Equipment Preparer_ENG _07_n°01 Users 17
PC : Permit Coordinator PA :Permit Acceptor EP : Equipment Preparer PU : Permit User
Shared and specific responsibilities

Participate in the development
of non-standard ISL
Review JSEA / Scope of NO
SWP Perform the Standard isolation list
work /risk controls /
required JSEA, request available?
isolation required
SWP YES
Attach certificates, ISL and
JSEA
Return the isolation key and Sign off the Confirm the Conduct /witness Conduct Take 5,
Zero Energy Lock / tag isoation points Isolate the equipment
documents to the PC ISL the Zero
Test EnergyTest
Verify risk controls and Secure isolation key, associated Secure the red lock key inside
Issue the
documents/fills - up the documents in the Main lock-box with a the remote lock box with an
Permit
Permit red lock orange lock
Bring back the remote Confirm the Zero Bring the remote lock
Sign-off the Start and work
lock box to the permit Energy Test, Sign- on box and the white copy
SWP completed
office the SWP of the permit at the
worksite
Authorize the Leave the Sign-off the ISL

De-isolate the Signs-off and closes
de-isolation and sign off worksite clean and the SWP
equipment the SW.
the isolation list and safe

Remote location work

The approval of the area Permit Coordinator is required to define an activity as
remote location work.
It must be stated in the JSEA and signed by the area superintendent or shift
Coordinator .
At the work place
Zero Energy
Test
Isolation
List
Isolation
List Equipment isolation
PA witnesses the Zero Energy
Test
Permit Office

Remote location work (next )

At the worksite
Zero Energy
Test
PT
Take
5
PA and PC sign-on the SWP

PA and PC attache padlocks on the
remote lock-box Perfom the start steps
EP put the isolation key in the  work starts
lock-box
Isolation
List
PT PT
Work completed Permit Office

PC authorizes and signs for de-isolation
 Perform end of work
steps Equipment de-isolation
Permit coordinator returnes to the
permit office
III
ISOLATION PROCEDURE :
1. Documentation
2. Equipment
3. Isolation standard
4. Equipment Preparation
Isolation documentations
Whenever Isolation is required, an Equipment preparer will refer to the

following documents:
ISOLATION LIST P&ID ISOLATION MATRIX

The standard isolation list
The list must :

 Be based on a risk assessment and industry best practices.
 Be developed under the authority of a Process Engineer/or Area Superintendent.
 Approved by the Area Superintendent.
 Identified any connections to the Distributed Control System. (DCS)
 Have a method of proving the effectiveness of the isolation through a Zero Energy
Test
Each area is responsible to:

 Develop a standard isolation list with a marked up P&ID.
 Conduct and maintain update inventory of standard isolation listt .
The standrd isolation lists are controled in Document Management System(DMS).

Isolation documentation
Non standard isolation list
The non standard isolation list is used if a standard isolation list is not available for the i
required isolation of the scope of work.
The list will be :
 Accompanied by a marked up P&ID
 Reviewed and verified by a Supervisor, other than the person who created it, to
ensure the isolation plan is adequate for the scope of work before being used to
conduct an Isolation.
 Reviewed on the completion of work for inclusion into the Standard Isolation list
register
when creating a non standard isolation list :

 never design a Non Standard Isolation List using a P&ID only,
 never assume that P&IDs are 100% correct,

P&ID :
It is a schematic drawing representing a process area of the plant.
A marked up P&ID must :

be reviewed and verified by a Supervisor
Accompanied by an Isolation List
N.B : Objects such as tanks, pumps, valves, piping and instruments are shown as
symbols to depict the process.
They are a tool used to identify:

 items of plant,
 process flows,
 origin of process flows,
 destination of process flows,
 vessel content,
 equipment type, etc.

In all cases an Isolation List:
is issued by the Permit Coordinator,

is used by Equipment Preparers while performing isolations,
must not be altered without the written authorisation of the Area
Superintendent,
must return completed to the Permit Coordinator so that it becomes
part of the PTW documentation.

Isolation equipment
Isolation locks
This red lock will have multiple identical locks, unique key, a
dedicated number( the same as the one of the key), and a
reference number.
It is used to ensure isolations are not removed until all jobs associated isolation
have been completed.
Yellow/Electrical lock
Yellow lock is used for electrical isolations in addition to the red

lock. The electrical lock will have multiple identical locks, unique
key, a dedicated number ( the same as the one of the key), a
reference/letter number.
Only electrician can lock electric devices.

Isolation equipment
• This tag must be attached to all isolation point locks

• It must be completed by the Equipment preparer
• Properly fixed to the isolation points
• Properly documented in the isolation list
The tag must clearly indicate :

 The installation date
 the name of the Equipment Preparer who installed the
lock
 The lock reference
 The safe work permit number.

Isolation equipment
Blue Blind Tag
It marks the exact location where the mechanical
isolation will be installed: flange, blind, spool removal
It must be completed by the Operation personnel

Securely fixed and documented on the isolation list.
The number of the blue blind tag must refer to the Permit to Work number and the
isolation point number on the list.
Blue Blind Location Tag does not allow employees to install the blind, blank flange or
remove the spool without the SWP signed on and effective.

Isolation equipment
Blind installed tag
Clearly marks the location of the mechanical isolation:

flange, blind, spool removal.
The Permit User(Equipment Preparer), working under a SWP to complete the

isolation, will: install the isolation with an attached red blind tags in the designated
locations, ensure that red blind tags are properly marked, securely fixed, and
documented in the blinding isolation list.
The red circle Tag must be identified with the same number as the corresponding Blind
Location Tag.
The blind installed Tag does not replace Isolation Tags.

Isolation standards - Requirements.
• All isolation points must be locked and tagged, according to the Permit to
Work procedure , and referring to the isolation list.
• Removal of spools or swinging of blanks or blinds to create an isolation

system must be done under a separate Work Permit
• All Isolation on Emergency Protection systems (fire and gas detectors,

emergency shutdown systems, safety shower system …) must be only
carried out with the prior authorization of the Area Superintendent.

Isolation standards - Requirements
There are three Isolation types or standards , which are outlined in the procedure and
must be respected on the implementation of the equipment preparation.
Isolation types :
Type 1: Positive Isolation
 Physical disconnection, and/or spool removal and fitting of blank flanges.
 Insertion of spades or spectacle blind

Type 2 : Double Block and Bleed

 Closed block valves with an open drain valve between them.
 Block valve and a blind with bleed valve between them
2015_Handout_Equipment Preparer_ENG
33
_07_n°01
Type 3 : Single Block and Bleed
 A closed block valve or device that will be confirmed as positively closed when the system
has a draining point downstream of the blocking point
34
_07_n°01
The isolation standard requires the use of isolation matrix before proceeding to any
isolation, to properly identify the equipment to be isolated, and for any high risk work
requirement and the isolation types:

If isolation standard cannot be met due to equipment or design restraints, a formal QRA
should be conducted.
The following types of valves can not be used for isolation purposes:
• Check valves
• Control valves
• Pressure Safety valves (PSV’s)
• Globe valves which are normally used as a control valve
• Push button, stop switches, interlocks, emergency stops and/or control systems
shall not be used as a mean of isolation.

Equipment Preparation
The Permit Coordinator initiates and confirms equipment preparation with:
the Area Supervisor
and/or the Maintenance Coordinator as identified in the PTW documents.
The Equipment Preparer implements hazard controls during equipment preparation under the direction of
the Area Supervisor, in compliance with:
standard operating procedures (SOP)
and Isolation List requirements.
Permit Equipment
Coordinator Preparer
Must provide an Isolation List Perform Isolation

Isolation required to the Equipment Preparer Process
+ any other isolation related

documents
+ Isolation hardware
SOP
Isolation procedure
• Identify
1
• Remove or contain
2
• Lock and Tag

3
• Sign off 1- Witness

4
• Prove
5
6 • Perform Zero Energy test
• Sign off 2 - Confirming

7
• Sign off 3 - Witness

8

Isolation procedure: 1. Identify
The Permit/Master Permit Id number must be

referenced on the Isolation List
The Lockbox Id number must be recorded on the

Isolation List
Equipment Preparers must have a clear understanding of the

intended scope of work
.Identify the correct :

 equipment to isolate,
 isolation points,
 way to isolate them.

P&ID No. / No. P&ID
A marked up P&ID is used as a reference for an Isolation List.
Comments or Special Conditions / OperationSupervisor /

Commentaires ou conditions spéciales Superviseur Opération
Any additional instructions related to the scope of work

to be performed will be:
specified in this section
and approved by an Operation Supervisor
2. Remove or contain
What does Isolation involve ?
Isolation of energy sources will involve :
 physical disconnection of electrical supply,
 closure of valves,
 draining,
 flushing,
 venting,
 purging of lines,
 installation of blanks/spades
 removal of spool pieces, etc.
Removal of spools or swinging of blanks or blinds to create an isolation system

requires a work permit separate to the SWP being isolated for.

2. Remove or contain
Supervisors or authorised persons are responsible to train Equipment

Preparers to be competent to :
 isolate,
 Perform isolations in plants, equipment or systems for which they have
been trained,
 Notify the Operations Superintendent when authorizations are
required.
The Equipment Preparers will report any known restrictions related to

isolations to their Supervisor.

3. Lock & Tag
Tag n° must be reported on the

relevant Isolation Tag
The lock ID to be attached on each isolation point must be reported on the

Isolation List
An Isolation Tag must be attached

to each single isolation point lock.
3. Lock and Tag
Red locks/Isolation lock Yellow locks/Electrical

lock Blind location and installation tag
For a mechanical isolation
(flanges, blinds, spool removal)
The Equipment Preparer must take control of the isolation

Identifies all kyes untill the Permit Coordinator secures them inside the
isolation point locks main lock – box.
_07_n°01 45
4. Sign off 1-Witness
For each isolation point that has been locked and tagged :
An Equipment Preparer will sign off the Isolation list
A second competent Equipment Preparer will verify each isolation
performed and then sign off the Isolation list

Sample of Completed and signed isolation list

5. Prove Isolation
Equipment Perform Attach lock and tag on Sign off the

Preparer Prove Isolation
Isolation isolation point isolation list
Proving process isolation involves :

 ensuring drain valves are clear to allow piping and equipment to empty of materials,
 gas testing in some process piping to ensure residual gases have been purged,
 checking :
 relief valves,
 pressure indicators (pressure gauge),
 level indicators on tanks and vessels,
 tank levels with a ‘dip stick’ to provide visual confirmation of zero level and that all
potential energy sources have been removed

6. . Perform Zero Energy Test
Equipment Attach lock Sign off Prove

Perform Perform Zero
Preparer and tag on the Isolation
Isolation Energy Test
isolation point Isolation list
The intent is to prove that the equipment is safe for the scope of work by verifying each
isolation point efficiency, or for certain case by doing a lot of checks to warranty that the
entire systems are de-energized, and/or drained or depressurized.
It’s a mean of ensuring the effective control of energy sources following equipment
preparation and throughout the activities.
The Zero Energy Test is completed once equipment isolations are

in place.
_07_n°01 49
7. Sign off 2- Confirmation
Zero Energy Test Performed by Equipment Preparer

Test de zéro énergie effectué par Chargé de consignation
Printname and sign / Nom et Signature Printname and sign / Nom et Signature
ZeroEnergy Test Confirmed by Witness

Test de zero énergie effectué par Témoin
Upon completion of the Zero Energy Test,the Equipment Preparer and his
witness mut sign off the isolation list.
_07_n°01 50
8. Sign off 3 - Witness
Zero Energy Test Performed by Equipment Preparer
Test de zéro énergie effectué par Chargé de consignation
ZeroEnergy Test Confirmed by Witness

Test de zero énergie effectué par Témoin
Upon full completion of isolation, an Equipment Preparer will:

 sign off this section together with the 2nd Competent Equipment Preparer, as a
witness of isolation and Zero Energy Test being performed,
 return all isolation related documents to the Permit Coordinator
 return isolation key(s) to the Permit Coordinator.
The Permit Coordinator shall ensure that the isolations conducted have
been witnessed .
Transfer of controls
An Isolation list must not be returned to the When all documents and key(s) are returned to
Permit Coordinator until it is signed off as
the Permit Coordinator:
confirmation that all associated equipment
and piping is properly:  He will confirm that the isolation list
(including Zero Energy Test) have been filled -
identified, up and signed off by the responsible person,
isolated,  The permit Acceptor ensures that the Zero
de-energised, Energy Test has been done.

 The Permit Users confirm that the Zero
depressurized,
Energy Test has been performed to ensure
locked-out,
that the energy sources withing the equipment
tagged and/or marked as necessary,
have been removed.
zero energy tested.
_07_n°01 52
De-isolation Procedure
• Obtain a signed authorization

1
• Proceed to de-isolation
2
• Sign-off the isolation list

3
• Conduct housekeeping
4
• Sign-off the SWP

5

1. Obtain a signed authorization
Permit Equipment
Coordinator Preparer
De-isolation Signs the Proceed to Sign-off the Sign-off

authorization isolation list de-isolation isolation list the SWP
Authorisation to De-isolate - Permit Coordinator

Autorisation de déverrouiller - Coordonateur de Permis
Printname and sign / Nom et Signature
De-isolated By
Déverrouillé par
The de-isolation requires the prior approval of the Permit Coordinator

and conducted following to the Supervisor requirement.

2 and 3. De-isolate and sign-off
All Equipment Preparer whose condut the de-isolation must sign-off the
isolation list.

2 and 3. De-isolate and sign-off (next)
Authorisation to De-isolate - Permit Coordinator

Autorisation de déverrouiller - Coordonateur de Permis
De-isolated By
Déverrouillé par
Once de-isolation completed,the Equipment Preparer will sign off the

isolation list.

4 and 5. Conduct housekeeping and sign-off
Equipment Permit
preparer Coordinator
Leave the Signs off Equipment

Isolation list Sign-off
worksite clean and closes released to
sign-off the SWP
and safe the SWP operation

IV
Particular Cases

Right to refuse to perform unsafe work
If, on reasonable grounds, the employee believes that there is an imminent danger
to his health and safety or to the health and safety of another employee, he
has the right to refuse to perform such an unsafe work.
However, the employee must notify immediately his Supervisor.

Isolation change
Isolation to SWP Remove padlocks from Authorize the isolation

be altered suspended Permit User the remote lock-box change
Area Superintendent
/Operation
Supervisor
Draw a single line to the Sign and date the

Add the new isolation Sign and date
altered or removed isolation on removed or altered
Area to the isolation list the new isolation
the isolation list isolation
Supervisor
Perform the changed Conduct Zero SWP

Equipment isolation/de-isolation Energy Test revalidated
Preparer

Works on protective systems
The Area Superintendent and the Emergency Response Team are required to co-sign the Safety
Equipment or System inhibit certificate (HS-6016).
A certificate is required for all activities that require the disabling of a Protective Safety System
including the following:
1. Emergency Shutdown Down and interlocked systems

2. Area and plant alarm warning systems
3. Gas detection systems
4. Safety showers and eyewash stations
5. Fire suppression deluge, sprinkler, CO2, dry chemical systems
6. Fire pumps, water supply and distribution systems
7. Fire Detection Systems (i.e. smoke, heat UV and IR)
The Area Superintendent must provide written notice to affected site personnel when a
Protective Safety System is taken offline, and when it is returned to service; notably for
points 3, 5, 6 and 7 above.
ERT will maintain a register of all those systems being disabled. In addition, all
impairments beyond the one shift period will be communicated by the Incident
commander to the Insurance Company. (cf. procedure HS 610 « Fire Hydrant System
Use »)
Testing and jogging procedure
All persons
Fills out the

Remove padlocks from Brings back the remote Takes the isolation key and Secures the Main lock-box
the remote lock box and lock box to the permit with orange lock and appropriate section
places a testing tag in the
sing-off the white SWP office testing tag of the testing and
Main lock-box
jogging form
Turn the local Start/Stop

Gives the testing /jogging form, isolation Gives authority to de-isolate the Brings back the
station into manual
document and isolation key, testing tag to concerned isolation points to the remote lock box the
position and/or stop
the Equipment Preparer appointed Equipment Preparer work site
button to off position
Initial beside each

Identify the points to be Place a testing tag
Place a testing tag onto all Re-energize the re-energized isolation
re-energized and proceed onto all re-energized
local start /Stop station designated point point in the
to de-isolation points
testing/jogging form
62
2015_Handout_Equipment Preparer_ENG _07_n°01
Testing and jogging procedure (next)
Secure the isolation Remove blue padlocks and testing

- Attach blue padlocks and tag,
key(s),ISL,testing/jogging form Proceed and tag from the remote lock box and
testing tag to the remote lock box
inside the remote lock box with a complete the test sign-off the white SWP
And sign-on the white SWP.
blue lock and tag and testing tag
Testing
team
Initial the re-isolated points

Identify the points to
Remove blue padlocks and Re-isolate and tag each on the testing and jogging
be re-isolated Remove the testing
testing tag from the remote isolation point as per the form
following the testing tags
lock box original isolation list Signal the final status of
and jogging form
isolated points
Perform the Zero Return the isolation

Energy Test and sign Brings back the Removes the orange Prepares the Main and
list,testing and jogging lock and testing tag from
off the testing and remote lock box to remote lock box for the
form and the isolation the Main lock-box
jogging form the permit office continuation of the work
key(s) to the permit office

Testing and jogging procedure (next)
At the end of the Testing/Jogging process, ALL isolations must be returned to the
original isolated position, in accordance with the isolation list, with isolation Tags and
Locks
If an electrician is required for re-isolating an electrical equipment, it has to be done

under the presence of an Equipment Preparer.
Where there is a requirement for an electrical motor to be direction tested only, the key
may be kept with the equipment preparer for the Testing or Jogging process. Following
the direction test the electrical isolation shall be secured in the isolated state .

Keep in mind that…
… not complying with rules and regulations may
lead you to…

Safety is my
business !

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EQUIPMENT PREPARER

Ref : HS - 601 Permit To Work System & Risk Management System

2015_Handout_Equipment Preparer_ENG _07_n°01 1

Procedure available in P drive Switch off your mobile phone

Pass rate : 85% Appreciation sheet

2015_Handout_Equipment Preparer_ENG _07_n°01 2

1. Plant Site Safety Induction (PSSI)

This document is a teaching tool to facilitate learning.

Compliance to the Permit to Work (PTW) applies to :

2015_Handout_Equipment Preparer_ENG _07_n°01 4

2015_Handout_Equipment Preparer_ENG _07_n°01 5

2015_Handout_Equipment Preparer_ENG _07_n°01 6

2015_Handout_Equipment Preparer_ENG _07_n°01 7

2015_Handout_Equipment Preparer_ENG _07_n°01 8

2015_Handout_Equipment Preparer_ENG _07_n°01 9

Only Equipment Preparers are authorized to perform the different types

To become competent as an Equipment Preparer, you must

2015_Handout_Equipment Preparer_ENG _07_n°01

2015_Handout_Equipment Preparer_ENG _07_n°01 11

Isolation is a physical removal of energy sources and substances, which

Isolation is to ensure that all potentially hazardous energy sources

2015_Handout_Equipment Preparer_ENG _07_n°01 12

 Equipment requiring electrical isolation

 Equipment requiring mechanical Isolation : inhibition of movement between equipment

 Nuclear Source Isolation

 Isolation of Fire and Emergency Protection System.

2015_Handout_Equipment Preparer_ENG _07_n°01 13

Only Equipment Preparers shall perform different types of Isolation.

 Only electrician can lock electric devices.

 Nuclear sources isolation are performed by competent and certified

 The FPS responsible (Fire Protection System) perform any protective

2015_Handout_Equipment Preparer_ENG _07_n°01 14

Isolation List Testing and

2015_Handout_Equipment Preparer_ENG _07_n°01 16

Area Permit Coordinator Equipment Permit

Shared and specific responsibilities

Authorize the Leave the Sign-off the ISL

2015_Handout_Equipment Preparer_ENG _07_n°01 18

Remote location work

At the work place

2015_Handout_Equipment Preparer_ENG _07_n°01 19

Remote location work (next )

PA and PC sign-on the SWP

Work completed Permit Office

Whenever Isolation is required, an Equipment preparer will refer to the

ISOLATION LIST P&ID ISOLATION MATRIX

2015_Handout_Equipment Preparer_ENG _07_n°01 22

The standard isolation list

The list must :

Each area is responsible to:

The standrd isolation lists are controled in Document Management System(DMS).

2015_Handout_Equipment Preparer_ENG _07_n°01 23

when creating a non standard isolation list :

2015_Handout_Equipment Preparer_ENG _07_n°01 24

A marked up P&ID must :

They are a tool used to identify:

2015_Handout_Equipment Preparer_ENG _07_n°01 25

In all cases an Isolation List:

is issued by the Permit Coordinator,

2015_Handout_Equipment Preparer_ENG _07_n°01 26

Yellow lock is used for electrical isolations in addition to the red

Only electrician can lock electric devices.