Objectives

TO REVIEW THE KEY FEATURES OF THE

ENERGY LOTO SYSTEM, SO THAT ALL
STAFF USING THE SYSTEM:
UNDERSTAND THE SYSTEM
REQUIREMENTS,KNOW THEIR
RESPONSIBILITY AND
CONSEQUENTLY ARE BETTER ABLE TO
SAFELY IMPLEMENT THE SYSTEM
 Course Outline
To achieve the Objectives we will cover the
following:
• Understanding what is ENERGY
ISOLATION?
• LOTO Tools: Group Locks, Lockout Boxes,
Department Locks, Tags and Certificates
• Typical Infractions & how to improve.
• Testing your knowledge.

LOTO Refresher Training is a ½ day program so

we target to complete by 1PM.
There will be a short break at 10:30
DON’T START YOUR DAY
LIKE THIS !

AND THINK!
What is ENERGY ????
WikipediA defines energy as: The ability to do work
What forms of energy can you think of that allow work to
be performed or becomes a HAZARD if released?

Electrical – transmissions lines, transformers, circuit

breakers, motors, lighting, impressed current of cathodic
protection
Hydraulic – liquid under pressure e.g. pumps, hydro
testing, hydraulic system
Pneumatic – air/gas systems under pressure, e.g. plant
air, hydrocarbon gas, gas cylinder
Types of ENERGY
Chemical – flammable, toxic, corrosive, reactive e.g.
acid & caustic (corrosive), hydrocarbons (flammable), H2S
(toxic), hydrogen peroxide & pyrophoric material (reactive)
Thermal – extreme temperature e.g. hot surface,
cryogenic materials, steam
Kinetic – moving objects e.g. fan blades, fan belts,
agitators, flywheels
Stored or potential – springs, counter weights, raised
loads
Radiation – ionizing source e.g. in level gauges,
radiography machine.
Release of ENERGY
What are the consequences when some of these
forms of energy are not controlled properly and
accidently released???
Injury to PEOPLE!
HSE BULLETIN

Issued: 05/09/2007 / 2007-010

Unforeseen Hazard

F a t a lit y

This incident demonstrates what can happen to anyone entering an unsafe environment that is
not under control. The following description is what is believed to have taken place, as no formal
investigation report has been released.

At a workshop in Nongbon area, in the province of

Rayong, Thailand, a furnace module to be sent to Nigeria
was being fabricated. On 5th August 2007, the company
conducted a pneumatic coil test at approximately 100
Bar. At the same time, an employee from an unrelated
project walked past the pressure-test area when the
Testing Flange blew off and struck the employee in the
head. The blow was so violent that the man was instantly
killed.

The area around the pressure test had not been identified in
any way: there were no barricades, no warning signs, no
standby person keeping watch to warn passers-by, also, there
had been no general warning of any testing taking place.

Consequently, the employee who walked past the testing area

was completely unaware of what was happening!

The message to everyone is to remain alert

at all times and anticipate any potentially
hazardous circumstances around you. This is
particularly important when you are in and
around a workshop, or construction site,
where pressure testing could be taking place.

Authorised for Issue by:

HSE Manager &Safety Committee (Melbourne)
Just imagine if this was your friend?
Shedden Uhde Pty Ltd
Release of ENERGY
What are the consequences when some of these
forms of energy are not controlled properly and
accidently released???
Damage to Equipment!

Imagine the forces involved in this over

pressure incident when V 603 Blew it’s Top
Release of ENERGY
What are the consequences when some of these
forms of energy are not controlled properly and
accidently released???
Damage to Equipment!

Imagine the forces involved in this over

pressure incident when V 603 Blew it’s Top
• in cases where electrical isolation is
required, a request for PTW must be
available before the EIC is issued by the
AA.
• The revised EIC has a section for weekly
revalidation that must be filled out by the
ACP (Chargeman)

STEP 2 ELECTRICAL ISOLATION

 EIC
• The main change to
the EIC is the
addition of a
revalidation section
similar to the PIC.
• The EIC must be
revalidated every
week by the
Chargeman. Both
original copy in the
substation and the
copy in the PTW
Room.
• The EIC copy is
attached to the PIC 11
 PIC (backside)
• The AAR (Ops) records breaker location isolation status
and tag number on PIC.

PHYSICAL ISOLATION CERTIFICATE

NO WORK IS SO URGENT THAT WE CANNOT TAKE TIME TO DO IT SAFELY Page 2 of 2
EPEMSB
OPEN /
CLOSED /
ISOLATION DEVICE LOCATION Deenergised OPS TAG NO Installed By: Date Installed Removed By Date Removed
Energised (tic)
(tic)

TO BE FILLED OUT BY ACP (CHARGEMAN) WHEN ELECTRICAL ISOLATION IS REQUIRED AND BEFORE JOB STARTS
BREAKER No./ LOCATION OPEN / DEENERGISED CLOSED / ENERGISED TAG No LOCK No

STOP WORK AND EVACUATE AREA ON HEARING OF EMERGENCY ALARM

Original PIC To Be Maintained and Displayed at the Control Room or Office Location Where the PTW is Issued

12
 PIC (backside)
• The Chargeman records the breaker location, isolation
status and tag and lock number on PIC.

PHYSICAL ISOLATION CERTIFICATE

NO WORK IS SO URGENT THAT WE CANNOT TAKE TIME TO DO IT SAFELY Page 2 of 2
EPEMSB
OPEN /
CLOSED /
ISOLATION DEVICE LOCATION Deenergised OPS TAG NO Installed By: Date Installed Removed By Date Removed
Energised (tic)
(tic)

TO BE FILLED OUT BY ACP (CHARGEMAN) WHEN ELECTRICAL ISOLATION IS REQUIRED AND BEFORE JOB STARTS
BREAKER No./ LOCATION OPEN / DEENERGISED CLOSED / ENERGISED TAG No LOCK No

STOP WORK AND EVACUATE AREA ON HEARING OF EMERGENCY ALARM

Original PIC To Be Maintained and Displayed at the Control Room or Office Location Where the PTW is Issued

13
• After isolation Lock and Tag in the
substation the AAR must conduct the Clear
and Try test in the field (Bump Test). Try to
start the equipment to confirm correct
isolation.
• Our OPU practice is for the Chargeman to
witness the Clear and Try test.

ELECTRICAL ISOLATION
STEP 3 IN THE FIELD
• Operations will prepare the equipment to
ensure it is safe to work on.
• Zero Energy State
• Flushed and drained of toxic and
other hazardous material as per SOP.

EQUIPMENT PREPARATION
STEP 4 IN THE FIELD
• Under the new LOTO system, Operations
will be the only discipline to hang locks and
tags at the field energy isolation points.
• The Group Lock System will be used by
operations for this task.

STEP 5 ISOLATION AT THE FIELD

 Group Locks
How to use and manage

With the Group LOTO System a series of

locks with a single common master key,
which are used together with tags to
isolate the system after which the key is
placed in a secured Lockout Box.

17
Group Locks
EACH GROUP OF LOCKS HAS A
GROUP NUMBER AND LOCK NUMBER

18
Group Locks

• THE GROUP LOCK

NUMBER
CORRESPONDS WITH
THE LOCKOUT BOX
NUMBER
• EACH LOCK IN THE
GROUP HAS AN
INDIVIDUAL LOCK
NUMBER

19
Group Locks
• WHEN NOT BEING USED,
THE LOCKS AND KEY
SHALL BE KEPT INSIDE
THE CORRESPONDING
LOCKOUT BOX.
• EACH GROUP OF LOCKS
IN OPERATIONS
DEPARTMENTS (ET UOM &
PE) HAS 10
LOCKS/GROUP.
• ET HAS 20 GROUPS OF
LOCKS IDENTIFIED AS
“ET G1-20 L1-10”
• PE HAS 20 GROUPS OF
LOCKS IDENTIFIED AS
“PE G1-20 L1-10
• WE HAVE 5 DIFFERENT
COLOURS FOR THE LOCK
GROUPS TO HELP WITH
IDENTIFICATION.
 Group Locks
Lockout:
When lockout of equipment is required the required number of
locks are removed from a lockout box together with the key and
are used to secure the energy isolating devices i.e. valves,
electrical breaker etc..

Locking Device
21
 Group Locks
Lockout:
If the equipment requires more than the 10 locks available in one
group then several groups may be used depending on the number
of isolation points requiring locks.

22
 Lockout Box
• AFTER ISOLATION OF THE
EQUIPMENT THE KEY FOR THE
GROUP LOCKS IS PLACED INSIDE
THE LOCKOUT BOX.
• IF MORE THAN ONE GRUP OF LOCKS
ARE USED THEN THE KEYS FOR
EACH GROUP ARE ALL PLACED IN
THE SAME LOCKOUT BOX.
• THE KEY FOR LOCKS USED BY THE
CHARGEMAN FOR ELECTRICAL
ISOLATION ARE ALSO PLACED
INSIDE THE LOCKOUT BOX
• THE LOCKOUT BOX IS THEN LOCKED
BY THE SS WITH AN OPERATIONS
DEPARTMENT LOCK
• WHEN THE RA APPLIES FOR A PTW
TO WORK ON THE EQUIPMENT HE
PUTS HIS DEPARTMENT LOCK ON
THE LOCKOUT BOX.

23
 Department Locks
• THESE LOCKS ARE
KEY DIFFERENT.
EACH LOCK HAS
AN INDIVIDUAL
KEY.
• THEY ARE ISSUED
TO EACH
DEPARTMENT IN
EPEMSB
• THEY ARE USED BY
THE AA AND RA TO
LOCK THE DOOR
ON THE LOCOUT
BOX.
• EACH LOCK IS
ENGRAVED WITH
THE DEPARTMENT
ID & LOCK
NUMBER.
 Department Lock ID
Department Quantity Labeling / Engraving Details
ET Operations 22 ET D1 inclusive to ET D22
UOM Operations 17 UO D1 inclusive to UO D17
PE Polymer 22 PEP D1 inclusive to PEP D22
PE Compounding 17 PEC D1 inclusive to PEC D17
Central Lab 4 CL D1 inclusive to CL D4
Technical Services Lab 4 TSL D1 inclusive to TSL D4
Admin Department 2 AD D1 inclusive to AD D2
Warehouse 2 WH D1 inclusive to WH D2
Engineering Department 2 ENG D1 inclusive to ENG D2
Engineering Services 12 EnS D1 inclusive to EnS D12
Mechanical 28 MEC D1 inclusive to MEC D28
Instrument 12 INST D1 inclusive to INST D12
Electrical Maintenance 10 EL D1 inclusive to EL D10
Inspection 13 INSP D1 inclusive to INSP D13
PE Technical 10 PET D1 inclusive to PET D10
ET Technical 10 ETT D1 inclusive to ETT D10
RPO 10 RPO D1 inclusive to RPO D10
 Lockout Box
• THE LOCKOUT ET
BOXES ARE SET UP UOM
IN THE PTW ISSUE
AREA.
• THESE CABINETS
ALSO HAVE
STORAGE FOR THE
TAGS AND A
SECURE PLACE
FOR THE
DEPARTMENT
LOCKS AND KEYS

26
 TAGS

• THE LOCKOUT
BOXES CABINETS
HAVE STORAGE
FOR THE TAGS

27
 TAGS
• Blue (plastic) –
Operations
• Red (plastic) –
Chargeman
• Brown (paper) –
Common disposable
tag used at Lockout
Box
• Green (paper) –
Spade/blind
• Yellow (plastic) –
Ionizing Radiation
28
 TAGS
• Blue Operations tags
are placed at all
isolation points i.e.
valves, breakers, stop
button etc
• Red Chargeman tags
are placed at breaker
by the Chargeman
• Brown tags are used at
Lockout Box by AA & RA
• Green tags are placed at
blind locations by
Operations.
• Yellow tags are placed at
Ionizing Radiation device
locations by RPO
29
• The new PIC will replace the existing
Mastercard.

STEP 6 APPROVAL OF PTW

 PIC
• The NEW PIC will replace
the existing Mastercard
• The function is similar to
the Mastercard (1 page
only).
• The active PIC will be kept
in the current slot used
for the Mastercard
• The PIC has a weekly
revalidation section that
must be filled out by the
SS every week. This is
done to confirm that the
system isolation is still
required
31
 PIC
• The AA lock number
used to secure the
Lockout Box is
recorded here.
• The RA lock number
used to secure the
Lockout Box is
recorded here

32
 PIC (backside)
• Additional information is required on the backside. Who
installed the lock and tag, the date and also who
removed the isolation and date.
• REMINDER
Blind tag
PHYSICAL ISOLATION CERTIFICATE
NO WORK IS SO URGENT THAT WE CANNOT TAKE TIME TO DO IT SAFELY
OPEN /
EPEMSB
Page 2 of 2
(GREEN)
numbers must
CLOSED /
ISOLATION DEVICE LOCATION Deenergised OPS TAG NO Installed By: Date Installed Removed By Date Removed
Energised (tic)
(tic)

also be recorded
on the PIC by
AAR.
•The RA must
confirm positive
isolation by
removing the
perforated
TO BE FILLED OUT BY ACP (CHARGEMAN) WHEN ELECTRICAL ISOLATION IS REQUIRED AND BEFORE JOB STARTS
section from
each green tag
BREAKER No./ LOCATION OPEN / DEENERGISED CLOSED / ENERGISED TAG No LOCK No

and attaching
STOP WORK AND EVACUATE AREA ON HEARING OF EMERGENCY ALARM
Original PIC To Be Maintained and Displayed at the Control Room or Office Location Where the PTW is Issued
them to the PIC.
33
• Using the new PIC

STEP 7 HAND BACK OF PTW

 PIC
• When the job is complete
and the RA returns and
signs off on the PTW, he
must remove his
department lock from the
Lockout Box and fill out
section 2 of the PIC.

35
• The EIC is issued for electrical return to
normal condition.
• Operations removes locks and tags from
field isolation devices

DE-ISOLATION
STEP 8 AT THE FIELD
• The 3 Special certificates are:???
• PIC, EIC & SSBOC
• The Safety System Bypass Override
Certificate has also been revised and needs
to be revalidated every week.
• Waiver available for extended long term
isolation for the Special Certificates.

OTHER: SPECIAL CERTIFICATES

 Safety System
Bypass/Override Cert.
SAFETY SYSTEM BYPASS/OVERRIDE Serial No.:

CERTIFICATE
PTW No.:
EPEMSB NO WORK IS SO URGENT THAT WE CANNOT TAKE TIME TO DO IT SAFELY

SECTION 1: GENERAL INFORMATION ( To Be Filled By Receiving Authority )

Location:  Field  FSC  DCS F&G Panel  Marshalling Rack

 Others: …………………………………………
Unit Area / Facility :

• Similar to the EIC the

Equipment No. : Tag No. : Date Required From : To:
Time Required From : To:

 Drawing attached ………………………………………………………………  Other ………………………………………………………………………

SECTION 2: WORK DESCRIPTION (To Be Filled By Receiving Authority )

main change to the Safety Integrity Level (SIL):……………………………….. (Note: No bypass is allowed for SIL 4 Safety System)

Reason for Safety System Bypass / Override

………………………………………………………………………………………………………………………………………………………………………… ………………………………………

SSB/O Cert is the

………………………………………………………………………………………………………………………………………………………………………… ………………………………………

………………………………………………………………………………………………………………………………………………………………………… ………………………………………

Effect on the System

addition of the weekly

………………………………………………………………………………………………………………………………………………………………………… ………………………………………

………………………………………………………………………………………………………………………………………………………………………… ………………………………………

………………………………………………………………………………………………………………………………………………………………………… ………………………………………
Method of Bypass / Override

revalidation section.
 Physical Isolation  Hardwire Jumper Temporary Change Setting  Temporary Remove Setting  Key Activation

Manual Force Reading  Software Disable Others: ………………………………………………………………………………………………

SECTION 3: PRECAUTIONS TO BE IMPLEMENTED (To Be Filled By Receiv ing Authority / Approving Authority)

Precaution to be done YES NO

Additional Precautions / Instruction

• The EIC must be

1. Bypass / Override activation is adequately
identified on site ………………………………………………………………………………………………………

………………………………………………………………………………………………………
2. Copy No 1: posted in the Control Room
………………………………………………………………………………………………………

revalidated every
I shall implement all precautions as specified above before work starts

Receiving Authority Name Signature Department Designation Date

SECTION 4: APPROVAL

week by the AA
This applicant is authorised to proceed with the Safety System Bypass / Override described above

Approving Authority Name Signature Department Designation Date

SECTION 5: WEEKLY REVALIDATION (Requirement for long term isolat ion to be reviewed daily/every shift by AA )
Week 2 3 4 5 6 7 8 9 10 11 12

AA Name

Signature

Date

SECTION 6: WORK COMPLETION

The above Safety System Bypass / Override is no longer required. The Bypass / Override has been removed and system is
back to normal.
Endorsed by Receiving Authority Endorsed by Approving Authority

Name: Date: Name: Date:

Signature: Time: Signature: Time:

STOP WORK AND EVACUATE AREA ON HEARING OF EMERGENCY ALARM

Distribution - Original: Display at Worksite Copy No. 1: Control Room Copy No. 2: PTW Issuing Area

38
 Special Certificate Waiver

EPEMSB has in AUTHORISATION FOR SPECIAL CERTIFICATE TO STAND

BEYOND THE NORMAL TWELVE WEEK VALIDITY PERIOD

place a Waiver that I hereby grant special authorisation that the following equipment:

Equipment Tag No:______________________ Equipment Name:______________________

may be applied in be allowed to remain in extended isolation without weekly revalidation and renewal of the Special
Certificate.
The Special Certificates are identified in GQP-HSE-014 Permit to Work Procedure, are either of

certain cases with

the following: Electrical isolation Certificate, Physical Isolation Certificate and Safety System
Bypass/Override Certificates

This Special Certificate No._____________________ will in this case be allowed to stand

approval from the

without renewal beyond the normal designated validity period of twelve weeks.
This authorisation will be terminated when there is a requirement to resume work on the above
mentioned equipment and hence issue a Permit to Work. At that time the old Special Certificate
will be closed and a new one issued for the same equipment isolation.

GM. This waiver Reason for prolonged isolation:

________________________________________________________________
________________________________________________________________

allows the Special ________________________________________________________________

Validity Period: _______________________

Certificates to Requested by RA Section

Name Signature Date

remain in effect
Manager
Endorsed by AA
Endorsed by Chargeman

beyond the 12
(as required)
Approval by GM

week period. It is
Confirmed this authorisation is cancelled due to :
 Expiry of validity period. This Authorisation is replaced.
 Work resume. New Special Certificate is issued.

applicable in cases Requested by RA Section

Manager
Name Signature Date

such as equipment
Endorsed by AA
Endorsed by Chargeman
(as required)

awaiting
Approval by GM

Note: This special dispensation of the normal stipulations outlined in the Permit to Work Procedure is

decommissioning
applicable only when justifiable reasons can be given to support the long term isolation such as mothballing
or equipment awaiting decommissioning.
39
 Roles & Responsibilities (1/4)
Approving Authority (AA):
• approving PTW for modification and/or maintenance
work on equipment or systems where energy
isolation is required. PTW application must be in
place before the EIC is issued
• ensure that the Job Method Statement JSA is
available.
• assessing the hazard associated with the work and
recommend control measures.
• ensure only trained and competent personnel
perform the preparation and isolation activities.

40
 Roles & Responsibilities (2/4)
Approving Authority Representative (AAR):
• Appointed by the Approving Authority to prepare
and isolate the equipment.
• May also be instructed to install any lockout devices
and tags under the supervision of the Approving
Authority.
• Shall be competent to operate the equipment and
understand the process / system being isolated.

41
 Roles & Responsibilities (3/4)
Receiving Authority (RA):
• Responsible for supervising the maintenance
activities
• Ensures that the system or equipment being
worked on has been safely isolated and
disabled with proper lockout and tags.
• Accepts the PTW issued for work to be carried
out under his supervision.

42
 Roles & Responsibilities (4/4)

Receiving Authority Representative (RAR):

• Responsible for carrying out maintenance works
• Checks and confirms that the system or
equipment being worked on has been safely
isolated and disabled with proper lockout and
tags.

43
 Special Case (1/2)

2. Short Duration Instrument Isolation

• Short duration tasks, e.g. routine calibration of instruments,
may be done with single valve isolations, and an instrument
technician may effect the isolation.
• A Permit to Work (PTW) is required and this must state that
the ‘Equipment has been Isolated without PIC’.
• If the job is strictly supervised, the lockout or tagout device
on the isolation valve(s) is not required.

44
 Special Case (1/2)
However, single valve isolations effected by instrument
technicians are NOT allowed under the following process
conditions:
Process fluid Pressure* Temperature*

Flammable - Flash point below >55Barg >200ºC

ambient temp.
Toxic - subject to USECHH - -
regulations
Line Breaking – containing - -
hazardous material
Line Breaking – containing
non-hazardous material >30Barg >50ºC
*either/or If the period of isolation is to be extended, or if the isolated instrument is to
be removed, then full isolation must be implemented by a process technician.
Under these circumstances the isolation valve(s) must be locked and tagged.

45
Thank You

46