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ANGLO FATAL RISK GUIDELINE ISOLATION

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ANGLO FATAL RISK GUIDELINE



ISOLATION




                                                  ISOLATION GUIDELINE

     AA_AFRG_00000600.doc                     APPROVED                 22 December 2008                 Page 1 of 66

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CONTENTS                                                                                                      PAGE
1         AIM                                                                                                          3
2         APLLICATION                                                                                                  3
3         DEFINITIONS                                                                                                  5
4         REASON FOR INCLUSION                                                                                      14
5         REQUIREMENTS                                                                                              14
6         PLANT AND EQUIPMENT REQUIREMENTS                                                                          15
7         SYSTEM AND PROCEDURAL REQUIREMENTS                                                                        25
8         PEOPLE REQUIREMENTS                                                                                       36
APPENDIX A: RELATED DOCUMENTS                                                                                       39
APPENDIX B: RECORD OF AMENDMENTS                                                                                    39
APPENDIX C: PETROLEUM PROCESS ISOLATION SELECTION                                                                   40
APPENDIX D: WMC ISOLATION SELECTION TOOL                                                                            46
APPENDIX E: WORSLEY ALUMINA ISOLATION SELECTION POINT TOOL                                                          50
APPENDIX F: OBJECTIVE AND PURPOSE OF A PERMIT TO WORK SYSTEM                                                        51
APPENDIX G: SAMPLE OF EXPECTED ROLE DEFINITION DETAIL ISSUER                                                        53
APPENDIX H: TEMPORARY EQUIPMENT TO ASSIST WITH LOCKING
ELECTRICAL EQUIPMENT                                                                                                55
APPENDIX I: TEMPORARY EQUIPMENT TO ASSIST WITH LOCKING VALVES                                                       58
APPENDIX J: TEMPORARY EQUIPMENT TO ASSIST WITH ATTACHING LOCKS 60
APPENDIX K: LOCK BOX                                                                                                61
APPENDIX L: ISOLATION LOCKS                                                                                         64
APPENDIX M: ISOLATION POINTS LABELLING EXAMPLES                                                                     65




                                                  ISOLATION GUIDELINE

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1         AIM
            To ensure that all machinery and equipment is isolated, locked out and made safe (all
            energy released) prior to any access, work or repair being carried out, in order to protect
            the health and safety of persons.

          This guideline refers to the implementation of the Anglo Fatal Risk Standard 5: Equipment
          Safeguarding and should be read in conjunction with that Standard.

          The guidelines contained in this document are considered as "highly recommended" and
          deviations are to be documented and justified. Full adherence to these guidelines will not
          be a factor in determining compliance with the Standards, since alternative methods can
          be available if justified on a risk basis.

          In case of conflict with requirements of any other Anglo document or guideline, the
          following hierarchy will apply:

          1. Anglo Safety Way                            -   ASW

          2. Anglo Fatal Risk Standards                  -   AFRS

          3. Anglo Fatal Risk Guidelines                 -   AFRG

          It is important that when implementing Standards the organisation takes cognizance of,
          and comply with the relevant legal requirements in the country of application.

2         APLLICATION
            This Standard is applicable, but not limited to all sources of energy including potential
            kinetic, elastic, chemical, electrical, mechanical, thermal (e.g. hot liquids, solids, gases),
            nuclear, static, rotational, out of balance, light and gravitational. Energy associated with
            processes such as materials handling, transport, pressure, vacuum, hydraulic,
            pneumatic and chemical processes, are also included. Moving and stationary machinery
            is included. This Standard stipulates the minimum requirements to which the isolation,
            lock-out and making safe procedures must comply.

            This Standard applies to all Anglo American Group managed businesses and operations,
            including contractors and visitors when involved in controlled activities.

          The purpose of this Guideline is to provide guidance and clarification on the
          requirements of the Anglo Fatal Risk Standard: Equipment Safeguarding, which
          describes the minimum acceptable requirements for the safeguarding of people
          from moving parts of equipment.

          This guideline has been developed to provide more detail and clarification for the
          implementation of the requirements of the Standard. This should enable sites to be more
          aligned with each other on what the boundaries are with regards to meeting the
          requirements.

          This guideline is by no means exhaustive and will be updated periodically and supported
          by good practice sharing. It is not intended as a template for achieving compliance.
                                                  ISOLATION GUIDELINE

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          Energy sources are present throughout Anglo operations in many forms.

          Some of the energy sources within our operations are:
          •    Chemical
          •    Thermal
          •    Pressure / Volume
          •    Gravitational
          •    Kinetic
          •    Electrical
          •    Electromagnetic
          •    Radiation
          •    Nuclear
          •    Potential
          •    Elastic
          •    Mechanical
          •    Static
          •    Rotational
          •    Out of balance
          •    Light

          Isolation related significant incidents occur within various work groups and types of work.
          A significant proportion of our potential fatalities have included steps where sources of
          energy were not isolated adequately. The causes and contributing factors to these
          incidents have been:
          •    failure to identify or recognize a source of energy
          •    inadequate training or competence
          •    inadequate lockout/tag out systems
          •    complacency
          •    working on, or isolation of, the wrong equipment
          •    Inadequate design/maintenance of isolators.

          All sites must identify and comply with all relevant local legislation, standards, licenses,
          permits and other requirements in relation to isolating equipment as well as the
          requirements of the Isolation Standard.




                                                  ISOLATION GUIDELINE

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3         DEFINITIONS
            Authorised              :   means a competent person tested and appointed in writing by the
            person                      responsible supervisor to do specific operations (i.e. operating
                                        electrical switchgear).

            Responsible             :   is the manager/engineer in charge of the Operations as per legal
            supervisor                  definitions or internal regulations.

            Operator                :   means the person in charge of the operation of some specific
                                        equipment or machinery.

            De-energise             :   means to remove effectively all possible sources of energy from
                                        the item, system, process, area or equipment in question.

            Earthed                 :   means connected to the general mass of earth in such a manner
                                        that will ensure at all times an immediate discharge of electrical
                                        energy without danger.

            Isolation               :   means to physically remove any connection or means to supply
                                        any form of energy to equipment in order to make energisation of
                                        such equipment impossible.

            Lock out                :   means to put a personal lock or appropriate device on to
                                        equipment in such a way that it would be impossible to connect,
                                        switch on or start, utilise or energise the equipment without
                                        removing the lock or device.

            Make safe               :   means to remove any threat or potential threat to health and safety
                                        posed by the source of energy, equipment, any equipment in the
                                        vicinity, any other substance or charge in the immediate area. This
                                        includes, but is not limited to, barricading, clamping, chocking,
                                        constraining, deflating, earthing, neutralising, purging and
                                        ventilating.

            Permit-to-work          :   means a form of written declaration signed and given by the
                                        person legally responsible for the Plant to the person in charge of
                                        work to be carried out on machinery or equipment that has been
                                        isolated, locked out and made safe.


            Certificate            :    Certificates are documents that define the core preparations
                                        required for work to proceed but do not, by themselves, authorise
                                        work to proceed. They cannot stand-alone and shall always be
                                        accompanied by a covering PTW.

            Competency             :    To have competency in a role is to have the ability to perform tasks
                                        and duties to the standard expected in employment. This ability can
                                        be defined as a combination of attributes such as knowledge, skills,
                                        abilities and attitudes providing adequate assurance of successful
                                        performance.

                                                  ISOLATION GUIDELINE

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            Competency             :   To have competency in a role is to have the ability to perform tasks
                                       and duties to the standard expected in employment. This ability can
                                       be defined as a combination of attributes such as knowledge, skills,
                                       abilities and attitudes providing adequate assurance of successful
                                       performance.

            Competency             :   Competency Standard is an industry or workplace determined
            Standard                   specification of performance which sets out the skills, knowledge
                                       and attitudes required to operate effectively in employment. In
                                       summary it is a group of competencies which are combined to
                                       develop a role e.g. an Isolation Officer Competency Standard could
                                       contain competencies such as risk assessment, JSA/ JHA
                                       development, purging of specific gas pipes, etc.

            Competency             :    (CBT) is training which develops the skills, knowledge and
            Based Training             attitudes required to achieve competency standards. Competencies
                                       are carefully selected to align with the chosen role.

                                       The supporting theory associated with each individual Competency
                                       is integrated with skill practice. Essential knowledge is learned to
                                       support the performance.

                                       The training is focused on outcomes and is typically constructed of
                                       modules broken into segments called learning outcomes, which are
                                       based on Competency Standards set by the operation. The trainee
                                       is assessed on what they can do rather than on the marks they
                                       have achieved through more traditional forms of testing.
                                       Competency Based Training assessment is designed to ensure the
                                       trainee is capable of consistent application of the obtained
                                       knowledge and skills to the standard of performance required.

                                       Detailed training materials are keyed to the competencies being
                                       achieved and are designed to support the acquisition of knowledge
                                       and skills. Satisfactory completion of training is based on
                                       achievement of all specified competencies.

            Critical               :   Critical Equipment is a piece of equipment or a structure whose
            Equipment                  failure, or not performing to design specification, has the potential
                                       to result in a Major Accident Event.

            Critical               :   A Critical Equipment Register is a register that provides a concise
            Equipment                  summary of all Critical Equipment that includes its design function
            Register                   (including operating limits), a unique identification, required
                                       performance standards (e.g.: minimum reliability) and maintenance
                                       requirements.

            Critical System        :   A Critical System is a system (hardware or software, including
                                       human behavior) whose operation outside expected performance
                                       has the potential to result in a Major Accident Event.


                                                  ISOLATION GUIDELINE

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                                       Some Critical Systems associated with the Permit to Work System
                                       include: Firewater System, Fire and Gas Monitoring Systems,
                                       Emergency Shutdown System and Protective Devices. Any work
                                       associated with these devices shall require the issue of a PTW.

            Designated             :   Specific points of isolation shall be clearly labelled at all times to
            Isolation Point            identify the circuit or system which they have direct control of the
                                       labels shall be applied following a process of pre-isolation
                                       identification using isolation lists, schematic (P&ID), drawings, etc.
                                       Labels should be physically verified before isolation.

            Emergency              :   An emergency is an abnormal occurrence that can pose a threat to
                                       the safety or health of employees, customers, local communities, or
                                       which can cause damage to assets or the environment.

            Fatal     Risk :           The Fatal Risk Standard is a document which outlines
            Standards                  requirements that are mandatory to all Anglo businesses and
                                       operations and contractors and visitors when involved in controlled
                                       activities. The Standards address specific fatal risk areas (e.g.
                                       hazardous materials management, molten materials management,
                                       surface mobile equipment, isolation, etc.).

            Group Isolation        :   Group isolations are achieved when there is a single common
                                       isolation point that isolates more than one unit of equipment.

            Hardware               :   Hardware overrides are process/equipment system overrides that
            Overrides                  either set or hold a device or defeat an output action for emergency
                                       and safety shutdown systems. Their functions are applied to
                                       control using power control circuits.

            High Voltage           :   Any voltage greater than 1000V (AC) or 1500V (DC) between
                                       conductors or above 900 VDC between conductors and earth up
                                       to 220kV or as defined by local legislation. (Activities involving
                                       voltages above 220Kv require separate risk based assessments).

            Hot Tapping            :   A repair, maintenance or servicing activity, which involves welding
                                       on a piece of equipment (pipelines, vessels, or tanks) under
                                       pressure, in order to install connections or appurtenances.

                                       Commonly used to replace or add sections of pipeline without the
                                       interruption of service for air, gas, water, steam, and chemical
                                       distribution systems.

            Hot Work               :   Any work which may introduce a source of ignition into an area in
                                       which flammable or combustible materials or oxygen may be
                                       present.




                                                  ISOLATION GUIDELINE

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                                       Examples of such work include:
                                       • electric welding;
                                       • use of equipment with naked flames such as burning torches,
                                         blow lamps, bitumen boilers,
                                       • portable shrink wrappers or space heaters;
                                       • equipment with heated elements such as soldering irons and
                                         stress relieving ovens;
                                       • grinding, concrete cutting or pile driving work which could
                                         produce sparks that may start a fire,
                                       • use of vehicles, tools or equipment powered by internal
                                         combustion engines and not certified for use in areas where Hot
                                         Work Permits are required;
                                       • use of cartridge operated tools and other explosive devices;
                                       • use of non-certified electrical equipment including battery
                                         operated vehicles; and
                                       • personal electrical equipment                such     as    radios,    portable
                                         telephones and cameras.

                                       Often there is a sub classification of hot work flame and hot work
                                       no flame.

            Intrusive Work         :   Where work impedes on equipment which under normal
                                       operating conditions contains an energy source, e.g. chemicals,
                                       kinetic, heat (low and high temperatures), light (lasers), stored
                                       energy (springs), sound (high level), pressure.

            Isolation              :   Isolation is achieved when the energy sources of plant, equipment
                                       or machinery is removed.

                                       Typical energy sources are electricity, pressure, chemical, radiation
                                       and gravity.

                                       Isolation should provide positive protection through the use of
                                       isolation devices/equipment which establishes a physical barrier or
                                       separation. All isolation devices/equipment shall either have a
                                       permanent or temporarily fitted locking device.

            Isolation              :   An Isolation Certificate is a permanent documented isolation
            Certificate                planning record. It is used to ensure that people are exposed to
                                       minimal risk of uncontrolled energy releases within a specific area
                                       or from a specific piece of equipment. It is manually written or
                                       prepared by the Permit Issuer or Isolation Officer. A marked up
                                       schematic drawing and/or P&ID is contained within the Certificate
                                       and is used to assist in identifying and communicating the
                                       isolations required.

                                                  ISOLATION GUIDELINE

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                                       Isolation Certificates are used for Non Routine Work or complex
                                       isolations such as;
                                       • isolation of multiple energy sources
                                       • irregular isolations
                                       • isolation of high potential energy sources
                                       • multiple isolation points (> 3 points)
                                       • isolation or de-isolation where sequence is critical
                                       • isolation for high risk activities/tasks.

                                       An Isolation Certificate is pre-prepared before commencing to
                                       isolate and contains information that enables a safe and effective
                                       isolation.

                                       The Certificate should:
                                       • identify energy sources
                                       • identify physical state of energy sources, both active and stored
                                       • contain a schematic drawing of the equipment being isolated
                                       • identify isolation points, there location and label details
                                       • identify pre-condition requirements                 (what     needs      to   be
                                         completed before commencing
                                       • isolations)
                                       • identify hazards and controls the Isolation Officer may be
                                         exposed to
                                       • record isolation sequence
                                       • identify and record purging, ventilation and gas testing method
                                         and results
                                       • identify residual energies, where complete isolation was not
                                         possible
                                       • record try/test methods, record verification steps
                                       • record Isolation Officer’s declaration of completion record de-
                                         isolation sequence
                                       • record Isolation Officer’s declaration of de-isolation.

                                       The Isolation Certificate shall be controlled within the sites
                                       document control system and changes to it cannot be made
                                       without using an approved change management process.




                                                  ISOLATION GUIDELINE

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            Isolation Officer      :   An Isolation Officer is an authorised person who has been
                                       appointed to isolate energy sources within a specific area of an
                                       operation. An Isolation Officer obtains authority following successful
                                       completion of Competency Based Training and demonstration of
                                       key attributes required for a safety critical role. An isolation officer
                                       should have extensive knowledge of the area of plant they are
                                       authorised to isolate, in particular the various energy sources.

            Isolation              :   Isolation Officer’s Locks should be uniformly coloured and only
            Officer’s Lock             used to secure Lock Boxes. Locks should be keyed alike for each
                                       specific area of the operation. The keys to these locks should be
                                       strictly controlled and only issued to specific area authorised
                                       Isolation Officers.

            Isolation Tag          :   An Isolation tag is a tag that is applied to an isolation point by
                                       the person who is responsible for ensuring that isolation
                                       requirements for the task have been met. The best practice is for
                                       the Isolation Tag to be secured to the Designated Isolation Point
                                       using the System Lock.

                                       Once a tag is applied, all use, operation or start up of
                                       plant/equipment is prohibited. Tags should be highly visible to
                                       prevent the inadvertent operation of plant and/or equipment.

            Job        Safety :        A Job Safety Analysis (JSA), sometimes known as a Job Hazard
            Analysis (JSA)             Analysis (JHA) is a procedure completed by the people actually
            or Job Hazard              conducting the work and helps integrate safety and health
            Analysis (JHA)             principles and practices into a specific scope of work. In a
                                       JSA/JHA, each basic step of the job is examined to identify
                                       potential hazards and to determine the safest way to do the job.

                                       There are four basic stages in developing a JSA/JHA. These are:
                                       • selecting the job to be analysed
                                       • breaking the job down into a sequence of steps
                                       • identifying potential hazards
                                       • determining preventive measures to overcome these hazards

            Lock Box               :   The Lock Box is a purpose designed box which has the dual
                                       function of providing a link between multiple isolations and the
                                       PTW documentation whilst securing the System Lock(s) key.
                                       Following isolations, all System Lock key(s) used at Designated
                                       Isolation Points are placed in the Lock Box.

                                       The Lock Box is locked with an Isolation Officer’s Lock, and fitted
                                       with an Isolation Tag prior to Permit Users attaching their Personal
                                       Danger Tags and locks.



                                                  ISOLATION GUIDELINE

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                                       The System Lock(s) key shall not be physically able to be
                                       removed unless all Personal Locks and the Isolation Officer’s Lock
                                       are removed.

                                       Lockout boxes are nominally for the sole purpose of controlling
                                       multiple locking points and/or controlling large numbers (typically
                                       >5) of personnel.

                                       The key to the Isolation Officer’s Lock shall remain under control of
                                       Isolation Officer at all times.

                                       The Isolation Officer shall not remove the Isolation Tag and
                                       Isolation Officer Lock from the Lock Box until the PTW has been
                                       handed back and signed off by the Permit Holder and all
                                       Personal Danger Tags and locks have been removed from the
                                       Lock Box.

                                       Removal of isolations shall not commence before approval has
                                       been given by the Permit Issuer.

            Major     Accident :       A Major Accident Event is any incident with the potential to lead to
            Event                      any of the following:
                                       • a fatality
                                       • serious environmental effect, including impairment of ecosystem
                                         function
                                       • ongoing significant social issues
                                       • significant adverse national media, non-government organisation
                                         (NGO) attention, or loss of license to operate.

            Multiple Isolation     :   Multiple isolation is a single isolation point that is locked and/or
                                       tagged by more than one person.

            Non        Routine :       Non Routine Work is any activity that is outside the regular
            Work                       activities of the operation or site. Non

                                       Routine Work is not normally covered by a management system
                                       procedure, work Instruction or checklist.

                                       Non Routine Work activities include, but are not limited to:
                                       • tasks that involve personnel who have not been deemed
                                         competent using a Competency Based Training,
                                       • high risk tasks
                                       • involve multiple work teams and disciplines
                                       • Isolation of energy sources for Intrusive Work
                                       • Isolation of multiple energy sources


                                                  ISOLATION GUIDELINE

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                                       • Working in a Confined Space
                                       • Working at Heights
                                       • Hot Work
                                       • Working with Radiation Sources
                                       • Excavation and Ground/Surface Penetration
                                       • High Voltage work
                                       • Removal of flooring or safety barriers
                                       • Installation, removal or modification of software overrides
                                       • Installation, removal or modification of hardware overrides
                                       • Inhibition of critical equipment or critical systems.

            Permit to Work :           The Permit to Work Register provides an overview of the state of
            Register                   Permits and associated documents at any time. The permit issuer
                                       shall register all permits and associated forms (Isolations,
                                       Certificates etc.) into the Logbook once active.

            Personal Danger :          A Personal Danger Tag is a tag that is personally applied by the
                                       individual (Permit User) prior to commencing work, on the isolated
            Tag                        plant or equipment or Lock Box. The tag is secured using a
                                       Personal Lock. A personal danger tag is a tag applied to an
                                       isolation point by the person who is responsible that the isolation
                                       requirements for the task have been met and is a tag that when
                                       applied prohibits all use, operation or start-up of plant and/or
                                       equipment.

                                       The individual who placed the Personal Danger Tag on the
                                       isolated piece of plant or equipment or Lock Box is the only person
                                       who can remove the tag. The only exception is when the Senior
                                       Manager at the operation, who must ensure the individual has left
                                       the site or operation, has given approval. The only exception for
                                       removal of the tag by others is when the designated authorised
                                       person at the operation, who must ensure the individual has left
                                       the site or operation, has given approval.

                                       When completing the tag, information should include the person’s
                                       name, employer’s details, date, time, isolation point or Lock Box
                                       details, type of work being completed and location of work.

                                       Personal Danger Tags are highly visible, red in colour and clearly
                                       identified with the word Danger and include a description of the
                                       intent of the tag e.g. “This tag may only be removed by: Name:
                                                ”




                                                  ISOLATION GUIDELINE

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            Personal               :   A Personnel Locking Device is a lock provided to an individual for
            Locking Device             the purpose of their own protection. Personal locks and danger tags
                                       are applied to Designated Isolation Points when Isolation is
                                       achieved. The personal lock is individually keyed and can only be
                                       used or removed by the key holder. The only exception is the site
                                       master key that can be used by the most Senior Manager at the
                                       operation after ensuring the individual has left the site or operation.

            Routine Work           :   Routine Work is work that does not require a PTW and is covered
                                       by a procedure, Work Instruction or checklist. People are qualified
                                       and deemed competent to perform the work safely.

                                       Routine Work involves activities that:
                                       • are conducted with a medium to high level of frequency (e.g. < 3
                                         months),
                                       • are low risk,
                                       • involve the isolation of one energy source only and
                                       • is completed by an individual or a work team.

            Short      Term :          A short-term isolation is isolation in place for one shift period or
            Isolations                 less.

            Long       Term :          A long-term isolation is isolation in place for more than one shift
            Isolations                 period.

            Software               :   Software overrides are process/equipment system overrides that
            Overrides                  either electronically set and hold a device or electronically defeat
                                       an output action for emergency and safety shutdown systems. Their
                                       functions are electronically initiated and applied to control rather
                                       than power circuits.

            System Lock            :   System Locks should be uniformly coloured to allow for easy
                                       identification and uniquely keyed. The locks should be used in
                                       conjunction with ‘scissors’ and Out of Service tags to secure
                                       isolation points. When using a Lock Box the System Lock keys are
                                       secured within the box. The management of the System Lock
                                       system should be controlled.

            System Tag             :   A system or isolation tag is a tag applied to an isolation point by the
                                       person who is responsible that the isolation requirements for the
                                       task have been met and is a tag that when applied prohibits all use,
                                       operation or start-up of plant and/or equipment.

                                       This tag is attached to the isolation point by an isolation system
                                       lock.




                                                  ISOLATION GUIDELINE

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            Work Instruction           A Work Instruction is a document which is designed to provide step
                                       by step instruction on how to complete a specific task. Work
                                       Instructions are developed using a JSA/JHA as a guide and
                                       providing further technical and sometimes visual detail. Work
                                       Instructions should be reviewed routinely according to the
                                       operation’s document control policies and safety systems to
                                       ensure the document represents best practice.

4         REASON FOR INCLUSION
            A significant proportion of our potential fatalities have included cases where sources of
            energy were not isolated adequately. The causes of and factors contributing to these
            incidents have been:
            •      Failure to identify or recognise a source of potential or stored energy;
            •      Inadequate training or lack of competence;
            •      Inadequate lock-out/tag-out systems;
            •      Complacency;
            •      Working on, or isolation of, the wrong equipment;
            •      Inadequate design/maintenance of isolators.

5         REQUIREMENTS
          This section is structured using exactly the same numbering sequence as the Fatal Risk
          Standard document. Each requirement is repeated in a box, followed by a statement of
          intent. This is followed by discussion and clarification of that particular requirement.

          Detail has been added to some, but not all requirements, as some sections were deemed
          self explanatory.

          This document does not represent a stand alone system but a list of requirements
          required to be included within several safe work systems at operations. It has been
          developed to provide enhanced understanding of the intent of each requirement within the
          isolation standard.

          Also included within the General Comments sections is advice on what is expected to
          meet compliance with these requirements. Of particular value are the examples obtained
          from operations who have demonstrated good practice.

          It is intended that guideline will be a ‘live’ document and as people tender good examples
          of equipment or practices these will be added to the guideline. Supporting the document
          continuous improvement cycle are the opportunities that arise from reviews of significant
          incidents and work conducted by the Champions.

          This guideline is also supported by the Permit to Work Guideline and permit to work
          systems are referenced throughout this document.

          Any recommendations for improvement should be directed to the corporate champion for
          Isolation.

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          Definitions for terms used in this Guideline are presented in Definitions.

6         PLANT AND EQUIPMENT REQUIREMENTS
          1.      Purchase, Design or Introduced Equipment

                   All equipment whether purchased or constructed (including hired and
                   contracted equipment), shall have the capability of being isolated physically
                   from all energy sources and shall meet the requirements of this Standard.

                  Intent

                  The intent of this requirement is for operations to have a system in place to ensure
                  that equipment entering or being constructed on a permanent and temporary basis
                  is suitable for isolation.

                  General Comments

                  Without formal systems in place to manage this requirement it will not be managed
                  effectively or efficiently and will not be sustainable in the long term.

                  The system should ensure that equipment requirements are assessed prior to
                  orders being placed and all incoming equipment is inspected to ensure it meets
                  compliance before being allowed to enter the site.

                  The system must interact with other systems and across departments on site such
                  as, but not limited to; security, purchasing, project and contracts management and
                  the contractor management systems.
          2.      Protection and Isolation Security

                   Isolation shall provide positive protection against harm and shall be achieved by
                   the use of locking devices or the establishment of a physical barrier or separation.

                  Intent

                  “Protection” – would be better being described as ‘isolation’. The intent of this
                  requirement is that equipment used for isolation purposes must be capable of
                  providing ZERO HARM to those working on the equipment and systems. Protection
                  is provided when the energy is contained, presents an acceptable level of risk to
                  people and the isolation point is physically ‘locked out’.

                   “Locking device” - Without getting into a discussion over the definition i.e. what is a
                  “locking device?” the intent of this direction is to provide security of the isolation
                  point to prevent inadvertent de-isolation. To de-isolate requires a conscious and
                  deliberate act. The acceptable method of locking an isolation point is a padlock that
                  requires a key to operate.

                  Temporary fitted devices to allow the attachment of a lock are available and
                  examples are included in Appendix J.



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                  General Comments
                  a.   Acceptable risk

                       The level of acceptable risk should be determined through the Anglo risk
                       assessment process that is designed to ascertain the suitability of an isolation
                       plan’s design or the equipment used. This assessment should be based on a
                       calculation of the potential consequences, exposure and probability of the
                       release of the energy source.

                       Example (1) - the type of isolation for working within a tank that normally
                       contains hydrocarbons (confined space) would typically be different to the type
                       of isolation required for work on a potable water line out in the open.

                       Example (2) – the type of spade used in a high pressure steam would be
                       different to the type used in a concentrated acid line.
                  b.   Permanent fitted devices for locking out

                       The better option is to have isolation devices that do not require further
                       equipment to attach a lock. In many cases extra equipment that enables the
                       attachment of a lock to secure the point of isolation is required. Examples of
                       equipment to lockout valves and electrical breakers are included in:
                       -   Appendix H
                       -   Appendix I, and
                       -   Appendix J
                       Electrical breakers with lockout capability fitted retrospectively




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                       Innovative approach to locking out valves (bleed – open, source – closed)
                       retrospectively




                       Valves with lock open or close capability available ‘off the shelf’




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                  c.   Areas of contention

                       There are situations where operations have particular equipment and processes
                       which make it difficult to achieve compliance with this requirement. Some of
                       these situations identified are discussed below.

                       c.1. ‘Securing (locking) of slip plates or blind flanges’ – when isolating piping,
                       where the use of valves is not acceptable or not practicable, operations are
                       installing flanges, spades or blinds to achieve protection. Some operations
                       secure these devices through the use of chains, locks and tags. This approach
                       is less about the security of the ‘isolation point’ and more about providing an
                       ‘interlocking process’ within the isolation system i.e. the key for the isolation
                       lock can be placed within a lock box which is locked closed by personal locks
                       belonging to members of a work team.

                       The placement of locks on flanges spades or blinds although potentially
                       possible is, for the most part difficult or impracticable, as this equipment is not
                       designed to be secured in this manner e.g. how would we lock every bolt on a
                       blind? Every bolt removal has potential to release pressure or contents.

                       The purpose of the lock used for isolation is to provide a mechanism that
                       prevents the inadvertent removal of the isolation or change of its status. To
                       remove isolation locks takes deliberate action. Lock removal is completed by an
                       authorized person who has access to the lock’s key and takes the necessary
                       steps as dictated by the system before de-isolating.

                       As blinds or spades are used for process control type activities, they could be
                       considered part of the containment envelope of the process system just as a
                       blank that has been located at the end of process pipe work for extended
                       periods. To break containment requires (should) a permit to work and in itself is
                       a stand-alone job which requires isolation and risk management tools to
                       achieve in a safe manner. To break containment takes a deliberate and focused
                       conscious action. As this is the case then securing the spade or blind is, for all
                       intention purposes, not considered an isolation point with respect to the original
                       work.

                       The process piping that is blanked or blinded for an ‘isolation’ is for all intention
                       purposes the same as the other neighboring piping, which may have blanks or
                       blinds inserted for ‘non isolation’ purposes. The likelihood of removal of these
                       devices inadvertently, is extremely low and the relationship between the
                       installation and removal can be adequately managed through the permit
                       system.

                       If we decide not to lock these devices then there must be other controls in place
                       to prevent inadvertent de-isolation.

                       Based upon the points raised above, if an operation uses flanges, spades or
                       blinds to achieve “positive protection” and they decide not to treat them as
                       designated isolation points i.e. ‘lock them out’, then to achieve compliance they
                       must have in place:
                       -   a permit to work system,
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                       -   a rigorous break of containment processes / systems,
                       -   blind/spade registers,
                       -   document and system links between the permit to work and the blind/ spade
                           registers to control de-isolation,
                       -   a tagging system for blinds/spades linked back to permit to work (perhaps a
                           tear off section on tag as well),
                       -   Monitoring tools (audits             –    systems      and     compliance,       behavioural
                           observations etc.),
                       -   qualified and competent people removing blinds,
                       -   the inclusion of marked up P&ID plans as part of the documentation
                           required,
                       -   compliance with relevant site isolation standards (it is usual to have a
                           standard to identify the required standard of isolation for each relevant
                           substance/pressure. i.e. for firewater a single isolation, for steam a double
                           block, for high pressure, or flammable substances a double block and
                           bleed.)
                       c.2. Isolation of equipment using a control circuit to open breakers and ‘secure’
                       the isolation

                       At some operations people working on underground conveyors and long wall
                       equipment are relying on the use of an ‘isolation switch’ which uses a control
                       circuit to activate the main electrical breaker remotely. This achieves isolation of
                       the ‘primary energy source’. Once the breaker is open the control circuit switch
                       is locked out. There is typically a layered protection approach to this system
                       with redundancies built in to allow for potential failures in the control circuit and
                       associated equipment.

                       This approach does not strictly meet the intent of this requirement as the
                       primary energy source is not secured at the point of interruption. “All
                       separations or physical barriers shall be provided with either a permanent or
                       temporarily fitted locking device”.

                       There are other considerations though on the effectiveness of the chosen
                       method as there are typically controls in place to maintain or improve the
                       integrity of the system.

                       For example at one of the operations other controls are in place, these are:
                       -   Continuous monitoring of the system whilst remote isolation is active.
                       -   ESR relay trips all drive power at the sub station circuit breaker (C/B) (point
                           of supply) under all fault conditions and will bring up a General Fault alarm.
                       -   Four different signal line faults ensuring the integrity of the signal line. Any
                           fault or failure of the signal line will fail to safety and not allow the conveyor
                           to start.
                       -   Belt speed – If the monitoring indicates any belt speed the system fails to
                           safety.
                       -   State of the main contactor to ensure it is open.
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                       -    Drive power not at zero – Checking both the current and voltage of all drive
                            motors.
                       -    Any fault of the above monitoring system will cause power to the respective
                            drives to trip at the sub station (point of supply) and not allow power to the
                            drives.
                       There should be an assessment of the integrity of this system. The approach
                       used in some operations is a System Integrity Level (SIL) assessment. The
                       outcome of this assessment is a SIL rating of the system. The petrochemical
                       industry uses this approach to assess control system adequacy in hazardous
                       areas. There is typically an assessment conducted upon installation of this
                       equipment. To meet the intent of this requirement operations using this
                       approach shall:
                       -    Conduct a risk assessment and analysis of the isolation requirements for all
                            activities to do with the conveyors and long wall equipment. The standard
                            risk assessment process would not be a suitable tool for this application.
                       -    Challenge every situation identified that cannot be isolated to provide
                            “positive protection”.
                       -    Determine that the risk identified is tolerable.
                      - Apply for an exemption
          3.      Personal Locking Devices

                   Personal locking devices shall be unique and:
                   −       not be combination locks
                   −       not have an unauthorized second-party master override key
                   −       Be kept under the exclusive control of the owning individual, and key(s)
                           shall not be transferred to another person for lock removal.

                  Intent

                  The intent is to have personal locks that require a key to open and only one key to
                  be available for each lock. The lock specifications should be such that the
                  manufacture never produces locks with the same key.

                  No master key should be available for personal locks without a formal authorization
                  process. The personal lock key must be in the possession of the individual the
                  corresponding lock is protecting.

                  General Comments

                  Some operations are purchasing locks with multiple keys then rely on individuals or
                  their supply department to dispose of the ‘extra’ keys. This is not good practice and
                  examples of this approach failing are often found.

                  The better approach is to purchase purpose made colour coded, isolation locks and
                  provide the supplier with the site’s requirements to prevent personal locks from
                  arriving on site with more than one key. The typical colour for personal locks is red.

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                  Further information on these locks is available in Appendix L. This and other
                  isolation system devices are available from most organizations that sell specialist
                  isolation equipment.




                  Lock Boxes

                  Lockout boxes, stations or equivalent shall be provided where required.

                  In some situations where the use of multiple locks attached to an isolation point
                  becomes difficult to manage or when there are multiple isolation points required for
                  a particular task, then a lock box arrangement is recommended.

                  A typical decision trigger for using a lock box is when a single, standard, isolation
                  lock hasp (6 holes) is not large enough for everyone to ‘lock on’.

                  Another trigger in use is when isolation requires more than 3 personal locks to
                  complete; a lock box arrangement is used. The ‘three lock rule’ allows for ‘simple’ or
                  low complexity isolations to be undertaken by individuals e.g. for a pump – two
                  valves and the electrical motor breaker.

                  Further examples of lock boxes that have been designed and developed to suit the
                  operation are included in Appendix K.




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          4.      Designated Isolation Points Labelling

                   Designated isolation points shall be labelled clearly to identify the circuit or system
                   being isolated or locked out. These labels shall be applied following a process of
                   pre-isolation identification using the lock-out procedure.

                  Intent

                  The intent of this requirement is that equipment used for isolation is labelled with
                  information that enables people isolating to easily identify it and the system or
                  energy source it isolates.

                  The labels must be applied after a review of the plant and equipment to identify what
                  points are required to isolate the energies present.

                  Where available, process and instrument drawings (P&IDs) and wiring diagrams
                  must be up to date before labelling the isolation points.

                  When people are isolating they must identify the isolation point using the label prior
                  to operating the isolation device.

                  General Comments

                  The better practice for labelling is to use easily recognisable permanent labels at the
                  “designated isolation points”. It should be clearly evident as people travel around
                  equipment where the isolation points are.

                  Most operations struggle with the enormity of this task. In many cases, the P&IDs
                  need to be updated in order to have accurate detail to include on the label.

                  It is recommended to take a risk based approach to selecting which isolation points
                  to label. The focus should be on the three elements of risk assessment,
                  consequences, exposure and probability in order to set appropriate priorities for the
                  labelling program.

                  The detail on the label should be able to provide people with enough information to
                  determine what equipment the isolation point relates to, the corresponding P&ID or
                  electrical drawing information (if applicable) and the related energy source.

                  It is recommended that valve labelling be attached beside the associated valve
                  rather onto the valve as the valve may be removed for service and re-located to
                  another location.




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                  Labelling examples (further examples included in Appendix M.)

                  Surface Mobile Equipment (SME) isolation point label format




                  Process piping isolation point tags/labels (etched stainless)




          5.      Personal Lock Tagging

                   All designated isolation points fitted with personal locking devices shall be
                   tagged. The isolation tagging system shall ensure that:
                   −    isolation points are identified positively, including the name of the person
                        locking out
                   −    the reason for the isolation is identified clearly
                   −    Isolation tags are highly visible to prevent inadvertent operation.




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                  Intent

                  The personal isolation tag (danger tag) shall be secured to the personal isolation
                  lock. A ‘danger tag’ should be in place where ever a personal lock is used i.e.
                  isolation point or lock box.

                  Personal danger tags shall be highly visible and contain the following information:
                  − a description of the isolation point,
                  − the work being performed that requires the isolation.

                  Although not stipulated within the standard the following requirements should be
                  included within the tagging system:
                  − The requirement to record, at an isolation point, the type of try/test or ‘test for
                    dead’. This is only required where isolation checklists (or similar) do not record
                    this information
                  − reference to any permits to work (if applicable)
                  − who conducted the isolation - if only using personal locks/ tags on the isolation
                    point or more than one person is ‘locking on’ to that point
                  − when the personal danger tag was placed on the isolation point or lock box, or
                  − when the isolation was conducted

                  Tag(s), whether personal danger or isolation system tags, shall remain available at
                  isolation points for the duration of the isolation and contain all of the required
                  information.

                  General Comments

                  The first lock and tag onto the isolation point should be the person isolating and they
                  should also be the last lock and tag off unless ownership is formally transferred to
                  another person. In this case this person should be the last ‘off’ and so forth.

                  At many operations people are tagging all personal locks on isolation points or lock
                  boxes. Another method to satisfy the intent of this requirement is to include at the
                  isolation point, or lock box, a tag (isolation tag) with most of the generic information
                  required. The personal locks, as they are added, should have permanently applied
                  the people’s name, company and role (sometimes a photo). In this case all the
                  requirements of the protocol are met provided the lock is easily recognizable as a
                  personal isolation lock. An example of this type of personal lock is included within
                  requirement # 3 of this guideline.

                  Using string to hold tags onto locks is not acceptable practice. The tag should be
                  secured to the lock by the shank of the lock using an eye or hole installed in the tag
                  during manufacture.




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7         SYSTEM AND PROCEDURAL REQUIREMENTS
          6.      Isolation Procedure

                   An isolation, lock-out and making safe procedure shall be in place to ensure
                   correct isolation and that all equipment is made safe prior to gaining access or
                   commencing any operation, cleaning, maintenance or repair work requiring access
                   to parts of a machine or removal of a guard or interlock. The procedures shall
                   define clearly the responsibilities of all parties involved.

                  Intent

                  All sites shall have a documented isolation, lockout and tag out procedure and
                  include definitions of appropriate treatment for routine isolations, non-routine
                  isolations, group, master and/or multiple isolations, short-term isolations and long-
                  term isolations (“mothballing” procedures are only required prior to such activity).

                  The isolation system shall contain direction on how isolations are managed for all
                  work activities. The isolation system shall be applied to all activities on site,
                  including contractor activities (e.g. construction, commissioning, operation,
                  maintenance, and return to service, emergency, modification or demolition of
                  equipment).



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                  It is paramount that the system has as few exceptions as possible. Emergency
                  situations, live testing and commissioning may provide some minor deviations from
                  the standard processes. These deviations should be formally risk assessed and
                  challenged to ensure the risk is maintained at an acceptable level.

                  General Comments

                  Specific isolation procedures should be available where the isolation task is
                  considered high risk. Similarly if the energy sources potential and/or the
                  equipment/system complexity are considered to pose significant risk to the incoming
                  work teams.

                  The equipment section of the isolation standard is often not effectively implemented
                  with respect to contractor and hire equipment. The resources required to maintain a
                  system that rigorously assesses and monitors the equipment entering site is often
                  not available at operations. For those sites with security controlled entry points the
                  task is easier as the gatehouse personnel can assist by becoming the ‘gatekeepers’
                  of the system that check to determine whether equipment has been approved to
                  enter site. Having single point accountability for contractors at operations will assist
                  the site in implementing an effective assessment and monitoring system.

                  Many of the isolation related significant incidents (~ 20%) that have occurred have
                  been during the construction phrase of an operation. Often the knowledge of
                  contractor employees on the project’s isolation systems is lacking. Training,
                  supervision and auditing are key to ensuring the systems chosen are used
                  effectively. It is difficult to introduce new people to the many systems in place at
                  construction sites and ensure they have a thorough knowledge of the isolation
                  system. Construction workers are often exposed to many types of systems as they
                  move from one job to the next.
          7.      Scope of the Isolation System

                   The lock-out procedure shall include the following:
                   −    visible indication of isolation
                   −    clear identification of the machinery or equipment to be locked out by the
                        operator
                   −    formal hand-over of the control of the equipment from the operator to the
                        authorised person
                   −    duties and responsibilities of both the operator and the authorised person
                   −    sequence of events to be followed during the procedure
                   −    formal hand-over of the control of the equipment back from the authorised person
                        to the operator
                   −    as determined by risk assessment, isolation of high-energy sources or other high-
                        risk work requires a “permit to work”. When permits are required, the authorised
                        person must isolate, test for dead and earth the equipment before issuing a
                        “permit” to the person responsible for the work. This person then completes the
                        lock-out according to the applicable procedure
                   −    a list of site-specific procedures for which a “permit to work” is required should be
                        approved and communicated by the responsible supervisor.

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                  Intent

                  The intent of this procedure is to formalize the process steps to; safely isolate / de-
                  isolate plant and equipment; transfer ownership of plant / equipment between the
                  normal plant ‘owner’ and maintenance personnel and/or other work groups. This
                  process shall be included within the operation’s isolation system documentation.

                  There will be degrees of formality in the record keeping side of this process. It is
                  acknowledged there will be situations where this requirement may not strictly apply
                  e.g. mobile equipment isolation, process operator ‘own’ isolation, etc. See the
                  “Situations where formal recording of this requirement may not apply” section below.

                  General Comments

                  A typical permit to work system manages these requirements and provides other
                  benefits such as defining the scope for people who receive ‘ownership’ of
                  equipment. An overview of the objective and purpose of a permit to work system is
                  available in Attachment E - Objective and Purpose of a Permit to Work System.

                  The lack of, or, failure to have effective permit to work systems has been identified
                  as a root causes in many significant catastrophes. Failures such as people working
                  on or isolating the wrong equipment can be avoided using a permit to work system.

                  For work considered to be ‘routine’, low risk and not of a complex nature, other
                  systems could be used to manage these requirements. See Definitions for further
                  explanation on the definition of ‘routine’ and ‘non-routine’.

                  Situations where formal recording of this requirement may not apply

                  Many operations are not recording the handover and hand back steps. This is
                  typically in situations where there is reliance on a tagging system alone and no other
                  formal system documentation is used i.e. no permits.

                  A good example of this practice is the typical mobile equipment isolation where a
                  lock and tag are the only formal visible declaration of ‘ownership’ of the equipment.
                  The transfer of ownership from the driver to the maintenance personnel is often not
                  formal or does not occur ‘face to face’.

                  The use of this type of system needs careful monitoring to ensure it remains formal
                  and is not used for situations where a permit to work system is more appropriate.

                  During normal operation of equipment where power is present and isolation forms
                  part of the operating procedure a separate isolation procedure is not required.




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          8.      Risk Assessment

                   The lock-out procedure shall begin with a risk assessment to ensure that work is
                   undertaken safely.

                  Intent

                  The intent of this requirement is for operations to have formally assessed how they
                  have decided to complete isolations for general and specific situations. The chosen
                  isolation methods must result from following a formalized risk assessment process.
                  This process may be completed during the development of the guideline and cover
                  general situations e.g. isolation of mobile equipment electrical circuits, isolation of
                  high voltage equipment etc. This aspect particularly applies to isolations involving
                  piping where there could be a variety of types or magnitude of energy and also a
                  variety of work methods requiring isolation being performed e.g. work within
                  confined spaces requires more thorough isolation than work on a low pressure
                  potable water line.

                  General Comments

                  a)   Risk Assessment for piping
                       -   General risk assessment techniques should be used to develop isolation
                           selection tools. Once the energy sources are identified the assessment
                           technique chosen should involve a qualitative calculation of the risk through
                           the examination of the potential consequences of exposure to the energy
                           source and the likelihood of this exposure occurring. The likelihood should
                           be considered as a function of exposure and probability. See the Anglo Risk
                           Management Guideline as a reference.
                       -   Whilst assessing the risk, consideration should be given to the
                           characteristics of the energy source, equipment, associated systems and
                           the intended work area. The scope of the intended work should also be
                           considered. All of these factors establish the risk profile for which an
                           isolation method is selected.
                       -   Some, but not all, of the factors requiring consideration are:
                       -   Physical state of energy sources (liquid, solid, vapour etc.)
                       -   Volume.
                       -   Potential flow rates
                       -   Toxicity
                       -   Flammability
                       -   Temperature
                       -   Pressure
                       -   Specific gravity (consider surroundings e.g. sumps and under flooring)
                       -   The natural ventilation of the surrounding area
                       -   The likelihood of any pressurizing of the line
                       -   The risks and hazards involved in providing the isolations

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                       -     Location of the work, i.e. confined space, limited access and egress
                       -     The proposed work that is associated with the isolation should be
                             considered as this will impact upon what potential outcomes could be
                             expected if the isolation fails.
                       -     Duration of the work
                       -     Determine the consequences that could most probably result from exposure
                             to these energies. For example: if people are working within an empty and
                             isolated tank the probability of the consequences of an isolation failure
                             would typically be greater than if they were working in an ‘open air’ area.
                             The normal isolation method for process piping containing a particular
                             substance may be a single valve closure where as spool removal or double
                             block and bleed (two valves isolated with an open bleed valve between
                             them) provides a higher level of safety for confined spaces.
                       -  The isolation method chosen should be assessed to determine whether the
                          integrity of the chosen method can be maintained throughout the duration of
                          the intended work i.e. valves may pass.
                       Note: The actual risk associated with performing isolation should be considered
                       and the appropriate method as dictated by the operations risk management
                       procedures should be used to assess and control the risk.
                  b)       Examples of isolation selection tools

                           The use of Isolation Selection Matrixes for assessing the characteristics of risk
                           and determining isolation methods is an effective approach to manage this
                           issue.

                           The Petroleum CSG – Isolation Selection Assessment tool, included in
                           Appendix C relies upon pre-selected assessment criteria which enable the
                           provision of a numerical rating for each of three factors. These three factors
                           are then multiplied together to determine the magnitude of the hazard. The
                           outcome of this calculation results in a numerical hazard rating which can be
                           reviewed against isolation methods rated numerically on a hierarchal potential
                           risk reduction basis.

                           The three factors are the Effect Factor (Location of work/equipment and
                           potential of energy source), Release Factor (pressure and line size and Time
                           Factor (duration and frequency of task).

                           There are similar tools in use at minerals processing operations and an
                           example is available in Appendix D - WMC Isolation Selection Tool and an
                           approach used within the Appendix D - Worsley Alumina Isolation Point
                           selection.

                  This (the isolation guideline) shall include, but not be limited to:
                       The role of work instructions, checklists, tagging requirements and the permit to
                       work system




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                       Related systems such as the Permit to Work, Excavation / Penetration, Hot
                       Work, Confined Space, Emergency Isolation process, …etc. should be outlined
                       within the isolation protocols and procedures for each operation.
                       A positive registration process for people working on isolated equipment
                       (personal tag, log sheet etc.)

                       This aspect of the requirement can be satisfied in a number of ways from permit
                       to work and tagging systems or registers. “Positive Registration” is documented
                       and signed record of people who are working on isolated equipment.
                       Changed requirements associated with the duration of the isolation and task/s,
                       or when tasks take longer than planned to complete

                       As work is completed on isolated equipment, unforeseen situations, that affect
                       the scope or expected duration of work, may arise. The isolation procedure
                       shall include how the operation will manage any changes associated with the
                       isolation.

                       The method of hand over or transfer between the outgoing and incoming
                       ‘owners’ of the isolation is required to be documented and should include the
                       transfer of information about any changes. The same formal handover between
                       work teams is also required.
                       Energy sources to be isolated (hazardous materials, mechanical, electrical etc.)
                       The physical state of the energy sources such as their phase (liquid, solid,
                       vapour etc.) and other characteristics (e.g. pressure, temperature, voltage etc.)
                       Controls required for the duration of the activity (temporary engineering and
                       operating changes, emergency procedures, personal protective equipment,
                       etc.)

                       This aspect of the requirement overlaps with the expected outcomes of a permit
                       to work system.

                       In situations where a permit system is not used or is not designed to cover
                       these aspects, for particular situations, then the isolation guideline shall satisfy
                       this aspect.
                       The requirements for formal contact with representatives in charge of each
                       facility area affected, (responsible supervisors) and the process for granting
                       written authorization to proceed

                       The transfer of ‘ownership’ from the plant and equipment owner to others is
                       required to be formally authorized. This authorization shall be recorded and
                       ‘signed off’ by the normal owner of the plant or equipment.

                       This ‘hand over’ of the owner ship (also the ‘hand back’) is another function of a
                       permit to work system. In situations where a permit system is not used or is not
                       designed to cover these aspects, for particular situations, then the isolation
                       procedure shall satisfy this aspect.
                       Special precautions when isolations cover one or more shift changeovers.

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                       An assessment should be made during isolation and job planning stages to
                       determine whether there are any precautions or peculiarities that exist that may
                       affect the safety of people i.e. ventilation monitoring requirements, gas
                       detection/sampling programs, etc.

                       These precautions should be recorded and be part of ownership ‘hand over’
                       processes between work teams. Ideally this process is best included within a
                       permit to work system.
                       Special precautions for the isolation of Critical Equipment and Systems.

                       Specific isolation procedures shall be in place for critical equipment (such as
                       critical alarms, emergency shutdown devices, relief and blow-down valves, fire
                       and gas detection and protection devices, and other items as designated in the
                       critical equipment register).

                       The intent of this requirement is that operations have documented procedures
                       in place for when individual pieces of critical equipment or critical systems are
                       isolated (removed) whilst the plant may continue to operate.

                       The procedures should include the necessary steps required to ensure the plant
                       and processes associated with the critical equipment/systems are left in a safe
                       state following isolation. A documented risk based contingency plan to ensure
                       the safety of personnel and equipment shall be completed.
                       Special precautions for Software Override Management.

                       Formal systems shall be in place for the approval, application and removal of
                       overrides in order to maintain the integrity of the plant. The application of
                       software overrides (and bridges) to the plant systems carries significant risk as
                       it reduces the operational integrity of the plant. These risks include:
                       Software overrides having unintentional consequences in removing or reducing
                       the effectiveness of personnel or equipment protection functions.
                       Software overrides having unintentional consequences in disturbing the normal
                       activities of other parties working in the plant.
                       Software overrides being left in place after they should be removed (with similar
                       impacts to the two points above).
                       The presence of bridges not being identified clearly - so that misunderstandings
                       of the present status of functionality occurs between individuals or groups, with
                       potential safety (or productivity) impacts resulting.




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          9.      Isolation Verification

                   All parties involved shall identify the equipment before the authorised person de-
                   ergises, isolates or locks out equipment. All parties involved shall ensure that the
                   equipment cannot be energised or operated inadvertently. There shall be provision
                   for multiple locks, if required. Each person working on the equipment shall apply
                   his own personal lock to prevent the isolation being removed.

                  Intent

                  The intent of this requirement is for all the parties involved in the task to verify that
                  they are protected against harm from inadvertent operations. The key words in this
                  requirement are “verify”. Verify means to confirm that all the steps required to
                  effectively isolating energy sources and hazardous materials has been completed.
                  This includes firstly the identification of the energy sources or hazardous materials
                  then what systems contain them, whether the isolation methods chosen are
                  appropriate, and lock and tags have been applied.

                  General Comments

                  In the case of high risk situations the use of a second/ independent person is
                  recommended to perform the verification step. This approach introduces a fresh set
                  of eyes to the planning and application of this plan thus reducing the opportunity for
                  human error. Dependant on the complexity of the equipment being isolated it is
                  often a good practice to involve the people who will be working on the isolated
                  equipment.

                  The verification process is an important step in isolating equipment and is often not
                  completed effectively or at all. To maintain effective verification processes requires
                  considerable focus to ensure the process doesn’t degrade. The verification process
                  offers extra layers of protection and is typically one of the last barriers between
                  injury and no injury. To remove this may not have an adverse outcome straight
                  away. That is until there are other failures in controls earlier in the process.
          10.     Testing

                   Once equipment has been isolated and locked out, it shall be the responsibility
                   of the authorised person to safely test that the equipment is made safe (all
                   energy is discharged). The type of test shall depend on the equipment but, in
                   all cases, all energy shall be discharged or controlled. This test shall be
                   described in the lock-out procedure. Only instruments approved for this
                   purpose shall be used for these tests. The tests shall include, but not be
                   limited to:
                   −    pressure
                   −    voltage, including induced voltage
                   −    redundant charges
                   −    elevated equipment



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                   −    enclosed areas
                   −    hazardous chemicals (particularly in confined spaces)
                   −    stored electrical energy
                   −    temperature
                   −    equipment under tension (e.g. conveyor belt)
                   −    equipment requiring regular operator access (e.g. chutes, screens)
                   −    sources of gas
                   −    mobile equipment.
                  Intent

                  The word in this requirement is to ensure operations have systems in place to check
                  the appropriateness and effectiveness of the isolation application. The key is to test
                  to confirm that the energy source is contained or dissipated (try/test or test for dead)

                  General Comments

                  Trying/testing of all systems and non-redundant isolations is an important
                  responsibility of the authorised person (to verify the integrity of the isolation and
                  ensure a zero energy state exists). In some cases it may be a good idea to involve
                  those about to work on the isolated equipment.

                  In reviewing significant incident reports it is often found that this step, which is the
                  last barrier before an isolation incident, is not performed.

                  Interlocks on electrical equipment may impact upon the ability to perform a try/test
                  step easily.
          11.     Securing equipment in the work area

                   All machinery or equipment that can cause harm in the immediate area shall also
                   be made safe.

                  The isolation, lockout and make safe requirements should be extended to all the
                  equipment, facilities and processes in the immediate area that could harm the crew
                  in charge of the work been conducted. This is especially relevant in those
                  “continuous flow” types of processes where activities are interdependent.
          12.     Documentation and Recording

                   Confirmation of isolation, lock-out, appropriate testing and making safe shall be
                   recorded and signed for by all affected parties.

                  The best way to approach this requirement in case of low or medium risk sort of
                  activity is through the Job Safety Analysis typically conducted before work is
                  initiated by the people involved. In the case of high risk type of activities, the work
                  permit should handle this authorization.




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          13.     Signage

                   A warning sign, stating that specific machinery has been de-energised because
                   work is in progress, shall be posted at the points of isolation.

                  This requirement can be satisfied with the use of proper personal or isolation
                  (system) tags where the reason for isolation is clearly specified as per requirement 5
                  of this Standard. A specific warning sign should only be required when a tag is not in
                  place at the isolation point, for whatever reason.
          14.     Clearance for Work

                   Only after all these procedures (Elements 7-13) have been adhered to, shall work
                   commence on the equipment.

                  Intent

                  The intent of this requirement is to manage the risk adequately. Where a ‘complete’
                  isolation cannot be achieved, a procedure shall be in place to mitigate hazards.
                  Special cases are those where any one of the following is not achievable:
                     a zero energy state
                     a test/try of isolation is not possible, or
                     Use of a locking device is not feasible

                  General Comments

                  Many operations have not conducted a systematic formal assessment of site to
                  identify special situations described. Relying on picking up these situations on a
                  case by case basis is not the best practice. An assessment of the operation to
                  identify these situations should be conducted and appropriate controls documented.

                  The clearance to work is not a permit. It is an outcome of a sequence of events
                  shown above.
          15.     Hand-over back to the Operator

                   After completion of the work, a hand-over procedure back to the operator shall be
                   in place.

                  A formal transfer of responsibility should take place to avoid any misunderstanding
                  or confusion about the completion of the work and the status of the equipment/
                  facilities.




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          16.     Risk Management and Audit

                   For audit trail and risk management, the responsible supervisor shall, on a
                   regular basis:
                   − re-assess the competence of the authorised persons
                   − audit the lock-out records and “permit to work” documents
                   − undertake a risk assessment on the lock-out procedure
                   − undertake planned task observations.

                  The intent of this requirement is to have a formal review program in place that
                  ensures the isolation and related systems are continually improving. The program
                  shall monitor system and in field compliance on a regular basis and shall be
                  documented. The results of these audits/ reviews shall be used to monitor the
                  adequacy of the system.

                  As part of the continual review process incident report trends should be considered
                  when reviewing systems.

                  System documents should be included within the sites document control system.
          17.     Incident Investigation / Learning

                   All safety incidents, including near hits, shall be reported, investigated and
                   analysed. Corrective and preventative actions shall be taken and closed out and
                   the learning’s shared as per the ANGLO SAFETY WAY Standard 11.

                  A formal system should be in place to review isolation related internal and external
                  incidents. The aim is to review lessons learnt from these incidents to assess the
                  potential for these events occurring at each operation.

                  Investigations should be extended to each time a personal lock is cut / removed by
                  someone other than the person that placed the lock. All attempts should be made to
                  locate the person who has left their lock on an isolation point. If persons can be
                  located and they have left the site, many operations require this person to return to
                  work and remove it. This practice re-enforces the criticality of the isolation system
                  and people learning from the experience, as the inconvenience associated with
                  returning to site is not easily forgotten (the impact of fatigue upon the safety of this
                  individual if they are to travel back to site should be considered).

                  If the person cannot be located and it is decided the lock needs to be cut off then
                  the work area should be inspected to ensure they are not present. The person
                  responsible for that area of the plant should be involved in the decision making
                  processes and provide authorization to remove locks.

                  Isolation or lock removal by other than the ‘standard’ isolation process requires,
                  should also be investigated and an incident report should be issued.




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8         PEOPLE REQUIREMENTS
          18.     Operator Identification

                   The person in charge of the operation of the equipment shall be clearly identified
                   and this shall be recorded. This person shall be identified as the operator for the
                   purposes of this Standard.

                  It is key to have a positive identification of the person in charge of the equipment or
                  machinery to be isolated (“owner”) in order to avoid confusion in the implementation
                  of the isolation standard. One of the most frequent causes of isolation-related
                  incidents is the isolation and/or the intervention of the wrong piece of equipment.

                  A person can be appointed as an operator in charge of a number of pieces of
                  equipment at the same time and this shall be recorded in writing as such.
          19.     Training

                   All individuals issued with personal locking devices shall be provided with training
                   and have their competence assessed on a regular basis.

                  Intent

                  Every person that could be potentially exposed to work under isolation procedures
                  should receive basic training on isolation basics in order to understand the reasons
                  and the practicalities of personalized locking/ tagging.

                  General Comments

                  Some Operations address this requirement during the site or area/ task induction for
                  new workers. A good check point to test this requirement is the completion of the
                  Job Safety Analysis by the work crew (definition provided in Definitions).
          20.     Responsible Supervisor role

                   The responsible supervisor is the person appointed in terms of applicable
                   legislation or internal regulations. The responsible supervisor shall:
                   −    ensure that all lock-out operations are carried out in terms of the lock-out
                        procedure
                   −    authorise suitably competent persons in accordance with requirements
                   −    ensure and record that all authorised persons remain competent (by
                        means of observation audits and re-training) to carry out their duties
                   −    ensure that the lock-out procedure remains current and that it is updated
                        when necessary (e.g. annually) to provide for equipment and/or process
                        modifications
                   −    ensure that the lock-out procedure is adhered to continually by conducting
                        verification exercises such as planned task observations.



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                  Intent

                  Clear responsibilities are established over the day to day application of the isolation
                  procedures. It is important that each role and the corresponding responsibilities
                  within the isolation system are clearly defined and documented. The accountability
                  and responsibilities for these roles should be clearly documented within the system.

                  Some good examples of detailed role definitions are included as appendixes within
                  the Permit to Work Guideline. An abstract of two of the roles associated with a
                  permit to work system is included in Appendix G – “Sample of Expected Role
                  Definition Detail”.

                  The people selected for key roles within isolations systems should be assessed
                  prior to being nominated for roles to ensure they possess the correct attributes
                  required by these important roles. A ‘ZERO HARM ethos is essential.

                  General Comments

                  A competency based training system and field assessment shall be in place to
                  approve personnel before they conduct isolation processes.

                  Competency based training should be structured and use should be made of
                  competencies developed from assessing what tasks people are expected to perform
                  for each nominated roles within the isolation system. The assessment should be
                  both theory and practical and aimed at determining whether the training has been
                  successful and whether the person demonstrates the correct skills.

                  The practical component should be completed such that people are exposing to
                  ‘real life’ situations and equipment.

                  All assessments should be challenging.

                  Further explanation of what a “competency based training” system means is
                  available in Definitions under “competency, competency standard and competency
                  based training”.

                  Behaviour based observations shall include tasks and activities associated with
                  isolation (e.g. observing someone actually isolating equipment and systems).

                  The operation shall have a system to review the observation system results with
                  flags (categories) to assist with the monitoring process. These flags shall be
                  monitored to identify trends.

                  Any need for additional specific retraining shall incorporate the results of these
                  observations.




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          21.     Authorised person role

                   The authorised person shall be responsible for the safe execution of isolation and
                   lock-out duties as per the lock-out procedure (Element 7).

                  The isolation, lockout and making safe task shall only be conducted by qualified
                  individuals whose competency has been regularly verified and authorized as such
                  by management. The competency based training principles discussed in the
                  previous requirement are also applicable in this case.

                  Roles and responsibilities for electrical, mechanical, or process isolation shall be
                  defined.




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APPENDIX A: RELATED DOCUMENTS

The Anglo Safety Way

Anglo Golden Rules

Anglo Fatal Risk Standard - Surface Mobile Equipment

Anglo Fatal Risk Standard - Underground Equipment

Anglo Fatal Risk Standard - Hazardous Materials

Anglo Fatal Risk Standard - Working at Heights



APPENDIX B: RECORD OF AMENDMENTS

Issue 0         :   New document (October 2008)




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APPENDIX C: PETROLEUM PROCESS ISOLATION SELECTION

The following Isolation Selection Table 1 indicates an isolation selection method to assist in
identifying the correct standard of isolation. Certain parameters have been established and input
into matrices, which formulate the Hazard Factor. The Hazard Factor calculation should be done
for all isolations.

The preferred standard of isolation is Double Block and Bleed for a Hazard Factor of 450 or less.
When this standard can be achieved the results of the Hazard Factor calculation should be
recorded on the Isolation Certificate, and DBB arrangements confirmed.

If the preferred standard of isolation, double block and bleed cannot be met, the process isolation
selection method should be referred to, to ensure work can progress in a compliant manner with a
lower isolation standard. This should be recorded on the isolation certificate.
•      If the Hazard Factor result is greater than 450, then a full risk assessment, Job Safety
       Analysis (JSA) is required.
•      This assessment should be recorded within the JSA and the OIM/Site Manager should
       sanction the isolation standard proposed.
•      A JSA shall be conducted for isolations with a Hazard Factor above 450 or for Confined
       Space Entry.

Process control valves and other operated valves, e.g. Emergency Shutdown Valves ESDV,
should not be relied upon, unless they are capable of being tightly shut off, disconnected from their
power source (if powered), locked in the shut position and the isolation proved to be effective by a
competent person carrying out a test.

Isolations of plant are of no value if they are not secure. It is vital that the isolation is maintained
throughout the work; generally all isolations should be made secure against disturbance. The
security mechanism can be a complex key system, a simple chain and padlock or a durable self-
locking tie wrap. Each secured valve should also be tagged and identified on the relevant isolation
certificate.

Many process valves are designated on P&ID’s as locked; the use of these valves is controlled via
a register. The Area Production Supervisor is responsible for ensuring the accuracy of the register.
Each locked valve is also tagged indicating whether it should be open or closed, and quoting the
register number.

The register contains details of valve numbers, the P&ID and line numbers, valve positions and
locations. A controlled set of P&ID’s should be kept with the register.




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APPENDIX D: WMC ISOLATION SELECTION TOOL

General

This tool is based on Quantitative Risk Assessment techniques and is designed to assist the
selection of an appropriate method of isolation of process plant using recognizable, readily
available parameters that are relevant to the hazard. The tool should be used along with common
sense, technical judgment and experience, especially when the tool provides a result hat is close
to a boundary between isolation methods.

PARAMETERS
1. Effect Matrix
     • Type of fluid (in terms of its flammability, toxicity or other hazardous properties, e.g.
       high/low temperatures, corrosion potential, etc.). See Table 2.
     • Situation (determining the potential for casualties, escalation or damage if there is a release
       of energy). See Table 1.

         These two parameters combined give an indication of the type of effect that might arise if
         the isolation fails. (See Table 3 – Effects Matrix)




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Note:
•       Vapour cloud explosions in congested or confined areas or jet fires may have the potential
        for knock on effects. Toxic releases may affect people over a wide area. If escalation is likely,
        consider increasing the severity of the situation type to a higher category.
•       In the case of a product containing more than one substance, use the most onerous
        substance type in the matrix.
2. Release Matrix
     • Line size and system pressure (these parameters will largely fix the potential release rate
       and therefore the extent of the area that could be affected).

These two parameters give a measure of the size of effect and they provide a ‘release’ factor from
the Release Matrix (see Table 4.)




                                                  ISOLATION GUIDELINE

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Table 4: Release matrix

                                                       System pressure

                                >10000KPa >5000KPa              >2000KPa         >1000KPa        <1000KPa

               >200mm           10             8                6                5               4
   Line size




               150mm            8              6                5                4               3

               100mm            6              4                3                3               2

               50mm             4              3                2                2               1

               <25mm            3              2                2                1                1

3. Time Matrix

          • Frequency of isolation procedure

          • Duration for which isolation is to remain in place

A frequent isolation for relatively long periods needs to be of a relatively high rating than an infrequent
one, which is to be in place for only a short time. These two parameters provide a ‘time’ factor from the
time matrix (see Table 5).

Table 5: Time Matrix

                                                            Duration

                                            > 7 days                   > 1 Shift                < 1 Shift

               Daily                               -                      10                          10
   Frequency




               Weekly                              -                      10                          7

               Monthly                          10                         7                          3

               Annually                            7                       3                          2

               Occasionally                        3                       2                          1

Note: the more frequent isolation introduces a greater risk that is also increased as the intended
duration increases. It is more difficult to maintain procedural controls due to handovers at shift
change between different groups of workers.

In determining frequency of isolation account needs to be taken of the “group effect” of a number
of items of similar duty on a plant e.g. a pump might typically require a seal change once every 12
months and therefore the frequency of isolation in the time matrix is annual. However if 4 such
pumps are installed the frequency of isolation would have to be increased to monthly.




                                                   ISOLATION GUIDELINE

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4. Hazard factor

     Combining the contributions of the three factors derives the hazard factor for isolation:

     Hazard factor = effects x release x time.

     The resulting Hazard Factor is a number in a range between 1 and 500

5. Selection of isolation standard

    There are three mechanical isolation standards.

     •      Standard 1 Single valve and bleed.

     •      Standard 2 Double block and bleed.

     •      Standard 3 physical disconnection or spool removal and fitting of blank flanges or insertion of
            spades or spectacle blinds. The particular isolation method is selected by using the following
            Table 6.




    Note:

    •    In all cases the seal integrity of each isolating valve for standard 2 and 3 must be confirmed
         prior to thee issue of a work permit.

    •    Bleeds and vents should be closed once it is confirmed that the energies have been controlled.




                                                  ISOLATION GUIDELINE

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APPENDIX E: WORSLEY ALUMINA ISOLATION SELECTION POINT TOOL

Isolation Point Selection– the Isolation Hierarchy of Control Matrix




                                                  ISOLATION GUIDELINE

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APPENDIX F: OBJECTIVE AND PURPOSE OF A PERMIT TO WORK SYSTEM

The primary objectives of a permit to work system are to exercise control over designated non-
routine activities by assigning responsibilities, ensure communication between work teams and key
personnel, ensure that hazards are identified and appropriate risk management precautions or
controls over the work being conducted are adopted.

The purpose of a Permit to Work system is to:
•      Provide a process for Supervisors to provide clearance and authorise non routine or high
       risk work
•      Clearly identify the location, specific plant and equipment and the nature and scope of the
       work to be carried out in relation to the area and process involved
•      Ensure that all hazards are identified and that appropriate controls are in place prior to work
       commencing and that they remain in place during work progress
•      Clearly identify the person(s) (employees and/or contractors) who:

       -      have overall responsibility for the control of the work

       -      are responsible for the execution of the work

       -      may be affected by the work.
•      Identify and document:

       -      personal protective equipment specific to the work

       -      other permits required for the scope of work to be completed

       -      safety devices such as pressure relief devices, interlocks, fire and gas detectors, deluges etc
              that have been inhibited or isolated

       -      emergency response procedures and equipment (where applicable).
•      Provide communication:

       -      to those affected by the work and status of progress until completion

       -      to personnel involved in carrying out the work ensuring they are briefed as to the scope and
              limitations of work, the isolations, the hazards and controls

       -      between those persons carrying out the work and those persons responsible for the overall
              control of the work.
•      Provide a documented formal hand-over process to ensure the relevant plant and equipment
       is available for taking out of service and the nominated work will not affect the safety of the
       rest of the facility
•      Ensure the isolations required for safe work is identified, documented, effected and tested
       (refer to AFRS No. 6)



                                                  ISOLATION GUIDELINE

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•      The plant and equipment, where required, has been decontaminated and as far is practicable
       the working environment has been made safe for personnel, without specialised personal
       protective equipment (which should be a last resort)
•      Provide authorisation to commence work
•      Enable the efficient coordination of PTWs by ensuring that active permits are displayed in a
       central location (e.g. control room or permit issue office) and a copy is available at the
       workplace
•      Provide a system that manages situations where the work continues beyond the completion of
       a single shift (for 24 hour operations) or beyond the end of the work day
•      Ensure that personnel carrying out the work have the appropriate skill and knowledge
•      Provide a formal hand-back process to ensure the work area is safe to return to normal
       operation when the work is completed
•      Provide a record of a safe system of work for non routine tasks or high risk work.




                                                  ISOLATION GUIDELINE

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APPENDIX G: SAMPLE OF EXPECTED ROLE DEFINITION DETAIL

Permit Issuer

Competency required:
•      Comprehensive in depth knowledge of the work environment and the processes including the
       area related hazards
•      Comprehensive in depth theoretical and practical knowledge of the Permit to Work System
•      Knowledge of competencies and skills required to perform work in their designated area
•      Technical skills related to the work being performed (e.g. Training in Risk Assessment,
       JSA/JHA, High Voltage awareness, Radiation awareness, Hot Work, Confined Space Entry
       etc.).

Responsible for:
•      Determining whether a PTW is required. Refer to PTW Requirement Criteria
•      Reviewing the PTW document and JSA/JHA(s) from the Permit Holder and agreeing the final
       set of hazard controls for the defined scope of work
•      Ensuring all inherent area and equipment hazards are identified, recorded on the PTW and
       captured within the JSA/JHA or Work Instruction
•      Reviewing the quality of the JSA/JHA or Work Instruction to ensure the document represents
       a structured risk analysis/hazard control approach
•      Defining who is responsible for the implementation of specific hazard controls and recording
       this on the permit e.g. equipment isolation
•      Ensuring the JSA/JHA/Work Instructions have been completed by the Permit Holder/Work
       Team and attached to the PTW
•      Defining the isolation requirements on an Isolation List
•      Initiating implementation of the hazard controls identified on the PTW as their responsibility
•      Confirming that all agreed hazard controls defined in Certificates have been completed signed
       off by authorised personnel and attached to the PTW
•      Confirming that the work site is safe for work to commence
•      Briefing the Permit Holder on the hazard controls that have been put in place.
•      Authorising the issue (signing) of the PTW
•      Identifying other work activities from neighbouring work teams which may impact on the work
       being proposed
•      Managing and maintaining the security of the isolation devices, key sets and Permit Issuers
       lock and key cabinet
•      Ensuring the original of all PTWs and associated Certificates are maintained.
•      Establishing a register of all live PTWs


                                                  ISOLATION GUIDELINE

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•        Formally handing over the control of active PTWs to an on-coming shift Permit Issuer as
         required e.g. on-coming shift Permit Issuer
•        Ensuring, when work is complete, the site is inspected to ensure that it has been left in a safe
         condition and ready for return to normal operation
•        Ensuring that work and isolations that impact upon Critical Equipment and Systems are
         authorised by the senior area management
•        Involving the site HSE Emergency Response Section for the isolation of fire detection and
         suppression systems
•        Initiating the removal of hazard controls following hand back of the PTW
•        Authorising closure of the PTW
•        Maintaining the integrity of permit records and archiving system ensuring PTW documentation
         is archived according to site policy.

Isolation Officer

Competency required:
    •      Technical skills to be able to perform and verify isolations within their designated area
    •      Comprehensive theoretical knowledge of the process equipment and systems within their
           designated area (for production areas)
    •      Comprehensive theoretical and practical ability to manage particular isolations within their area
           or discipline
    •      Comprehensive knowledge of the Permit to Work System including the responsibilities of the
           Isolation Officer, Permit Issuer, Permit Holder, Permit User.

High Voltage Isolation Officer
    •      Technical skills to be able to perform and verify High Voltage isolations within their designated
           area. This work shall only be performed by qualified electrical people and is not required for the
           other non High Voltage isolations.

Is responsible for:
    •      Developing a strong working relationship with the designated Permit Issuer
    •      Planning isolations according to defined scopes of work. Defining the isolation requirements
    •      Performing isolations according to the requirements of the operation’s isolation procedures
    •      Testing for residual energies following isolation
    •      Establishing and monitoring the effectiveness of purging and ventilation systems
    •      Ensuring a verification of isolation integrity is undertaken
    •      Documenting/ signing for Isolation Certification
    •      Conducting routine inspections of the work environment

                                                  ISOLATION GUIDELINE

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APPENDIX H: TEMPORARY EQUIPMENT TO ASSIST WITH LOCKING ELECTRICAL
EQUIPMENT

This equipment is part of the master lock range and is available through any master lock supplier.

Circuit Breaker Lockout Devices
•      Easy to apply and lock; no tools required
•      Versatile covers lock out most circuits breakers:
         −   No. 491 oversized breaker device fits toggle switches to 63.5mm wide x 22.2mm thick
         −   No. 492 for single pole circuit switches having recessed side-holes
         −   No. 493 with convenient thumbwheel, for 277 and 120 volt switches
         −   No. 494 with convenient thumbwheel, for 480/600 volt switches
         −   No. 495 with universal multi-pole devices for breakers with tie-bar
•      Position cover over switch (in “OFF” position). Secure. Apply padlock. Use Master Lock                           No.
       7C5RED padlock for maximum locking flexibility
•      Sold in packs containing six units (except No. 491)
•      No. 490 fuse blockout, with a tag, provides effective OSHA tagout of a fuse block




        No.490                              No.491                             No.492




        No.493                              No.494                             No.495




                                                  ISOLATION GUIDELINE

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Circuit Breaker Switch Padlock

Provides the Flexibility to Effectively Lock Out Breaker Switches
•    Flexible steel cable shackle allows padlock to properly lock all
     types of circuit breaker lockout devices
•    Flexi-cable allows the lock body to be moved out of the way, and
     panel door to be closed properly
•    Fits the tight space constraints within circuit breaker shutoff boxes
•    Numerous key changes are available to minimise the possibility of
     unwanted key duplication


Circuit Breaker Switch Padlock

7C5RED

Provides the flexibility to effectively lockout Breaker Switches




                                                  ISOLATION GUIDELINE

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                                                  ISOLATION GUIDELINE

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APPENDIX I: TEMPORARY EQUIPMENT TO ASSIST WITH LOCKING VALVES




                                                  ISOLATION GUIDELINE

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Examples easy to use universal valve lockout equipment
•      Universal Fit effectively locks out all valves from 9.5mm to 101.5mm
•      Single model fits a variety of sizes and styles eliminating the need for valve specific lockout
       devices
•      Easy to use, compact and flexible
•      Complete with high-visibility, re-usable, write-on safety labels
•      Designed for harsh environments




8611 Adjustable Cable Lockout

−    Infinitely adjustable for secure fit every time

−    Tough multi strand 6mm x 1830mm clear vinyl
     coated steel cable.

−    Lightweight Xenoy body for extreme conditions.

−    Temperature Rating up to 93oC




                                                  ISOLATION GUIDELINE

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APPENDIX J: TEMPORARY EQUIPMENT TO ASSIST WITH ATTACHING LOCKS

Safety Lockout Hasps
•      Multiple Styles and Sizes available to fit most needs:
•      Spark resistant aluminium
•      Pry proof steel
•      Dielectric plastic
•      Dual jaw aluminium




          0420      0421                      416                         418                    419




                   429               428




                                                  ISOLATION GUIDELINE

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APPENDIX K: LOCK BOX




                                                  ISOLATION GUIDELINE

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                                                  ISOLATION GUIDELINE

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Lock Box for very large work teams
       Lock box for very
       large work teams




                                                  ISOLATION GUIDELINE

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APPENDIX L: ISOLATION LOCKS




                                                  ISOLATION GUIDELINE

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APPENDIX M: ISOLATION POINTS LABELLING EXAMPLES




                                                  ISOLATION GUIDELINE

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                                                  ISOLATION GUIDELINE

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