Conducting safe isolation
Industrial Version
Loss Prevention Safety Campaign
Outline
▪ Importance of isolation
▪ Steps to perform safe isolation
▪ Roles and responsibilities
▪ Types of isolation
▪ Removal of lock out devices
Saudi Aramco: Company General Use
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Click to advance
What happened?
Isolation integrity was not verified
Saudi Aramco: Company General Use
Incident analysis:
▪ multiple MOVs were passing.
fatalities ▪ work began without proper
isolation.
▪ flange was opened before the
injuries tank was emptied.
▪ gas test not performed when
flange was initially unbolted.
▪ work continued in spite of the
crude flow.
▪ work continued in a flammable
atmosphere.
▪ uncontrolled ignition sources
(vehicles).
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Importance of isolation
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Lock out/Tagout (LOTO)
Definition:
▪ Safety procedure that ensures that
energy sources are properly isolated to
prevent unintended release or
unexpected start up before the
completion of maintenance or repair
work.
▪ LOTO is for everyone.
Saudi Aramco: Company General Use
Importance of isolation
Why is isolation important? When do you isolate?
▪ Provides protection of workers ▪ Before maintenance or repair
and assets when performing work starts where there is
maintenance, inspection, or potential for any uncontrolled
repair. release of hazardous energy.
▪ Controls hazardous energy ▪ Before any work requiring a line
sources. break.
▪ Prevents loss of primary ▪ Before any confined space entry.
containment.
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Failing to isolate correctly
Failure to:
• Stop equipment.
• Disconnect from power source.
• Remove residual energy.
• Depressurize before line opening.
• Prevent unexpected restarting.
• Clear the area before restarting.
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Steps to perform isolation
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Steps to perform isolation
1 Identify
2 Communicate
▪ energy sources with all affected personnel** before
▪ potential hazards * work begins.
▪ potential locations --------------------------------------
** affected by the shut down/isolation.
-------------------------------------
Might require countersignatures on
* Hazard Identification and Control, permits from affected organizations.
Section 2 on the work permit
3 PPE
4 Shutdown
must be worn appropriately for job. machine or equipment in a safe
manner.
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Loss Prevention Department
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Steps to perform isolation
5 Isolate 8 Verify
valves, process pipes, etc. proper isolation has been
performed through an authorized
employee:
6 LOTO Procedures ✓ permit Issuers double check
with permit Receivers.
with all affected personnel before
work begins.
7 Clear
area of personnel and equipment.
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Roles and responsibilities
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Roles and responsibilities
Management
▪ Develop isolation, lock out, and hold tag
procedures for their operation in
compliance with GI 6.012.
▪ Develop specific isolation, lock out, and
hold tag procedures for hazardous
processes.
▪ Train relevant personnel in all elements of
the organization’s isolation, lock out, and
use of hold tag program.
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Roles and responsibilities
Operations & Maintenance
▪ Implement locally developed isolation/lock out
procedures appropriate for the task.
▪ Implement isolation/lock out procedures (GI 6.012).
▪ Provide isolation/lock out equipment.
▪ Check and verify isolation.
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Roles and responsibilities
Contractors & Work Crew 1/3
▪ Implement the proponent organization's isolation procedure.
▪ Check and verify the isolation.
▪ All workers must have individual protection.
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Roles and responsibilities
Contractors & Work Crew 2/3
Group lock out procedure:
▪ The proponent representative must lock and tag each
isolation point with single keyed locks and place the key in a
group lock out box.
▪ Maintenance/construction supervisor must lock and tag each
isolation point and place the key(s) in a group lock out box.
▪ The proponent representative must then install a lock on the
group lock out box first and maintain possession of key(s)
until the job is complete.
▪ Each member of the maintenance/construction crew must
then place a lock and tag on the group lock out box and
maintain possession of key until the job is complete.
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Roles and responsibilities
Contractors & Work Crew 3/3
Group lock out procedure (Continued):
▪ If crew members leave the job site temporarily, their locks
and tags may be left installed.
▪ If a shift change occurs while the work is incomplete, the
oncoming shift may replace the previous shift’s locks and tags
with their own locks and tags.
▪ Proponent’s locks and tags may be left installed, following a
detailed review of the installed locks and tags.
▪ Keys for the locks must be transferred at this time.
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Types of isolation
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Process piping and equipment isolation
LOW Protection level HIGH
Single Double
Block Block & Blinding Disconnection
Valve Bleed
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Process piping and equipment isolation Click to advance
Single Block Valve
How to
▪ Close, Lock and Tag.
▪ Drain, vent and purge content.
0 psig
100 ▪ Ensure/check isolation integrity.
When to use it
▪ Simple/routine maintenance activities.
▪ Primary isolation for blind installation.
▪ Not used for confined space/hot work.
Preference
Positive isolation? NO
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Process piping and equipment isolation Click to advance
Double block and bleed (DB&B)
How to
▪ Close, Lock and Tag block valves.
100
0 psig
▪ Drain/Vent valve:
□ Make sure is not clogged/blocked.
□ Attach a hose/hard piping to it.
□ Open, lock and tag drain valve.
□ Drain to a safe location.
▪ Ensure/check isolation integrity.
When to use it
▪ Simple/routine maintenance activities.
▪ Primary isolation for blind installation.
▪ Not used for confined space/hot work.
Preference
safe location
Positive isolation? NO
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Process piping and equipment isolation Click to advance
Blinding 1/2
How to
0 psig
100
▪ Close, Lock and Tag.
▪ Drain, vent and purge content.
▪ Ensure/check isolation integrity.
▪ Unbolt flange and separate faces.
▪ Insert blind and tag .
When to use it
▪ Hot work activities/ confined spaces.
Blind must: Preference
▪ be rated; same pressure/temperature
as flange joint.
Positive isolation? YES
▪ be stamped with rating.
▪ have matching gasket.
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Process piping and equipment isolation
Blinding 2/2
0 psig
Isolation plan includes:
▪ Drawings of all isolation points,
drains, and vents.
▪ Blind list to track installation/removal
of blinds.
▪ Steps for depressurization, draining,
purging, and disposing of drained
material.
▪ Site preparation steps (e.g. covering
sewers, stopping hot work).
▪ Proper sequence for installing blinds.
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Saudi Aramco: Company General Use
Process piping and equipment isolation Click to advance
Disconnection
How to
0 psig
100
▪ Close, Lock, and Tag.
▪ Drain, vent, and purge content.
▪ Ensure/check isolation integrity.
▪ Unbolt the flanges and remove the
section of the pipe.
▪ Insert flange blind at the process side
and tag.
When to use it
▪ Long term maintenance.
▪ Hot work activities/confined spaces.
Preference
Positive isolation? YES
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Electrical isolation Click to advance
Identify Notify Lock Tag Clear Try
▪ Locations ▪ affected
▪ Type personnel
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Loss Prevention Department
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High voltage is unique
▪ inherent/special hazards
Do not attempt to isolate unless:
▪ proper Power Operations Department isolation permits completed
▪ you are properly trained according to GI 2.721
▪ you use the proper arc rated PPE
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Removal of lock out devices
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Loss Prevention Department
Removal of lock out devices
Lock out devices can be removed when: Proponent organization
▪ the job is complete. ▪ is the first to install and last to
remove locks and tags.
▪ a crew member leaves the job site
permanently.
▪ locks and tags are changed during shift
Supervisors
changes.
▪ must check that the area is safe to
return to service.
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Saudi Aramco: Company General Use
Procedure for removal of lock out devices
Notify all personnel Remove lock out/tagout devices
▪ It is vital that you ▪ The person who placed each
communicate with all lock and tag must be the one to
affected personnel that the remove it.
lock out/tagout devices are
being removed. ▪ If the person who put the lock
and tag in place is not available,
▪ Ensure that all employees follow GI 6.012 for removal
and contractors are instructions.
removed from the area or
are a safe distance from ▪ If you are not authorized, do not
the equipment that is being remove a lock or a tag.
re-energized.
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Learn more
▪ The LOTO course BET 40069962 is designed to teach employees/contractors
how to identify equipment, energy and/or systems that require the
application of LOTO.
▪ This classroom course also outlines how to apply the correct isolation
methods to make systems safe before any work can be performed, and how
to safely return equipment to operational state for safe operations.
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Stop Work authority
▪ All personnel have the authority to
stop any unsafe work.
▪ If you observe any unsafe work that has
the potential to injure personnel,
damage equipment, or harm the
environment, you are empowered to
stop work and report your concerns to a
supervisor.
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References
▪ GI 2.100 Work Permit System
▪ GI 6.012 Isolation, Lock out and Use of Hold Tags
▪ GI. 2.721 Electrical Arc Flash Hazard Mitigation
▪ GI 2.709 Gas Testing Using Portable Gas Monitors
▪ Construction Safety Manual, Chapter I-5, Isolation, Lock out and Use of Hold
Tags
▪ SMS Manual, Element 6, Safe Operations
▪ Safety Handbook
33 03/08/2017
Loss Prevention Department
Saudi Aramco: Company General Use
Thank you
