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MECHANICAL LOCK OUT TAG OUT PROCEDURE

Equipment description: ASU

Tag/Item number(s): N/A

A 02 07.07.2009 ES SW GJ ICC ISSUED FOR COMPANY COMMENTS


O 01 01.08.2008 DV SW JS ICC ISSUED FOR COMPANY COMMENTS
Proj. Contr Date By Chkd Appr. Status Revision reason for issue description
Rev. Rev

Linde Project ID: 1110 A05M Linde Project Code: PEARL QATAR
Shell Project No.: HP-3000-QAT Contractor name:
Contractor Project No.: 5887 Unit: ASU

Linde
Engineering
Contractor Contract No.: PI-092 PCWBS: Z

PEARL GTL Contractor Doc No: 0100 W-PE 0042 Rev: 02


Orig. Org.:
PROJECT
QATAR LIN Project Doc No: T-4.240.737 Rev: A

Intellectual property rights reserved.


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QATAR Proj Doc No: T-4.240.737 Rev: A

TABLE OF CONTENTS

1 PURPOSE...........................................................................................................................3

2 SCOPE................................................................................................................................3

3 DEFINITIONS AND ABBREVIATIONS..............................................................................3


3.1 Definitions...................................................................................................................................................................3

3.2 Abbreviations.............................................................................................................................................................5

4 REFERENCES....................................................................................................................5

5 ROLES AND RESPONSIBILITIES.....................................................................................6


5.1 Construction Manager..............................................................................................................................................6

5.2 HSSE Site Manager...................................................................................................................................................6

5.3 Discipline Superintendents.......................................................................................................................................6

5.4 Subcontractors...........................................................................................................................................................6

6 RISKS.................................................................................................................................6

7 PROCEDURE.....................................................................................................................7
7.1 Training......................................................................................................................................................................7

7.2 Lock out tag out process............................................................................................................................................7


7.2.1 General....................................................................................................................................................................7
7.2.2 Lock Out / Tag Out Devices...................................................................................................................................8
7.2.3 Application.............................................................................................................................................................8
7.2.4 Group Lock Out / Tag Out......................................................................................................................................9
7.2.5 Procedure................................................................................................................................................................9
7.2.6 Testing Equipment during Lock Out....................................................................................................................10
7.2.7 Energise the equipment, machine and/or process to ensure that it is operating properly...................................11
7.2.8 Methods of Locking Out Controls........................................................................................................................11
7.2.9 Locks, Blocks and Tags.........................................................................................................................................11
7.2.10 Restoring Equipment to Service......................................................................................................................14
7.2.11 Temporary removal..........................................................................................................................................14
7.2.12 Shift or Personnel Changes.............................................................................................................................14
7.2.13 Periodic Inspection...........................................................................................................................................14

ATTACHMENTS.....................................................................................................................15
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QATAR Proj Doc No: T-4.240.737 Rev: A

1 Purpose
The purpose of this document is to establish a systematic procedure to be used to de-
energise or render inoperable any hazardous systems, valves, switches, machine,
equipment, and / or process for the purposes of construction, repair, maintenance, or
installation.

The procedure also prevents the unauthorised, unplanned, unscheduled start-up or


operation of de-energised machinery, equipment or processes.

It is Linde LE's responsibility to ensure that training is available for its employees and
that this information is communicated to its employees who are expected to be operating a
lock out / tag out system. It is Subcontractors' responsibility to ensure that training is
available for their employees and that this information is communicated to their employees.

This document does not cover the requirement for the isolation of electrical power
installations. For isolation of electrical systems refer to Pearl GTL Electrical Safety Rules T-
4.599.556.

2 Scope
This document addresses all mechanical, pneumatic and hydraulic systems and
equipment that may be required to be isolated during construction, commissioning, testing,
inspection, maintenance and repair / replacement carried out on the Pearl GTL ASU Project
by Linde LE or its Subcontractors.

3 Definitions and abbreviations


3.1 Definitions
Affected Employee
An employee whose job requires him/her to operate or use a machine or
equipment on which servicing or maintenance is being performed under lockout
or tag out, or whose job requires him/her to work in an area in which such
servicing or maintenance is being performed.

Authorised Employee (Competent Person)


A person who locks out or tags out machines or equipment to perform
service or maintenance on that machine or equipment. An affected employee
becomes an authorised employee when that employee's duties include servicing
or maintenance covered in these guidelines.

Capable of being Locked Out


An energy isolating device is capable of being locked out if it has a hasp or
other means of attachment to which or through which a lock can be affixed, or if
it has a locking mechanism built into it. Other energy isolating devices are
capable of being locked out, if block out or lock out can be achieved without the
need to dismantle, rebuild, or replace the energy isolating device or permanently
altering its energy control capability.

Energised
Connected to an energy source, or containing residual or stored energy.
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Energy Isolating Device


A mechanical device that physically prevents the transmission or release of
energy, including but not limited to the following:
 a manually-operated circuit breaker;
 a disconnect switch,
 a manually operated switch by which the conductors of the circuit can be
disconnected from all ungrounded conductors, and, in addition, no pole
can be operated independently,
 a line valve,
 a block valve,
 any similar device used to block or isolate energy

Push buttons selector switches and other control circuit devices are not
energy isolating devices.

Energy Source
Any source of electrical, hydraulic, pneumatic, chemical, thermal, or other
energy

Hot Tap
A procedure used in the repair, maintenance and services activities that
involves welding on a piece of equipment (pipelines, vessel or tanks) under
pressure, in order to install connection or appurtenances. It is commonly used to
replace or add sections of pipeline without the interruption of service for air, gas,
water, steam or petrochemical distribution systems.

Lock Out
The placement of a lock out device on an energy isolating device, in
accordance with an established procedure, ensuring that the energy isolating
device and the equipment being controlled cannot be operated until the lockout
device is removed.

Lock Out Device


A device that uses a positive means such as a lock, either a key or
combination type, to hold an energy isolating device in a safe position and
prevent the energising of the machine or equipment. Also included are blank
flanges and slip blinds.

NOTE: Lockout devices shall be standardized within the facility in at least one of
the following criteria:
 colour,
 shape,
 size.

Normal Production Operations


The utilisation of a machine or equipment to perform its normal operation

Servicing and / or Maintenance


Workplace activities such as constructing, installing, setting up, adjusting,
inspecting, modifying, and maintaining and / or servicing machines or equipment.
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QATAR Proj Doc No: T-4.240.737 Rev: A

These activities include lubrication, cleaning or un-jamming of machines or


equipment and making adjustments or tool changes where the employee may be
exposed to the unexpected energising or start up of equipment or release of
hazardous energy.

Setting Up
Any work performed to prepare a machine or equipment to perform its
normal production operation.

Tag Out
The placement of a tag out device on an energy isolating device, in
accordance with an established procedure, to indicate the energy isolating device
and the equipment being controlled may not be operated until the tag out device
is removed.

NOTE: Tag out devices shall be standardised in print and format, their attachment
devices shall be a non-reusable type, attached by hand, self locking, with a
minimum unlocking strength of no less than 50 pounds and having the general
design and basic characteristics of being at least equivalent to a one piece all
environment tolerant nylon cable tie.

Tag Out Device


A prominent warning device, such as a tag and a means of attachment, which can be
easily, fastened to an energy isolating device in accordance with an established procedure,
to indicate that the energy isolation device and the equipment being controlled may not be
operated until the tag out device is removed.

3.2 Abbreviations
Item Description
GTL Gas to Liquids
IC Implementation Contractor
LOTO Lock Out / Tag Out
PMC Project Management Contractor
QSGTL Qatar Shell GTL
RLC Ras Laffan City
TSTI Total Safety Task Instruction

4 REFERENCES

PROJECT SPECIFICATIONS Part IV, Chapter 9, Appendix 1 Chapter 2.4


PROJECT SPECIFICATIONS Part IV, Chapter 9, Appendix 1 Chapter 2.10
PROJECT SPECIFICATIONS Part IV, Chapter 9, Appendix 1 Chapter 2.13
PROJECT SPECIFICATIONS Part IV, Chapter 9, Appendix 1 Chapter 2.8
Shell Yellow Guide Electrical Safety
5887-ON-PR-HM-013 PERMIT TO WORK PROCEDURE
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5 Roles and Responsibilities


5.1 Site Manager
The Site Manager is responsible for compliance with this procedure and
shall provide the personnel, facilities and other resources necessary to effectively
implement, administer and enforce this procedure. The Site Manager is
responsible for the implementation of this procedure.

5.2 HSSE Site Manager


The HSSE Site Manager is responsible for the development of an effective
training program for this procedure. The HSSE Site Manager is responsible for
auditing of the implementation and the effectiveness of this procedure.

5.3 Discipline Superintendents


The Discipline Superintendents are responsible for the implementation of
this procedure.

5.4 Subcontractors
All subcontractors are responsible for the development of their Lock out/Tag
out procedure (in line with this procedure), the implementation and the training
of their employees.

Subcontractors shall ensure that all its employees and all lower tier sub
contractors comply and actively participate with its requirements.

6 Risks
Failure to adequately identify and guard against the hazards associated with
equipment isolation may result in serious injury, death, damage to assets and
loss of local and international reputation.
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7 Procedure
7.1 Training
All personnel involved in the isolation of equipment and processes will be
fully trained in the requirements of this procedure and how it interfaces with the
TSTI and the Permit to Work Process.
All personnel authorised to perform a lock out-tag out shall receive training in the
following:
 Recognition of hazardous energy sources,
 Types and magnitudes of hazardous energy sources,
 Methods and means necessary for energy isolation and control,
 The lock out tag out procedure.

Affected Employees:
 Instruction in the purpose and use of the lock out / tag out program
 All other employees whose work operations are or may be in the area
where
 Energy control procedures may be used.

7.2 Lock out tag out process

7.2.1 General

The lock out system shall be used if the equipment is capable of accepting a
lock out device. If the equipment is not capable of being locked out, the tag out
system shall be used.

When / where possible, a tag out system is to be used in addition to the lock
out.

Lock out / block out means that any energy source, whether it is electrical,
hydraulic, mechanical, compressed air or any other source that might cause
unexpected movement, must be disengaged or blocked and electrical sources
must be deenergised and locked or blocked to prevent inadvertent movement.
Potential energy that may need to be blocked can come from suspended parts
(subject to gravity) or may be energy stored in springs.

When major replacement of parts or repair is to be performed on or to


equipment, processes and / or machinery it must be designed to accept a lock
out device.

Lock out-tag out devices are to be colour coded and used only for lock out
operations. The lock out-tag out device must show the identity of the person who
applied the device.
The tag out device shall have the words: "DO NOT OPERATE" and warn against
the hazardous condition of the equipment/process if it becomes energised.
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All activities relating to lock out / tag out shall be clearly defined within the
relevant sections of the TSTI and identified on the Permit to Work documentation.
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7.2.2 Lock Out / Tag Out Devices

Lock out devices shall be used, unless the usage of a lock out device would
result in the need to dismantle, rebuild, replace the energy isolating device, or
permanently alter its energy control capability.

When a tag out device is used on any energy isolating device that is capable
of being locked out the tag out device shall be attached at the same location that
the lockout would have been.

It shall be demonstrated that the tag out program will obtain the level of
safety equivalent to that obtained by using the lockout program.

In demonstrating that the level of safety is equivalent to that of the lockout


program, all provisions of the tag out guidelines shall be followed.

Additional means to consider as part of the demonstration of full employee


protection shall include the implementation of additional safety measures such as
the removal of an isolating circuit element, blocking of a controlling switch,
opening of an extra disconnecting device, or the removal of a valve handle to
reduce the likely hood of inadvertent energising.

NOTE: Lock out / tag out devices shall be singularly identified, and shall be the
only device(s) used for controlling energy and shall not be used for other
purposes.

7.2.3 Application

Affected employees shall be notified by the CONTRACTOR supervision or the


authorised employee of lock out / tag out applications or removal. The
notification shall be given before the controls are applied and after they are
removed from the machine or equipment.

Before an authorised or affected employee turns off a machine, or a piece of


equipment the authorised employee shall have knowledge of the type and
magnitude of the energy, the hazards of the energy to be controlled, and the
method or means to control the energy. The machine or equipment shall be
turned off or shut down using procedures established for that specific job. An
orderly shut down must be utilised to avoid hazards to employees.

All energy isolating devices that are needed to control the energy to the
machine or equipment shall be physically located and operated in such a manner
as to isolate the energy source(s). Lock out and or tag out devices shall be affixed
to energy isolating devices by an authorised employee and when used, affixed in
such a manner that it will hold the device in a safe or off position.

Following the application of the isolation device(s), all potentially hazardous


stored or residual energy shall be relieved, disconnected, restrained, or other
wise rendered safe. If re-accumulation is possible, verification of the safe
isolation shall continue until the job is complete or the possibility no longer
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exists. Prior to start of the job, the authorised employee shall verify that the
isolation has been accomplished.

7.2.4 Group Lock Out / Tag Out

When service and/or maintenance is performed by a crew, craft,


department, or other group, a documented procedure shall be used to afford
employees the level of protection equivalent to that provided by personal lock
out / tag out procedure.

Primary responsibility is vested in one authorised employee for a set


number of employees working under the protection of the group lock out / tag
out procedure.

Provisions for the authorised employee to ascertain the exposure status of


individual group members (i.e., CONTRACTORS group Lock out /Tag out Permit).

Where more than one work group, craft, department, etc. is involved, the
assignment of the lock out / tag out coordination to one authorised employee.

Each authorised employee shall affix a personal lock out / tag out device to
the group lock out / tag out device, group lock box, or comparable mechanism at
the beginning of the job and remove at the end of the job.

Picture 1 Example of Group Lockout device.

7.2.5 Procedure

The lock out / tag out process must be fully identified on the TSTI and/or
Permit to Work. A survey of the equipment/process is to be conducted by a
person(s) who are thoroughly familiar with its operation and associated hazards
in order to identify which equipment should be locked and blocked out.

Once equipment / processes are identified, lockout, block out, tag out
devices must be selected and made available.
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Locate and mark the disconnecting means indicating their function (e.g.
crane, welding machine, etc.). A sign or sticker, "LOCKOUT HERE" should be
placed at the disconnecting point to assist personnel in selecting the correct
lockout devices.

Personnel authorised to shut off equipment, process and or machine shall:


locate and identify all energising devices (i.e. circuit breakers, valves, etc.). They
shall give advance notice to all affected personnel that a lock out / tag out of
equipment, process or machine is scheduled to occur.

Know and follow the shutdown procedure for the equipment, process or
machines that is to receive the work. Steam, air, and hydraulic lines shall be
bled, drained, and cleaned out. There shall be no pressure in these lines or in
reservoir tanks. Any mechanism under load or pressure, such as springs, should
be released and blocked.

Install lockout devices, (devices to carry the name and badge number) so as
to prevent the equipment from being started or activated while work is being
performed.

NB. ALL ENERGY SOURCES WHICH COULD ACTIVATE THE MACHINE MUST
LOCATED AND BE LOCKED OUT.

Install lock out/tag out devices so as to prevent the equipment from being
started or activated while work is being performed, once installed the person
responsible for the isolation shall test its effectiveness by trying to activate the
equipment, process or machine at the equipment's/process's "off-on" switch or
valve before proceeding with work, If the equipment, process or machine fails to
become energised upon trying the "off-on" switch or valve the equipment,
process and or machine is considered locked out of service.

If more than one individual is required to lock-out equipment each person


shall place their personal lock and tag on the isolating device.

When multiple locks cannot be used; a multiple lock hasp can be used.

7.2.6 Testing Equipment during Lock Out

Where, when during maintenance and repair operations, machinery may


require to be tested, and therefore, energised before additional maintenance
work can be performed, the following procedure shall be followed:
 Ensure all personnel are moved to a position of safety.
 Remove all tools and materials from the equipment.
 Remove lockout devices, and re-energise systems following the
established safe procedure.
 Proceed with the required testing of the equipment.

On completion of the test, neutralise all energy sources, purge all systems
and lock out prior to continuing work. Before continuing work, the Permit to Work
shall be reissued. Upon completion of work, check the following to ensure that:
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 Non-essential items have been removed,


 Equipment components are operationally intact,
 All personnel are in a position of safety,
 Lock out / tag out devices shall be removed by the isolation personnel
who applied the devices.
7.2.7 Energise the equipment, machine and/or process to ensure that it is operating
properly.

On removal of the lock out/tag out device the person responsible for the
isolation shall inform the permitting authority and the area supervisor that the
equipment is now operable and safe to use.

7.2.8 Methods of Locking Out Controls

There are various ways to lock out a piece of equipment. Where the main
disconnect switch has one opening a locking strap can be installed. If more than
one employee works on the equipment, a lock out adapter suitable for the
installation of several locks must be used, enabling all isolation personnel from
various disciplines to lock out the machine with their individual locks.

If the switches are in a metal box, the box itself must be locked out. If a fuse
was removed in order to de-energise the equipment, the fuse box must be
locked. If the controls are in a metal-covered box, a common hasp can be welded
or riveted to the door, along with a lock staple. The switch can be "opened" and
the door closed and padlocked. Fuse boxes can also be locked in this manner.

Machines or processes activated by compressed air, gas, or steam will have


valves that control movement. These valves will not only need to be locked out
but also bled to release any back pressure.

7.2.9 Locks, Blocks and Tags

7.2.9.1 Locks

All isolation personnel must have their own lock and the only key to that
lock. The lock should be substantial and durable and shall be identifiable to the
isolation person. In addition, locks can be colour-coded to indicate different shifts
or disciplines.

When more than one worker is servicing a piece of equipment that must be
locked out, a lockout adapter can be used which allows all workers to place their
locks on the disconnecting means. After the work is completed, each worker will
remove his lock and the machine can be returned to service.
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Picture 2 Example of Safety Lock out Hasp

7.2.9.2 Tags

DO NOT USE TAGS ONLY! Use tags or signs in addition to locks. The tags
must state:
The name of the person who is working on the equipment, their badge number
and the date the tag was put in place.
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7.2.9.3 Blocks

Blocks shall be used on any equipment that might inadvertently move by


sliding, failing, or rolling. They shall be placed so as to make a piece of
equipment safe to be repaired or serviced. Blocks must always be placed under
raised lifts. Blocks, special brackets, or special stands must be available and
always used.

Isolation of a piping system is achieved by the placement of a blind. The


blind shall be of metal and a minimum of 6 mm in thickness. It shall be attached
by a minimum of 4 bolts to the piping flange. The blind shall be installed with a
suitable gasket. This will ensure that air, steam or liquids will not pass if the
system is activated.

Before blinds or blocks are installed, bleed down steam, air, gas or hydraulic
lines, etc. to get rid of any pressure. In addition, coiled springs, spring-loaded
devices, or suspended loads must be released so that their stored energy will not
result in inadvertent movement.

Figure 3: Example of Valve (b)lock.


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7.2.10 Restoring Equipment to Service

On completion of the work when the equipment is ready to be returned to


normal operation and energy restored the procedure below must be followed:
 Remove all tools and equipment used during the work.
 Ensure that that all equipment components are operationally intact,
including guards and safety devices. If any of the guards are damaged or
defective repair or replace them before removing lock outs.
 Remove each lock out device using the correct removal sequence.
 Make a visual check before restoring energy ensuring all personnel are in a
position of safety and well clear of the equipment before doing so.
EXCEPTION: When the authorised employee who installed the device(s) is
unavailable to remove it, the device may be removed under the supervision of
the Linde LE's Discipline Superintendents in charge of the job, provided:
o Specific procedures and training for such removal have been
developed, documented and entered as an appendix to the lock
out / tag out guidelines.
The specific procedures shall include:
o Verifying that the authorized employee is not on the job site.
o Making reasonable efforts to contact the authorised employee to
inform them that the isolating device(s) will be removed.
o Ensuring that the authorised employee is informed of the changes
before they resume work.

7.2.11 Temporary removal

In situations where the lock out / tag out devices have to be temporarily
removed for the purpose of testing or positioning the machine, equipment, and
components thereof, the following sequence shall be followed:
o Clear the machine or equipment of tools and/or material.
o Remove employees from the machine or equipment area.
o Energize and complete the testing or positioning.
o De-energise all systems and repeat isolation procedures.

7.2.12 Shift or Personnel Changes

Specific procedures shall be used during shift or personnel changes to


ensure the orderly transfer of lock out / tag out devices and the continuity of
protection of the on coming and off going employees.

7.2.13 Periodic Inspection

A periodic inspection of the lock out / tag out program will be conducted at
least annually. The inspection is conducted to ensure the procedure and
requirements are being followed. The inspection shall be performed by an
authorised employee other than the authorised employee over the lock out / tag
out being inspected. Any deviations and or inadequacies identified will be
corrected.
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Where lock out procedures is being used, an interview will be conducted with the
authorised employee regarding their responsibilities under the program.
Where tag out procedures are being used, interviews with all authorised and
affected employees will be conducted regarding each employee's responsibility
under the program including the elements of training received.

The completion of the periodic inspection must be certified. The certification


shall include the following:
o Date of the inspection.
o Identification of the machine or equipment inspected.
o The employees included in the inspection.
o The authorised employee conducting the inspection.

8. Attachments
8.1 Attachment 1: Sample Tags and Locks
8.2 Attachment 2: Authority to Remove Tag Forms
8.3 Attachment 3: LOTO Register
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8.1 Attachemnt 1: Sample Tags and Locks


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8.2 Attachment 2: Authority to Remove Tag Forms

Authority to Remove Tag / Lock

The above mentioned employee has failed to remove their Personal Danger Tag
and Lock.
(Print name of person named on tag)

I,

(Please print name of person requesting removal of tag)

(a) Have made all


efforts to
contact (Print name of person named on tag)
Both on site and off site with no success.

(b) Have made a thorough examination of the equipment isolated to verify


that
It is safe to remove tag / lock (must be confirmed by SHES and Competent
Person)

(c) Now request authority to remove their Personal Danger Tag and Lock.

Date:

(Signed by Person Requesting Authority)


Date:

(Confirmed by SHES Representative)


Date:

(Confirmed by Competent Person)


Date:

(Authorization signature by Site Manager or Delegate)


8.3 Attachment 3: LOTO Register

Date Initials of Date Initials of


Item Equipment No Location Lock No.
Installed Installer Removed Remover

Intellectual property rights reserved.

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