How To Reduce Risk From An Accident

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1 Port Hedland Port Authority Isolation and Tagging Procedure PR M002

2 TABLE OF CONTENTS 1 OBJECTIVE SCOPE ASSOCIATED DOCUMENTS ASSOCIATED REFERENCES DEFINITIONS GENERAL SAFETY Competency to Perform Isolations High Voltage Isolations for Electrical Access LOCKS AND USERS General Requirements Lock Identification Registers Lock/Key Register Isolation Officers Personal Lock Holders (Red Personal Isolation Locks) Yellow Isolation Locks Visitor Locks & Tags Record Keeping TAGS Personal Danger Tags Contractor Personnel Attaching the Tag Removing the Tag Isolation Tags Attaching the Tag Out of Service Tags Attaching the tag Information Tag Attaching the tag Removal of Information Tag: HASPS & LOCKBOXES hole hasp D HASP hole hasp Page 2 of 50

3 10.2 Lockboxes Maintenance Shift Log Isolation Numbering / Isolation Register TYPES OF ISOLATIONS Approval to Remove Equipment from Service for the purpose of Isolation Minor Isolation Raising a Minor Isolation Closing a Minor Isolation Locking onto a Minor Isolation Locking Off a Minor Isolation Multi-Point Isolation Major Isolation Multi-Point & Major Isolation Permit System Raising an Isolation Permit (for Multi-Point or Major Isolations) Issuing an Isolation Permit Transfer of Isolation Permit to new Permit Holder Task Supervisor Actions: Sign On the Isolation Permit Task Supervisor Actions: Sign Off the Isolation Permit Task Supervisor Actions: Task handover to another Task Supervisor: Task Supervisor Actions: Work is complete and the equipment is safe to use Task Supervisor Actions: Work is not complete Locking and Tagging On/Off an Isolation Permit Personnel Locking On the Isolation Permit Personnel Locking Off the Isolation Permit Additional Isolation Permit Changes to the Isolation Points of an Isolation Statement Closing an Isolation Permit Emergency or Cyclone Preparation METHODS OF ISOLATION Electrical Isolation Devices: General Electrical Isolating Devices with a Visible Physical Break Electrical Isolating Devices with Phase Indicator Lights Electrical Isolation Devices that do not have a Visible Physical Break or Phase Indicator Lights Page 3 of 50

4 Electrical Isolating Devices that have no means of determining if Load Side Electrical Energy has been disconnected De-Contactor Circuit Breakers Electrical Isolating Devices that cannot be locked High Voltage (HV) Isolation: General High Voltage Access Permits Isolation of High Voltage Motors where there is no potential for contact with High Voltage Apparatus Heavy Mobile Equipment (HME), Light Vehicles & Other Mobile Equipment Heavy Mobile Equipment Light Vehicles & Other Mobile equipment Mechanical Isolations Valves & Process Lines/Vessels (Water, Fire Systems, Diesel, Oil, Slurry Water, Air, Sewerage) ISOLATION ERROR OR VIOLATION Failure to Remove a Lock or Tag Failure to transfer or incorrectly sign off on a Permit document as Task Supervisor or Permit Holder Completed Tag found on floor or ground Tag Missing from a locked Isolation Point Inability to lock an Isolation Point Key Misplaced or Missing Key Found Lock Misplaced or Missing Lock Found Unexpected movement of stored energy RESPONSIBILITIES Registered Mine Manager Nominated Person Isolation Officer Authorising Officer Task Supervisor Permit Holder High Voltage Operator High Voltage Assistant Work Group Page 4 of 50

5 14.10 Substation Entry Utah Bulk Loading Facility & Eastern Harbour Motor Control Centre (MCC) Access LEVELS OF AUTHORITY FOR ISOLATIONS EMERGENCY CONTACTS PROCESS OWNER Page 5 of 50

6 1 OBJECTIVE The purpose of the PHPA Isolation & Tagging Procedure is to ensure the safety of all personnel on the PHPA sites from injury caused by an uncontrolled release of energy. The procedures are designed to comply with Statutory Regulations and with PHPA Health and Safety Standards. This purpose shall be achieved by ensuring that where practicable Positive Isolation is used for the protection of personnel working under a system of isolation on PHPA sites. Where positive isolation is not practicable, operational controls that permit controlled movement when a positive isolation is not in place must be included within a Detailed Work Instruction (DWI) or Safe Work Method Statement (SWMS). This shall be approved in writing from the Registered Mine Manager for that specific task. Should a DWI or SWMS not exist for that task, a Job Hazard Analysis (JHA) shall be written and approved by the Registered Mine Manager or deputy before commencing that task. 2 SCOPE The PHPA Isolation & Tagging Procedures apply to all operations on PHPA work sites that involve work tasks with a risk of a hazardous release of energy (e.g. electrical, mechanical, chemical energy). This includes all in-loading and out-loading conveyor systems at Utah Bulk Loading Facility and Berth 01. This procedure outlines the methods to be used when performing isolations on plant and equipment to prevent accidental release of energy sources whilst personnel are performing work on plant and equipment. A key requirement in preventing accidental energy release is to ensure that where practicable all isolation points are positively isolated. This will be achieved by ensuring that: Electrical equipment is proven to be de-energised and the isolation points locked. Mechanical Isolations are proven de-energised, systems bled, pressure released and locked in the case of valves and restraining devices and an air gap provided or the use of spades or blanks in the case of pipelines. The system will require: Training and assessment to ensure personnel are competent to carry out the tasks required by these procedures. The use of padlocks to maintain the integrity of the isolation/s at the specified isolation point/s. The use of tags with padlocks to identify ownership and control. Notes: Where guards are not fitted, the lanyard pull cable is the limit at which any part of the body or implement in contact with the body can approach the conveyor, whether moving idle, unless the conveyor has been positively isolated. Isolations involving High Voltage shall only be carried out by appointed persons, and may require specifically designed switching procedures which differ from the procedures referred to in this and related documents. Please refer to PHPA PR M003 High Voltage Access Procedure. Page 6 of 50

7 3 ASSOCIATED DOCUMENTS DOC M001 PHPA General Guidelines on Maintenance Work, Contractor and Operational Activities within PHPA Jurisdiction DOC HS002 PHPA OHS Management Plan PR C001 Contractor Management FM M003 Request for Isolation Permit FM M004 Isolation Statement FM M005 Isolation Permit FM M006 Forced Lock Removal Form PHPA Detailed Work Instructions (DWI) PHPA Safe Work Method Statements (SWMS) PR M003 High Voltage Access Procedure High Voltage Switching Procedures QUBE Safe Work Method Statements (SWMS) QUBE Detailed Work Instructions (DWI) 4 ASSOCIATED REFERENCES Occupational Safety and Health Act 1984 Occupational Safety and Health Regulations 1996 Mines Safety and Inspection Act 1994 Mines Safety and Inspection Regulations 1995 Page 7 of 50

8 6 DEFINITIONS Term Definition ALARP As Low as Reasonably Practicable [ALARP] defines that wherever there is a risk present to people it must be balanced against the sacrifice needed to eliminate or reduce the risk. In any assessment as to whether risks have been reduced ALARP, measures to reduce risk can be ruled out only if the sacrifice involved in taking them would be grossly disproportionate to the benefits of the risk reduction Area Owner The Area Owner is the person responsible for the equipment or process at the time of isolation (usually the direct supervisor of the equipment operator) Authority A written permission given by the Registered Mine Manager or delegate on matters relating to the PHPA Isolation and Tagging Procedure. Authorising Officer A person who is trained and deemed competent and is appointed in writing by the Nominated Person to undertake the duties of Authorising Officer in accordance with PHPA Isolation & Tagging Procedure; this person shall undertake the duties of Authorising Officer under an Isolation Permit. Competent Person A person who has, to the satisfaction of the Nominated Person, acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to be deemed competent to perform specific tasks safely and correctly. Contractor Any firm or any person not an employee of PHPA engaged / commissioned to do work on any PHPA site Contractor Supervisor The competent person nominated to PHPA by a Contractor to accept responsibility for ensuring all Contractor s personnel follow this Isolation and Tagging Procedure, PHPA procedures and policies, including procedures related to permits. Cyclone Tie-Down A person delegated as the coordinator as per PR M005 Eastern Coordinator Harbour Cyclone Preparation and PR M006 Utah Cyclone Preparation Procedures. Cyclone Recovery A person delegated as the coordinator as per PR M005 Eastern Coordinator Harbour Cyclone Preparation and PR M006 Utah Cyclone Preparation Procedures. De-Isolate / Re-energise Reconnect or enable an energy source to equipment. DWI A PHPA Detailed Work Instruction document. Emergency An emergency is an abnormal occurrence that can pose a threat to the safety or health of employees, contractors, local communities, customers, or which can cause significant damage to assets or the environment Extra-Low Voltage Not Exceeding 50 V a.c. or 120 V ripple-free d.c. (AS 3000: ) D Hasp A device used to allow multiple locks to be attached to a Single Isolation Point, with space available for locks to be attached. 6 Hole Hasp A device used to allow multiple locks to be attached to a Single Isolation Point, with up to 6 holes available for locks 12 Hole Hasp A device used to allow multiple locks to be attached to a Single Isolation Point, with up to 12 holes available for locks Page 8 of 50

9 Term Definition HV High Voltage Voltage in excess of 1000 v a.c. or 1500 v d.c. (AS 3000: ) High Voltage Access Permit A printed form generated under these Regulations which authorizes access to Isolated and Earthed (Dead) High Voltage Electrical Apparatus HV Isolation Assistant An individual trained and assessed as a competent High Voltage (HV) Isolation Assistant and authorised in writing by the RMM. HV Operator An individual trained & assessed as competent in the operation of High Voltage (HV) apparatus for the purpose of isolation and authorised in writing by the RMM Information Tag A printed tag used to communicate a message about the conditions of entry, status of equipment or any other relevant information. Isolation A means of preventing the transmission, build-up or unintentional release of pressure/energy/power by whatever means necessary to ensure that the plant or equipment is safe to work on. Isolation Incident Any non-compliance with the Isolation and Tagging Procedure. Isolation Lock (Yellow) A yellow lock used for security to lockout for the purpose of isolation Isolation Officer A person who is trained and deemed competent and is appointed in writing by the RMM to undertake the duties of Isolation Officer in accordance with PHPA Isolation & Tagging Procedure. Isolation Statement A detailed plan of the isolation points needed to effectively deenergise or make a piece of plant safe. Isolation Permit A control and assessment system used to ensure the safety of all personnel on the PHPA sites from injury caused by an uncontrolled release of energy whilst performing work on plant and equipment. Isolation Point An approved mechanism/device which controls the energy source for the purpose of isolating or de-isolating a piece of plant or system of plant. Note: Devices such as emergency stops, pull wire switches or any other devices associated with control systems shall not be used as primary approved isolation points unless authorised by the RMM. Isolation Register An electronic file register which contains all isolation information based on the request, statement and permit requirements for isolations to be carried out. The Isolation Register shall generate the number for all isolations. This shall be handed over upon shift change to the next shift via the Maintenance Shift Log. Isolation Tag A printed tag which is attached to all Isolation Points identifying the type of isolation by isolation number and lock box number where applicable. JHA Job Hazard Analysis (can also been known as Job Safety Analysis) Lock Box A lockable box that shall be used in conjunction with Multi-Point or Major Isolations for personnel to lock onto: Lock Box used for less than 15 personnel Master Lock Box used for less than 30 personnel LV Low Voltage Exceeding extra-low voltage, but not exceeding 1000 v a.c. or 1500V d.c. (AS 3000: ) Maintenance Shift Log An electronic register of occurrences during each shift period that is handed over to the following shift upon change over for information and actions if required. Page 9 of 50

10 Term Major Isolation Major Isolation Officer Minor Isolation Minor Isolation Officer Multi-Point Isolation Nominated Person Out of Service Tag Permit Holder Personal Danger Locks and Tag Personal Lock Holder Definition A Major Isolation should generally be used for: Complex jobs where a greater degree of control is required Where the number of people working on a job exceeds 12 and/or The number of isolation points required exceeds 15 An individual authorised to place red personal isolation lock, blue isolation locks and yellow isolation locks, plus Personal Danger Tag and Isolation Tags on multiple isolation points for the intention of isolating the plant or equipment for complex jobs or jobs exceeding 5 personnel (Multi-Point & Major Isolation types); this person shall undertake the duties of Major Isolation Officer under an Isolation Permit. An Isolation where: There is one (1) isolation point There are five (5) or less personnel required to work under the isolation The person raising the isolation & performing the work is a Minor Isolation Officer and authorised for that piece of equipment. An individual authorised to place a red personal isolation lock and Personal Danger Tag, plus a yellow isolation lock and Isolation Tag on a single isolation point for the intention of isolating the plant or equipment for less than 5 personnel. An Isolation where: There is more than one (1) isolation point, but no more than fifteen (15) isolation points There are twelve (12) or less personnel required to work under the isolation The person raising the isolation & performing the work is a Multi-Point Isolation Officer and authorised for that piece of equipment. A person who has, to the satisfaction of the Registered Mine Manager, acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly and has been is appointed in writing to act as Nominated Person. The Nominated Person shall be responsible for appointing and authorising Isolation Officers, Authorising Officers & Competent Persons. A tag used to identify equipment which is faulty and/or dangerous and shall not to be used or operated. A person who has acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly in that specific area; this person shall undertake the duties of Permit Holder under an Isolation Permit. A lock and tag applied by a person with the primary objective to provide personal protection to an individual working on plant and equipment. Must be removed at the end of each job or shift. An individual competent and authorised to place a personal lock on a Page 10 of 50

11 Term PHPA Point Isolation Locks (Blue) Positive Isolation Refresher Training Registered Mine Manager Request for Isolation Permit Shall Should SWMS Task Supervisor Visitor Yellow Isolation Pocket Definition piece of equipment or lock box for the intention of working on that equipment / system. They shall be trained in this procedure and assessed as competent. Port Hedland Port Authority Common keyed locks placed by an authorised Isolation Officer, placed on an individual isolation points for the purpose of isolating a piece of plant or system of plant; usually Blue. An isolation where physical barriers have been put in place to isolate all forms of energy irrespective of changes in conditions. Refresher training on the Isolation and Tagging Procedure and systems to be undertaken annually or at a relevant time designated by the RMM or Nominated Person. The individual registered with the Mines Act as being the Accountable person for mine site. A detailed request form indicating the area, equipment and isolation points needed to effectively de-energise or make a piece of plant safe. The Isolation Statement is compiled from the information contained within the Request for Isolation Permit. Indicates the requirement is mandatory Indicates the requirement is recommended Safe Work Method Statement document. A person who has acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly in that specific area; typically a tradesperson, team leader or supervisor. The Task Supervisor is responsible for the safe execution and completion of the work. A person not intending to perform work. Visitors must be supervised at all times by a PHPA personnel member trained in Isolation & Tagging Procedures. The Isolation Permit is displayed at the lock box and is retained inside the Yellow Isolation Pocket, which as affixed to the lockbox using the Yellow Padlock. Page 11 of 50

12 7 GENERAL SAFETY The primary objective is to provide personal protection to persons working on plant and equipment. A secondary consideration is the prevention of damage to equipment and environment. The procedure applies equally to servicing, repairs, inspections, testing and adjustments, cleaning and pre-start checks. In all of these instances the PHPA Isolation and Tagging Procedure shall be followed. REMEMBER: FAILURE TO FOLLOW THE PROCEDURE COULD RESULT IN DEATH, DISABLEMENT, PERSONAL INJURY OR DAMAGE. FOR THAT REASON, UNAUTHORISED REMOVAL OF TAGS OR OTHER VIOLATIONS OF THE ISOLATION AND TAGGING PROCEDURE MAY RESULT IN DISCIPLINARY ACTION. This procedure is required to protect individuals or groups of personnel from physical injury or through contact with or exposure to the following types of energies: Chemical (corrosives, gases, toxic materials) Electricity Radiation (induction sources, lasers) Mechanical (e.g. kinetic) Pressure Gravitational Thermal Stored Energy This procedure is to be applied in circumstances where: Personnel are required to work on or within contact distance of any of the above energies Where there is a potential for contact and harm to people, equipment or the environment. The PHPA Isolation and Tagging Procedure applies to all mobile and fixed plant and equipment at all operations. Once the equipment has been isolated, the equipment SHALL not be attempted to be started until: Each individual has removed their own Personal Danger tags and locks from all isolation points, lockbox or lockout stations. The isolation locks and tags have been removed by an authorised person. The isolation switch has been moved to the on position. Only authorised personnel will be allowed to isolate plant and equipment, a minimum competency of Minor Isolation Officer will enable personnel to isolate mobile or fixed plant. Isolation of energies may be established using the following methods: Breaking electrical circuits by using one of these three methods stated in section 12. Page 12 of 50

13 Note: Devices such as emergency stops, pull wire switches or any other devices associated with control systems shall not be used as primary approved isolation points. Closing valves in flow or delivery systems carrying pressure, gas, liquids, slurry, steam or venting to atmosphere to release stored pressure. Open valves in flow or delivery systems carrying pressure, gas, liquids, slurry, steam or venting to atmosphere to release stored pressure. Physically securing an object to control gravitational forces using pins, slings or chocks, belt clamps. 7.1 Competency to Perform Isolations Only persons, who have completed Isolation Officer Level of Isolation and Tagging training and have been assessed, deemed competent and authorised are able to perform isolations. Once trained, assessed and deemed competent, they shall be appointed in writing by the Nominated Person to undertake the duties of Isolation Officer in accordance with the PHPA Isolation & Tagging Procedure. 7.2 High Voltage Isolations for Electrical Access Refer to PR M003 High Voltage Access Procedure. No person shall make personal contact, either directly or through any conducting object with any high voltage conductor believed to be dead, unless the conductor has been effectively earthed and short-circuited and is complying with all the requirements of the High Voltage Switching Procedure. High Voltage apparatus, which is to be earthed and short-circuited, shall be proven to be dead and safe for earthing and short-circuited by use of equipment specifically designed for the purpose and used in accordance with the manufacturer s instructions. Page 13 of 50

14 8 LOCKS AND USERS 8.1 General Requirements Locks shall be of a type approved by the Registered Mine Manager. 8.2 Lock Identification Red Lock Personal Danger Locks shall be a set of one to six locks per person, and shall be clearly marked with individually stamped number on the lock for identification Yellow Lock Used to secure isolation points for Minor Isolations and lock box for group isolations (Multipoint and Major Isolations) Blue Lock Clearly marked with lock box number and used on isolation points for group isolations (Multipoint and Major Isolations) (set of 15 each) Used for HV Access Isolations refer to PR M003 High Voltage Access Procedure 8.3 Registers The following Registers shall be kept by PHPA in the Myosh system. The Registers shall be audited by the PHPA Safety Department on a regular basis: Lock/Key Register 8.4 Isolation Officers The following registers outlining the authorised people who have been issued with locks and keys shall be maintained Isolation Officers Personal Lock Holders This Register shall have the Name of the Person, Date of Examination, Name of Examiner, and Level of Authority (i.e. type of isolation, area of authority, voltage levels) Expiry Date and Lock Number. The Registered Mine Manager shall nominate a person in each operational area who will be responsible for approving and authorising Isolation Officers. Personnel who are to be deemed an Isolation Officer shall first be trained in the Isolation and Tagging procedure, hold relevant experience in the plant and pass the relevant competencies The Isolation Officer s will be authorised to carry and place Isolation Locks. The Isolation Officer training (for the equipment specified) shall clearly identify the types of isolations that they are allowed to complete (Radiation, Electrical, Mechanical) Only authorised, trained and competent personnel shall be allowed to carry out Isolations on specific plant and equipment. Page 14 of 50

15 8.5 Personal Lock Holders (Red Personal Isolation Locks) Personnel who are Personal Lock Holders shall be trained and deemed competent in the PHPA Isolation & Tagging Procedure. PHPA personnel that are to be issued with a personal lockset and key shall first be trained in the Isolation and Tagging Procedure and pass the competencies for Minor Isolations at minimum. Personal Locks and Keys shall be issued to personnel by their Supervisor. A minimum of one personal lock to be issued to each person. A maximum of a lock set of 6 is required to be issued to personnel authorised to conduct Minor Isolations as per section 11.2 A person shall not use another person s lock(s) and key. No person shall place another person s lock No person shall remove another person s lock unless authorised. Refer section 11 All the locks on a lock set shall use the same key Only one key to be issued per lockset Personal locks and key shall be marked with a unique identification number A personal lock holder shall gain permission by making positive contact with Permit Holder or Isolation officer prior to attaching their personal lock and tag to isolation points. A personal lock holder shall not isolate plant and/or equipment, except for appointed Minor Isolation Officers as per section 11.2 A record of Personal Lock Holders shall be maintained in Training database and displayed in Maintenance Department. Records shall be kept with cross reference to the engraved identification code and the name of the person to whom the lockset was issued. 8.6 Yellow Isolation Locks Yellow Group Isolation Locks are used to lock the blue lock keys in the lockbox or lockout station under a Multi-Point or Major Isolation. One isolation key will be issued to each Isolation Officer. All isolation locks shall use the same key. Isolation lock key shall be marked with a unique identification number. Spare locks and keys shall be kept at a central location at each site. 8.7 Visitor Locks & Tags Visitor Locks and Tags may be issued where: A person who has not completed PHPA Isolation & Tagging training (visitor) and is required to lock onto an isolation point as a visitor. A personal lock holder that does not have possession of, or has not been issued their own lock, is required to lock onto an isolation point. Visitor locks shall be supplied by PHPA out of the visitor lock station and shall be issued to a visitor when deemed necessary by the Electrical Supervisor or Maintenance Superintendent. The visitor name, company, and contact number shall be recorded for return. Page 15 of 50

16 Visitors must be supervised by a person trained in the Isolation & Tagging Procedures. The supervisor of the visitor must witness the signature of the visitor s Personal Danger Tag and also be locked on to same point. 8.8 Record Keeping The following records pertaining this procedure are to be maintained at each site / location: Request for Isolation Isolation Statement Isolation Permit HV Switching Procedures used for isolation of plant Records are to be retained as per the PHPA PR ICT002 Recordkeeping Procedure. The following records pertaining to authorised personnel are to be maintained in the Mines Record Book: Statutory Letters of Appointment detailing site authorisation of Isolation Officers Statutory Letters of Appointment detailing site authorisation of High Voltage Operators / Assistants for the purpose of isolations The following records are to be kept in the PHPA safety management & training system (MYOSH): Record of all incidents and accidents related to the use of the Isolation and Tagging Procedure Training competencies and completion date Page 16 of 50

17 9 TAGS The use of tags is considered an administrative control and as such only provides limited protection to people and plant; therefore in all cases a physical isolation must be used in conjunction with a tag to prevent the accidental activation of an isolation point. 9.1 Personal Danger Tags Any person required to work on the equipment must place their clearly identified personal lock and tag on a hasp located on the isolation point or lock box. Remember, the main isolation point Shall Be turned and locked to the off position. The isolation should be tested and proven prior to the commencement of work by testing for absence of electrical power or stored energy. A Personal Danger Tag is for single use only and must be destroyed on completion of task. Do not assume that it is isolated - Confirm that it is isolated! The Personal Danger Tag and lock are designed to give personal protection and to highlight that the employee/s whose name appears on the Personal Danger Tag are engaged in carrying out tasks to the tagged equipment and could be at risk if the machine were to be started or moved Contractor Personnel All contractors and visitors working on PHPA sites shall conduct isolations in accordance with this procedure. Personnel shall also follow this procedure in relation to tag use. All contract personnel must place their personal lock and Personnel Danger Tag on the isolation point whilst in the presence of the Task Supervisor. All Personal Danger Tag Reminder stubs found on the bottom section of the tag shall be handed to the Task Supervisor for that task/work group prior to commencing task/work. This will confirm that contractor personnel have: 1. Completed the Personal Danger Tag correctly 2. Locked on to the correct lockbox and associated Isolation Permit for the task 3. Ensured confirmation of task completion during the lock off process Where a contractor or visitor has any queries or uncertainty when undertaking tasks within this procedure, they shall refer to their Task Supervisor or delegate from PHPA. Page 17 of 50

18 9.1.2 Attaching the Tag The person attaching the tag must completely fill the tag with the following information: Name & company of person placing tag The classification/department the person works for The date that the tag was placed The equipment / plant the tag was placed on Contact number Work order / job number if applicable Signature Page 18 of 50

19 It is important to clearly identify the exact piece of equipment that the tag and lock was placed on to allow identification of those personnel working on the plant. NOTE: Each and every person working on the job must place their own Personal Danger Tag / Personal Lock before the job commences only after the isolation has been tested and proven effective. Once placed it must remain in place for the duration that the person is on the job Removing the Tag No person shall remove another person s Personal Danger Tag. Only the person who signs and attaches the Personal Danger Tag can remove it. If a Personal Danger Tag has been left on the equipment at the end of the shift then that person will be contacted to return to site in their own time to remove their Personal Danger Tag. If that person cannot be contacted or is in an unfit state to return to site or is off on R/R then the approved tag removal procedure will be instigated (as per section 11.1). YOUR Personal Danger tag and lock are to be removed from the equipment by only you on completion of the task or at the end of the shift. Page 19 of 50

20 9.2 Isolation Tags The Isolation Tag Indicates equipment has been isolated by an Isolation Officer. Any item of equipment or machinery marked with an Isolation Tag shall not be operated. The equipment must be in an Isolated position, thereby removing energy from the circuit. A hasp is to be placed on the isolation point and a completed Isolation Tag with an Isolation Lock shall be placed on the hasp Attaching the Tag The Isolation Officer must print the following information on the tag: Isolation number Lockbox The date that the tag was placed How the isolation was confirmed Page 20 of 50

21 The equipment owner or area supervisor must be notified as soon as possible if the equipment has been fixed to ensure that the tag can be removed and the plant reinstated. NOTE: Anyone conducting repairs on plant or equipment will be required to place their own Personal Danger tag and lock on the hasp or corresponding lock box before commencing work. If the repair is not complete within the shift or they are called away, they must remove their Personal Danger tag/lock. The Permit Holder shall ensure the Isolation Tag & lock remains and if repairs are not complete, an Out of Service tag shall be attached to the isolation point and plant equipment controls. Page 21 of 50

22 9.3 Out of Service Tags The Out of Service Tag allows for faulty, unsafe or permanently disabled equipment to be taken out of service to prevent further use or damage to the equipment. Any item of equipment or machinery marked with an Out of Service Tag shall not be operated or used except for the direct purpose of repair by an authorised person. The isolation switch on the equipment must be switched to the off position, thereby removing power to the circuit. A completed yellow Out of Service Tag must then be placed on the isolation point. If it is a power tool or other hand tools or apparatus or equipment that is not energised, the Out of Service Tag should be securely attached to the defective device. Page 22 of 50

23 9.3.1 Attaching the tag The following information shall be printed on the tag: Equipment name Name of person placing tag Classification of fault/reason for out of service The date that the tag was placed It is important to clearly identify the exact reason for placing the tag to allow proper analysis and rectification of the problem. The equipment owner or area supervisor must be notified as soon as possible of the condition and the reason it has been placed Out of Service. Once a piece of equipment has been tagged Out of Service to conduct repairs, the equipment must be isolated in accordance with this procedure. An Out Of Service Tag shall REMAIN attached to the device or main isolation point of the equipment during the time that the repairs or servicing and inspection are being carried out. This ensures that even when left unattended, the unsafe condition of the equipment is communicated readily to any person. Anyone can place an Out of Service Tag on faulty plant/equipment; however only authorised personnel or an authorised delegate can remove it. Only a qualified person in the maintenance or repair of that piece of equipment may then remove the tag once repairs are complete. Page 23 of 50

24 9.4 Information Tag In some instances instruction needs to be given about a specific piece of equipment, barricading of a designated area. In these instances an information tag shall be used. The tag shall be placed by personnel to communicate a message about the conditions of entry, status of equipment or any other relevant information. In the event an Information Tag has been placed all personnel shall read the information Attaching the tag The person attaching the tag must completely fill out the tag with the following information: Print their name The department the person works for The date and the time that the tag was placed The equipment / plant the tag was placed on Page 24 of 50

25 9.4.2 Removal of Information Tag: Removal of Information Tags shall only occur once the information is no longer relevant Prior to removal of tag contact the area owner Any person may remove the tag once the steps above are completed Page 25 of 50

26 10 HASPS & LOCKBOXES Hasps are used to allow multiple locks to be placed on an Isolation point hole hasp This is used for Minor Isolations when requirement is 5 or less personnel to lock on D HASP This is used for Minor Isolations when requirement 5 or less personnel to lock on hole hasp This is used for Isolations when requirement 12 or less personnel to lock on. Page 26 of 50

27 10.2 Lockboxes PHPA has 4 different types of Lock Box which are used as follows; Master Lockbox For use with a Major Isolation Involving greater than twelve (12) people Involving more than fifteen (15) locks Blue Lock Box For use with Multi-Point and Major Isolations For use with up to twelve (12) people per lockbox For use with up to fifteen (15) locks Red Lock Box For use with Isolations that require HV Access 10.3 Maintenance Shift Log The electronic log used by Maintenance team for recording all isolation and deisolations. This is for all isolations except Minor Isolations Isolation Numbering / Isolation Register The numbering of Isolations placed on the permit will be sourced from the Isolation Register. The register is to be filled in showing: Date Lockbox number Isolation number Equipment to be isolated Requestor Name Isolation Officer No Isolation and Isolation permit are to begin until all information is completed on the Isolation Register. Page 27 of 50

28 11 TYPES OF ISOLATIONS Three (3) types of isolation are used on all PHPA sites: Minor Isolation Multipoint Isolation Major Isolation 11.1 Approval to Remove Equipment from Service for the purpose of Isolation Prior to performing the isolation, approval should be gained from the area owner or the person responsible for its operation. The Area Owner is the person responsible for the equipment or process at the time of isolation (usually the direct supervisor of the equipment). The person responsible for the equipment s operation is usually the equipment operator. To remove equipment from service, the following process should occur: a. At a suitable time prior to performing the isolation, the Task Supervisor or Isolation Officer should seek verbal approval from the Area Owner to remove equipment from service. This approval should be recorded in the relevant maintenance or plant log. b. Immediately prior to performing the isolation, the Isolation Officer should seek agreement from the equipment operator that the equipment will be removed from service. c. The equipment operator should prepare the equipment / process for isolation (e.g. run product off conveyor belts and stop the plant). d. The equipment operator should advise the Isolation Officer that the equipment is ready for isolation and records the event in the relevant plant log book. e. The Isolation Officer performs the isolation Minor Isolation Minor Isolations shall be used in situations where: There is one (1) isolation point There are five (5) or less personnel required to work under the isolation The person raising the isolation and performing the work is a Minor Isolation Officer and authorised for that piece of equipment Controls used with a Minor Isolation are: JHA, DWI or SWMS Personal Locks (Red) Personal Danger Tags Yellow Isolation Lock Blue Isolation Tag Six (6) Hole Hasp or D Hasp Electrical personnel may perform Minor Isolations utilising any approved isolation point Non-electrical personnel shall perform the isolation by means of a local isolator and shall be confirmed by the use of phase indicator lights Page 28 of 50

29 Alternatively, if no phase indicator lights are present (i.e. a hand valve) then the person shall confirm that the power has been disconnected from the load side of the isolating device, through testing by attempting to start the machine from the local control station and confirm that the machine did not start. Other local isolations may be performed by means of a de-contactor, valve etc. Typically a Minor Isolation may be used for: Isolations that can be carried out by means of a local isolator situated in the field This may include such tasks as: Low voltage isolations Mechanical isolations Mobile Plant isolations Raising a Minor Isolation a. The Minor Isolation Officer shall receive approval to take the equipment out of service from the equipment owner or person responsible for its operation. b. The Minor Isolation Officer shall identify the isolation point for the equipment and complete the risk assessment (JHA), recording the isolation point on the JHA. c. If an existing generic DWI or SWMS exists for that equipment, it may be used provided that the Minor Isolation Officer ensures that the generic DWI or SWMS is suitable for the scope of work to be performed. d. The Minor Isolation Officer shall operate the isolation device and place a hasp on the isolation point and secure it with a Yellow Isolation Lock and Isolation Tag. e. The Minor Isolation Officer is to place his / her Personal Lock, Personal Danger Tag and Isolation Tag on the isolation point. f. The Minor Isolation Officer shall confirm the isolation as per the risk assessment, DWI or SWMS. g. The work/task may commence Closing a Minor Isolation The Minor Isolation Officer or Task Supervisor shall inspect the work area and ensure that the work is complete, the equipment is assembled and safe to operate. Work is complete & equipment is safe to operate If the work is complete and the equipment is safe to operate the Minor Isolation Officer shall: a. Ensure all Personal Danger tags (if Applicable) are removed b. Remove his / her Personal Lock, Personal Danger Tag, Isolation Tag, Yellow Isolation Lock and hasp and from the isolation point. c. Operate the isolation point to the in service position if applicable. d. Attach Isolation Tag to JHA and work order for isolation confirmation and records Page 29 of 50

30 e. Destroy the Personal Danger Tag(s) by tearing into at least 2 pieces and dispose of the tag. f. Notify the equipment owner or person responsible for its operation that the equipment may be returned to service. Work is not complete and equipment is not safe to operate If the work is not complete and / or the equipment is not safe to operate the Minor Isolation Officer shall: a. Ensure all Personal Danger tags (if Applicable) are removed)attach Out of Service Tags to the equipment isolation and / or control points b. Remove his / her Personal Lock and Isolation Tag from the isolation point. c. Destroy the Personal Danger Tag by tearing them into at least 2 pieces and dispose of the tags. d. Attach Isolation Tag to JHA and work order for isolation confirmation and records. e. Notify the equipment owner or person responsible for its operation that the equipment is not safe for return to service. f. Complete and attach Out of Service tag to the equipment. g. Advise the appropriate maintenance personnel of the equipment status Locking onto a Minor Isolation Personnel requiring the Minor Isolation for protection shall: a. Obtain the permission of the Minor Isolation Officer, to place their personal lock and danger tag on the isolation b. Demonstrate a satisfactory understanding of the safe area of work covered under the isolation. c. Complete a Personal Danger Tag with their name, date, company, contact details and job / work area. d. Confirm isolation point with the Minor Isolation Officer. e. Place their Personal Lock and Personal Danger Tag on hasp attached to the isolation point in the presence of the Minor Isolation Officer. Should there be insufficient holes left on the hasp, the isolation must be changed to a Multi-Point Isolation. The attachment to another lock or hasp is not permitted Locking Off a Minor Isolation When their work is complete, or when they leave site, or as directed by the Minor Isolation Officer, the lock holder shall: a. Remove their Personal Lock and Personal Danger Tag from the hasp. b. Destroy the Personal Danger Tag by tearing it into at least 2 pieces and disposing of the tag. Page 30 of 50

31 11.3 Multi-Point Isolation Multi-Point Isolations shall be used in situations where: There is more than one (1) isolation point, but no more than fifteen (15) isolation points. There are less than twelve (12) personnel required to work under the isolation. The personnel raising the isolation are Major Isolation Officer/s and authorised for that piece of equipment. Controls used with Multi-Point Isolations are: Request for Isolation Permit form Isolation Statement Isolation Register JHA, DWI or SWMS Isolation Permit Lockbox (Blue) Personal Locks (Red) Personal Danger Tags Yellow Isolation Locks Blue Isolation Locks Blue Isolation Tag Maintenance Shift Log Hasp 11.4 Major Isolation A Major Isolation shall be used in situations where: The job is complex and a greater degree of control is required There are up to or exceeding twelve (12) personnel required to work under the isolation and / or There are up to or exceeding fifteen (15) isolation points The personnel raising the isolation are Major Isolation Officer/s and authorised for that piece of equipment. High Voltage Equipment Controls used with a Major Isolations are: Request for Isolation Permit form Isolation Statement Isolation Register JHA, DWI or SWMS Isolation Permit Lockbox (Blue or Master) Personal Locks (Red) Personal Danger Tags Yellow Isolation Locks Blue Isolation Locks Blue Isolation Tag Maintenance Shift Log Hasp Page 31 of 50

32 11.5 Multi-Point & Major Isolation Permit System Raising an Isolation Permit (for Multi-Point or Major Isolations) a. A Request for Isolation Permit form is completed by the person requesting access for the work. b. A Major Isolation Officer identifies all isolation points and compiles the Isolation Statement, based on the information supplied on the Request for Isolation Permit. c. The Major Isolation Officer obtains approval to take the equipment out of service from the equipment operator. d. The Major Isolation Officer enters the Isolation Number and Lockbox Number in the Isolation Register Issuing an Isolation Permit a. The Major Isolation Officer identifies the Isolation Type (Multi-Point or Major), Isolation Number, Lockbox Number, Date and Time on the Isolation Permit. b. The Major Isolation Officer writes the reason for the isolation from the Request for Isolation on the Isolation Statement and Permit c. The Major Isolation Officer lists the equipment to be isolated under the Isolation Permit. d. The Major Isolation Officer performs the isolation and places the locks and tags in accordance with the Isolation Statement. Blue Isolation locks and Isolation Tags are attached to the isolation points. The Isolation Number is recorded on each Isolation Tag. e. The Major Isolation Officer confirms the number of locks placed. The key to the isolation locks are locked inside the lockbox by placing yellow isolation lock on the lockbox. An isolation tag is placed on the isolation lock. The Isolation Number is recorded on the Isolation Tag. f. The Major Isolation Officer signs the Isolation Permit. g. The Authorising Officer checks that the isolations are in place and are in accordance with the Isolation Request and Statement. The isolation points are confirmed locked and tagged with the Isolation Number and date recorded on each isolation tag. h. The Authorising Officer signs the Isolation Permit as verification that the isolation is in place i. The Permit Holder must ensure that: The isolations are in accordance with the Request for Isolation, either via the Isolation Statement or by viewing the physical isolation points. All Task Supervisors are aware of the isolations in place and confirm they cover the tasks being undertaken. The isolation number is recorded on the isolation tags and permits. j. The Permit Holder confirms and signs the Isolation Permit. k. The Isolation Permit is placed in either the Yellow Isolation Pocket, attached to the lockbox, or to the master lockbox. Ensure that the front page of the Isolation Permit is clearly shown and all signatories to the permit are clearly visible. Page 32 of 50

33 Transfer of Isolation Permit to new Permit Holder a. When the Permit Holder leaves site for any reason and work is to continue under the permit, the Isolation Permit must be transferred to a new Permit Holder. b. The current Permit Holder shall advise the new Permit Holder of any special circumstances pertaining to the permit in person. c. The current Permit Holder shall sign the Transfer of Permit Holder section of the Isolation Permit to relinquish control of the permit, with date and time. d. The new Permit Holder shall sign on to the Transfer of Permit Holder section of the Isolation Permit to accept responsibility for the permit, with date and time accepted. Personnel already locked on are not required to lock off during this process. Additional personnel are not permitted to lock on during this process Task Supervisor Actions: Sign On the Isolation Permit The Task Supervisor is the person who is responsible for: The safe execution and completion of each specific job covered by the Isolation Permit. Ensuring that members of the work party read and sign on to the JHA pertaining to their work. Ensuring that members of the work party read and understand the safe areas of work covered by the Isolation Permit. a. The Task Supervisor reads the Permit Isolation and checks the equipment listed as isolated. They ensure the Isolation Permit covers the scope of work for the specific job for the work group. Clarification may be sought from Permit Holder or Isolation Officer. b. The Task Supervisor then receives permission from the Permit Holder to sign on to the Isolation Permit. c. The Task Supervisor shall demonstrate a thorough understanding of the areas / equipment covered under the Isolation Permit d. The Task Supervisor signs onto the Isolation Permit by: Entering the work order or other reference number, if applicable Enters the equipment to be worked on Writes his / her name, company and contact details Enters the date and time that they are signing on to the permit Enters his / her signature to complete sign on e. The Task Supervisor enters the Isolation Number on to the JHA pertaining to the work Task Supervisor Actions: Sign Off the Isolation Permit If the Task Supervisor does not change for the duration of the Isolation Permit, the Task Supervisor does not have to sign off until the job is complete, or the end of the shift, the Isolation Permit is closed or as required by the Permit Holder. Page 33 of 50