1207660915844 ril lockout tagout standard rev 1 apr 2008

7/28/2019 1207660915844 RIL Lockout Tagout Standard Rev 1 Apr 2008

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RIL Group StandardsLockout / Tagout


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Document Control Details

Revision Date Reason For Issue Compiled by Approved by

1 Apr 08 Corporate Standard Dinesh Vaidya Dr Prasad Tipnis

Next Review Date

Apr 09

User Notes: - The Centre for Health Safety and Environment Excellence (CHSEE) is thecustodian of this document and is responsible for the Administration and Authorisation of thisStandard. CHSEE is responsible for confirming the accuracy and integrity of content andproposed changes to the Standard.

Controlled copy of the current version of this document is held at CHSEE and also available onits portal. Any printed / electronic copy of this document is uncontrolled. It is recommendedthat users verify that the version being used by them is the current version by referring to thecontrolled version


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Lockout/ Tagout RIL Group Standard

Acknowledgement

The management acknowledges the contributions of the following individuals for being a part of theinter-site workgroup and for their assistance in preparing this standard on Lockout /Tagout:

Location Members

CHSEE Mr. Dinesh Vaidya Mr. Vijay Kumar

Jamnagar Mr. DC Boliya Mr. PV Raju

Hazira

Mr. AM Bagul Mr. DR Kumar

Patalganga Mr. VR Kulkarni Mr. KR Kamat

Vadodara Mr. AM Bhavsar Mr. KN Sharma

Nagothane Mr. RV Shukla Mr. SK Hanamshet

Gandhar Mr. SB Sonar Mr. NK Pandey

The management also acknowledges the guidance and help of the following experts from DuPont SafetyResources.

Agency Members

DuPont Safety Resources Mr. Dirk Eikemans Dr. Anil Bhaskar

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Table of Contents

DOCUMENT CONTROL DETAILS .......................................................... 1ACKNOWLEDGEMENT.......................................................................... 2DOCUMENT ISSUE ................................................................................4ABBREVIATIONS ..................................................................................51. INTRODUCTION.........................................................................6

1.1. Intent and Purpose........................................................... 62. SCOPE AND FIELD OF APPLICATION ........................................6

2.1. Scope................................................................................ 62.2. Field of Application ...........................................................7

3. REFERENCES ............................................................................. 74. MANAGEMENT RESPONSIBILITIES .......................................... 75. DEFINITIONS ............................................................................. 76. STANDARDS/GUIDELINES ...................................................... 10

6.1. General ...........................................................................106.2. Principles ........................................................................106.3. Lockout Procedures......................................................... 11

6.3.1. Overview.............................................................. 11

6.3.2. Procedure ............................................................ 11

6.4. Procedure Audit .............................................................. 156.5. Lockout Types ................................................................. 15

6.5.1. Prevention of exposure to electrical hazards ........ 156.5.2. Simple lockout ..................................................... 15

6.5.3. Complex lockout ..................................................15

6.6. Lockout Locks .................................................................166.7. Danger Tags ....................................................................166.8. Authorised person Training and Documentation.............166.9. Line Breaks ..................................................................... 176.10. Confined Spaces .............................................................. 17

7. MANAGEMENT SYSTEMS ........................................................ 177.1. Support Resources .......................................................... 177.2. Management Records...................................................... 177.3. Audit Requirements ........................................................ 177.4. Standard Renewal Process .............................................. 177.5. Deviation Process............................................................ 177.6. Training and Communication Requirements................... 177.7. Contact............................................................................ 17

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Document Issue

The Lockout /Tagout Standard is issued by the Centre for Health, Safety & EnvironmentExcellence (CHSEE), on behalf of Reliance Industries Limited management and form a part ofthe of Reliance Industries Limited HSE management system.

Name: ...............................................................................................................................................................

Signed: ................................................................................................................................................

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Date: .................................................................................................................................................


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Abbreviations

HSE - Health Safety and Environment CHSEE Centre for Health Safety and Environment Excellence GMS - Group Manufacturing Services ReSOP - - Reliance Safety Observation Process

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LoTo - Lock out and tag out


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1. IntroductionThe company recognizes that during servicing and/or maintenance of equipment,personnel have the potential to be involved in a serious or fatal incident caused by theunexpected start-up of equipment or the release of stored energy. The standard outlinesmeasures for controlling hazardous energies-electrical, mechanical, hydraulic,

pneumatic, chemical, thermal, and other energy sources. This standard has beendeveloped to establish procedures for the control of hazardous energy, hereafter calledLockout/ Tagout.

1.1. Intent and PurposeThe intent of this Standard is to ensure a formal approach to managing risk forpersonnel from hazardous energy. This Standard is deliberately prescriptive. TheStandard is designed to reduce the number and frequency of incidents related tohazardous energy.

This standard was developed by an inter-site workgroup with guidance of

experts from DuPont Safety Resources. A number of key elements were definedupon which a fail safe Lockout and Tagout system could be built. These keyelements were subsequently further modified and developed into a series ofpractices. The practices which have been identified here are equally applicableacross all locations and group companies. This will also help in bringing about aconsistency in the process used across all locations.

These guidelines will help to provide a new impetus towards achieving the bestin class safety standards. This revision-0 release of the standard is formulatedbased on world class practices and with the help of DuPont Safety Resources.

Comments and feedback would be appreciated to further enhance this process.

All such comments and feedback may be addressed [email protected]. The comments and feedback would beconsolidated and shall be used during the review and revision of future releases.

2. Scope and field of application

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2.1. ScopeThis standard specifies the minimum mandatory requirements and advisoryguidance for controlling hazardous energy. It also describes i) how to achieveand maintain the security of any isolation made and ii) releasing the equipmentfrom lockout.

Sites should be aware that local regulations may impose mandatory requirementsnot reflected in this standard. The most stringent mandatory requirement shallapply.

Businesses/Locations should be aware that local regulations might imposeconditions not reflected in this standard. Additional information on regulationscomes from a number of sources, including Statutory/Regulatory Documents.

While the intent of the Standards is to bring in homogeneity across allBusinesses / locations in the implementation of the standards, certain provisionsare kept to allow some latitude to the implementing locations. However, those

requirements in this standard which are noted in italics are mandatory. Anyquestion regarding the interpretation of the standards in respect of mandatory


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versus non mandatory should be referred to the Centre for HSE Excellence forclarification.

2.2. Field of ApplicationSee the HSE Protocol, Corporate Policy

3. ReferencesCorporate Policy

HSE Protocol

HSE Commitment

Responsible Care *

Corporate Standards

RIL Standard -Confined Space Entry

RIL Standard -Line Breaks

RIL Standard - Electrical Safety Management

Engineering Standards

Safe Practices Using Mobile Equipment in the Vicinity of Electric Lines andCables

4. Management ResponsibilitiesLine management at locations, businesses and functions has the responsibility toimplement this standard.

5. DefinitionsAffected personany person who operates or maintains or works on a machinery orequipment that is subjected to lockout/ tagout.

Authorised person an employee or contracted or contractor or a contractoremployee trained and authorised in the lockout/tag out procedure to make and verifyisolations.

Complex lockoutLockouts that may involve multiple:

Crafts Employers Hazardous energy sources Lockout points People

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Shifts


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Control devicea device used to execute a system change by manual, remote,automatic, or partially automatic means (e.g., push buttons, emergency buttons orstops, selector switches, and other control-circuit type devices).

Energy-isolating devicea mechanical device that physically prevents thetransmission or release of energy, including but not limited to, the following:

A manually operated electrical circuit breaker A Fuse A disconnect switch A manually operated switch that disconnects a circuit from all ungrounded

supply conductors and prevents all poles from being operated independently.

A line valve

Slip plates, blanks, and physical disconnections

A mechanical block or any similar device used to block or isolate energy.Hazardous energyAny source of electrical, mechanical, hydraulic, pneumatic,chemical, thermal, nuclear radiation or any other energy that, if not controlled, couldcause injury to personnel or damage to property and/or environment.

Electrical hazards are present when conductors or components that may beelectrically energized could cause injury to personnel or damage to property.

Mechanical hazards are present when the unexpected start-up of the system,equipment, or machine, or the release of stored energy while adjusting,maintaining, or servicing systems, equipment, or machines could cause injury topersonnel or damage to property.

Process hazards are present when the unexpected release of gases, liquids, orsolids could cause injury to personnel or damage to property. These hazards canexist during such tasks as installation, fabrication, servicing, or maintenance ofpipelines, vessels, or associated equipment

IsolationSeparation of the equipment, machinery or area where work is to occurfrom sources of hazardous energy or materials in such a way that only a conscious anddeliberate act can restore the connection.

Lockone of three types of locking mechanisms:

DiscreteLocks that are different from one another; each can only be openedby one key.

Personala discrete lock, individually keyed, issued to an individual for his orher use in securing isolations.

Series or systemA group of locks that are opened by a single key and areused in area/ complex lockouts. Various sets of locks may be in use; however,only one key can open any given lock in a particular set.

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Lockingplacing a lockout device on a hazardous-energy-isolating device at a point of


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isolation.

LockoutIsolation of a source of hazardous energy, including releasing any residualhazardous energy that might be present, and securing an isolation point by locking it.

Lockout deviceA piece of equipment that prevents the unauthorised or accidental

operation of a hazardous-energy-isolating device.

Location: Reliance operated Manufacturing Group Companies / Locations, FunctionalUnit, all other places where the business transact

Person in chargeA qualified and Authorised person who is specifically appointedwith overall responsibility for a lockout/tagout to place and keep all hazardous energysources under lockout/tagout and to account for all persons working on the job or task.

Proprietor/owner/operatorthe person or group responsible for the operation of amachine, system, or equipment.

Qualified persona person trained and authorised to work with the equipment andunderstands the hazards involved.

Stored energyHazardous energy that can continue to exist after equipment isisolated (e.g., the hazardous energy contained in springs, flywheels, pressurized fluids orgases, pneumatically controlled devices, capacitors, or gravity).

Taggingplacing a specific tag on a lock or point of isolation to identify who placed thelock and when it was placed.

TagoutPlacement of a DangerDo Not Operate tag (without a lock).

Testingwhen a qualified person verifies the absence of voltage using a site-approvedtesting device.

Troubleshootinga process for identifying malfunctioning components within asystem that is done in both energized and de-energized systems.

Try/tryingproving the effectiveness of isolation by attempting to make a machine,system, or equipment operate with out being inhibited by interlocks or other means thatwould impede the try step.


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6. Standards/Guidelines6.1. General

Lockout/tagout is performed to prevent injury to personnel or damage toproperty and or environment by the unexpected release of hazardous

energy/materials. When planning a lockout, it is important to consider thenature of all hazardous energy/materials that may be present.

6.2. PrinciplesThe following principles govern all lockouts/tagouts:

All sources of hazardous energy shall be identified prior to initiatingany lockout/tagout.

All sources of hazardous energy shall be removed or controlled prior topotential exposure to the hazards. Examples of removing or controlling

hazardous energy are as follows:

Disconnecting power and discharging any capacitance Isolating pressure sources and releasing the pressure Stopping rotating devices and securing them from further

movement

Releasing stored hazardous energy Lowering or securing equipment to prevent movement caused by

gravity

Protecting equipment from external forces (e.g., wind) that maycause movement

Before starting work, each individual working on a task mustdetermine, to his or her satisfaction, that appropriate isolations are inplace and the isolations are secure for the task in which he or she isinvolved.

Where a lock can be applied, tagout alone shall not be used to controlexposure to sources of hazardous energy. Where a lock cannot be

applied, site procedures shall address the use of tagout and theadditional steps essential to help ensure a level of safety equivalent tothat obtained by using lockout. Other means shall be used to secureaccess to the device, where possible.

Each person potentially exposed to the hazardous energy must place alock and tag, when a lock can be applied. Individuals who enter thehazard zone of a lockout shall be considered potentially exposed to thehazard.

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Note: An exception to this principle shall only be made when the location has a writtenprocedure describing the method of controlling, accounting for, and recording anindividuals involvement in the lockout.


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Each person potentially exposed to the hazardous energy mustparticipate in the lockout/tagout.

Clear communication of the lockouts/tagouts status shall be ongoing. An energy source shall be considered energized until the source is

removed and the energy isolation is verified according to theLockout/Tagout Procedure.

Note: Exposure to hazardous material shall be controlled in accordance with themandatory provisions of RIL Standard Line breaks

An effective verification (try) step must be performed. All interlocks thatmay prevent an effective try step must be accounted for.

A test for the absence of voltage must be performed for all electricalhazards.

6.3. Lockout Procedures6.3.1. Overview

Each site shall establish written procedures for controlling andmethodologies for isolating hazardous energy. The procedures shallinclude the following information:

How the hazardous energy sources are to be controlled for theduration of the work

Who is responsible for determining that the hazardous energysources are controlled for the duration of the work

The responsibilities of all personnel involved in the work Mandatory training requirements

6.3.2.ProcedureAt a minimum, each sites lockout procedure must include details on the

following elements:

Removing the source of hazardous energy and hazardousmaterials

Addressing exposure to hazards while performing thelockout/tagout

Installing lockout devices Verifying that the hazardous energy source has been removed Trying the equipment to determine that the hazardous energy is

under control

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Developing a method for helping ensure the continuity oflockouts across shifts


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Releasing the equipment from lockout Describing the specific measures to be used to enforce the

procedures mandatory requirements

Identifying and listing lockout points for tasks with multiplelockout points

Review periodically (at least once a month) lockout/tagoutcompletion in the areas.

6.3.2.1. Removing the source of hazardous energy andhazardous materials

All personnel who use site lockout procedures must know thefollowing information:

The specific hazardous-energy-isolating devices forthe task to be performed

The type of hazardous energy supply or hazardousmaterial

The type and location of the disconnecting/isolatingdevice acceptable for the hazardous energy source orhazardous material

The means and hazards of operating thedisconnecting/isolating device

The means of installing a lockout device

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Note: Push buttons, selector switches, and other control-circuit typedevices are not hazardous-energy-isolating devices. Control andsolenoid valves are not adequate means of providing isolation for fluids.Control valves that are designed for use as hazardous-energy-isolatingdevices and that provide an effective isolation from the hazardousenergy may be used in alignment with the mandatory requirements ofRIL Standard Line Breaks

A method must be used to verify that the hazardous energysource or hazardous material has been removed and that thehazardous energy isolation is complete. In some instances,

the try step is sufficient; in other instances, only testing canverify the isolation is complete.

Where hazardous energy can re-accumulate due to systemdesign, configuration, or installation, a means of preventingthis re-accumulation must be used. An example of possiblehazardous energy re-accumulation is in a long electrical cablethat has a high capacitance. When the system or equipmentcontains a source of stored hazardous energy (e.g., springs,flywheels, gravitational effects, or capacitors), the storedhazardous energy must be relieved or otherwise blocked withcomponents that control the potential hazard. The

advisability of installing protective grounds in complex orhigh-energy electrical systems should be considered. (See RIL


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Standard Electrical Safety Management)

Fuel-powered, engine-driven equipment (sometimes calledportable equipment) must be rendered inoperable by securemeans (e.g., by disconnecting and removing the batterycables or removing the spark-plug wire or equivalent).

6.3.2.2. Installing lockout devicesThe lockout device must be installed in a way that helpsensure that inadvertent operation of the hazardous-energy-isolating device is impossible.

Each site must define in written procedures the method ofcontrolling or securing the keys for the lockout devices for alllockouts.

Each person potentially exposed to the hazardous energy

must place a lock and tag, when a lock can be applied.

Note: An exception to this principle shall only be made when the sitehas a written procedure describing the method of controlling,accounting for, and recording an individuals involvement in thelockout.

In case of complex lockout/tagout involving multiple agencies e.g.,electrical and mechanical contractors and Company personnel, a clearcommunication line must be established to all parties involved inlockout/tagout

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6.3.2.3. Verifying that the hazardous energy source has beenremoved

All isolations shall be verified to determine that thehazardous energy has been removed.

The following are examples of how to verify the removal ofhazardous energy sources: opening drains; viewing pressuregauges, site glasses, or level indicators; visually verifying thatrotating equipment has stopped; visually verifying thatcomponents have been disconnected (e.g., couplings, belts,and chains have been removed); and verifying that storedhazardous energy has been removed or is appropriately

blocked.

Caution: Gauges/Indicators should be viewed before thehazardous energy source is removed to confirm they are inworking order. Drains can become blocked and not functionas designed.

When verifying isolations, personnel should take precautionsto avoid putting themselves at risk or creating additionalhazards.

For tasks where there is exposure to electrical hazards, abreak in the power conductors should be visually inspected,

where possible. All lockouts must include verification of acomplete physical break in the power conductors by testing


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for absence of voltage with a site-approved voltage-detectingdevice.

Note: For information on Test before Touch and testing for the

absence of voltage, refer to RIL Standard Electrical SafetyManagement

6.3.2.4. Trying the equipment to determine that thehazardous energy is under control

When the equipment is tried (i.e., the control deviceoperated) to verify its isolation from sources of hazardousenergy or hazardous materials, the area surrounding theequipment shall be cleared of people and equipment thatcould be injured or damaged prior to attempting to start theequipment. Try procedures must help ensure the isolationof all sources of hazardous energy and the positive control ofhazardous materials by trying to start or move the

equipment. The try procedure must also account for allitems (e.g., interlocks) that may prohibit the equipment fromstarting or moving.

6.3.2.5. Releasing the equipment from lockoutBefore the equipment or pipeline is released back to theproprietor, the people working on it shall determine that it issafe to reintroduce the hazardous energy or materialto theequipment or pipeline. The equipments status shall beconveyed to the proprietor when the equipment is releasedfrom lockout. The proprietor shall inspect or otherwise verify

the integrity of the pipeline or equipment before hazardousenergy or hazardous material is reintroduced. Thisverification may include leak testing, pressure testing, orsimple visual inspection.

Where work extends over multiple days or shifts, a lockoutdevice may be permitted to remain in place for the duration ofthe work period. However, the individual shall verify thelockout is in place after any absence from the work site. Eachperson who installed a lock should remove it when his or her work is complete.

Sites shall establish a procedure, including the mandatorylevel of authorization, for removing an absentees lock. Oncethe installers unavailability (i.e., not on site) is confirmed,formal authorization for removing the lock should be given. Ifsomeone other than the installer removes a lock, the installershall be informed immediately on his or her return to workthat the lock was removed.

Where lockouts extend beyond one shift, the lockout/job planshall address the continuity of the lockout across the shifts.

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6.3.2.6. Review periodically (at least once a month)lockout/tagout completion in the areas.


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Each site to establish procedure to periodically review (atleast once a month) ALL active lockout/tagout.

Identify the cause(s) of non-release of lockout/tagout beyondspecified period.

Methodology to release the above lockout/tagout thusidentified.

6.4. Procedure AuditEach site shall establish an audit process to determine

How often to audit. If the established procedure is being followed. If there are deficiencies in the established procedure. If there are deficiencies in understanding the established procedure.The person responsible for the procedure and other knowledgeable personnelshall audit the procedure.

6.5. Lockout Types6.5.1. Prevention of exposure to electrical hazards

Where an electrical hazard is a possibility, caution should be exercised toverify that all possible sources of hazardous electrical energy are

controlled. Persons making the lockout shall be suitably qualified toassess and address the electrical hazards associated with the lockout.

Additional steps are taken for lockouts work on or near potentiallyenergized electrical equipment. For more information, refer to RILStandard Electrical Safety Management

6.5.2.Simple lockoutA simple lockout is accomplished by individuals placing personal locksand tags directly on the points of isolation. This is the preferred methodof lockout and should be used when appropriate.

6.5.3.Complex lockoutFor complex lockouts, each site shall define the following in writing:

The person in charge shall be responsible for keeping allhazardous energy sources, hazardous materials, and electrical,process, and mechanical hazards under control as the workprogresses.

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When multiple employers are working on the same process,everyone involved in the work must understand and observe the

mandatory requirements of all the lockout procedures of all theemployers involved.


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The lockout process must cover all issues identified in allemployer procedures.

6.6. Lockout LocksLockout locks shall only be used to control hazardous energy. In certain

situations, an individual Authorised person may apply multiple locks keyed to asingle key. Locks are an essential element of a lockout device. However, thelockout device may include other components if the assembly effectivelycontains the source of hazardous energy.

All lockout locks shall be identified as follows:

Series or system locks shall indicate the lockbox number, system, orequipment being locked out.

Personal and discrete locks shall indicate the individual who applied thelock.

The information may be on a danger tag attached to the lock or may be on thelock. The preferred method is to use a danger tag with the locks.

6.7. Danger TagsDanger tags shall be designed to be different from all other tags available atthe site. Each site shall establish a mandatory requirement for danger tagdesign for all lockout applications. The danger tag shall be readily identifiableas a danger tag. The tags should include standardized verbiage (e.g., DangerDo Not Operate or DangerDo Not Remove Without Authority). The dangertag must have unique identification number and must provide space for thename of the Authorised person and the date the tag is installed and the Permit

Number. It may also provide space for other information (e.g., the craft or thereason for the tag). Danger tags and its contents must be able to withstand theenvironment in which they are used for the duration of the lockout.

Danger tags shall not be used for any other purpose than to indicate anisolation point for controlling hazardous energy.

6.8. Authorised person Training and DocumentationAll Authorised persons shall be trained to the degree warranted by their jobassignments. They shall be retrained whenever their job assignments change orwhenever the hazardous energy control procedure changes.

Note: A job may change by reassignment or by equipment modification.

Documentation shall exist for each Authorised person who has been trained.This documentation shall include the following information:

Authorised persons name and job assignment Employer Date of training Content of the training received Name of the person conducting the training

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Method of verifying the Authorised persons understanding of the training


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Documentation may be maintained in a computer-based system but should bemade available in hard copy form on request.

6.9. Line BreaksSee HSE Standard for mandatory requirements and advisory guidance on

lockout associated with line breaks. The mandatory requirements of both HSEStandard on Line Breaks and this standard must be followed when makingline breaks.

6.10.Confined SpacesSee HSE Standard for mandatory requirements and advisory guidance onworking in confined spaces. The mandatory requirements of both HSEStandard Confined Space Entry and this standard must be followed whenworking in confined spaces.

7. Management Systems7.1. Support Resources

Site and business HSE resources are available to assist with implementation ofthis standard.

7.2. Management RecordsRecords shall be retained in compliance with the Statutory Requirements,Corporate Records and Information Management Program.

7.3. Audit RequirementsEach site or region should audit compliance with this standard as part of its HSEaudit program.

7.4. Standard Renewal ProcessThis standard shall be reviewed and revised as necessary and, at a minimum,not later than five years from the date of the last revision.

7.5. Deviation ProcessDeviations from this standard must be authorised by the site President for the

relevant site after consultation with the HSE Excellence Center and no-objection from the company Corporate HSE Council. Deviations must bedocumented, and documentation must include the relevant facts supporting thedeviation decision. Deviation authorization must be renewed periodically andno less frequently than every three years.

7.6. Training and Communication RequirementsEach location business and site should provide training as appropriate. SeeSection 6.8 for specific mandatory requirements.

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7.7. ContactThe contact for this document is the Centre for HSE Excellence (CHSEE).