isolation and release of equipment

ISOLATION AND RELEASE OF EQUIPMENT/SYSTEMS FOR WORK

Procedure Number: HES - 203

CPL HES Isolation and Release of Equipment/Systems for Work

Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

CONTENTS

ISOLATION AND RELEASE OF EQUIPMENT/SYSTEMS FOR WORK HES-203

Section Title Page

1.0 Purpose 203 – 1

2.0 Scope 203 – 1

3.0 Prerequisites 203 – 2

4.0 Process overview 203 – 3

5.0 Instructions 203 – 4 5.1 Prepare for Isolation 203 – 4 5.2 Equipment System Shutdown 203 – 6

5.3 Equipment System Isolation 203 – 6

5.4 Equipment System Lockout/Tagout 203 – 9 5.5 Shift Change 203 – 11 5.6 Verification of Compliance 203 – 11

5.7 Removal of Lockout/Tagout Device(s) by Persons Other Than Authorized Employee Who Installed It 203 – 12

5.8 Tagout Procedures when Lockout Is Not Feasible 203 – 12

6.0 Roles and Responsibilities 203 – 13

7.0 Reporting Requirements 203 – 14

8.0 Documentation and Record Retention 203 – 14

9.0 Variances 203 – 14

Appendices

Appendix A Glossary

Appendix B References Used in This Procedure


Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix C Equipment Specific Procedure Sheet

Appendix D Additional Equipment/Systems Information

Appendix E (removed)

Appendix F Annual Verification of Compliance

Appendix G Examples of Logout/Tagout Scenarios


1 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

1.0 Purpose The purpose of this procedure is to:

• Prevent injury to personnel by requiring that specific precautions be taken before and during service, maintenance, and/or repair activities on equipment and pipeline systems.

• Prevent incidents resulting from: o the unexpected energizing or start-up of equipment; o release of stored energy; and o exposure to harmful materials during cleaning, servicing, or adjusting of machines,

equipment, or pipeline systems.

• Establish the minimum requirements for using lockout and tagout devices to isolate potentially hazardous energy or substance sources, while employees are servicing and/or maintaining equipment and pipeline systems, where the unexpected start-up of equipment pipeline systems or release of energy could cause injury.

• Establish the minimum requirements used to warn other workers that they must not operate a device which has been locked or tagged out.

• Establish the hazardous energy/substance control (lockout/tagout) program to be used at company locations and the locations where company employees work.

• Verify compliance with Occupational Safety and Health Administration (OSHA) regulation 29 CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout).

2.0 Scope

2.1 Personnel, Activities, and Equipment Covered by this Procedure

This procedure applies to all personnel, company or contractor, working in or on Chevron Pipe Line Company (CPL) owned, operated, or maintained facilities.

This procedure must be followed by employees whose duties require them to service and maintain equipment/systems in which the “unexpected” energization or start-up of equipment/system, or the release of stored energy could cause injury.

2.2 Exemptions from this Procedure The following are exemptions from this procedure:

• Work on cord and plug connected electric equipment for which exposure to the hazards of unexpected energization or start-up of the equipment is controlled by the



unplugging of the equipment from the energy source, and by the plug being under the exclusive control of the employee performing the servicing or maintenance.

• Hot Tap operation is a special operation. Refer to CPL’s procedures, the Corporation Piping manual, or to the Corporation Pipeline manual - Section 850.

3.0 Prerequisites • All personnel, company or contractor, involved in isolation and release of

equipment/systems for work must be trained on the contents of this procedure. • Contractors or qualified third-party contractors will not be allowed to initiate

lockout/tagout.



4.0 Process Overview

Work Servicing andMaintenance is required

Does anEquipment

Specific ProcedureSheet Exist?

Shutdown and isolate theequipment/system

Verify that equipment/system is fully isolated,locked and tagged, and

cannot be energized

Develop EquipmentSpecific Procedure

Sheet

Conduct work

Secure the equipment/system (lockout and

tagout)

Recommissionand start-up

equipment/system

Dissipate all storedenergy (continual

verification is requireduntil servicing and

maintenance is complete)

NO

YES



5.0 Instructions

5.1 Prepare for Isolation An Equipment Specific Procedure Sheet must be developed prior to isolating and releasing equipment/system for work using CPL-679. Existing Equipment Specific Procedure sheets documented at the facility must be followed.

5.1.1. Equipment Specific Procedure Sheets

Developing the Equipment Specific Procedure Sheet

Developing the Equipment Specific Procedure Sheet requires the following steps:

1. A CPL authorized employee must:

a) In the General section, identify: i) Location ii) Equipment/system iii) Work description iv) Procedure number v) Annual verification date vi) Written by and date

b) In the List of Equipment, Energy Sources and Energy Isolating Devices section, identify: i) All associate equipment requiring isolation and release of energy ii) Their energy sources iii) Energy isolating devices (i.e., blinds, valves, switches, etc.) used to

isolate the piece of equipment

c) In the Sketch of Isolation section, make a simple sketch or attach existing drawings of the equipment/system being isolated, showing energy isolation devices.

d) In the Procedure Description in Sequence section document the steps required to: i) Notify affected employees. ii) Shutdown equipment/system. iii) Isolate energy. iv) Verify energy isolation. v) Dissipate energy. vi) Verify energy dissipation and reaccumulation. vii) Secure (lockout/tagout) equipment/system. viii) Restore equipment/system to service.

e) Prior to work beginning, submit the Equipment Specific Procedure Sheet to a CPL employee other than the author and with equal or greater qualifications for review.



2. The CPL employee, other than the author and with equal or greater qualifications, must:

a) Review the Equipment Specific Procedure Sheet for completeness and accuracy;

b) Sign his or her name in the Approval Signature section for verification, and date; and

c) Submit the Equipment Specific Procedure Sheet to the CPL Team Leader, responsible for the asset, for approval.

3. The CPL Team Leader responsible for the asset must:

a) Review the Equipment Specific Procedure Sheet for completeness and accuracy;

b) Sign his or her name in the Approval Signature section for approval, and date; and

c) Submit the Equipment Specific Procedure Sheet into the Field Team file system.

NOTE: When unplanned events require work to be completed immediately and the Team Leader/designee is not available by fax or telephone to discuss and/or sign the Equipment Specific Procedure Sheet, work may be conducted after the review of the Equipment Specific Procedure Sheet of the second authorized employee. The Team Leader should review the Equipment Specific Procedure Sheet with the authorized employee as soon as practical, then sign and approve.

5.1.2 Utilizing the Equipment Specific Procedure Sheet

Utilizing the Equipment Specific Procedure Sheet requires the following steps:

1. A CPL authorized employee must: a) Inspect the Equipment Specific Procedure Sheet for completeness and

accuracy; b) Sign his or her name in the Verification/Authorization Signature section

for verification that energy control procedures are specified, and date; c) Review the Equipment Specific Procedure Sheet with all affected

employees (usually done during safety meeting in preparation for the job);

d) Sign his or her name in the Verification/Authorization Signature section for verification that affected employees have been notified, and date;

e) Initiate the isolation of equipment/system; f) Initial each step in the Procedure Description in Sequence section for

verification that it is completed;



g) Sign his or her name in the Verification/Authorization Signature section for verification that equipment is isolated and secured, and date; and

h) Submit the Equipment Specific Procedure Sheet to the authorized employee(s) for review.

2. The authorized employee(s) must:

a) Review the Equipment Specific Procedure Sheet for existing conditions;

b) Sign his or her name in the Verification/Authorization Signature section for verification that conditions are understood, and date; and

c) Submit the Equipment Specific Procedure Sheet to the CPL authorized employee.

3. The CPL authorized employee must: a) Review the Equipment Specific Procedure Sheet for completeness and

accuracy; and b) Sign his or her name in the Verification/Authorization Signature section

for verification that equipment/system isolation is complete, and date.

5.2 Equipment/System Shutdown Notify all affected employee(s) of the impending shutdown of the equipment/system as described in the Equipment Specific Procedure Sheet. The nearest operating control device (i.e., depress stop button, open switch, close valve, etc.) should be used in accomplishing the shutdown. An orderly shutdown must be used to avoid any additional or increased hazards to employees as a result of equipment being de-energized/isolated.

5.3 Equipment/System Isolation 5.3.1 Equipment/System Isolation Methods

Blinding Blinding is the required method of isolation for work involving confined space entries. Equipment must be blinded as close to the equipment as practical, usually the first flange at the vessel or tank. Blinding is the preferred method of isolation for work not involving confined space entries, such as: • Isolation of pipes, traps, vessels, and tanks. • Opening lines for repairs or alterations.

NOTE: Double block and bleed is acceptable with Team Leader approval.

• Taking equipment out of service for maintenance. • Where existing block valves cannot safely isolate hazardous energy sources

(block valve leaks) prior to blinding, the isolation process should be



expanded to include the closest adjacent equipment where blinds can be safely installed.

Prior to releasing equipment for work, blinding of connected lines and breaking and plugging of smaller screwed lines must be required. Blinds must be properly designed to withstand backpressure expected. Consult with the Technical Services Group as needed.

Double Block and Bleed Double block and bleed may be used as a means of isolation if it is determined that it is more hazardous to insert/remove blinds. Double block and bleed is acceptable provided all of the following conditions are met: • Team Leader has approved it • Used for isolation only (no confined space entries) • Bleeder is clear, open and free of obstructions • Isolation block valves are proven to hold (no leakage from bleeders)

All double block and bleed isolations must have both block valves secured (locked and tagged at the hand wheel as well as electrically) in the closed position. The bleeder must be locked and tagged in the open position. For any other work activity associated with the piece of equipment once the equipment/system has been isolated and the energy dissipated, refer to the appropriate procedure(s) (i.e. Hot Work, Respiratory Protection, etc.). A General Twin Seal or WKM Power Seal type valve (not Safety Seal) may serve as a double block and bleed, provided: • the valve has been fully closed, locked, and tagged; • the inner chamber bleeder valve(s) have been locked and tagged in the open

position to the atmosphere and verified clear and free of obstruction; and • all inner chamber relief valve or overpressure piping must be disconnected,

capped, and tagged.

Single Block

Single block valves must not be relied upon as safe isolation for service or maintenance work. Short duration tasks (not to exceed 60 minutes in which you do not walk away from the task) not requiring “Open Flame” hot work (see note below), such as installation of a blind or boilermaker or cleaning a strainer, launching/receiving pigs, are permitted against a single block valve, if it can be verified that the system is de-pressured downstream of the block valve. The valve must be locked and tagged electrically if applicable.

NOTE: ”Non-Open Flame” work can be performed as long as no “Open Flame” hot work takes place. If the specific work and use of equipment is required (such as a crane with an internal combustion engine), you will still need to execute safe work, and hot work permits (“Non-Open Flame”) and perform the necessary monitoring.



5.3.2 Electrical Isolation A qualified employee is required to perform the work that has the potential for “electric shock or other injuries resulting from either direct or indirect electrical contacts”, as defined by Electrical Safe Work Practices (HES-206). To isolate electrical energy, electrical supply circuits must be de-energized by one or all of the following actions: • Securing (lock and tag) a circuit breaker or other power control in the "Open"

or "Off" position; • Physically removing a circuit breaker or fuse; and/or • Physically breaking an electrical circuit (interlocks).

NOTE: If a device has Supervisory Control and Data Acquisition System (SCADA) control capability, the device must be control disabled through SCADA as well as in the field (at the local facility).

WARNING: Software isolating devices from Programmable Logic Controller (PLC) systems are not considered lockout devices, and are not to be used in place of physical locks.

5.3.3 Stored or Residual Energy Some examples of stored or residual energy include: • Springs • Capacitors • Fan blades • Elevated machine members • Rotating flywheels • Hydraulic systems • Air, gas, steam, or water pressure

To prevent the release of energy during servicing and maintenance of the equipment, all potentially stored or residual energy must be dissipated or restrained by methods such as: • Tying down • Grounding • Blocking • Bleeding down

5.3.4 Verification of Isolation Prior to starting work on equipment/system that has been locked and tagged out, the authorized CPL employee must verify that isolation and de-energization of the equipment/system has been accomplished per the Equipment Specific Procedure Sheet. Continual verification of isolation and depressurization is required throughout the isolation process.



5.4 Equipment/System Lockout/Tagout Each isolated hazardous energy/substance source must be secured by locking and tagging before servicing, and/or maintenance work is started to ensure that the energy isolating devices and equipment being controlled cannot be operated until the lockout and tagout devices have been removed, providing protection to all employees associated with the servicing and maintenance of the equipment.

Equipment and systems where locks cannot reasonably be applied must have hazardous energy secured through the use of blinds, drop out spools, breaking of connections, tying of fan blades, etc. Use of these techniques would constitute securing the energy source. The use of appropriate tags is also required.

Upstream block valves must be secured, locked, and tagged, prior to inserting blinds.

Once secured, equipment/systems must remain isolated, secured, and tagged for the duration of the maintenance work.

5.4.1 Types of Lockout/Tagout

Personal Lockout/Tagout Personal equipment lockout/tagout is the process whereby each person accepts responsibility for his/her own safety when servicing or maintaining equipment/system, by placing their own personal (operations, mechanical, or electrical) lock and tag on the energy isolating devices. This covers most situations where the work is in one location where the one authorized employee can directly account for all isolations and work that is going on. This may be a single person conducting the work or a group conducting the work, each of which will place individual locks and tags on the energy isolating device(s). Use of a multi-lock hasp or other device may be required.

Group Lockout/Tagout Group lockout/tagout is the process whereby primary responsibility is vested in a principal authorized employee(s) for a set number of employees working under the protection of a group (i.e., crew, craft, department, location, etc.) lockout or tagout device.

Group Lockout/Tagout without Lock Box A group lockout/tagout without a lock box may be used when a group of employees are involved in the servicing and maintenance of equipment/system.

NOTE: Contractors or qualified third-party contractors will not be allowed to initiate lockout/tagout, but will participate as necessary to meet the lockout/tagout requirements and ensure their employee safety.



A CPL principal authorized employee from Operations must: • place a lockout/tagout device upon each hazardous energy/substance

isolation device, using a lockout hasp, as described in the Equipment Specific Procedure Sheet; and

• be the first to place and last to remove their lockout and tagout devices. Each principal authorized employee responsible for a group (i.e., crew, craft, department, location, etc.) must then place a lockout and tagout device upon each hazardous energy isolation device as described in the Equipment Specific Procedure Sheet. Each principal authorized employee is responsible for the overall safety of their group, the safekeeping of his/her key, and the removal of his/her lockout and tagout devices upon completion of work. Each authorized employee must confirm that all hazardous energy has been isolated and/or de-energized by physically going to each isolating device where a lock and tag has been placed, or by talking with the principal authorized employee to confirm all energy isolating devices have been installed.

Group Lockout/Tagout with Lock Box A group lockout/tagout with a lock box may be used when a group of employees are involved in the servicing and maintenance of equipment/system.

NOTE: Contractors or qualified third-party contractors will not be allowed to initiate lock-out/tag-out.

A CPL principal authorized employee from Operations must: • Place a lockout/tagout device upon each hazardous energy/substance

isolation device as described in the Equipment Specific Procedure Sheet; • Place the key(s) inside a lockbox; • Place a lockout/tagout device upon the lockbox; and • Be the first to place and last to remove their lockout and tagout device

from the lockbox. Each principal authorized employee must confirm that all hazardous energy has been isolated and/or de-energized by physically going to each isolating device where a lock and tag has been placed, or by talking with the operations principal authorized employee to confirm all energy isolating devices have been installed. Each principal authorized employee responsible for a group (i.e. crew, craft, department, location, etc.) must place a lockout and tagout device upon the lockbox. Each principal authorized employee is responsible for the overall safety of their group, the safekeeping of their key, and the removal of their lockout and tagout device upon completion of work.



Each authorized employee must confirm that all hazardous energy has been isolated and/or de-energized by physically going to each isolating device where a lock and tag has been placed or by talking with their principal authorized employee to confirm all energy isolating devices have been installed.

NOTE: See Appendix G for examples of each lockout/tagout scenario.

FIGURE 203.1: Multiple Group Equipment Isolation

Operations CTPC Prinicpal Authorized Employee

Principal Authorized Employee

Authorized Employee(i.e., Operations, Mechanical,

Electrical, etc.)

Principal Authorized Employee

Authorized Employee(i.e., Operations, Mechanical,

Electrical, etc.)

5.5 Shift Change During a shift change, the following actions will take place:

• The exiting CPL authorized/principal authorized employee and the principal authorized employees ensure the incoming people fully understand the work to be performed under this Equipment Isolation procedure by having a procedure review meeting.

• The entering CPL authorized/principal authorized employee reviews and signs the Equipment Specific Procedure Sheet indicating they have read, understood, and confirmed that all equipment on the Equipment Specific Procedure Sheet is still locked out and tagged out.

5.6 Verification of Compliance All Equipment Specific Procedure sheets must be reviewed on an annual basis by the Team Leader or other persons having knowledge of this procedure (HES 203) and the equipment isolation process. The methods for completing the Annual Verification of the Equipment Specific procedures are to evaluate one of the following:



• The procedure as it is being applied at least once per year. (The review cannot be by the person who completed the Equipment Specific Procedure Sheet.)

• The procedures at a team meeting with all authorized employees who could be expected to utilize the procedures.

The purpose of the verification is to correct any departures or inadequacies observed. The departures and inadequacies must be recorded. The annual verification of compliance should be documented on the Annual Verification of Compliance form (CPL-203) in Appendix F.

5.7 Removal of Lockout/Tagout Device(s) by Persons Other than Authorized Employee Who Installed It

Under normal circumstances, a lockout/tagout device must be removed only by the authorized employee who installed it. Where removal by someone else is necessary, the steps listed below must be followed:

• The removal of a lockout/tagout device must be done only under the direction of the Team Leader in charge of the asset, after he/she has verified that it is safe to remove it.

• The Team Leader must verify in advance that the authorized employee who applied the lockout/tagout device is not at the facility.

• Reasonable efforts must be made to contact the authorized employee to inform him/her that the lockout device is being removed.

• The Team Leader must verify that the authorized employee has been informed of the removal of the lockout device before he/she resumes work at the facility.

5.8 Tagout Procedures when Lockout Is Not Feasible Tagout procedures must be used only when a hazardous energy/substance isolating device is not capable of being locked out. If it becomes necessary to use a tagout, the following procedures must be used in addition to the ones described for lockout.

Equipment Specific Procedure sheets relating to the application and removal of lockout devices are applicable also to tagout devices.

Additional measures must be considered to make the protection afforded by the tagout procedure equivalent to that provided by the lockout procedure. These include, but are not limited to, removal of a circuit breaker, removal of fuses, the blocking of a controlling switch, or the opening of an extra disconnecting device.

Where a tag cannot be affixed directly to the hazardous energy/substance isolating device, it must be located as close as safely possible to the device.

Tagout devices must be affixed in such a manner as will clearly indicate that the operation or movement of hazardous energy/substance isolating devices from the "safe" or "off" position is prohibited.

The tagout device used by the company must:



• Have a standard format (refer to Appendix A); • Be able to withstand wear and the environment to which it is exposed; • Be secured so that it cannot be accidentally detached during use; and • Identify the person who applies it.

The tag attachment mechanism must be non-reusable, attachable by hand, self-lockable, non-releasable, with a minimum unfastening strength of no less than 50 pounds. Reusable, non-lockable, easily detachable mechanisms, such as, but not limited to, string, cord, or adhesive, must not be permitted.

Just as in the lockout procedures, tags must not be removed from the hazardous energy/substance isolating device without authorization of the authorized employee responsible for it, and is never to be bypassed, ignored, or otherwise defeated. Other requirements outlined for lockout must also be followed for tagout.

When tagout is used, employees must be trained in the limitations of tags and in the above tagout procedures.

6.0 Roles and Responsibilities

6.1 All Employees All employees are responsible for:

• Understanding the purpose and use of Equipment Isolation procedures; • Recognizing locks and tags; • Not removing locks and tags; • Not operating equipment with locks and tags; • Recognizing hazardous energy sources and the means to control them; and • Initiating, following, and completing equipment isolation procedures.

6.2 Authorized Employees Authorized employees are responsible for:

• The overall safety and job execution of Equipment Isolation procedures; • Clear and complete communications to all affected personnel; and • Authorization of job completion and return to service.

6.3 Principal Authorized Employees Principal authorized employees are responsible for:

• The overall safety and job execution of a their designated Group during a Group Equipment Isolation; and

• Complete and clear communications to the authorized employees in their group during the entire isolation, work, and re-commissioning of the equipment/system.



6.4 CPL Authorized/Principal Authorized Employees CPL authorized/principal authorized employees are responsible for ensuring that:

• The equipment is shutdown, isolated and secured, and locked and tagged; and • All locks and tags are removed and equipment is ready for service.

6.5 Qualified Employees Qualified employees are responsible for:

• De-energizing the electrical equipment they are qualified to secure; • Verifying electrical circuits have been isolated and tested; and • Verifying that electrical equipment can be safely re energized.

6.6 Team Leader Team leaders are responsible for verifying that:

• Equipment Specific Procedure sheets are completed for the servicing, maintenance, and/or repair of each piece of equipment; and

• Annual Verification of Compliance is completed for each Equipment Specific Procedure Sheet kept on file.

7.0 Reporting Requirements Reporting requirements are not applicable to this procedure (HES 203).

8.0 Documentation and Record Retention The following records need to be kept on file at the Field Team office:

• Equipment Specific Procedure sheets must be kept on file for as long as the equipment exists.

• Tags from each service, maintenance, and/or repair need to be kept on file if there is an incident associated with the work.

• Annual Verification of Compliance must also be kept on file.

9.0 Variances Any variance from this procedure requires an approved MOC. Refer to HES-104 Management of Change, Variance Proposal.


A 1 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix A – Glossary 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 tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.

Authorized Employee An Operations employee who locks or tags out machines or equipment in order for servicing and maintenance of the equipment or machine to be performed.

Double Block and Bleed The closure of a line, duct, or pipe by:

• closing and locking or tagging two in-line valves; and • opening and locking or tagging a drain or vent valve in the line between the two

closed valves.

Electrician's Lock A lock assigned to one authorized electrician employee. This lock is used only to protect the individual qualified employee holder of the lock. Only the individual assigned the lock will have a key to the lock. This lock is red.

Energy Isolating Device A mechanical device that physically prevents the transmission or release of any type of energy. It is capable of receiving a lockout device or tag. Examples of energy isolating devices include circuit breakers, disconnect switches, line valves, blind flanges, and other similar devices.

NOTE: Push buttons, selector switches, or other control circuit devices are not considered isolating devices.

Blind flanges are considered energy isolating devices when they are securely installed and tagged and when they are of adequate size and design (thickness, gasket surface, bolts, etc.) to provide full protection from any anticipated release of energy.

"Skillets" or "spectacle blinds" may be used in lieu of blind flanges if the CPL authorized/principal authorized employee determines that they provide equivalent protection.

NOTE: Bolts must be used in all boltholes.



Hazardous Energy Source Any source of energy that could lead to injury of personnel, to fire, or to equipment damage, spill, or release. The five common categories of hazardous energy are:

• Electrical (110 v AC or greater) • Chemical (gases, vapors, liquids, acids, caustics, flammables) • Thermal (steam, heat, etc.) • Mechanical (hydraulic pressure, springs, rotating flywheels, fan blades, etc.) • Radiation/Density Gauge

Lockout Device A device that utilizes a positive means, such as a padlock, chain, wire rope, lockout shield, etc., to secure an energy isolating device in a safe position and prevent it from being moved.

The term "secured" refers to the application of a lockout device or creation of physical barrier between a potentially exposed person and hazardous energy.

Mechanic's Lock A lock assigned to one person performing maintenance work. This lock is used to protect only the individual holder of the lock. Only the individual assigned the lock will have a key to the lock. This lock is blue.

Operations Any employee who is involved in the operation, maintenance, or servicing of a pipeline system or plant process and designated to initiate isolation.

Operations Lock A lock assigned to one person acting as the operations representative. This lock is used to protect only the individual holder of the lock. Only the individual assigned the lock will have a key to the lock. This lock is yellow.

Padlock Each team must have an assigned series of keyed padlocks in sufficient numbers to meet foreseeable needs.

• Personal locks are to be identifiable by color (craft) and have only a single key. • Group locks may be keyed the same for each department/craft as long as the Equipment

Specific Procedure outlines the process for the safekeeping of the key(s) for the duration of the work.

Principal Authorized Employee An authorized person with authority to place and remove a group lock for a specified group of workers when these workers do not place personal locks on the isolating devices. This person will be assigned during Group Isolations.



Qualified Employee Qualified employees have received the training required to perform maintenance that exposes them to electrical equipment as specified in 29 CFR 1910.331-333. These employees are responsible for:

• de-energizing electrical equipment; • verifying that an electrical circuit has been isolated; and • ensuring that electrical equipment can be safely re-energized.

Tagout Device This is a “Danger Tag” with appropriate wording written on it. It is securely attached where an energy isolating device would have been installed to indicate that the:

• device may not be activated; • equipment may not be activated; and • equipment may not be operated.

This tag must be attached with a single use nylon tie capable of withstanding 50 lbs. of force.

Tags This tag is placed with a lockout device or energy isolating device. The tag color either matches the lock color or may be red on white danger tags with appropriate wording. The tags may include, but are not limited to the following:

• GO-1492 (Red) Authorized Electrician's Lock and Tag • GO-1493 (Yellow) Authorized Operator's Lock and Tag • GO-1494 (Blue) Authorized Mechanic's Lock and Tag • GO-1495 (White/Red Lettering) Danger Tag, Utility • GO-1705 (Gray) Instrument Mechanic Danger Tag

Verification of Continuing Equipment Isolation Verification of Continuing Equipment Isolation means monitoring all the sources of energy reaccumulation identified on the Equipment Specific Procedure Sheet. At a minimum, this means periodically checking the status of locks and tags. Other examples include monitoring pressure gauges, liquid levels, electrical current, temperatures, etc.


C1 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix B – References Used in this Procedure Safety Procedure Description 29 CFR 1910.147 The Control of Hazardous Energy (Lockout/Tagout)

29 CFR 1910.331-333 Electrical Lockout/Tagout

HES-201 Confined Space Entry

HES-206 Electrical Safe Work Practices


C2 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix C – Equipment Specific Procedure Sheet CPL-679 Equipment Specific Procedure Sheet

http://cpl.chevron.com/manuals/cplhesgp/Gen203/gen_203appendixC.docx�


D1 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix D – Additional Equipment/Systems Information The following are specific information and safety procedures to be followed in releasing equipment and pipelines for mechanical work.

1. Piping Blinding or double block and bleed is required for all types of hydrocarbon service. A line must be completely isolated prior to repairs including breaking and plugging any small lines that can introduce hydrocarbon to the work area. A single block that has been locked and depressurized is adequate for installing a blind.

Bleeders used to assure de-pressured conditions should be cause for particular concern. In some services they may become plugged, or if infrequently used may fill with scale. In no case must a wire be used to clear a plugged valve. Use a hydraulic ram or a bleeder reamer designed for this purpose. Also, bleeders should be locked open only when used for isolation as part of a double block and bleed.

If a valve, relief valve, or an orifice plate is being removed, a single block isolation may be used in lieu of slip blinding if blinding presents a greater hazard, and if a replacement or plate blinds of adequate design are installed once the valve or orifice plate is out. The single blocks must be locked and tagged. (Control valve removal is discussed below.) The replacement part or blinds must be installed immediately after removal, and the piping must never be left open.

The use of high-pressure plugs, fireman plugs, plumber plugs, stopples, etc., could possibly be used in special situations as a second isolation where only a single valve is available. This should be given careful consideration, taking into account manufacturer's recommendations and limitations of the equipment. An MOC must be approved as this would be a variance from this procedure.

2. Pumps Pumps being removed for repair elsewhere (i.e., shop repair) do not require an MOC to physically pull the pump without isolation blinds in place. The isolation valves, however, must be tagged and locked in the closed position. After the pump has been pulled, the suction and discharge lines must be blind flanged as soon as safe and practical.

Pumps being isolated for in-place mechanical work, such as a rotor replacement or seal change, should be slip blinded, and the driver and valves electrically locked out and tagged. In situations where blinding creates a greater hazard than working against a locked and tagged single block, mechanical seal assemblies may be removed against a single block (without blinding) as long as the unit is not left unattended. If the unit must be left unattended, a dummy seal of proper design can be used, if available, to seal the pump; otherwise, it must be blinded while out of service. If this is not feasible, then an alternative isolation method may be used only after an MOC is approved.



In preparation for blinding, the suction and discharge valves must be tagged and locked in the closed position.

All closed vents, remote seal flush, or other external source of hydrocarbon to the work area must be isolated using blinds.

In the event line size or other circumstances prevent the installation of blinds, unions may be broken and plugged, spools removed and plate blinds installed, or fittings removed and lines capped or plugged. All open flanges must be blind flanged.

Pump case and/or line bleeder valves must be opened to ensure that the pump case is drained and empty. All bleeder valves opened must be left in the open position and tagged.

Care should be exercised when bleeding the pump case to avoid release of excessive hydrocarbons or hazardous chemicals. Pressure should be released slowly and under controlled conditions.

3. Drivers Electric drivers must be isolated by opening or removing the electrical circuit breaker and then applying a tag and lock.

4. Control Valves Control valves being removed for repair elsewhere (e.g. valve shops) do not require an MOC to physically pull the control valve without isolation blinds in place. However, the isolation valves must be tagged and locked in the closed position. Immediately after the control valve has been pulled, the inlet and outlet lines must be blind flanged.

Control valves being isolated for mechanical work in place must be slip blinded. However, if blinding creates a greater exposure hazard than another isolation method, then an alternative isolation method may be used provided that an MOC is completed.

5. Confined Spaces For confined space entry requirements, see HES Procedure 201, Confined Space Entry.

Double blocks and bleeders are not permitted as a substitute for blinding or dropping of spool pieces.

NOTE: This is not required for confined space entry into a valve vault where piping and valves are passing through the vault.

When isolating hazardous energy sources prior to confined space entries, equipment must be blinded and spaced as close to the equipment as practical, usually the first flange at the vessel.

6. Tank Isolation For tank entry and maintenance work, all connections are to be day-lighted or blinded.

In those cases where it is necessary to access an external floating tank roof for regulatory or other inspections and associated minor repair work, isolation may be achieved by locking out



and tagging out the tank suction and discharge valves and other utility connections as necessary to "still" the tank. Blinding or day-lighting is not necessary for this activity.

7. Use of Mud Plugs as Vapor Barrier The use of drilling mud and other clay-like material can be used for sealing open pipelines to act as a vapor barrier to reduce Lower Explosive Limit (LEL).

These plugs must not be relied on to retain pressure or free liquid.

When using mud plugs, a vent line must be installed on the line side of the plug to reduce the possibility of pressure buildup. Installation of pressure indication and continuous monitoring of the pressure is required to verify pressure is not increasing. The vent line should be extended to a safe location downwind from the work site.

Do not work in front of the plug.

Use a light nitrogen purge to sweep any vapors out of the line through the vent and monitor continuously for LEL.

Remove vent line and valves and use Thread-O-Ring to leave minimal fittings remaining on line.


F 1 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix F – Annual Verification of Compliance

CPL –203 Annual Verification of Compliance

http://cpl.chevron.com/manuals/cplhesgp/Gen203/gen_203appendixF.doc�


G 1 Revised/Printed January 2012, Uncontrolled when printed HES 203 Isolation and Release of Equipment / Systems for Work (Lockout/Tagout)

Appendix G – Examples of Lockout/Tagout Scenarios

1. Personal Equipment/System Lockout/Tagout Personal equipment lockout/tagout is the process whereby each person accepts responsibility for his/her own safety when servicing or maintaining equipment/system, by placing their own personal (operations, mechanical, or electrical) lock and tag on the energy isolating devices. This covers most situations where the work is in one location where the one authorized employee can directly account for all isolations and work that is going on. This may be a single person conducting the work or a single group conducting the work, who will place individual locks and tags on the energy isolating devices.

The authorized employee must:

a. Identify the equipment to be maintained or serviced;

b. Complete the Equipment Specific Procedure Sheet if one does not exist;

c. Notify all affected persons, as identified by the Equipment Specific Procedure Sheet, that a shutdown of equipment/system is about to commence. After each notification that step is completed, confirm by initialing the Equipment Specific Procedure Sheet on page 2;

d. Shut down the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each shutdown step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

e. Isolate the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each isolation step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f. Release, dissipate, and/or restrain hazardous energy sources, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g. Initially and continually verify that the energy and/or reaccumulation of energy has been eliminated, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

h. Install all lockout and tagout devices, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

i. Review with all authorized employees the conditions identified in the completed Equipment Specific Procedure Sheet, visiting each isolation point when possible;

j. Ensure authorized employees understand conditions; confirm by having the contract supervisor sign the Equipment Specific Procedure Sheet; and



k. Identify that lockout/tagout Equipment Isolation is complete on the equipment/system; confirm by signing the Equipment Specific Procedure Sheet under the “Approved Signatures” heading.

Once the work is complete, the authorized employee must:

a. Inspect to ensure that non-essential items have been removed and equipment/system components are operationally intact, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

b. Check to ensure that all employees have been safely positioned or removed, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

c. Each authorized employee must remove their own lockout and tagout devices, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

d. Notify all affected persons, as identified by the Equipment Specific Procedure Sheet, that a start-up of equipment/system is about to commence. After each notification step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

e. Energize equipment/system, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f. start up the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each start-up step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g. identify that start-up is complete, confirm by signing the Equipment Specific Procedure Sheet; and

h. place completed Equipment Specific Procedure Sheet in the Field Team office file.

2. Group Equipment/System Lockout/Tagout Group lockout/tagout is the process whereby primary responsibility is vested in a principal authorized employee(s) for a set number of employees working under the protection of a group (i.e.; crew, craft, department, location, etc.) lockout or tagout device.



2.1. Group Lockout/Tagout without Lock Box 1. The CPL authorized employee must:

a) identify the equipment to be maintained or serviced; b) complete the Equipment Specific Procedure Sheet if one does not exist; c) notify all affected persons, as identified by the Equipment Specific Procedure

Sheet, that a shutdown of equipment/system is about to commence. After each notification step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

d) ensure the shutdown of the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each shutdown step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

e) ensure the isolation of the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each isolation step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f) ensure the release, dissipation, and/or restraint of hazardous energy sources, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g) ensure that the initial and continual verification of energy and/or reaccumulation of energy has been eliminated, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet; and

h) identify all groups and the principal authorized employees responsible for the assigned groups;.

2. The following steps include actions from both the CPL authorized employee and the principal authorized employee(s): a) The CPL authorized/principal authorized employee representing Operations (first

lock on) must install all lockout and tagout devices for their group as identified by the Equipment Specific Procedure Sheet. The CPL authorized employee must confirm the lockout/tagout step is complete by initialing the Equipment Specific Procedure Sheet.

b) The principal authorized employee(s) representing other groups must install all lockout and tagout devices for their group. These required lockout and tagout devices are determined by the principal authorized employee representing the group.

c) The principal authorized employee(s) must review with all authorized employees the conditions identified in the completed Equipment Specific Procedure Sheet, visiting each isolation point when possible.

d) The principal authorized employee(s) must then notify the CPL authorized/principal authorized employee that the lockout/tagout devices have been installed.



e) The CPL authorized/principal authorized employee then identifies that the lockout/tagout Equipment Isolation is complete on the equipment/system, and confirms by signing the Equipment Specific Procedure Sheet.

3. Once the work is complete, the CPL authorized/principal authorized employee must: a) verify that non-essential items have been removed and that equipment/system

components are operationally intact, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

b) verify that all employees have been safely positioned or removed, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

c) each principal authorized employee(s) must remove their group lockout and tagout devices as identified by the Equipment Specific Procedure Sheet. After each lockout/tagout step is completed, inform the CPL authorized/principal authorized employee. The CPL authorized/principal authorized employee must confirm that the removal lockout/tagout step is complete by initialing the Equipment Specific Procedure Sheet;

d) notify all affected persons, as identified by the Equipment Specific Procedure Sheet, that a start-up of equipment/system is about to commence. After each notification step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

e) energize equipment/system, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f) start up the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each start-up step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g) identify that start-up is complete; confirm by signing the Equipment Specific Procedure Sheet; and

h) place completed Equipment Specific Procedure Sheet in the Field Team office file.

2.2. Group Lockout/Tagout with Lock Box 1. The CPL authorized/principal authorized employee must:

a) Identify the equipment to be maintained or serviced; b) Complete the Equipment Specific Procedure Sheet if one does not exist; c) Notify all affected persons, as identified by the Equipment Specific Procedure


d) Ensure the shutdown of the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each shutdown step is completed, confirm by initialing the Equipment Specific Procedure Sheet;



e) Ensure the isolation of the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each isolation step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f) Ensure the release, dissipation, and/or restraint of hazardous energy sources, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g) Ensure that the initial and continual verification of energy and/or reaccumulation of energy has been eliminated, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet; and

h) Identify all groups and the principal authorized employees responsible for the assigned groups.

2. The following steps include actions from both the CPL authorized/principal authorized employee and the principal authorized employee(s): a) The CPL authorized employee representing operations (first lock on) must install

all lockout and tagout devices for their group, as identified by the Equipment Specific Procedure Sheet. After each lockout/tagout step is completed, place the key(s) to the lock(s) in the lock box, place a lock and tag on the lockbox, and inform the CPL principal authorized employee. The CPL authorized/principal authorized employee must confirm the lockout/tagout step is complete by initialing the Equipment Specific Procedure Sheet.

b) Each principal authorized employee must confirm that all hazardous energy has been isolated and/or de-energized by physically going to each isolating device where a lock and tag has been placed, or by talking with the operations principal authorized employee to confirm all energy isolating devices have been installed.

c) The principal authorized employee(s) representing their groups must install their group lockout and tagout device for their group on the lockbox.

d) The principal authorized employee(s) must review with all authorized employees the conditions identified in the completed Equipment Specific Procedure Sheet, visiting each isolation point when possible.

e) The principal authorized employee(s) must then notify the CPL authorized/principal authorized employee that the lockout/tagout devices have been installed.

f) The CPL authorized/principal authorized employee then identifies that lockout/tagout equipment isolation is complete on the equipment/system and confirms by signing the Equipment Specific Procedure Sheet.



3. Once the work is complete, the authorized CPL employee must: a) Verify that non-essential items have been removed, and that equipment/system


b) Verify that all employees have been safely positioned or removed, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

c) Each principal authorized employee(s) must remove their group lockout and tagout device from the lockbox as identified by the Equipment Specific Procedure Sheet;

d) CPL authorized employee representing operations (last lock off) must remove all lockout and tagout device(s) from the lockbox and retrieve the key(s) for the removal of all lockout/tagout devices for their group, as identified by the Equipment Specific Procedure Sheet. After each lockout/tagout step is completed, inform the CPL principal authorized employee. The authorized CPL employee must confirm the lockout/tagout step is complete by initialing the Equipment Specific Procedure Sheet;

e) Notify all affected persons, as identified by the Equipment Specific Procedure Sheet, that a start-up of equipment/system is about to commence. After each notification step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f) Energize equipment/system, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g) Start up the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each start-up step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

h) Identify that start-up is complete; confirm by signing the Equipment Specific Procedure Sheet; and

i) Place completed Equipment Specific Procedure Sheet in the Field Team office file.

2.3. Multiple Location Group Lockout/Tagout

1. The CPL authorized employee must: a) Identify the equipment to be maintained or serviced; b) Complete the Equipment Specific Procedure Sheet if one does not exist; c) Notify all affected persons, as identified by the Equipment Specific Procedure




d) Ensure the shutdown of the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each shutdown step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

e) Ensure the isolation of the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each isolation step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f) Ensure the release, dissipation, and/or restraint of hazardous energy sources, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g) Ensure that the initial and continual verification of energy and/or reaccumulation of energy has been eliminated, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet; and

h) Identify all groups and the principal authorized employees responsible for the assigned groups.

2. The following steps include actions from both the CPL authorized/principal authorized employee and the principal authorized employee(s): a) The CPL authorized employee(s) representing operations (first lock on) must

install all lockout and tagout devices at each location for their group, as identified by the Equipment Specific Procedure Sheet. After each lockout/tagout step is completed at each location, the principal authorized employee is responsible for maintaining control of the key(s) to the lockout/tagout devices for their location. The CPL authorized employee must confirm the lockout/tagout step is complete by initialing the Equipment Specific Procedure Sheet.

b) The principal authorized employee(s) must review with all authorized employees the isolation points, visiting each isolation point when possible.

c) The principal authorized employee(s) must then notify the CPL authorized/principal authorized employee(s) that the lockout/tagout devices have been installed.

d) The CPL authorized/principal authorized employee(s) then identifies that the lockout/tagout Equipment Isolation is complete on the equipment/system and confirms by signing the Equipment Specific Procedure Sheet.

3. Once the work is complete, the CPL authorized/principal authorized employee(s) must: a) Verify that non-essential items have been removed and that equipment/system


b) Verify that all employees have been safely positioned or removed, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

c) Each principal authorized employee(s) must remove their group lockout and tagout device(s) at their location and notify the CPL authorized/principal



authorized employee that all lockout/tagout devices have been removed. The authorized CPL employee must confirm the lockout/tagout step is complete by initialing the Equipment Specific Procedure Sheet;

d) Notify all affected persons, as identified by the Equipment Specific Procedure Sheet, that a start-up of equipment/system is about to commence. After each notification step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

e) Energize equipment/system, as identified by the Equipment Specific Procedure Sheet. After each step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

f) Start up the equipment/system, as identified by the Equipment Specific Procedure Sheet. After each start-up step is completed, confirm by initialing the Equipment Specific Procedure Sheet;

g) Identify that start-up is complete; confirm by signing the Equipment Specific Procedure Sheet; and

h) Place completed Equipment Specific Procedure Sheet in the Field Team office file.

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