Linde Project ID: 1110 A05M Linde Project Code: PEARL QATAR
Shell Project No.: HP-3000-QAT Contractor name:
Contractor Project No.: 5887 Unit: ASU
Linde
Engineering
Contractor Contract No.: PI-092 PCWBS: Z
TABLE OF CONTENTS
1 PURPOSE...........................................................................................................................3
2 SCOPE................................................................................................................................3
3.2 Abbreviations.............................................................................................................................................................5
4 REFERENCES....................................................................................................................5
5.4 Subcontractors...........................................................................................................................................................6
6 RISKS.................................................................................................................................6
7 PROCEDURE.....................................................................................................................7
7.1 Training......................................................................................................................................................................7
ATTACHMENTS.....................................................................................................................15
PEARL GTL PROJECT - Contractor Doc No: 0100 W-PE 0042 Rev: 02 Page: 3 of 20
QATAR Proj Doc No: T-4.240.737 Rev: A
1 Purpose
The purpose of this document is to establish a systematic procedure to be used to de-
energise or render inoperable any hazardous systems, valves, switches, machine,
equipment, and / or process for the purposes of construction, repair, maintenance, or
installation.
It is Linde LE's responsibility to ensure that training is available for its employees and
that this information is communicated to its employees who are expected to be operating a
lock out / tag out system. It is Subcontractors' responsibility to ensure that training is
available for their employees and that this information is communicated to their employees.
This document does not cover the requirement for the isolation of electrical power
installations. For isolation of electrical systems refer to Pearl GTL Electrical Safety Rules T-
4.599.556.
2 Scope
This document addresses all mechanical, pneumatic and hydraulic systems and
equipment that may be required to be isolated during construction, commissioning, testing,
inspection, maintenance and repair / replacement carried out on the Pearl GTL ASU Project
by Linde LE or its Subcontractors.
Energised
Connected to an energy source, or containing residual or stored energy.
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QATAR Proj Doc No: T-4.240.737 Rev: A
Push buttons selector switches and other control circuit devices are not
energy isolating devices.
Energy Source
Any source of electrical, hydraulic, pneumatic, chemical, thermal, or other
energy
Hot Tap
A procedure used in the repair, maintenance and services activities that
involves welding on a piece of equipment (pipelines, vessel or tanks) under
pressure, in order to install connection or appurtenances. It is commonly used to
replace or add sections of pipeline without the interruption of service for air, gas,
water, steam or petrochemical distribution systems.
Lock Out
The placement of a lock out device on an energy isolating device, in
accordance with an established procedure, ensuring that the energy isolating
device and the equipment being controlled cannot be operated until the lockout
device is removed.
NOTE: Lockout devices shall be standardized within the facility in at least one of
the following criteria:
colour,
shape,
size.
Setting Up
Any work performed to prepare a machine or equipment to perform its
normal production operation.
Tag Out
The placement of a tag out device on an energy isolating device, in
accordance with an established procedure, to indicate the energy isolating device
and the equipment being controlled may not be operated until the tag out device
is removed.
NOTE: Tag out devices shall be standardised in print and format, their attachment
devices shall be a non-reusable type, attached by hand, self locking, with a
minimum unlocking strength of no less than 50 pounds and having the general
design and basic characteristics of being at least equivalent to a one piece all
environment tolerant nylon cable tie.
3.2 Abbreviations
Item Description
GTL Gas to Liquids
IC Implementation Contractor
LOTO Lock Out / Tag Out
PMC Project Management Contractor
QSGTL Qatar Shell GTL
RLC Ras Laffan City
TSTI Total Safety Task Instruction
4 REFERENCES
5.4 Subcontractors
All subcontractors are responsible for the development of their Lock out/Tag
out procedure (in line with this procedure), the implementation and the training
of their employees.
Subcontractors shall ensure that all its employees and all lower tier sub
contractors comply and actively participate with its requirements.
6 Risks
Failure to adequately identify and guard against the hazards associated with
equipment isolation may result in serious injury, death, damage to assets and
loss of local and international reputation.
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7 Procedure
7.1 Training
All personnel involved in the isolation of equipment and processes will be
fully trained in the requirements of this procedure and how it interfaces with the
TSTI and the Permit to Work Process.
All personnel authorised to perform a lock out-tag out shall receive training in the
following:
Recognition of hazardous energy sources,
Types and magnitudes of hazardous energy sources,
Methods and means necessary for energy isolation and control,
The lock out tag out procedure.
Affected Employees:
Instruction in the purpose and use of the lock out / tag out program
All other employees whose work operations are or may be in the area
where
Energy control procedures may be used.
7.2.1 General
The lock out system shall be used if the equipment is capable of accepting a
lock out device. If the equipment is not capable of being locked out, the tag out
system shall be used.
When / where possible, a tag out system is to be used in addition to the lock
out.
Lock out / block out means that any energy source, whether it is electrical,
hydraulic, mechanical, compressed air or any other source that might cause
unexpected movement, must be disengaged or blocked and electrical sources
must be deenergised and locked or blocked to prevent inadvertent movement.
Potential energy that may need to be blocked can come from suspended parts
(subject to gravity) or may be energy stored in springs.
Lock out-tag out devices are to be colour coded and used only for lock out
operations. The lock out-tag out device must show the identity of the person who
applied the device.
The tag out device shall have the words: "DO NOT OPERATE" and warn against
the hazardous condition of the equipment/process if it becomes energised.
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QATAR Proj Doc No: T-4.240.737 Rev: A
All activities relating to lock out / tag out shall be clearly defined within the
relevant sections of the TSTI and identified on the Permit to Work documentation.
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Lock out devices shall be used, unless the usage of a lock out device would
result in the need to dismantle, rebuild, replace the energy isolating device, or
permanently alter its energy control capability.
When a tag out device is used on any energy isolating device that is capable
of being locked out the tag out device shall be attached at the same location that
the lockout would have been.
It shall be demonstrated that the tag out program will obtain the level of
safety equivalent to that obtained by using the lockout program.
NOTE: Lock out / tag out devices shall be singularly identified, and shall be the
only device(s) used for controlling energy and shall not be used for other
purposes.
7.2.3 Application
All energy isolating devices that are needed to control the energy to the
machine or equipment shall be physically located and operated in such a manner
as to isolate the energy source(s). Lock out and or tag out devices shall be affixed
to energy isolating devices by an authorised employee and when used, affixed in
such a manner that it will hold the device in a safe or off position.
exists. Prior to start of the job, the authorised employee shall verify that the
isolation has been accomplished.
Where more than one work group, craft, department, etc. is involved, the
assignment of the lock out / tag out coordination to one authorised employee.
Each authorised employee shall affix a personal lock out / tag out device to
the group lock out / tag out device, group lock box, or comparable mechanism at
the beginning of the job and remove at the end of the job.
7.2.5 Procedure
The lock out / tag out process must be fully identified on the TSTI and/or
Permit to Work. A survey of the equipment/process is to be conducted by a
person(s) who are thoroughly familiar with its operation and associated hazards
in order to identify which equipment should be locked and blocked out.
Once equipment / processes are identified, lockout, block out, tag out
devices must be selected and made available.
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QATAR Proj Doc No: T-4.240.737 Rev: A
Locate and mark the disconnecting means indicating their function (e.g.
crane, welding machine, etc.). A sign or sticker, "LOCKOUT HERE" should be
placed at the disconnecting point to assist personnel in selecting the correct
lockout devices.
Know and follow the shutdown procedure for the equipment, process or
machines that is to receive the work. Steam, air, and hydraulic lines shall be
bled, drained, and cleaned out. There shall be no pressure in these lines or in
reservoir tanks. Any mechanism under load or pressure, such as springs, should
be released and blocked.
Install lockout devices, (devices to carry the name and badge number) so as
to prevent the equipment from being started or activated while work is being
performed.
NB. ALL ENERGY SOURCES WHICH COULD ACTIVATE THE MACHINE MUST
LOCATED AND BE LOCKED OUT.
Install lock out/tag out devices so as to prevent the equipment from being
started or activated while work is being performed, once installed the person
responsible for the isolation shall test its effectiveness by trying to activate the
equipment, process or machine at the equipment's/process's "off-on" switch or
valve before proceeding with work, If the equipment, process or machine fails to
become energised upon trying the "off-on" switch or valve the equipment,
process and or machine is considered locked out of service.
When multiple locks cannot be used; a multiple lock hasp can be used.
On completion of the test, neutralise all energy sources, purge all systems
and lock out prior to continuing work. Before continuing work, the Permit to Work
shall be reissued. Upon completion of work, check the following to ensure that:
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QATAR Proj Doc No: T-4.240.737 Rev: A
On removal of the lock out/tag out device the person responsible for the
isolation shall inform the permitting authority and the area supervisor that the
equipment is now operable and safe to use.
There are various ways to lock out a piece of equipment. Where the main
disconnect switch has one opening a locking strap can be installed. If more than
one employee works on the equipment, a lock out adapter suitable for the
installation of several locks must be used, enabling all isolation personnel from
various disciplines to lock out the machine with their individual locks.
If the switches are in a metal box, the box itself must be locked out. If a fuse
was removed in order to de-energise the equipment, the fuse box must be
locked. If the controls are in a metal-covered box, a common hasp can be welded
or riveted to the door, along with a lock staple. The switch can be "opened" and
the door closed and padlocked. Fuse boxes can also be locked in this manner.
7.2.9.1 Locks
All isolation personnel must have their own lock and the only key to that
lock. The lock should be substantial and durable and shall be identifiable to the
isolation person. In addition, locks can be colour-coded to indicate different shifts
or disciplines.
When more than one worker is servicing a piece of equipment that must be
locked out, a lockout adapter can be used which allows all workers to place their
locks on the disconnecting means. After the work is completed, each worker will
remove his lock and the machine can be returned to service.
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QATAR Proj Doc No: T-4.240.737 Rev: A
7.2.9.2 Tags
DO NOT USE TAGS ONLY! Use tags or signs in addition to locks. The tags
must state:
The name of the person who is working on the equipment, their badge number
and the date the tag was put in place.
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7.2.9.3 Blocks
Before blinds or blocks are installed, bleed down steam, air, gas or hydraulic
lines, etc. to get rid of any pressure. In addition, coiled springs, spring-loaded
devices, or suspended loads must be released so that their stored energy will not
result in inadvertent movement.
In situations where the lock out / tag out devices have to be temporarily
removed for the purpose of testing or positioning the machine, equipment, and
components thereof, the following sequence shall be followed:
o Clear the machine or equipment of tools and/or material.
o Remove employees from the machine or equipment area.
o Energize and complete the testing or positioning.
o De-energise all systems and repeat isolation procedures.
A periodic inspection of the lock out / tag out program will be conducted at
least annually. The inspection is conducted to ensure the procedure and
requirements are being followed. The inspection shall be performed by an
authorised employee other than the authorised employee over the lock out / tag
out being inspected. Any deviations and or inadequacies identified will be
corrected.
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QATAR Proj Doc No: T-4.240.737 Rev: A
Where lock out procedures is being used, an interview will be conducted with the
authorised employee regarding their responsibilities under the program.
Where tag out procedures are being used, interviews with all authorised and
affected employees will be conducted regarding each employee's responsibility
under the program including the elements of training received.
8. Attachments
8.1 Attachment 1: Sample Tags and Locks
8.2 Attachment 2: Authority to Remove Tag Forms
8.3 Attachment 3: LOTO Register
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QATAR Proj Doc No: T-4.240.737 Rev: A
The above mentioned employee has failed to remove their Personal Danger Tag
and Lock.
(Print name of person named on tag)
I,
(c) Now request authority to remove their Personal Danger Tag and Lock.
Date: