Day 3: Energy Isolation and LOTO Principles PDF

Classification: Tasnee - General Information 1 Classification: Tasnee - General Information 2 Classification: Tasnee - General Information ❑ Knowing the hazardous for every energy type ❑ Knowing the sources for every energy type ❑ Knowing the possible injuries for every energy type and the first res...

Classification: Tasnee - General Information 1 Classification: Tasnee - General Information 2 Classification: Tasnee - General Information ❑ Knowing the hazardous for every energy type ❑ Knowing the sources for every energy type ❑ Knowing the possible injuries for every energy type and the first response to those injuries ❑ Knowing the hazard prevention, isolation and LOTO ❑ Prevent any undesirable event by using the proper isolation methods for all types of energy ❑ Respond to and assist in any undesirable event situations arising from any hazardous energy 3 Classification: Tasnee - General Information ❑ Thermal Energy ❑ Mechanical Energy ❑ Pressure Energy ❑ Chemical Energy ❑ Electrical Energy ❑ Radiant Energy 4 Classification: Tasnee - General Information ❑Thermal energy ❑Exhausts, hot surfaces ❑Open flame work ❑Flare ❑Mechanical energy ❑Stored Energy ❑Walking, tripping ❑Working at height, overboard ❑Overhead equipment ❑Lifting operations ❑Kinetic, Dynamic Energy ❑Vehicles, engines ❑Rotation /moving parts ❑Powered systems, hand tools ❑Chemical Energy ❑Chemicals ❑Noxious atmosphere ❑Explosives ❑Electrical Energy ❑Electrical power generation ❑Electrical driven equipment ❑Electrical installation, appliances ❑Radiant Energy ❑Visible sunlight ❑Microwave oven ❑Radio transmitter ❑GSM antenna ❑Pressure Energy ❑HC Process ❑Compressed gas cylinders ❑Utility compressed air ❑Instrument air 5 Classification: Tasnee - General Information “ Is an Energy That Will transmit heat or cold to another system ” Thermal Energy Hazard sources ❑ Heat stress /Cold (weather during night) ❑ Steam systems (non-insulated system parts, valve hand wheels) ❑ Engines exhaust pipes, cutting torches, welding equipment, open flame work and flares Thermal Energy Possible injuries ❑ Hypothermia “under cooling” / overheating “sun/environment” and burns Thermal Energy Prevention ❑ Suitable clothing and PPE. ❑ Using barricaded and warning signs. ❑ Suitable cooling media. 6 Classification: Tasnee - General Information “ An object can store energy as the result of its position ” Potential energy when not moving Stored Mechanical Energy Hazard sources ❑ Slippery or obstructed surfaces ❑ Excavations, trenching ❑ Walking, tripping, Ladders and Step ladders ❑ Working at heights, Scaffolding works. ❑ Equipment stored on racks or roofs in a warehouse ❑ Materials stacked on the top of each other ❑ Stored elements or materials falling from loads being raised Stored Mechanical Energy Possible injuries ❑ Bruises, wounds, twisted or sprained ankle or knee. ❑ Fractures of legs, arms, skull and Ankle ❑ permanent disability or Fatality 7 Classification: Tasnee - General Information Stored Mechanical Energy Hazard Prevention ❑ Good housekeeping and proper PPE ❑ Cover holes or penetrations ❑ Barricading of excavations, safe slope of excavation ❑ Ladders situated properly, well maintained ❑ Never stay underneath an elevated load. ❑ Check all containers and scaffolding for loose objects prior to lifting ❑ Solid and stable racks in warehouses and solid packing material when stacking 8 Classification: Tasnee - General Information 9 Classification: Tasnee - General Information “ An object can store energy as the result of its motion ” Potential energy of motion. Kinetic Mechanical Energy Hazard sources ❑ Operating (driving) cars, trucks, buses and engines ❑ Engines moving parts Kinetic Mechanical Energy Possible injuries ❑ Cuts, Bruises & Amputation ❑ Minor burn wound and Fractures ❑ Fatalities Kinetic Mechanical Energy Hazard Prevention ❑ Defensive driving training and comply with traffic. regulations ❑ Protective covers around moving parts and warning signs. ❑ Use the right tools right for the right job. 10 Classification: Tasnee - General Information Pressure Energy Hazard sources ❑ Hydrocarbon Process ❑ Compressed gas cylinders, Utility compressed air and instrument air ❑ Hydro jetting activities Water Injection Pressure Energy Possible injuries ❑ Leakages of high-pressure liquids can cause eye and skin injuries with loss of eye as ultimate consequence. ❑ Whipping and slamming air coupling can kill ❑ Injuries due to the sudden explosive release of pressure (rupture of pipeline / HP air hose / equipment) ❑ Injuries due to the release of trapped pressure Pressure Energy Hazard Prevention ❑ Do not operate valves (if you are not authorized) ❑ De-pressurize system before any work or maintenance to start on the system ❑ Use whip-checks to control air-couplings ❑ Do not pressurize systems not meant for pressurizing 11 Classification: Tasnee - General Information “ Is something that will change the nature of an element ” Chemical Energy Hazard sources ❑ Exposing and working in a contaminated noxious atmosphere. (Pits, tanks, confined spaces, exhausts, wells etc.) ❑ Handling of hazardous substances and products. Chemical Energy Possible injuries ❑ Chemical burns to skin and or eyes ❑ Toxic effect of chemicals when inhaled or swallowed ❑ Asphyxiation when oxygen content < 19.5 % by volume in a confined space ❑ Fire due to explosion Chemical Energy Hazard Prevention ❑ Applying procedure for the handling and storage of chemicals and Appropriate PPE ❑ Using portable and fixed gas detectors. 12 Classification: Tasnee - General Information “ Is some electrons which are moving from a point to another point ” Electrical Energy Hazard sources ❑ Electrical power generation and electrical driven equipment ❑ Electrical installation, appliances ❑ Transformers and high Voltage stations ❑ Static electricity, cables, Short circuit and bad connections. Electrical Energy Possible injuries ❑ Electrocution and electric shock ❑ Burns and arc flash ( flashover ) ❑ Fire or injuries Electrical Energy Hazard Prevention ❑ using only certified equipment according to international standards. ❑ Regular inspections and PM ❑ Proper earthing of electrostatic, lightning and proper cables insulations 13 Classification: Tasnee - General Information “ Is an energy that travels in transverse waves ” Radiant Energy Hazard sources ❑ Visible sunlight and high energy radiation ❑ Radio transmitter and GSM antenna Radiant Energy Possible injuries ❑ Radiant energy can cause burns and sun rays cause “sun-burns” ❑ The UV is part of the sun-light and can cause skin cancer when skin is exposed long time to the UV-light emitting source ❑ Exposed to welding emitting Radiant Energy Hazard Prevention ❑ Do not expose human skin to the sun for long time ❑ Using appropriate PPE When welding ❑ Identify radiant energy sources ❑ De-energize and Lock out the equipment 14 Classification: Tasnee - General Information Energy source. Any equipment or process may produce or transfer energy like Electrical, Process, Mechanical energy. Energy Isolation: Physically preventing transmission or release of energy, by disconnecting or mechanically blocking the equipment from the energy source. This is accomplished by locking out (for example a manually operated electrical circuit breaker); disconnect switch, valve, or installing a mechanical device such as a slip plate, blind etc. Lock Out Device: A device that utilizes a positive means such as a lock, either key or combination type, to hold a mechanical or electrical energy isolating device in a safe position and prevent the energizing of a machine or equipment/ A padlock that is uniquely identified by number and controlled in a register and used to isolate or lock-out equipment or electrical circuits. Positive isolation: The installation of blind or disconnecting piping in process lines or process equipment to prevent the passage of toxic and/ or flammable substances. When screwed piping is used, caps or plugs may be used to blind the open lines. Process Isolation: A means of preventing a liquid or gas process stream, from being conveyed past a pre-defined point. This can be accomplished by closing and locking a valve or positive isolation. 15 Classification: Tasnee - General Information ❑ Raise the alarm ❑ Make the area as safe as possible. ❑ Remove the victim(s) from unsafe area if not safe keep the victim on the spot till specialized personnel arrive. ❑ Give first aid to the victim if it is manageable. ❑ Mechanical ❑ Do not remove object from victim ❑ Take victim to safe area ❑ Pressurized media ❑ Shut upstream valve, Switch of pump or compressor ❑ Open drain valve ❑ Chemical ❑ Flush affected area and eventual victim with good amounts of water using safety shower / eye wash ❑ Ventilation ❑ Cover with inert dust/powder or inert gas 16 Classification: Tasnee - General Information ❑ Electrical ❑ Switch off electrical supply at nearest possible circuit-breaker, if not possible switch off main station or substation switchboard ❑ Thermal ❑ Use water to cool wounds, medical examination always required ❑ Radiation ❑ Switch off radiation source (e.g. welding equipment) ❑ Cover victim in case of sun burns, remove from direct sun rays and cool with water 17 Classification: Tasnee - General Information ❑ All process and non process equipment to be worked on shall be made safe before the work permit is issued. ❑ All process equipment to be worked on must be positively identified by tagging prior to the start the work as follows: ❑ All required information must be written on the tag, equipment number, name, date and signature of safe maker. ❑ It is not allowed to display a general tag on equipment for work to be performed. ❑ Tags can be attached to equipment by any appropriate means suitable for the application. ❑ Tags must be placed in a clearly visible position. ❑ After completion of all task, it is the responsibility of the Safe maker (area operator) to remove the tags after work completion. ❑ No Tagging required: ❑ ❑ ❑ ❑ If it is not connected to process equipment Zero checks on transmitters MPI and wall thickness tests X-rays 18 Classification: Tasnee - General Information ❑ Energy Isolation including: ❑ Electrical Isolation. ❑ Process Isolation. ❑ Mechanical Isolation. ❑ Electrical Isolation. ❑ Before deenergizing, the equipment shall be off condition. ❑ Equipment tag information shall be matching with the Master Tag List. ❑ “Bump Test” shall be done to ensure equipment cannot be restarted. ❑ Low Voltage to be isolated by qualified and trained Operations representative. ❑ Medium and High Voltage to be isolated by qualified and trained Electrical Technician. ❑ Energy isolation form to be completed for each discipline. ❑ Process Isolation including the following categories: ❑ Positive Isolation by means of Installing Rated Blind or Disconnecting Pipe ( for Hot Work and/or Confide Space Entry ) ❑ Proved Isolation by Double Block & Bleed isolation method ( for Cold Work only) ❑ Isolation process Isolated by Single Valve & Bleed for Cold Work in very limited cases where prove isolation is not possible 19 Classification: Tasnee - General Information ❑ Mechanical Isolation including physical restraining movement due to its weight, stored energy or affect of wind circulation even after power is isolated. ❑ Rotating equipment, where available, shall be positively stopped (pinned, locked or equivalent) ❑ Some methods are used disconnecting belts, chain drives and mechanical links on shaft driven equipment’s, ❑ Disconnect mechanical drivers, shafts, secure mechanical parts, disconnect steam heat tracing, ❑ Pressurized actuators, fail open/ fail closed valves in accumulators and rundown tanks are considered mechanical isolation. ❑ Equipment / system isolation requirements any isolated equipment / system shall contain all and/or the following: ❑ Master Tag list that prepared and verified by shift supervisor for listing and identifying all locked valves and/or locked electrical source. ❑ Master blind list that prepared by area staff of operations, Approved by Area Owner for listing and identifying all blinds and pipe disconnection. ❑ Marked-up P&ID 20 Classification: Tasnee - General Information 21 Classification: Tasnee - General Information 22 Classification: Tasnee - General Information ENERGY ISOLATION WORKFLOW Responsibility Action Permit Issuer 1 Identifying energy isolation requirement 1 2 Providing isolation plan document to Safe Maker (e.g. Tag List, P&ID,..etc) 2 3 Executing Electrical Isolation as provided plan. 3 4 Executing Process Isolation as provided plan. 4 5 Executing Mechanical Isolation as provided plan. 5 6 fill all of the energy isolation form and permit form 6 7 Handover all Energy isolation locks keys to Permit issuer. 7 8 Review and approve proper energy isolation execution. 8 9 Place all locks key in the group isolation box. 9 10 Sign energy isolation form 10 11 Place operation lock in group isolation box and tag energy isolation form 11 12 Inform Permit receiver the equipment ready for handover. 12 13 Meet with Permit issue at group isolation box and place receiver lock 13 14 Fill new energy isolation form for and tag to the receiver lock. 14 # Safe Maker Permit Receiver 15 Once task completion, Meet with issue at group isolation box and remove receiver lock. 15 16 16 Sign receiver lock removal at energy isolation form. 17 Once all permit related to the energy isolation closed, apply removal for operation lock. 17 18 18 Sign Operation lock removal at energy isolation form. 23 Classification: Tasnee - General Information MASTER BLIND LIST Plant Area Equipment Number Equipment Description 1) No scratch or change on this form is allowed & no changes to the form design & content is allowed. 2) Confirmation of installation & removal shall be filled & signed by the person who physically implemented it in the field. Isolation Box Number: P&ID Number 3) Shortcuts: RB: Rated Blind. DL: Disconnect line. P/C: Plugged/Capped Issuer Lock Number Line Number Size Blind Tag Number Description RB DL Operation Maintenance Method SN Purpose Of Isolation Confirmation for correct size, gasket type, pressure class, bolts & installation P/C Name Date Installation Confirmation Signature Time Name Date Time Removal Confirmation Signature Name Date Time Signature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Area Owner Remarks (if any): Prepared by (Area Staff) Final Installation acceptance (Operation Supervisor) Signature Name Area Owner Approval Date Final Removal acceptance (Operation Supervisor) Name Signature Date Signature Signature Date Initial /Signature 3rd quarter Date Initial /Signature 4th quarter Date Initial /Signature 1st quarter Date Initial /Signature 2nd quarter Date Initial /Signature 3rd quarter Date Initial /Signature 4th quarter Area Owner Initial /Signature 2nd quarter Area Owner Date Area Owner 1st quarter Area Owner Long Term isolation exceeding 30 days from initial date of implementation I declare that the equipment that has been blinded well maintained under my control and audited regularly in quarterly basis confirming the equipment conditions are not changed Area Owner Approval Name Date Signature Area Owner Date Area Owner Name Area Owner Date Area Owner Name Date Initial /Signature 24 Classification: Tasnee - General Information 25 Classification: Tasnee - General Information 26 Classification: Tasnee - General Information 27 Classification: Tasnee - General Information ❑ Process Isolation including the following categories: ❑ Positive Isolation ❑ Process Isolated by Installing Rated Blind or Disconnecting Pipe. ❑ Considered as process isolation for Hot Work and/or Confide Space Entry. ❑ To verify that the isolation valves are holding, Bleeder must show no leakage. ❑ All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. 28 Classification: Tasnee - General Information ❑ Process Isolation including the following categories: ❑ Proved Isolation ❑ Process Isolated by Double Block & Bleed method is Considered as process isolation for Cold Work only. ❑ Double Block & Bleed method is closing of two positives shut off valves and opening a bleed (vent/drain) valve in between. ❑ The theory behind this method is that if the first isolation valve fails, the material in the line would discharge through the bleed valve and not into the work area. ❑ In some cases, valves used for a double block and bleed may be remotely or automatically operated. ❑ In some cases, the energy supply (air, electricity, etc.) shall be disconnected and the position of the valve shall be assured by a spring, pin or other locking device. ❑ Isolation valves shall verify are properly holding and Bleeders must show no leakage. ❑ All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. ❑ Safe maker shall visit the area frequently to check and ensure the isolation integrity. 29 Classification: Tasnee - General Information ❑ Process Isolation including the following categories: ❑ Isolation ❑ Process Isolated by Single Valve & Bleed is Considered for Cold Work in very limited cases where provision of Double Block & Bleed not available at asset and with satisfying protection and mitigation condition. ❑ Single valve with bleed method limited to be used for non-hazardous materiel (such as LP water, LP air, LP N2, etc.). ❑ In-case hazardous materiel involved and required to use this method then area owner approval is required. ❑ Single valve with Bleed limited as isolation for Cold Work activities ❑ Isolation valves shall properly hold, and Bleeder(s) must show no leakage. ❑ All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. ❑ Safe maker shall visit the area frequently to check and ensure the isolation integrity and no hazards in the area. ❑ Repair jobs on equipment shall continue without interruption and without the technician leaving the equipment. 30 Classification: Tasnee - General Information ❑ The blind handle shall extend out several (3 inches) beyond the outside diameter of the flanges and serves as an indicator that a blind is in place to install the blind tag number. ❑ Blind shall be seen from ground level if it is on pipe rack or high elevation. ❑ For single activity yellow strip shall be tie to blind location to be visible from any distance and red strip for more than one activity. ❑ Orifice flanges may be used for blinding, but the following actions shall be taken to ensure orifice plates are not mistaken for blinds: ❑ Highlight on the blind list the fact that a blind has been installed in an orifice flange. ❑ The orifice plate should be hung on the flange from which it is removed, or nearby to verify its removal. ❑ Blind tag number shall be reflected in Master blind list ❑ Maintenance review shall be obtained for correct size, gasket type, pressure class and bolts before installation. ❑ Maintenance and Operation shall verify the blind(s) are installed as per the Master blind list 31 and then signs. Classification: Tasnee - General Information ❑ Whenever positive isolation is not possible for individual vessels or pieces of equipment, ❑ A line may be blinded at some distance from the vessel OR ❑ several pieces of equipment may be isolated as a single unit OR ❑ System blinding ensuring that all of the equipment in the system is made gas free and kept that way OR ❑ All hydrocarbons, chemical and other process and utilities lines entering or leaving the Unit must be positively isolated at the Unit Battery Limits for shutdown or turnaround work. ❑ Whenever positive isolation is not possible at all, a detailed risk assessment shall be conducted and approved by risk authority approval. ❑ In case entering an underground confined space such as pits, trenches, or manholes to which pipelines are connected or passing through and which cannot be blinded, disconnected, or completely isolated, a detailed JSA shall be conducted to ensure safe performance of the required work. ❑ It shall be prepared and approved by the concerned department issuing the permit. ❑ It shall be ensured that there is no leakage from any of the lines passing through the confined space that is to be entered. ❑ in case of leakage the line(s) shall be positively isolated. 32 Classification: Tasnee - General Information 33 Classification: Tasnee - General Information 34 Classification: Tasnee - General Information 35 Classification: Tasnee - General Information 36