Procedure

Work Health and Safety

Energy tag and lockout

Document number: PRO-00014

This document is the property of Seqwater. It must not be copied or reproduced in any way whatsoever without the authority of Seqwater. This document is uncontrolled when printed. An electronic database manages and stores the controlled version.

Rev no. / Description / Process Owner / Approved for issue
Position / Name / Signature / Position / Name / Date / Signature
5 / Approved / Manager, WHS / Anthony Newbold / See TRIM Ref: D16/38650 / General Manager, SPS / Nikki Potteri-Collie / 22/02/16 / See TRIM Ref: D16/38650

L\317670788.3

Corporate Safety - Procedure
Energy Tag and Lockout /

Energy Tag and Lock Out Procedure

Contents(suggested headings)

1.Purpose

2.Scope

3.Roles and Responsibilities

4.Isolation framework

4.1Hazards associated with plant

4.2Isolation processes

4.3Isolation instructions

4.4Work that can be performed on plant that is not isolated

4.5Permits

4.6Disciplinary process

5.Isolation requirements

5.1Work activity planning

5.2Key isolation requirements

5.3Isolations for principal contractor projects

6.Verifying isolations

6.1Verifying electrical isolations (low voltage)

6.2Verifying electrical isolations (high voltage)

7.Inch and test requirements

8.Break in work requirements

9.Out of service requirements

10.Isolation equipment

10.1Removal of isolation locks and tags

10.2Forced removal of locks and tags

10.3Detached tags

11.Training requirements

12.Monitoring and audit

13.Record keeping

14.References

14.1Legislation and other requirements

14.2Supporting procedures

14.3Supporting documents, forms and templates

15.Definitions

Appendix A – Simple isolation process steps

Appendix B – Complex isolation process steps

Appendix C – Tiered isolation process steps

Appendix D – Inch and test process

Appendix E – Break in work process steps

Appendix F – Out of service process steps

Appendix G – Specifications for isolation equipment

Appendix H – Isolation Training Requirements

1.Purpose

Seqwater is committed to the health and safety of all people at the workplace. This procedureforms part of Seqwater’s Permit Access Safety System (PASS) by definingthe processes to isolate energy sources to allow workers to safely perform work activities at Seqwater workplaces.

This procedure supports the requirements described in Element 9 – Operational control of Seqwater’s Work Health and Safety (WHS) Management System Framework.

This procedure adopts and is consistent with the requirements outlined in:

  • Work Health and Safety Act 2011 (Qld)
  • Work Health and Safety Regulation 2011 (Qld)
  • Electrical Safety Act 2002 (Qld)
  • Electrical Safety Regulation 2013 (Qld)
  • Electrical Safety Code of Practice 2013 - Managing electrical risks in the workplace (Qld)

2.Scope

This procedure applies to all Seqwater workers, business groups and work activities.

3.Roles and Responsibilities

Role / Responsibilities
Managers /
  • Ensure this procedure is effectively communicated and implemented within their area of responsibility.

Line supervisor /
  • Ensure that the requirements of this procedure are implemented within their area of responsibility.
  • Complete workplace monitoring activities to verify the implementation and effectiveness of this procedure.
  • Ensure appropriate information, instruction and training is provided to each of their employees for planning and performing isolations.

Access officer /
  • Manage access to workplaces within their area of responsibility.
  • Liaise with workers planning and performing isolations to manage the impacts of the isolations on normal workplace operations.
  • Enter and manage information in the PASS CIS Module.

Work coordinator /
  • Plan work activities to identify all isolation and risk control requirements.
  • Manage and monitor workers performing work activities under the control of an isolation.
  • Ensure all isolations and risk controls are in place prior to the work activity being undertaken to enable the work activity to be safely performed.
When a work coordinator also performs the role of an isolation officer, the work coordinator assumes the responsibilities applicable to that role as well.
Isolation officer /
  • Identify isolation points required to complete the isolation.
  • Identify isolation equipment required to complete the isolation.
  • Develop isolation instructions to document the steps required to successfully complete an isolation.
  • Perform all isolations in accordance with the isolation instruction.
  • Confirm the status of isolations with the work coordinator and access officer.

WHS team /
  • Provide WHS resources to support the implementation and monitoring of this procedure.
  • Undertake reviews and inspections of work conducted at Seqwater workplaces to verify compliance withthe requirements of this procedure.
  • Provide guidance and/or training on energy tag and lock out as required or when requested.

Workers /
  • Comply with all site access requirements when entering and leaving site.
  • Confirm that all isolations have been implemented and are effective before commencing a work activity under the control of an isolation.
  • Attacha blue personal lock and personal danger tag to the lock board before commencing the work activity under the control of the isolation.
  • Comply with all risk controls defined in the JSEA/SWMS or high-risk work permits.
  • Report all incidents to Seqwater's incident hotline (07) 3270 4040.

4.Isolation framework

4.1Hazards associated with plant

During normal operations, workers are protected from plant hazards through risk controls such as shielding or guarding of moving parts, or because the energysource associated with the item of plant is contained within the plant,such as pressurised water or air contained in a pipeline or vessel.

When workers are required to perform a work activity on the item of plant, the risk controls may have to be removed to perform the work. Where risk controls are removed from an item of plant, alternate methods of protecting the worker from plant hazards must be implemented.

When performing a work activity on an item of plant, protection may be required from:

  • movement or operation of the plant
  • contact with energy used to operate the plant
  • contact with energy produced or carried by the plant
  • contact with energy stored within the plant.

When performing a work activity on an item of plant, the following forms of energy may be encountered:

  • electrical energy (electrical power supply, static charges, batteries, solar feed, capacitors)
  • mechanical energy (moving or rotating machinery)
  • pressure energy (water, compressed air, gas, hydraulic fluid)
  • gravitational energy (moving vehicles, counterweights)
  • potential energy (springs)
  • thermal energy (heat, cold)
  • noise
  • non-ionising radiation (microwaves).

Work on de-energised electrical equipment shall only proceed if the electrical equipment is isolated and any other exposed conductors or conductive parts in the work area are either:

  • de-energised and isolated; or
  • separated by barriers or are an appropriate distance based on risk assessment (workers should refer to the Electrical Safety Procedure (PRO-00006) for exclusion zones for electrical parts).

Processes for identifying and managing hazards are established in the WHS Hazard Identification and Risk Management Procedure (PRO-00657).

4.2Isolationprocesses

When performing a work activity where the isolation of an energy source is required, the following process is used:

  1. Plan the isolation
  2. Identify isolation points
  3. Stop the plant (where required)
  4. Isolate energy sources and discharge any stored energy
  5. Attach isolation locks and tags (where possible or otherwise ensure that the plant cannot be re-energised)
  6. Verify isolations are effective (i.e. test for dead / prove for dead)
  7. Perform work activity
  8. Remove isolation locks and tags
  9. Reinstate energy sources
  10. Test and confirm operational status of plant
  11. Return isolation equipment.

The specific requirements for each isolation will vary depending on the plant being isolated and the complexity of the required isolation. To address these requirements Seqwater use four isolation processes:

  • simple isolation
  • complex isolation
  • tiered isolation
  • High Voltage (HV) isolation (Note – the processes used for HV isolation do not form part of this procedure. Workers should refer to the Electrical Safety Procedure (PRO-00006) for HV isolation requirements).

Each isolation will need to be suitable to support ongoing operational requirements and be appropriate for the particular work activity being performed.

4.2.1Simple isolation process requirements

The simple isolation process is used when the isolation of the energy source can be achieved by either:

  • unplugging the energy supply; or
  • removing an ignition key (for mobile plant); or
  • switching a proven single point isolator to perform operational maintenance (Note: the proven single point isolator could be an electrical isolation switch or an isolation valve).

Where the requirements for a simple isolation cannot be met, a complex or tiered isolation process must be implemented.

Simple isolations do not require an isolation instruction, however the steps required to isolate, verify the isolation is effective, de-isolate and reinstate the item of plant must be clearly documented in a Job Plan or JSEA/SWMS for the work activity being performed.

Examples of work activities that may be performed under the control of a simple isolation include:

  • maintenance of a sump pump where the electrical lead for the pump can be unplugged from a General Purpose Outlet (GPO)
  • servicing of mobile plant and light vehicles where the key can be removed from the ignition of the plant or vehicle
  • operational maintenance on a pumpwhere the electrical supply can be isolated and the isolation secured at the proven local isolator
  • test and tag of electrical equipment
  • changing a light bulb / fluro tube.

The steps associated with a simple isolation process are detailed in Appendix A.

4.2.2Complex isolation process requirements

The complex isolation process is used where multiple sources of energy need to be isolated to make an item of plant safe.

The complex isolation process must not be used where multiple work activities are being performed by multiple work groups under the control of a single (primary) isolation. In these situations thetiered isolation process defined in Section 4.2.3 must be used.

Examples of work activities that may be performed under the control of a complex isolation include:

  • replacing a scour valve on a trunk main
  • performing annual maintenance on a centrifuge
  • replacing a pure water pump
  • replacing a hard wired air conditioner in a Seqwater office
  • draining and cleaning a reservoir.

The steps associated with a complex isolation process are detailed in Appendix B.

4.2.3Tiered isolation process requirements

A tiered isolation process is used where multiple work activities are being performed by multiple work groups under the control of a single (primary) isolation.

The tiered isolation process ensures that the primary isolation is not removed until all work activities being performed under the control of subordinate isolations have been completed.

Examples of work activities that require a tiered isolation include:

  • shutdown of a Water Treatment Plant (WTP) to perform multiple annual maintenance activities
  • isolation of a section of trunk main to allow multiple work activities to be performed simultaneously.

The steps associated with a tiered isolation process are detailed in Appendix C.

4.2.4High voltage isolations

High voltage isolations must only be performed by qualified and experienced electrical workers.

The process for performing high voltage isolations and the training and qualification requirements for electrical workers performing high voltage isolations are defined in the WHS Electrical Safety Procedure (PRO-00006).

Details of high voltage switching forms used to complete a high voltage isolation must be referenced in the plant isolation instruction for the work activity being performed.

4.3Isolation instructions

Isolation instructions are used to document the process that will be implemented to protect workers from sources of hazardous energy. They clearly define the steps required to ensure that all energy sources associated with an item of plant are isolated and/or dissipated, and will continue to be isolated and/or dissipated for the duration of a work activity.

Seqwater uses the Plant Isolation Instruction (TEM-00077) to document all isolation instructions.

4.3.1Who can develop an isolation instruction

Isolation instructions may only be developed by workers who meet the following criteria:

  • Have successfully completed the Authorised Isolator Assessment for the site where the isolation is being performed (refer to the Authorised Isolator Assessment Work Instruction (PRO-02008); and
  • Hold the appropriate qualification for the type of isolation being performed; and
  • Have successfully completed all PASS isolation training modules and associated competency assessments.
  • Developing isolation instructions

Isolation instructions must be developed collaboratively to ensure that all isolation points are identified and isolation impacts are considered.

The following process is used to develop an isolation instruction:

  1. Identify the type/s of energy sources to be isolated.
  2. Confirm who needs to be involved in the development of the isolation instruction, considering the following:
  3. For isolations that only require operational workers to complete the isolation (e.g. isolating a filter at a WTP to inspect the filter media), the isolation instruction may be developed by operational workers without consulting with any other stakeholders.
  4. For isolations that require trade specific isolations (i.e. electrical, mechanical), the isolation instruction must be developed collaboratively between the relevant trade/s and operational workers.
  5. Write the isolation instruction clearly defining:
  6. The steps required to isolate the item of plant.
  7. The description and location of the isolation points (refer to section 4.3.5 for asset numbering requirements).
  8. The process that will be used verify the isolation (test for dead / prove for dead process).
  9. The steps required to de-isolate the item of plant.
  1. Approving and saving isolation instructions

Once an isolation instruction has been used and proven to be effective in isolating an item of plant it must be saved in Q-Pulse by the isolation officeras a controlled document with the relevant operations coordinator identified as the document approver.

Note: isolation instructions that include isolation points that are not identified by an identification tag (or other identification marker) cannot be saved as a controlled document for future use untilappropriate identification tags or other identification markers have been installed.

4.3.4Using previously developed and approved isolation instructions

All previously developed and approved isolation instructions must be reviewed by the isolation officer before being used to confirm:

  • the isolation instruction is still valid (i.e. to confirm the asset has not been modified or altered in a way that affects the isolation); and
  • that the control mechanisms and isolation steps remain appropriate and that there are no modifications or alterations to the plant that could give rise to a new or different risk to health and safety that the existing control measure may not effectively control; and
  • the isolation points are numbered in accordance with the isolation instruction (i.e. to confirm that the identification tags or markers have not been changed).

Where a change is identified, the version of the isolation instruction stored in Q-Pulse must also be updated by the isolation officer.

4.3.5Asset numbering

Where possible, asset identification numbers should be used to describe isolation points in an isolation instruction.

Where an isolation point does not have an identification tag or other identification marker attached, a request to create a number should be sent to the Engineering and Technical Support Team .

4.4Work that can be performed on plant that is not isolated

4.4.1Livelow voltage electrical work

In certain circumstances it may be necessary to perform a work activity on an item of plant that has not been isolated from electrical energy sources.

Refer to the WHS Electrical Safety Procedure (PRO-00006) for further information on the requirements for performing live electrical work.

Note: Performing a test for dead / prove for dead process on electrical equipment at Seqwater workplaces is considered to be live electrical work. Specific requirements for performing a test for dead / prove for dead process on electrical equipment are defined in section 6 of this procedure.

4.4.2Dynamic work

In certain circumstances it may be necessary to perform a work activity on an item of plant that is still operating and has not been isolated from energy sources. Work activities such as greasing, making minor adjustments, monitoring, identifying operational issues, etc. may require the item of plant to remain in an energised and operating state whilst the work activity is performed.

Where guards or other plant protection devices need to be removed in order to perform dynamic work, specific risk controls must be implemented to manage the risks of working near moving parts (refer to the process for identifying and managing hazards established in the WHS Hazard Identification and Risk Management Procedure (PRO-00657)).

Any dynamic work activity that exposes a worker to an energy source (other than electrical energy) must be:

  • planned by the worker performing the work activity; and
  • undertaken in accordance with specific risk controls identified.

A JSEA/SWMS must be developed for all dynamic work activities.

4.5Permits

In addition to the development of a JSEA/SWMS and an isolation instruction to manage a work activity, specific permits may also be required to manage the operational impacts and other hazards associated with work activities involving isolations.

The work coordinator must assess the operational impacts and hazards associated with each work activity to ensure that appropriate permits are completed.

Specific triggers and requirements for the use of permits are defined in the WHS PASS Procedure (PRO-01820).

4.6Disciplinary process

Unauthorised removal of isolation locks and/or isolation tags, blue personal locks and/or personal danger tags, out of service locks and/or tags or a failure to follow correct isolation procedures has the potential to cause serious injury or death and/or serious equipment damage.As such, conduct of this nature will be treated seriously and may result in dismissal of the employee for serious misconduct.

Individuals found to have contravened any requirements of this procedure may be subject to disciplinary action in accordance with Seqwater’s Discipline Procedure (PRO-00962).

5.Isolation requirements

5.1Work activity planning

Work activity planning is critical to successfully completing a work activity. When planning work activities the following should be considered: