RIL Group Standards Lockout / Tagout

Document Control Details

Revision 1 Date Apr 08 Reason For Issue Corporate Standard Compiled by Dinesh Vaidya Approved by Dr Prasad Tipnis

Next Review Date Apr 09

User Notes: - The Centre for Health Safety and Environment Excellence (CHSEE) is the custodian of this document and is responsible for the Administration and Authorisation of this Standard. CHSEE is responsible for confirming the accuracy and integrity of content and proposed changes to the Standard.
Controlled copy of the current version of this document is held at CHSEE and also available on its portal. Any printed / electronic copy of this document is uncontrolled. It is recommended that users verify that the version being used by them is the current version by referring to the controlled version

Lockout/ Tagout RIL Group Standard

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

Location

Members
Mr. Dinesh Vaidya Mr. Vijay Kumar Mr. DC Boliya Mr. PV Raju Mr. AM Bagul Mr. DR Kumar Mr. VR Kulkarni Mr. KR Kamat Mr. AM Bhavsar Mr. KN Sharma Mr. RV Shukla Mr. SK Hanamshet Mr. SB Sonar Mr. NK Pandey

CHSEE Jamnagar Hazira Patalganga Vadodara Nagothane Gandhar

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

Agency

Members
Mr. Dirk Eikemans Dr. Anil Bhaskar

DuPont Safety Resources

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Table of Contents
DOCUMENT CONTROL DETAILS .......................................................... 1 ACKNOWLEDGEMENT..........................................................................2 DOCUMENT ISSUE ................................................................................4 ABBREVIATIONS .................................................................................. 5 1. INTRODUCTION .........................................................................6 1.1. Intent and Purpose ........................................................... 6 2. SCOPE AND FIELD OF APPLICATION ........................................6 2.1. Scope................................................................................ 6 2.2. Field of Application ...........................................................7 3. REFERENCES ............................................................................. 7 4. MANAGEMENT RESPONSIBILITIES .......................................... 7 5. DEFINITIONS ............................................................................. 7 6. STANDARDS/GUIDELINES ...................................................... 10 6.1. General ...........................................................................10 6.2. Principles ........................................................................10 6.3. Lockout Procedures......................................................... 11 6.3.1. Overview .............................................................. 11 6.3.2. Procedure ............................................................ 11 6.4. Procedure Audit .............................................................. 15 6.5. Lockout Types ................................................................. 15 6.5.1. Prevention of exposure to electrical hazards ........ 15 6.5.2. Simple lockout ..................................................... 15 6.5.3. Complex lockout .................................................. 15 6.6. Lockout Locks ................................................................. 16 6.7. Danger Tags .................................................................... 16 6.8. Authorised person Training and Documentation............. 16 6.9. Line Breaks ..................................................................... 17 6.10. Confined Spaces .............................................................. 17 7. MANAGEMENT SYSTEMS ........................................................ 17 7.1. Support Resources .......................................................... 17 7.2. Management Records ...................................................... 17 7.3. Audit Requirements ........................................................ 17 7.4. Standard Renewal Process .............................................. 17 7.5. Deviation Process ............................................................ 17 7.6. Training and Communication Requirements................... 17 7.7. Contact ............................................................................ 17

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

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

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

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

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Lockout/ Tagout RIL Group Standard

Abbreviations
HSE CHSEE GMS ReSOP LoTo - Health Safety and Environment Centre for Health Safety and Environment Excellence - Group Manufacturing Services - Reliance Safety Observation Process - Lock out and tag out

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1. Introduction
The company recognizes that during servicing and/or maintenance of equipment, personnel have the potential to be involved in a serious or fatal incident caused by the unexpected start-up of equipment or the release of stored energy. The standard outlines measures for controlling hazardous energies-electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources. This standard has been developed to establish procedures for the control of hazardous energy, hereafter called Lockout/ Tagout.

1.1.

Intent and Purpose

The intent of this Standard is to ensure a formal approach to managing risk for personnel from hazardous energy. This Standard is deliberately prescriptive. The Standard is designed to reduce the number and frequency of incidents related to hazardous energy. This standard was developed by an inter-site workgroup with guidance of experts from DuPont Safety Resources. A number of key elements were defined upon which a fail safe Lockout and Tagout system could be built. These key elements were subsequently further modified and developed into a series of practices. The practices which have been identified here are equally applicable across all locations and group companies. This will also help in bringing about a consistency in the process used across all locations. These guidelines will help to provide a new impetus towards achieving the best in class safety standards. This revision-0 release of the standard is formulated based on world class practices and with the help of DuPont Safety Resources. Comments and feedback would be appreciated to further enhance this process. All such comments and feedback may be addressed to HSE.ExcellenceCentre@ril.com. The comments and feedback would be consolidated and shall be used during the review and revision of future releases.

2. Scope and field of application 2.1. Scope

This standard specifies the minimum mandatory requirements and advisory guidance for controlling hazardous energy. It also describes i) how to achieve and maintain the security of any isolation made and ii) releasing the equipment from lockout. Sites should be aware that local regulations may impose mandatory requirements not reflected in this standard. The most stringent mandatory requirement shall apply. Businesses/Locations should be aware that local regulations might impose conditions not reflected in this standard. Additional information on regulations comes from a number of sources, including Statutory/Regulatory Documents. While the intent of the Standards is to bring in homogeneity across all Businesses / locations in the implementation of the standards, certain provisions are kept to allow some latitude to the implementing locations. However, those requirements in this standard which are noted in italics are mandatory. Any question regarding the interpretation of the standards in respect of mandatory
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versus non mandatory should be referred to the Centre for HSE Excellence for clarification.

2.2. Field of Application

See the HSE Protocol, Corporate Policy

3. References
Corporate Policy HSE Protocol HSE Commitment Responsible Care * Corporate Standards RIL Standard -Confined Space Entry RIL Standard -Line Breaks RIL Standard - Electrical Safety Management Engineering Standards Safe Practices Using Mobile Equipment in the Vicinity of Electric Lines and Cables

4. Management Responsibilities
Line management at locations, businesses and functions has the responsibility to implement this standard.

5. Definitions
Affected personany person who operates or maintains or works on a machinery or equipment that is subjected to lockout/ tagout. Authorised person an employee or contracted or contractor or a contractor employee trained and authorised in the lockout/tag out procedure to make and verify isolations. Complex lockoutLockouts that may involve multiple:

Crafts Employers Hazardous energy sources Lockout points People Shifts

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Control devicea device used to execute a system change by manual, remote, automatic, or partially automatic means (e.g., push buttons, emergency buttons or stops, selector switches, and other control-circuit type devices). Energy-isolating devicea mechanical device that physically prevents the transmission or release of energy, including but not limited to, the following:

A manually operated electrical circuit breaker A Fuse A disconnect switch A manually operated switch that disconnects a circuit from all ungrounded supply conductors and prevents all poles from being operated independently. A line valve Slip plates, blanks, and physical disconnections A mechanical block or any similar device used to block or isolate energy.

Hazardous energyAny source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, nuclear radiation or any other energy that, if not controlled, could cause injury to personnel or damage to property and/or environment.

Electrical hazards are present when conductors or components that may be electrically energized could cause injury to personnel or damage to property. Mechanical hazards are present when the unexpected start-up of the system, equipment, or machine, or the release of stored energy while adjusting, maintaining, or servicing systems, equipment, or machines could cause injury to personnel or damage to property. Process hazards are present when the unexpected release of gases, liquids, or solids could cause injury to personnel or damage to property. These hazards can exist during such tasks as installation, fabrication, servicing, or maintenance of pipelines, vessels, or associated equipment

IsolationSeparation of the equipment, machinery or area where work is to occur from sources of hazardous energy or materials in such a way that only a conscious and deliberate act can restore the connection. Lockone of three types of locking mechanisms:

DiscreteLocks that are different from one another; each can only be opened by one key. Personala discrete lock, individually keyed, issued to an individual for his or her use in securing isolations. Series or systemA group of locks that are opened by a single key and are used in area/ complex lockouts. Various sets of locks may be in use; however, only one key can open any given lock in a particular set.

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

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isolation. LockoutIsolation of a source of hazardous energy, including releasing any residual hazardous energy that might be present, and securing an isolation point by locking it. Lockout deviceA piece of equipment that prevents the unauthorised or accidental operation of a hazardous-energy-isolating device. Location: Reliance operated Manufacturing Group Companies / Locations, Functional Unit, all other places where the business transact Person in chargeA qualified and Authorised person who is specifically appointed with overall responsibility for a lockout/tagout to place and keep all hazardous energy sources under lockout/tagout and to account for all persons working on the job or task. Proprietor/owner/operatorthe person or group responsible for the operation of a machine, system, or equipment. Qualified persona person trained and authorised to work with the equipment and understands the hazards involved. Stored energyHazardous energy that can continue to exist after equipment is isolated (e.g., the hazardous energy contained in springs, flywheels, pressurized fluids or gases, pneumatically controlled devices, capacitors, or gravity). Taggingplacing a specific tag on a lock or point of isolation to identify who placed the lock and when it was placed. TagoutPlacement of a DangerDo Not Operate tag (without a lock). Testingwhen a qualified person verifies the absence of voltage using a site-approved testing device. Troubleshootinga process for identifying malfunctioning components within a system that is done in both energized and de-energized systems. Try/tryingproving the effectiveness of isolation by attempting to make a machine, system, or equipment operate with out being inhibited by interlocks or other means that would impede the try step.

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6. Standards/Guidelines 6.1. General

Lockout/tagout is performed to prevent injury to personnel or damage to property and or environment by the unexpected release of hazardous energy/materials. When planning a lockout, it is important to consider the nature of all hazardous energy/materials that may be present.

6.2. Principles
The following principles govern all lockouts/tagouts: All sources of hazardous energy shall be identified prior to initiating any lockout/tagout. All sources of hazardous energy shall be removed or controlled prior to potential exposure to the hazards. Examples of removing or controlling hazardous energy are as follows:

Disconnecting power and discharging any capacitance Isolating pressure sources and releasing the pressure Stopping rotating devices and securing them from further movement Releasing stored hazardous energy Lowering or securing equipment to prevent movement caused by gravity Protecting equipment from external forces (e.g., wind) that may cause movement

Before starting work, each individual working on a task must determine, to his or her satisfaction, that appropriate isolations are in place and the isolations are secure for the task in which he or she is involved. Where a lock can be applied, tagout alone shall not be used to control exposure to sources of hazardous energy. Where a lock cannot be applied, site procedures shall address the use of tagout and the additional steps essential to help ensure a level of safety equivalent to that obtained by using lockout. Other means shall be used to secure access to the device, where possible. Each person potentially exposed to the hazardous energy must place a lock and tag, when a lock can be applied. Individuals who enter the hazard zone of a lockout shall be considered potentially exposed to the hazard.

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

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Each person potentially exposed to the hazardous energy must participate in the lockout/tagout. Clear communication of the lockouts/tagouts status shall be ongoing. An energy source shall be considered energized until the source is removed and the energy isolation is verified according to the Lockout/Tagout Procedure.

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

An effective verification (try) step must be performed. All interlocks that may prevent an effective try step must be accounted for. A test for the absence of voltage must be performed for all electrical hazards.

6.3. Lockout Procedures

6.3.1. Overview Each site shall establish written procedures for controlling and methodologies for isolating hazardous energy. The procedures shall include the following information:

How the hazardous energy sources are to be controlled for the duration of the work Who is responsible for determining that the hazardous energy sources are controlled for the duration of the work The responsibilities of all personnel involved in the work Mandatory training requirements

6.3.2. Procedure At a minimum, each sites lockout procedure must include details on the following elements:

Removing the source of hazardous energy and hazardous materials Addressing exposure lockout/tagout to hazards while performing the

Installing lockout devices Verifying that the hazardous energy source has been removed Trying the equipment to determine that the hazardous energy is under control Developing a method for helping ensure the continuity of lockouts across shifts

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Releasing the equipment from lockout Describing the specific measures to be used to enforce the procedures mandatory requirements Identifying and listing lockout points for tasks with multiple lockout points Review periodically (at least once a month) lockout/tagout completion in the areas. Removing the source of hazardous energy and hazardous materials All personnel who use site lockout procedures must know the following information: The specific hazardous-energy-isolating devices for the task to be performed The type of hazardous energy supply or hazardous material The type and location of the disconnecting/isolating device acceptable for the hazardous energy source or hazardous material The means and hazards disconnecting/isolating device of operating the

6.3.2.1.

The means of installing a lockout device

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

A method must be used to verify that the hazardous energy source or hazardous material has been removed and that the hazardous energy isolation is complete. In some instances, the try step is sufficient; in other instances, only testing can verify the isolation is complete. Where hazardous energy can re-accumulate due to system design, configuration, or installation, a means of preventing this re-accumulation must be used. An example of possible hazardous energy re-accumulation is in a long electrical cable that has a high capacitance. When the system or equipment contains a source of stored hazardous energy (e.g., springs, flywheels, gravitational effects, or capacitors), the stored hazardous energy must be relieved or otherwise blocked with components that control the potential hazard. The advisability of installing protective grounds in complex or high-energy electrical systems should be considered. (See RIL
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Standard Electrical Safety Management) Fuel-powered, engine-driven equipment (sometimes called portable equipment) must be rendered inoperable by secure means (e.g., by disconnecting and removing the battery cables or removing the spark-plug wire or equivalent). 6.3.2.2. Installing lockout devices The lockout device must be installed in a way that helps ensure that inadvertent operation of the hazardous-energyisolating device is impossible. Each site must define in written procedures the method of controlling or securing the keys for the lockout devices for all lockouts. Each person potentially exposed to the hazardous energy must place a lock and tag, when a lock can be applied.
Note: An exception to this principle shall only be made when the site has a written procedure describing the method of controlling, accounting for, and recording an individuals involvement in the lockout. In case of complex lockout/tagout involving multiple agencies e.g., electrical and mechanical contractors and Company personnel, a clear communication line must be established to all parties involved in lockout/tagout

6.3.2.3.

Verifying that the hazardous energy source has been removed All isolations shall be verified to determine that the hazardous energy has been removed. The following are examples of how to verify the removal of hazardous energy sources: opening drains; viewing pressure gauges, site glasses, or level indicators; visually verifying that rotating equipment has stopped; visually verifying that components have been disconnected (e.g., couplings, belts, and chains have been removed); and verifying that stored hazardous energy has been removed or is appropriately blocked.
Caution: Gauges/Indicators should be viewed before the hazardous energy source is removed to confirm they are in working order. Drains can become blocked and not function as designed. When verifying isolations, personnel should take precautions to avoid putting themselves at risk or creating additional hazards.

For tasks where there is exposure to electrical hazards, a break in the power conductors should be visually inspected, where possible. All lockouts must include verification of a complete physical break in the power conductors by testing
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for absence of voltage with a site-approved voltage-detecting device.

Note: For information on Test before Touch and testing for the absence of voltage, refer to RIL Standard Electrical Safety

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

When the equipment is tried (i.e., the control device operated) to verify its isolation from sources of hazardous energy or hazardous materials, the area surrounding the equipment shall be cleared of people and equipment that could be injured or damaged prior to attempting to start the equipment. Try procedures must help ensure the isolation of all sources of hazardous energy and the positive control of hazardous materials by trying to start or move the equipment. The try procedure must also account for all items (e.g., interlocks) that may prohibit the equipment from starting or moving. 6.3.2.5. Releasing the equipment from lockout Before the equipment or pipeline is released back to the proprietor, the people working on it shall determine that it is safe to reintroduce the hazardous energy or material to the equipment or pipeline. The equipments status shall be conveyed to the proprietor when the equipment is released from lockout. The proprietor shall inspect or otherwise verify the integrity of the pipeline or equipment before hazardous energy or hazardous material is reintroduced. This verification may include leak testing, pressure testing, or simple visual inspection. Where work extends over multiple days or shifts, a lockout device may be permitted to remain in place for the duration of the work period. However, the individual shall verify the lockout is in place after any absence from the work site. Each person who installed a lock should remove it when his or her work is complete. Sites shall establish a procedure, including the mandatory level of authorization, for removing an absentees lock. Once the installers unavailability (i.e., not on site) is confirmed, formal authorization for removing the lock should be given. If someone other than the installer removes a lock, the installer shall be informed immediately on his or her return to work that the lock was removed. Where lockouts extend beyond one shift, the lockout/job plan shall address the continuity of the lockout across the shifts. 6.3.2.6. Review periodically (at least once lockout/tagout completion in the areas. a month)

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Each site to establish procedure to periodically review (at least once a month) ALL active lockout/tagout. Identify the cause(s) of non-release of lockout/tagout beyond specified period. Methodology to release the above lockout/tagout thus identified.

6.4. Procedure Audit

Each site shall establish an audit process to determine How often to audit. If the established procedure is being followed. If there are deficiencies in the established procedure. If there are deficiencies in understanding the established procedure.

The person responsible for the procedure and other knowledgeable personnel shall audit the procedure.

6.5. Lockout Types

6.5.1. Prevention of exposure to electrical hazards Where an electrical hazard is a possibility, caution should be exercised to verify that all possible sources of hazardous electrical energy are controlled. Persons making the lockout shall be suitably qualified to assess and address the electrical hazards associated with the lockout. Additional steps are taken for lockouts work on or near potentially energized electrical equipment. For more information, refer to RIL Standard Electrical Safety Management 6.5.2. Simple lockout A simple lockout is accomplished by individuals placing personal locks and tags directly on the points of isolation. This is the preferred method of lockout and should be used when appropriate. 6.5.3. Complex lockout For complex lockouts, each site shall define the following in writing: The person in charge shall be responsible for keeping all hazardous energy sources, hazardous materials, and electrical, process, and mechanical hazards under control as the work progresses. When multiple employers are working on the same process, everyone involved in the work must understand and observe the mandatory requirements of all the lockout procedures of all the employers involved.

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

6.6. Lockout Locks

Lockout locks shall only be used to control hazardous energy. In certain situations, an individual Authorised person may apply multiple locks keyed to a single key. Locks are an essential element of a lockout device. However, the lockout device may include other components if the assembly effectively contains the source of hazardous energy. All lockout locks shall be identified as follows: Series or system locks shall indicate the lockbox number, system, or equipment being locked out. Personal and discrete locks shall indicate the individual who applied the lock.

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

6.7. Danger Tags

Danger tags shall be designed to be different from all other tags available at the site. Each site shall establish a mandatory requirement for danger tag design for all lockout applications. The danger tag shall be readily identifiable as a danger tag. The tags should include standardized verbiage (e.g., Danger Do Not Operate or DangerDo Not Remove Without Authority). The danger tag must have unique identification number and must provide space for the name of the Authorised person and the date the tag is installed and the Permit Number. It may also provide space for other information (e.g., the craft or the reason for the tag). Danger tags and its contents must be able to withstand the environment in which they are used for the duration of the lockout. Danger tags shall not be used for any other purpose than to indicate an isolation point for controlling hazardous energy.

6.8. Authorised person Training and Documentation

All Authorised persons shall be trained to the degree warranted by their job assignments. They shall be retrained whenever their job assignments change or whenever the hazardous energy control procedure changes.
Note: A job may change by reassignment or by equipment modification.

Documentation shall exist for each Authorised person who has been trained. This documentation shall include the following information: Authorised persons name and job assignment Employer Date of training Content of the training received Name of the person conducting the training Method of verifying the Authorised persons understanding of the training

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

6.9. Line Breaks

See HSE Standard for mandatory requirements and advisory guidance on lockout associated with line breaks. The mandatory requirements of both HSE Standard on Line Breaks and this standard must be followed when making line breaks.

6.10. Confined Spaces

See HSE Standard for mandatory requirements and advisory guidance on working in confined spaces. The mandatory requirements of both HSE Standard Confined Space Entry and this standard must be followed when working in confined spaces.

7. Management Systems 7.1. Support Resources

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

7.2. Management Records

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

7.3. Audit Requirements

Each site or region should audit compliance with this standard as part of its HSE audit program.

7.4. Standard Renewal Process

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

7.5. Deviation Process

Deviations from this standard must be authorised by the site President for the relevant site after consultation with the HSE Excellence Center and noobjection from the company Corporate HSE Council. Deviations must be documented, and documentation must include the relevant facts supporting the deviation decision. Deviation authorization must be renewed periodically and no less frequently than every three years.

7.6. Training and Communication Requirements

Each location business and site should provide training as appropriate. See Section 6.8 for specific mandatory requirements.

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