Safety, Health & Environment (SHE) Enterprise-wide Isolation and Lockout Manual This Enterprise-wide Principle applies generally to the following Aurizon entities and each of their subsidiaries: Aurizon Holdings Limited Aurizon Network Pty Ltd Aurizon Operations Limited Australia Western Railroad Pty Ltd Interail Australia Pty Ltd Australia Eastern Railroad Pty Ltd Aurizon Finance Pty Ltd

For rail safety accreditation purposes, this Enterprise-wide Manual applies to and forms part of the Approved Safety Management System of the following entities:

Accredited Entities

Jurisdiction/s National QLD (ONRSR)

Aurizon Network Pty Ltd Aurizon Operations Limited Australia Western Railroad Pty Ltd Interail Australia Pty Ltd Australia Eastern Railroad Pty Ltd

X X X

(DTMR)

X X X X

SHE ENTERPRISE-WIDE MANUAL

Isolation and Lockout Operating Manual

Contents 1. 2. 3. 4. 5. 6.

Purpose .......................................................................................................................................... 4 Scope .............................................................................................................................................. 4 References ...................................................................................................................................... 5 Definitions ...................................................................................................................................... 5 Roles and Responsibilities ............................................................................................................. 8 Isolation Plans ................................................................................................................................ 9 6.1 Determine when Isolation Plans are required ............................................................................... 9 6.2 Plan Preparation .......................................................................................................................... 9 6.3 Plan Requirements ..................................................................................................................... 10 6.4 Modifying a Plan/Variation ....................................................................................................... 10 6.4.1 Major Variation from the Authorised Isolation Plan ................................................................... 10 6.4.2 Minor Variation from the Authorised Isolation Plan ................................................................... 11 7. Harmful sources of energy checklist ........................................................................................... 11 8. Verification .................................................................................................................................. 11 8.1 Generic Verification Steps ......................................................................................................... 12 9. Isolation and Lockout Equipment ............................................................................................... 14 9.1 Types of Isolation Hardware ...................................................................................................... 14 9.2 General rules for all Isolation Locks .......................................................................................... 15 9.3 Personal Locks .......................................................................................................................... 15 9.4 Equipment Locks....................................................................................................................... 16 9.5 Group Locks.............................................................................................................................. 16 9.6 Multi-Lock Device .................................................................................................................... 17 9.7 Lock Boxes & Group Isolation Boards....................................................................................... 17 9.8 Isolator Labelling & Locking Standards ..................................................................................... 17 10. Isolation and Lockout Equipment ............................................................................................... 18 10.1 General - Team.......................................................................................................................... 18 10.2 Rules - Team ............................................................................................................................. 18 10.3 Isolating - Team ........................................................................................................................ 18 10.4 Lifting the Isolation - Team ....................................................................................................... 19 11. Isolating Person Working Alone ................................................................................................. 19 11.1 General – Working Alone .......................................................................................................... 19 11.2 Rules – Working Alone ............................................................................................................. 19 11.3 Isolating - Working Alone ......................................................................................................... 20 11.4 Lifting the Isolation – Working Alone ....................................................................................... 20 12. Group Isolation ............................................................................................................................ 20 12.1 General - Group......................................................................................................................... 20 12.2 How to Set & Work Under a Group Isolation ............................................................................. 21 12.3 Preparation - Group ................................................................................................................... 21 12.4 Isolating - Group ....................................................................................................................... 21 12.5 Lockbox/Group Isolation Board (GIB) Activation ..................................................................... 21 12.6 Attaching Person Locks - Group ................................................................................................ 22 12.7 Change of Isolating Person - Group ........................................................................................... 22 12.8 Overlapping of Lockbox / Group Isolation Boards ..................................................................... 23 12.9 How to De-activate a Lockbox / Group Isolation Board – Group................................................ 24 12.10 Inactive Lockbox/Group Isolation .............................................................................................. 24 12.11 Changes to Isolation Condition or scope of work ....................................................................... 24 13. Emergency Response ................................................................................................................... 25 14. Training, Accreditation & Authorisation Requirements............................................................ 25 14.1 Training General ....................................................................................................................... 25 14.2 Enterprise Training .................................................................................................................... 25 14.3 Area/Site Specific Isolation Training ......................................................................................... 26 14-MAN-002-COM

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Isolation and Lockout Operating Manual 14.4 Training Requirements for Isolation Roles ................................................................................. 26 14.5 Accreditation Process ................................................................................................................ 27 14.6 Confirmation of Competence Process ........................................................................................ 27 15. Isolation Incidents........................................................................................................................ 27 15.1 Deviation from this manual........................................................................................................ 27 15.2 Isolation Breaches ..................................................................................................................... 27 16. Process for Locks Left Attached ................................................................................................. 28 16.1 Personal Locks left on Isolators or Group Isolation Boards ........................................................ 28 16.2 Equipment/Group Lock left on an Isolator/Lockbox or Group Isolation Board ........................... 28 17. Access Isolation and Immobilisation ........................................................................................... 28 17.1 Access Isolation ........................................................................................................................ 29 17.2 Immobilisation .......................................................................................................................... 29 18. Use of Tags ................................................................................................................................... 29 18.1 Use of “Out of Service” Tags..................................................................................................... 29 18.2 Test in Progress Tags ................................................................................................................. 31 18.3 Information Tags ....................................................................................................................... 31 19. Monitoring and Review ............................................................................................................... 31 20. Testing of Equipment .................................................................................................................. 32 21. Critical Equipment Isolations ..................................................................................................... 34 22. Revision History........................................................................................................................... 34 APPENDIX A – Tags/Signs ..................................................................................................................... 35 APPENDIX B - Personal Lock Investigation & Removal Report .......................................................... 36 APPENDIX C – Management of Contractors and Visitors (Responsibilities) ....................................... 37 APPENDIX D – Isolation Decision Checklist Template ......................................................................... 38 APPENDIX E – Shift Handover of Isolation ........................................................................................... 39 APPENDIX F – Harmful Sources of Energy and Precautions ............................................................... 40 APPENDIX G – Linking Lockbox / Group Isolation Board examples................................................... 42

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Purpose

1.

This document sets out Aurizon’s rules:   

For the positive isolation of equipment from harmful energy sources; To prevent exposure of employees, contractors and visitors to movement or energisation of Plant, Structures or Equipment; and To manage any item of Plant, Structure or Equipment that is defective and is not suitable for use.

This document provides the detail on how to achieve compliance to the enterprise Isolation Lockout Standard 14-STD-003-COM, the specific training requirements for employees with allocated isolation & lockout roles and the process in which isolation and lockout processes are reviewed and audited.

Scope

2.

General application: This document applies to all activities undertaken by Aurizon and its subsidiaries for all instances where Plant, Structures or Equipment must be:  Isolated from all relevant harmful sources of energy, and/or  Prevented from unauthorised movement, and/or  Prevented from being able to be operated, in the event of faulty or damaged equipment and/or  Protected from inadvertent movement of other Plant entering or within the work area and/or  Isolated to provide a safe working environment and/or prevent damage to equipment. Specific circumstances: The following Aurizon activities apply isolation and lockout approaches which differ from this manual because of the specific nature of the activities: 





Overhead Line Equipment (OHLE) risks managed by SAF-STD-0141-ELE-NET Electrical Traction Systems Standards Manual – this is a legislative requirement and addresses the associated hazards Trackside Protection Methods managed by Aurizon Network Safety Management System: SAF-STD-0148-SWK-NET - Queensland Network Rules and Procedures and SAF-STD-0144SWK-NET - Accessing the Rail Corridor where Aurizon Network is the Railway Infrastructure Manager. Safeworking risks managed through key standards within the Aurizon Network Safety Management System, such as: SAF-STD-0036 - General Operational Safety Manual, SAFSTD-0040-SWK-NET - Remote Controlled Signalling Manual, SAF-STD-0041 - Direct Traffic Control Manual, SAF-STD-0148-SWK-NET - Queensland Network Rules and Procedures,SAF-STD-0088-SWK-NET - Shunting Procedures Manual and SAF-STD-0119SWK-NET - Safety in Yards, Facilities, Sidings and Workshops. Rail safety risks are also proactively managed through the SPAD/SWB and Derailment Communities of Competence.

As part of Aurizon’s continuous improvement process, Aurizon expects the above activities (and the risks which flow from them) to be monitored and analysed regularly, and where practicable, for the procedures and principles in this manual to be applied to the activities. NOTE: Aurizon acknowledges that external companies and other Rail Infrastructure Managers, may not incorporate the principles in this manual into existing safe systems of work, however as part of Aurizon’s continuous improvement process, it is the expectation that Aurizon will take a collaborative approach where practicable, with these entities to apply the intent of the Isolation & Lockout principles in this manual to the greatest possible extent. 14-MAN-002-COM

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3.

References

14-STD-003-COM 04-PRI-014

Isolation and Lockout SHE Risk Management

04-FRM-001-COM

Safety Risk Assessment Template

04-STD-001-COM

Stop! Take Time and Switch On

17-STD-001-COM

SHE Management System - Definitions

GEN/PRI/14/FORM 04

Aurizon record classification and retention schedule Isolation & Lockout SharePoint Site

4.

Definitions

Complex Isolation

Designated Isolation Point Energised Work

Equipment Lock (Yellow) Group Isolation

Group Lock (Green)

Group Isolation Board

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Complex isolation is when more than 3 individual isolation devices or more than 2 energy sources are involved. Complex isolations require a documented Isolation Plan authorised by an Isolation Planner and approved by a responsible manager or nominee. A clearly labelled physical location designated by the Responsible Manager where an Isolator is secured by an Isolating Person. Work that cannot be performed with equipment isolated and locked out. Energised Work may include tasks such as testing, adjusting, inspecting, post and pre-maintenance tasks and pre-start checks. All energised work requires formal risk assessment and authorisation by a Responsible Manager or nominee. A yellow, Master Safety Series™ 410 or 406 Xenoy Safety Padlock used to secure equipment in the isolated condition. Equipment locks must be uniquely keyed. Group Isolation is a system used to:  Ensure that all harmful sources of energy are isolated and locked before people start work.  Work on major pieces of plant and equipment where several isolators to be locked out. (Rather than attach a Personal Lock to each isolator the Protected Person only attaches one Personal Lock to a Lockbox  Group Isolation is the preferred system of isolation when a number of people are involved or a number of isolators are to be locked and should be implemented where ever practical. A green Master Safety Series™ 410 or 406 Xenoy Safety Padlock that secures the keys of all equipment locks inside a Lockbox (or similar) after the respective isolations have been verified. Completed Isolation plans are to be placed with/ attached to the Group Isolation Board or Lock box. Group locks must be uniquely keyed. A specifically designed board/enclosure used to: - Secure Equipment Lock (yellow lock) keys inside post isolation, - Provide a mechanical interlock such that the Equipment Lock keys cannot be removed once the box is secured by the Group Lock (Green), and - Allows the work team’s Personal Locks (red) to also secure the lockbox thereby preventing inadvertent de-isolation. - Allows for Isolation Plans, Isolating Person Handover Sheets and other relevant documents to be accessed by employees as required Version: 1.0

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Isolation and Lockout Operating Manual Harmful Sources of Energy

Immobilise

Isolation

Isolation Boundary Isolation Plan

Isolation Planner

Isolating Person Isolating Person In Charge Isolator

Lockbox

Lockout

Lockout Station Multi–lock Device

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Are forms that are likely to cause harm by its capacity to move or change an object by the application of force. Types of harmful energy include but are not limited to: electricity, heat, gas, pressurised fluids, steam, and chemicals. It may also be kinetic or potential energy, toxic, biological substances or radiation. Action taken to immobilise mobile equipment and plant such that people can work on it safely without inadvertent movement occurring. Not to be used for intrusive work where contact between an energy source and people may occur (e.g. repair or maintenance activities). A state where energy is blocked and residual energy is removed by the use of a device that positively separates or blocks the energy sources. The device must not be capable of remote operation. Isolation also includes a verification process to check the effectiveness of the Isolation. This describes the extent or coverage of the isolation where people are protected by their personal locks. A plan developed by an Isolation Planner for achieving Isolation. The Isolation Plan will be used by the Isolating Person to establish and verify the isolation. An accredited person who assesses the risks and plans the method of isolation. An Isolation Planner is appointed by the Responsible Manager to plan isolations, has successfully completed approved training and has practical experience and technical knowledge of isolation requirements relevant to the Plant, Structures or Equipment. A person authorised by a Responsible Manager to perform isolations and attach locks to Isolators. The Isolating Person in charge of an isolation, and who controls a group isolation with a Group Lock. A device (e.g. a switch, Battery isolator, circuit breaker, valve) that physically disconnects or directly blocks the supply of energy including stored energy in a positive way (i.e. positive isolator). These devices are not capable of being remotely operated when in the isolated position. They must be capable of being locked in the safe position. Devices such as push buttons, emergency stops, control valves, controllers, rail wedges and stops are not positive isolators. A specifically designed sturdy box used to: - Secure Equipment Lock (yellow lock) keys inside post isolation, - Provide a mechanical interlock such that the Equipment Lock keys cannot be removed once the box is secured by the Group Lock (Green), and - Allows the work team’s Personal Locks (red) to also secure the lockbox thereby preventing inadvertent de-isolation. A process of physically securing a de-energised state or block so it can be controlled by those it protects. A Lockout is secured with an Equipment Lock (Yellow) and/or Personal Lock (Red). A board used to house lockout equipment, Equipment Locks, Group Locks, multi lock devices and tags. A device which can secure an isolator in the safe (isolation) position and can be secured by a number of locks. Can be used on the Protected Person locking bar of a group isolation board as an extension of the Protected Person locking bar without the requirement to install an equipment lock on it. This is for the purpose of allowing more people to attach their personal lock onto the group isolation board. Version: 1.0

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Isolation and Lockout Operating Manual Personal Lock (Red)

Plant Protected Person Responsible Manager Safe System of Work (SSOW)

Shall Simple Isolation

Supervisor Suspended for testing sign

Team Isolation

Testing program

Verification

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A red, uniquely keyed, Master Safety Series™ 410 or 406 Xenoy Safety Padlock lock used by a Protected Person to secure: - An individual isolator in a working alone isolation - A multi-lock device in a multi-lock isolation; or the keys for equipment locks in a group isolation. A Personal Lock must be permanently and clearly labelled with the first name, last name and service number of the Protected Person A generic term used for locomotives, rail vehicles, forklifts, heavy vehicles, motor vehicles, rigid and non-rigid vehicles, and track vehicles. A person protected by the placement of their red Personal Lock under Isolation. A Level 5 manager or above responsible for development and implementation of isolation and lockout plans within their business. A safe system of work is a formal process which results from systematic examination of a task in order to identify all the hazards. It defines methods to ensure that hazards are eliminated or risks minimised and monitored to ensure the processes are followed. Examples of a SSOW could be one or a combination of the following: Risk Assessment, Safe Work Method Statement, Standard Operating Procedures or Work Instructions, Operational Manual, Permit(s) to Work, active supervision, auditing and monitoring. Shall is a mandatory requirement. A simple isolation is when three (3) or less individual isolation devices and/or two (2) or less energy sources are involved. Simple isolations shall be documented on SWMS, JSEA, a formal documented process or on a STOP! Take Time and Switch On. The area Supervisor, Team Leader or Operator responsible for the plant/rail operations area and equipment. A sign with the words ‘Suspended For Testing’ placed into the document holder of the lock box by the Isolating Person, identifying that they have suspended the related ask thus allowing the temporary de-isolation and re-energisation of equipment for the purpose of testing. A Team Isolation is where each Worker protected under the isolation places their Personal Lock(s) on isolation point(s) via lockout device (e.g. multi-lock device) once the Isolating Person has implemented and verified the isolation, and secured it with equipment locks. A formal document (i.e. a Safe Work Method Statement/local standard operating procedure etc.) used to control the de-isolation of equipment for the purpose of testing or fault finding. Testing programs also ensure the equipment is re-isolated (after the testing activity) in accordance with the requirements of an isolation. The act of confirming that the isolation has successfully removed the intended harmful source of energy by using an appropriate testing method.

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5.

Roles and Responsibilities

Role and Description Vice President

Responsible Manager

Responsibilities             

Isolating Person

           

Protected Person

      

Isolation Planner

  

Assign operational area ownership, Ensure an isolation system has been implemented within their area of responsibility in accordance with this Manual, Report on compliance against this Manual. Ensuring a Safe System for Isolation & Lockout has been implemented for plant, structure and equipment within their area of ownership, Authorise Isolation Planners and Isolating Persons and arrange accreditation, Have procedures such that plant, structure and equipment can be isolated safely, Have procedures to assess competency of persons required to carry out isolation tasks, Have processes in place to check that all isolations are planned, carried out, locked, verified, Have accredited Isolating Persons in control of keys to Equipment and Group Locks, Have procedures to indicate isolations to contractors and to witness them applying Personal Locks, Investigate all breaches and enact corrective actions, Undertake 1st Party Audits against this Manual, Authorise work to cease immediately if a task is not being performed in accordance with this manual, Authorising the forced removal of any padlock. Have thorough knowledge of all harmful sources of energy, Identify all hazards to determine isolation requirements, Identify the relevant isolation devices, Establish that all necessary isolation hardware is available, Identify the method to isolate the harmful sources of energy, Identify the method to verify the isolation, Develops documented isolation plans, Ensure isolation plans are checked and authorised by the discipline area, File isolation plans. Gain permission from the relevant Supervisor before isolating, Carry out isolations in accordance with the Isolation Plans, Safe Work Method Statements (SWMS) or Job Safety Environment Analysis (JSEA), Secure each isolator, Verify each isolation, Complete all relevant isolations and restore as required, Notify Protected Persons that the isolation has been completed, Document simple isolations in a STOP! Take Time and Switch On. Secure the isolation by attaching a red Personal Lock, Notify any isolation problems to Isolating Person (in-charge) or their Supervisor, Not attempt to operate a secured isolator, Not remove a lock other than their own, Understand the Isolation Plans for an isolation (if applicable).

NOTE: A person can fulfil multiple roles (e.g. Isolation Planner, Isolating Person and Protected Person) as long as they are accredited. 14-MAN-002-COM

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Isolation and Lockout Operating Manual Refer to Appendix D for isolation role action and decision flow details.

Isolation Plans

6.

This section is to provide a standard for the development of isolation plans and provide direction when isolation plans can be developed.     

6.1

Certain types of isolations shall have an authorised written plan. The Isolation Plan shall contain specific requirements. Isolation plans for complex isolations can only be written by accredited Isolation Planners. There are specific requirements for modifying isolation plans. Isolation plans can include existing yard protection methods and controls to enhance required isolations (e.g. Stop signs, railway track signals etc.)

Determine when Isolation Plans are required

Complex Isolations An isolation is deemed complex if it involves:  Any more than three (3) individual isolation devices and/or  Any more than two (2) energy sources. A written Isolation Plan is required to plan and document the execution of any complex isolation. Simple Isolations An Isolation is deemed simple if it involves:  Three (3) or less individual isolation devices and/or  Two (2) or less energy sources Isolation plans can be developed for simple isolations if deemed required as part of a Safe System of Work. Tasks requiring isolation of harmful sources of energy must have the isolation requirements included as part of a Safe Work Method Statements (SWMS), Job Safety Environment Analysis (JSEA) or as part of a STOP! Take Time and Switch On completed by the Isolating Person.

6.2

Plan Preparation

An accredited Isolation Planner is responsible for preparing isolation plans and isolation steps in work instructions, standard operating procedures and on Isolation Plan Forms. The Isolation Plan details the individual items to be isolated. The Isolation Planner shall inspect the work site to determine what requires isolation and the boundary of the isolation and hazards. Section 7 Harmful Sources of Energy Checklist (in this Manual) shall be used to ensure all harmful sources of energy are identified when developing the isolation plan. As guidance for the development of isolation plans, the process steps below can be used: 

Develop an Isolation Planning Tool (IPT). Guidance on development of such a tool is provided by COC I&L HRA2 – Guide: Development of Isolation Planning Tools for Mobile Plant and Rollingstock. If an isolation planning tool is not available, refer to the list of hazardous energy

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Isolation and Lockout Operating Manual sources (Section 7), and sources of technical information, including subject matter experts will need to be included in the development of the plan. 

Conduct an Isolation Planning Risk Assessment (refer to Safety Risk Assessment Template 04-FRM-001-COM)



Compile an Isolation Plan (Refer to the Aurizon Isolation & Lockout SharePoint Site for examples)

6.3

Plan Requirements

The following is the minimum content of any isolation plan:        

The DESCRIPTION – of the plan (i.e. Details of the task/equipment to be isolated in the plan). The LOCATION – of the isolator (e.g. Switch room, basement, control room, panel, rail operations area etc.) The TYPE of the isolator (e.g. switch, valve, rail point) The LABEL – Isolator identification, clear and unique from other equipment. The ACTION – required to be undertaken to place the isolator in the safe (isolation) position (e.g. ‘open switch’, ‘close valve’, ‘open drain valve’ etc.). A list of subject matter experts necessary for the development of the Isolation Plan A list of all considered hazards VERIFICATION steps.

Include operational comments such as, ‘open valve slowly to prevent water hammer’. The Verification Guidelines, Section 8 of this Document shall be used as a reference for verification steps. The plan also needs to be CHECKED and AUTHORISED – checking shall be conducted by another Isolation Planner for each discipline included in the plan. They must ensure that all harmful sources of energy have been identified and the plan is technically correct and in accordance with 6.2. Each Isolation Planner will sign and date the plan in the ‘Checked by’ section of the plan for their discipline. Authorisation of the Isolation Plan shall occur as per the site specific document management process (e.g. Responsible Manager). The contents of previous Isolation Plans shall not be replicated (in part or full) when developing an Isolation Plan for new or separate activities. Every Isolation Plan is required to be developed from the ground up to ensure the contents are fully correct and applicable to the new isolation being planned.

6.4

Modifying a Plan/Variation

6.4.1 Major Variation from the Authorised Isolation Plan If any part of the Isolation Plan requires a major amendment, the Responsible Manager or nominee has to be informed and the change shall be reviewed by two (2) accredited Isolation Planners, which include mechanical and/or electrical disciplines if required, before the Group Isolation Lockbox can be activated. The final verification shall be initialled by both Isolation Planners.

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Isolation and Lockout Operating Manual Amendments that require the planning and writing of a new Isolation Plan include, but are not limited to the following:      

Change to the original scope that extends the original isolation boundary, Impacts on an additional plant unit, Impacts on an additional process that needs to be isolated, Is the second successive amendment to the same step in the isolation plan? Is the third successive amendment to the isolation plan? Report the incident using the current incident reporting system (SHEM).

6.4.2 Minor Variation from the Authorised Isolation Plan If an Isolation Plan contains a small number of errors or omissions that:  Do not impact on the original scope of work or  Do not impact on the intent of the plan or  Do not add or remove any steps The Isolating Person shall carry out the following steps:  Stop work and inform the Responsible Manager or nominee and Isolation Planner and seek approval to proceed with the variation,  If approval is given make the required change to the plan,  Carry out the plan with the approved change,  If there is any doubt regarding the integrity of the plan, an Isolation Planner for the area shall be consulted.

7.

Harmful sources of energy checklist

The purpose of this section is to provide a list of harmful sources of energy to check for when writing an isolation plan. Energy sources can originate from various sources and shall be isolated before work is carried out on equipment. This list shall be referred to when designing an Isolation Plan in conjunction with equipment documentation and consultation with workers who are experienced in the area (e.g. Electrical Supervisors). Refer to Appendix F for the list of harmful sources of energy, examples of associated hazards and precautions.

8.

Verification

Verification is an important step in the isolation process. All isolations shall be verified to ensure that identified harmful sources of energy are removed or restrained from harming people, plant or equipment. The isolation process is not complete or considered safe until verification is complete and isolation has been secured. There are generic verification steps for all isolations and guidelines for different types of harmful sources of energy. The specific steps for verification are described in the Isolation Plan, work instruction, standard procedure or personal STOP! Take Time and Switch On booklet.

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Isolation and Lockout Operating Manual 8.1

Generic Verification Steps

The following is a general guide for verification tests to ensure the effectiveness of isolation. These are not specific tests for all isolations nor are they the only tests that may need to be carried out to verify the effectiveness of an isolation. The Isolation Planner shall determine the appropriate verification test(s) for each specific isolation step. NOTE In the event of a verification test demonstrating that an isolation has NOT been achieved then: ISOLATION MUST NOT PROCEED! The Isolating Person must check to see if the Isolation Plan has been followed correctly. 

If the Isolation Plan was not followed correctly then:  Stop work  Contact Isolation Planner  Review Plan



If the Isolation Plan was followed correctly then this indicates that the plan is incorrect or an isolator is defective.



If the plan is incorrect, stop the isolation and write “NO” in the “Confirm step” section of the plan and advise the Isolation Planner who will arrange for a new Isolation Plan to be prepared



If an isolator is defective or labelling incorrect/missing, arrange to have the isolator repaired and when repaired proceed with the isolation or refer to an accredited Isolation Planner to assess alternate means of isolation.

If any of the above occur, a SHEM incident report shall be generated

Verification steps shall include but not be limited to the following:     

Confirm no identification errors were made (correct isolator). Confirm the isolator is in the safe position. Ensure all stored energy is dissipated or restrained. Test for zero energy state. Observe a change of state of energy when isolating.

Using the Operation of Controls as a Verification Test: Operation of controls may only be used as a verification method if the risk level of the task being performed is evaluated as low. Consideration shall be given to control circuits which are often interlocked with various other conditions. Other tests in conjunction with operation of controls may be required in these circumstances. 14-MAN-002-COM

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Isolation and Lockout Operating Manual Electrical (extra low & low voltage) less than 1000V AC or 1500V DC In addition to the Generic Verification Steps above, the following shall be considered when planning the verification:    

Confirmation that a physical gap exists in the circuit (e.g. switch contacts open, isolating device withdrawn, fuses withdrawn, etc.) Testing for zero volts and verification of the test instrument against a known energy source. Operation of a local control (e.g. start / stop push buttons) Confirmation that discharge straps are secured.

Note: Only a qualified Electrical Worker with approval from their Responsible Manager is permitted to complete electrical isolations that require exposing potentially live components of a Low Voltage electrical circuit. Live electrical work shall be performed in accordance with the relevant regional Electrical Safety regulations (e.g. Part 3 of the Electrical Safety Regulation 2013 QLD). Water In addition to the Generic Verification Steps above, the following shall be considered when planning the verification:        

Confirmation that drain valves are in the correct position. Ensuring that adequate air bleed valves are open. Ensuring that manual and automatic sectioning valves are opened. Checking for isolator leakage. Ensuring adequate vents are left open. Testing for zero pressure. Unless determined in the risk assessment carried out in relation to the isolation, the minimum requirement for drain or verification points is that they be proven prior to the isolation. If the integrity of the isolation is such that the verification drain has to remain open, the verification point shall be locked as part of the isolation plan.

Hydraulic and Pneumatic (Pressure) In addition to the Generic Verification Steps above, the following shall be considered when planning the verification:           

Confirmation that the drain / vent valves are in the correct position. Confirmation that the Accumulator and / or Receiver drain valves are in the correct position. Checking the indicator on isolation valve stem is in line with valve body for open, 90 degrees to valve when closed. Confirmation that all actuators (cylinders, motors) are in the zero energy position. Operation of manual overrides on valves. Draining or bleeding residual pressure from circuit. Bleeding system fully using test hose, and testing for zero pressure using a gauge or test hose. Ensuring that re-accumulation of pressure is not possible. Confirmation that pressure gauges indicate loss of pressure when the isolation (drain / vent) is operated. Opening of vent valve and listening to sound of all air being released (pneumatics only). Operation of local pump stop / start controls in conjunction with the verification steps.

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Isolation and Lockout Operating Manual Steam and Compressed Air In addition to the Generic Verification Steps above, the following shall be considered when planning the verification:     

Confirmation that the vent valves are secured open. Ensuring manual and automatic sectioning valves are opened. Observing a drop in system pressure when vent valves are opened. Checking for isolator leakage. Confirmation that a re-accumulation of pressure is not possible.

Gas All Gas Isolations and verifications shall be conducted by a person who is competent in the gas isolation and verification operations and the use of the relevant equipment. Testing for the presence of any flammable gas or vapour shall take place and this includes continuous testing at all potential sources. A technical expert in gas isolations shall be required when planning isolations. Inadvertent Rail Traffic Movement In addition to the Generic Verification Steps above, the following are some examples to be considered when planning the verification for Rail Traffic:  Confirm hand brake applied  Apply independent brake and observe brake cylinder pressure moves to 500 kpa  Make Emergency brake application; and observe zero pressure in the brake pipe  Confirm reverser handle removed  Confirm lockable wheel chocks installed  Deactivate generator field circuit breaker and observe circuit breaker shows “open” on display panel

9.

Isolation and Lockout Equipment

9.1

Types of Isolation Hardware          

Personal Locks (Red) Equipment Locks (Yellow) Group Locks (Green) Identification Tags Multi-lock Device/s Isolator/s Group Isolation Board Lock Box Locking devices Suspended for Testing signs

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General rules for all Isolation Locks        

9.3

Only Master Safety Series™ 410 or 406 Xenoy Safety Padlock locks may be used. Never de-face or paint isolation locks. Never attempt to bypass or operate an isolator with an isolation lock attached. Where Isolation keys or locks are lost or found it shall be reported to your Supervisor/Team Leader. Isolators shall only be locked in the safe (isolation) position. Isolation System Locks shall never be used to secure isolators in the non-isolation position. Never attach a lock to another lock Isolation padlocks shall be used for isolations only

Personal Locks Attaching Personal Locks is carried out for worker protection by each Protected Person working under an isolation. Locking is carried out to prevent the accidental or inadvertent movement of the isolators.

Each worker shall attach their Personal Lock to a Lockbox or Multi-lock device (attached to each isolation point) before commencing work. If an Isolating Person is working alone they can place their lock directly onto the isolator – See Section 11. For more information on how Contractors and Visitors are managed under the principles described in this manual refer to Appendix C Personal Lock Rules  RED in colour.  Used for personal protection only.  Uniquely keyed, the key kept under the exclusive control of the Protected Person  Permanently and clearly labelled with the first name, last name and service number of the Protected Person, and  Keys shall not be transferred to another worker for lock removal  Can have an information tag attached containing information to aid in identification of the lock for one off situations (e.g. Visitors or Contractors) Personal Lock users shall:  Attach their own Personal Lock/s.  Never attach another person’s Personal Lock.  Never depend on someone else’s Personal Lock for their personal protection - except as provided for in an Emergency – See Section 13  Never lend their Personal Lock to anyone.  Never remove a Personal Lock from an Isolator other than the one bearing their name, except as provided for in Section 16 (Lock left on isolator)  On completion of work or when leaving the job site, remove their personal lock.

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Equipment Locks Equipment Locks are used to secure isolators in the safe (isolation) position, to prevent the accidental or inadvertent movement of the isolator. They are only attached after the isolation has been carried out by an Isolating Person. Their labels display the name of the Isolating Person or identity of the Lockbox. When attached to a Multi-lock device under Team Isolation it indicates that the isolation has been carried out and verified by an Isolating Person.

Equipment Lock Rules  Have no master keys.  Be uniquely keyed with only one key being available onsite for each lock.  Never be used for personal protection  Only be attached or removed by an Isolating Person.  Be used to secure isolators in the safe (isolation) position.  Be used to identify a link to another isolation if attached to a Lockbox or “Personnel Lock” section of a Group Isolation Board – See section 12.4  Have an information tag attached containing information about the isolation that it is a part of to aid in identification of the lock.

9.5

Group Locks Group Locks are used by the Isolating Person (the Isolating Person in control of the isolation) to secure the keys of all equipment locks inside a lockbox/lock board after an isolation has been carried out and verified to the Isolation Plan, so that the Isolating Person has control of the integrity of the isolation, and to maintain that integrity during shift changes.

Group Lock Rules  Never be used for personal protection.  Only be used on Lockboxes or Group Isolation Boards  Only be attached and removed from Lockboxes by Isolating Persons.  Be uniquely keyed with only one key being available onsite for each lock.  Never be used to lock a Group Isolation Board/Lockbox in the de-activated state  Have an information tag attached containing information about the isolation and to aid in identification of the lock.

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Multi-Lock Device    

9.7

A multi-lock device is used to attach more than one lock to an isolator. Multi lock device shall not be removed from the locking device when it has a lock attached. When a multi lock device is used on an isolator it shall have an equipment lock attached. Multi lock devices shall not be daisychained on an isolation point. If more than five Protected Persons require to lock-on then a lockbox shall be used – see section 9.7.

Lock Boxes & Group Isolation Boards

A specifically designed sturdy box (Lockbox), board/enclosure (Group Isolation Board) and:  Have a compartment to secure all Equipment Lock (Yellow lock) keys inside post isolation,  Provide a mechanical interlock such that the Equipment Lock keys cannot be removed once the Lockbox/Group Isolation Board is secured by the Group Lock (Green lock), and  Allows the work team’s Personal Locks (Red locks) to also secure the lockbox/Group Isolation Board thereby preventing inadvertent de-isolation.  Have the ability to store and display the Isolation Plan, Work Instruction and Isolating Person Handover sheet external to the lockbox/Group Isolation Board (e.g. plastic sleeve/pouch attached to lockbox/group isolation board)  The Lockbox/Group Isolation Board shall be located outside of the 3m network danger zone or in a position of safety (e.g. on board a track vehicle if authority is in place for the occupied track)  Have a unique identification name or number.

9.8

Isolator Labelling & Locking Standards

All isolators shall:  Be permanently and uniquely labelled; this will be in accordance with the local plant identification system requirements;  Clearly show the isolator status The preferred indication is:  Electrical isolations  Fluid isolators 14-MAN-002-COM

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10. Isolation and Lockout Equipment 10.1

General - Team

A Team Isolation is where each Worker protected under the isolation places their Personal Lock(s) on isolation point(s) via lockout device (e.g. multi-lock device) once the Isolating Person has implemented and verified the isolation, and secured it with equipment locks.

10.2  

Rules - Team If a Multi lock device is to be used, an Equipment Lock must be attached. A Lockbox can be used for Team Isolations if the isolation point cannot securely/safely host multiple locks on a multi-lock device or due to a requirement to manage large numbers of Protected Persons (e.g. Locomotive battery isolation).

NOTE: If a Lockbox is used, then Lockbox activation shall be followed as per section 12.5   

10.3

Equipment Locks shall be attached before any Personal Locks are attached and shall not be removed until all Personal Locks have been removed. This indicates that the isolation has been carried out and verified by an Isolating Person. When the Isolating Person is part of the work crew and has attached an Equipment Lock, the Isolating Person shall also attach a Personal Lock to the Multi-lock device. The Isolating Person in charge shall not be changed during a Team Isolation. If this is likely to occur during the course of the isolation, a Group Isolation shall be implemented instead and the Isolating Person changeover process followed as per Section 12.7.

Isolating - Team

The Isolating Person shall:  Obtain permission before isolating.  Ensure that the isolator(s) cover the equipment being work on.  Check the ISOLATOR TYPE, LABEL and LOCATION.  Follow the selected Isolation Plan, isolation process specified in the SWMS / JSEA, or steps identified using the STOP! Take Time and Switch On.  Conduct the verification process. Refer Section 8: Verification. 14-MAN-002-COM

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Attach an Equipment Lock and a Multi-lock device to the isolator. The Equipment Lock key must be kept under the exclusive control of the Isolating Person Advise the Protected Persons that the isolation is complete and where to attach their Personal Locks.

For Remote Verification: If verification is to be carried out away from the isolator attach an Equipment Lock directly to the isolators and then proceed with the verification. This prevents Protected Persons from attaching their Personal Locks until the isolation has been verified. Attach the multi-lock device and/or equipment lock once verification is complete.

10.4

Lifting the Isolation - Team

Protected Persons shall:  Remove their Personal Lock on leaving the job.  Advise the Team Leader/Manager and attach an Out of Service Tag, if necessary, where work has not been completed. The Isolating Person shall:  Check that controls are in the required position.  Ensure that it is safe to lift the isolation.  Get permission to lift the isolation if required  Remove Equipment Locks and return isolators to their normal operating position  Notify Area/Workshop owner (or workgroup supervisor) when isolation has been lifted. NOTE: If a multi-lock device has been used, Equipment Locks shall not be removed if any Personal Locks are still attached.

11. Isolating Person Working Alone 11.1

General – Working Alone

The Protected Person working alone shall:  Be a competent Isolating Person.  Be responsible for the application and verification of the isolation.  Attach their Personal Lock directly to the isolator after Isolation and Verification steps are complete. NOTE: Tasks requiring isolation of hazardous energy sources shall have the isolation requirements included as part of SWMS, JSEA or as part of a STOP! Take Time and Switch On completed by the Isolation Person – Refer to Section 6.1

11.2

Rules – Working Alone

The Isolating Person may attach a Personal Lock directly to the isolator after Isolation and Verification steps are complete. If for any reason a Multi-lock device is to be used, (e.g. the lock cannot be physically attached to the isolator) a Multi-lock device with an Equipment Lock shall be attached to the isolator and the Isolation Person then attaches a Personal Lock to the Multilock device.

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Isolating - Working Alone

The Isolating Person shall:  Obtain permission before isolating  Notify the Area/Workshop owner.  Ensure that the isolator points cover the equipment being worked on.  Check the ISOLATOR TYPE, LABEL and LOCATION.  Follow the selected Isolation Plan, isolation process specified in the SWMS / JSEA, or steps identified using the STOP! Take Time and Switch On.  Conduct the verification process. Refer Section 08: Verification.  Attach a Personal Lock directly on the isolator, or isolating device. For Remote Verification: If verification is to be carried out away from the isolator attach an Equipment Lock directly to the isolators and then proceed with the verification. This prevents Protected Persons from attaching their Personal Locks until the isolation has been verified. Once verification is complete remove the Equipment Lock and attach the Personal Lock.

11.4

Lifting the Isolation – Working Alone

The Isolating Person shall:      

Check that controls are in the required position Ensure that it is safe to lift the isolation Obtain permission to lift the isolation if required Remove Personal Lock(s) and return isolators to their normal operating position Notify Area/Workshop owner isolation has been lifted Advise the Team Leader/Manager and attach an Out of Service Tag, if necessary, where work is not complete or it is not safe for use.

12. Group Isolation 12.1

General - Group

Group Isolation is a system used to:  Ensure that all harmful sources of energy are isolated and locked before people start work.  Work on major pieces of plant and equipment where several isolators to be locked out. (Rather than attach a Personal Lock to each isolator the Protected Person only attaches one Personal Lock to a Lockbox – See section 9.8 Lockboxes) Group Isolation is the preferred system of isolation when a number of people are involved or a number of isolators are to be locked and should be implemented where ever practical. When an Isolating Person carries out the isolation of the equipment as per the Isolation Plan they shall ensure they sign each step of the Isolation Plan as it is carried out and it is also cross checked and signed by a competent second worker. NOTE: A competent second worker for this purpose will be an accredited Protected Person as per section 14.

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12.2

How to Set & Work Under a Group Isolation

The four stages for setting up a Group Isolation are: 1. Preparation: The responsible Isolating Person obtains the equipment and plan for the isolation and discusses requirements with the Area/Workshop Owner and Isolation Planner (if required) 2. Isolating: The Isolating Person carries out each step in the Isolation Plan. 3. Lockbox/Group Isolation Board Activation: The Isolating Person secures the Lockbox/Group Isolation Board with a Group Lock. 4. Attaching Personal Locks: Protected Persons attach Personal locks to the Lockbox/Group Isolation Board

12.3

Preparation - Group

When preparing for a Group Isolation the Isolation Planner shall:  Ensure that the Isolation Plan is correct for the task being carried out.  Ensure the Isolation Plan contains the Lockbox identity. This is to provide a link between the Isolation Plan, the Lockbox and the equipment locks on the isolators. When preparing for a Group Isolation, the Isolating Person shall:  Check the document control information on the plan to ensure that it is authorised and in date.  Ensure that permission to isolate is given by the Area/Workshop owner.  Place the Lockbox close to, and visible from the workplace where possible.  Check that the lockbox and the locks and keys to be used are clearly labelled.

12.4

Isolating - Group

When carrying out each step of the Isolation Plan the Isolating Person shall:  Ensure the Equipment Lock label or tag refers to the Lockbox identity.  Ensure that every step that has been assigned is carried out as described in the isolation plan.  Ensure they sign each step of the Isolation Plan as it is carried out and it is also cross checked and signed by a competent second worker

12.5

Lockbox/Group Isolation Board (GIB) Activation

When the Isolating Person activates a Lockbox/GIB they shall:  Ensure that each isolation step has been carried out.  Obtain a deactivated Lockbox and secure the Isolation Plan or work instruction to the Lockbox (e.g. plastic A4 sleeve attached via a lanyard to the Lockbox)  Lock ALL Equipment Lock keys in the Lockbox/GIB by attaching a Group Lock to the Lockbox/GIB. The Green Lock now signifies the Lockbox/GIB is active and the isolation process has been completed.  Ensure the key for the Group Isolation lock is in a secure location, preferably on the person of the responsible Isolating Person.  Instruct the worker/s on the boundaries of the isolation and where to attach their personal locks. This is to ensure that everyone understands what equipment is isolated and where they are safe to work.  Complete the Isolating Person Handover sheet. This is to be updated if the Isolating Person changes at any point whilst the Isolation is active. NOTE: The Isolation Handover sheet shall reside with the Lockbox/GIB at all times, if required. 14-MAN-002-COM

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Attaching Person Locks - Group

The Protected Person shall ensure: The Lockbox is active, by checking for:     

A Group Lock attached to the Lockbox An authorised Isolation Plan or work instruction The Equipment Lock keys locked in the Lockbox A current Isolating Person (Identified on the handover sheet for complex isolations only) The equipment they are about to work on is on the list of isolated equipment attached to the Lockbox.

The Protected Person shall:    

12.7

Check with the Isolating Person, if unsure about anything Attach their Personal Lock to the Lockbox. Advise the Isolating Person if work is not complete. REMOVE their personal lock if they need to leave the job site and when work is completed.

Change of Isolating Person - Group

Change Over Process When the current Isolating Person is required to change (e.g. leave the site, end of shift), a relieving Isolating Person shall continue in this role. A formal hand over discussion shall occur addressing the following:  The boundaries of the isolation  A review of the Isolation Plan and verification tests  Communication regarding any changes to the group isolation since the relieving Isolating Person was last on the job (long duration tasks only) The relieving Isolating Person shall enter their name onto the handover sheet on the attached to the Lockbox. The Group Lock continues to remain on the Lockbox during handover process. Ensure the key for the Group Isolation lock is in a secure location, preferably on the person of the Isolating Person in control of the isolation. Refer to Appendix E for process chart and template. NOTE: Protected Persons may continue to perform their work on the isolated equipment during the handover providing there is a current Isolating Person in control of the isolation at the worksite.

Change over requirements if there is no current Isolating Person If there is a period of time where there is no current Isolating Person, the Isolating Person shall:  Deactivate the Lockbox/Group board (as per Section 12.9) or  Make the Lockbox/Group board Inactive (as per Section 12.10).

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12.8

Overlapping of Lockbox / Group Isolation Boards

Linking of Lockbox/Group Isolation Boards Group isolations can be linked by using equipment locks. A ‘Linking’ Lockbox or Group Isolation Board (GIB) is used to link other Group Isolations. The steps in the isolation procedure for the Linking Lockbox or GIB require equipment locks to be attached to the Lockbox or personal lock bar of the other group isolations. This equipment lock ensures that whenever the Linking Group Isolation is active the other Group Isolations must also remain active. Linking boards has two main advantages:  

A protected person only has to attach one personal lock to the Linking Board to enable them to work on the equipment covered by all the Group Isolations encompassed by the linking procedure. If the Linking Lockbox or Group Board is deactivated work carried out under the other Group Isolations can continue as long as protected persons have a personal lock attached to the relevant lockbox/board. This enables areas/equipment to be de-isolated and tested/commissioned while work is being carried out in other sections. This requires careful planning and assessment of risks associated with the de-isolation process.

Rules - Linking of Group Isolations    

Lockboxes/GIB are to only be linked by an encompassing isolation plan. Any changes to any of the linked isolations will require a complete removal of locks from the Linking Lockbox or GIB and lifting of the Linking Lockbox or GIB Isolation plan Group Isolations linked by Equipment Locks are included as an isolator steps in the procedure The linked lockbox/GIB will be treated as an isolation point.

NOTE: When interfacing with external parties (e.g. Mine sites) it is allowed to accept a third party lock on a linked lockbox/GIB if the following conditions have been met:  The external party work is assessed by a Responsible Manager to be separate to any Aurizon work, and;  The external party Isolation procedures have been assessed by a Responsible Manager as being equal to, or better than Aurizon standards as required by this Manual, and; These assessments have been formally conducted and evidence of this recorded (e.g. contained in the IRMP/SIA etc.). Refer to Appendix G for examples of setting up a linked Lockbox/GIB.

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How to De-activate a Lockbox / Group Isolation Board – Group

Before Deactivation The Isolating Person shall:  Check that all work has been completed  Notify the area/site owner.  Attach an Out of Service tag to the Lockbox/GIB if work has not been completed. Deactivation To deactivate a Lockbox the Isolating Person shall:  Ensure there are no Personal Locks remaining on the lockbox  Remove the Group Lock allowing access to the Equipment Lock keys.  Remove the Isolation Plan or work instruction  Remove Equipment Locks and return isolators to their normal operating position.  Advise the Area/Workshop owner that the Lockbox has been deactivated and isolation lifted.  Discuss any special requirements with the Isolation Planner  Mark on the Isolation Plan each step as being de-isolated  Store the completed Isolation Plan in the site record management system.

12.10 Inactive Lockbox/Group Isolation Requirements For periods where there is no current Isolating Person onsite and no protected worker working within the isolation boundary as per the Isolation Plan but the isolation is required to remain in place (e.g. no work will be conducted afternoon/night shift but to be recommenced the following dayshift), the lockbox shall be securely covered (made inactive) and a yellow Out of Service Tag be placed on the lockbox cover detailing the reason for the inactivity by the Isolating Person. The green group lock shall remain in place to ensure the yellow equipment keys for each isolation point remains secure. Prior to re-activating the lockbox/group isolation, the incoming Isolation Person shall check that all isolation points are in place according to the Isolation Plan and verification has been completed. Once the Isolation Person has ensured that the isolation has been correctly established, the Isolation Person shall update the isolation handover sheet. Once completed the Isolation Person can then remove the yellow warning Out of Service Tag and lockbox cover for Protected Persons to attached personal locks.

12.11 Changes to Isolation Condition or scope of work What to do if the Isolation Condition Changes STOP! If there are any changes that may affect the isolation conditions during the course of work then the Isolating Person shall STOP all work, clear workers from the area and advise the area owner, as there may be harmful sources of energy in the work area. The Isolation Planner will investigate and take a course of action to re-establish the isolation. 14-MAN-002-COM

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Isolation and Lockout Operating Manual What to do if the Scope of Work Changes STOP! If there are changes to the scope of work or Isolation Boundary the Isolating Person shall advise the area owner who in consultation with the isolation planner will determine if the Isolation Plan has to be reviewed before proceeding with the job.

13. Emergency Response In cases where Emergency Services need to access a current Isolation and Lockout, all workers involved shall follow the Emergency Response Procedures for that location. The Isolation Planner/Isolating Person shall be the contact for Emergencies Services. In an emergency situation the Isolation Planner/Isolating Person shall:    

Be responsible to the Emergency Services at all times while they require access to Isolation and Lockout area, Follow any directions issued by Emergency Services Use their own Personal Locks on a Lockbox/GIB or Team Isolations whenever Emergency Services are in the isolated area, if applicable or asked and safe to do so. Assist the Emergency responders as required.

NOTE: The External services have a statutory right to control the situation once they have been called on site. In these cases all workers shall assist the emergency services as directed.

14. Training, Accreditation & Authorisation Requirements 14.1      

14.2   

Training General All workers covered by this Manual shall be trained and assessed for competency before being deemed accredited and commencing work (e.g. new workers). Records of workers trained and accreditation shall be kept in the SAP LMS system. Each Responsible Manager or nominee is responsible for ensuring that their workers and contractors are instructed and assessed for the role they are conducting in the Isolation and Lockout process. Records shall be kept for auditing purposes. All workers involved in isolations will have current competency in their accredited isolation role(s). The need for periodic assessment of competency will be determined by the Responsible Manager or nominee. Training requirements are to be determined by the Responsible Manager or nominee (Supported by a Training Needs Analysis - TNA). Function/area specific training may be required (subject to a TNA) that includes how to carry out isolation responsibilities within specific work areas or sites (e.g. isolations to specific plant or equipment shall be assessed and signed off by the responsible manager, or an assessment performed to achieve the plant or equipment specific qualification)

Enterprise Training Foundation – This training provides an introduction to the isolation system and overview of the core fundamentals of the isolation process. Protected Person – This training provides specific responsibilities and requirements of a Protected Person and accredits participants to be able to use Personal Locks. Isolating Person – This training accredits participants to implement isolations for simple and complex isolations by following isolation plans as required. It also accredits participants to use Group Locks to enable Group Isolations.

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Isolation Planner – This training accredits participants to develop and review Isolation Plans. Responsible Manager – This training is for Managers who are required to manage functional areas which use Isolation and lockout.



LMS Qualification Numbers: Course Name Isolation & Lockout – Foundation Isolation & Lockout – Protected Person Isolation & Lockout – Isolating Person Isolation & Lockout – Isolation Planner Isolation & Lockout – Responsible Manager

14.3  

14.4

Qualification Code Q40010653 Q40007531 Q40007532 Q40007533 Q40007534

Area/Site Specific Isolation Training Training in departmental isolations and procedures is required for people who carry out roles as Isolation Person and Isolation Planner. The format of the training is determined by the department. Accreditation in isolation roles shall meet requirements in section 14.4

Training Requirements for Isolation Roles

Protected Person  Foundation Training  Protected Person Training Isolating Person  Foundation Training  Protected Person Training  Isolating Person Training  Knowledge of area/site procedures for isolations  Experienced in area/site operations  Competent to perform relevant isolations as per trade/discipline qualifications (e.g. electrician, rail safety worker etc.)  Practical Demonstration of: o Follow isolation plans for job role o Isolate, verify and lock nominated equipment o Recognise defective isolators o Follow isolations plans (simple and complex) o Establish Group Isolations Isolation Planner  Foundation Training  Protected Person Training  Isolating Person Training  Isolation Planner Training  Suitable trade or technical qualifications to work with the systems subject of the isolations.  Thorough knowledge of the plant or equipment components and energy sources  Demonstrated competence to plan isolations for specific plant or equipment  Experienced in area/site operations  Apply risk assessment processes in the field of isolation as per 04-PRI-014

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Isolation and Lockout Operating Manual Responsible Manager  Foundation Training  Protected Person Training  Responsible Manager Training  Demonstrate understanding of Responsible Manager responsibilities as per this document.  Understanding of assurance and 1st party audit processes (e.g. Efficiency Testing and High Consequence Activity cards)

14.5

Accreditation Process

Workers and contractors will be deemed accredited to perform the nominated Isolation & Lockout roles when the following criteria has been met:    

14.6

Completion of relevant Isolation & Lockout training courses as per 14.2 above Successful completion of Theoretical Assessment for each course Successful completion of Practical Assessment (for Isolating Person & Isolation Planner only) Authorisation to perform Isolating Person and Isolation Planner roles by the area/site nominated Responsible Manager.

Confirmation of Competence Process

As determined by each function by TNA, each worker will undergo refresher training to confirm competence for the nominated Isolation & Lockout roles. Confirmation of competence will be deemed achieved when the following criteria has been met:  

Practical demonstration of applied knowledge in the field by an Efficiency Test (as per 07STD-001-COM). NOTE: Record of efficiency test shall be in SHEM and completed within the last 12 months) Successful completion of relevant Theoretical Assessment for the nominated Isolation & Lockout role (as per 14.2).

15. Isolation Incidents 15.1

Deviation from this manual

Any deviations from the requirements described in this Manual shall be reported in SHEM and investigated immediately. The responsibility for the investigation and follow up lies with the immediate Supervisor/Manager of the worker/s involved and is to include the manager or owner of the area. Investigations of deviations from the requirements described in this Manual shall be reported in SHEM.

15.2

Isolation Breaches

Workers who breach the requirements of this Manual shall be managed under Aurizon’s Code of Conduct. Such workers may be relieved of their normal duties pending an investigation of the incident. Isolation breaches include, but not limited to:  Not placing a lockout device for personal protection  Removing another workers lockout device without authority  Failing to remove a personal lockout device at the end of the work or shift.  Operating or attempting to operate any switch, or other control, or energizing any equipment with any tags and/or lockout devices attached  Not following an isolation plan. This includes isolations as part of yard/road protection plans.

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Isolation and Lockout Operating Manual 

Unauthorised removal of Out of Service Tags placed on faulty/unsafe equipment and Lockboxes.

Investigations of deviations from the requirements described in this Manual shall be reported in SHEM.

16. Process for Locks Left Attached 16.1

Personal Locks left on Isolators or Group Isolation Boards

Where a worker has left the job and failed to remove a Personal Lock, the Responsible Manager responsible for the equipment may authorise a Supervisor to remove that workers Personal Lock provided all the following requirements are met:     

All practical efforts have been made to contact the worker at work and have them remove their Personal Lock, All practical efforts have been made to contact the worker off site and have them return to work to remove their Personal Lock; The Responsible Manager has authorised this process before forcibly removing the Personal Lock (Lock investigation and removal report form shall be completed – See Appendix B); The Responsible Manager has ensured that the equipment is now safe to operate, and the worker cannot be located; and All practical efforts have been made to ensure that the worker is advised that their Personal Lock is to be, or has been, forcibly removed and ensure the worker could not return to the job and be endangered by the equipment being operated.

Where a Responsible Manager or nominee has authorised removal of a Personal Lock that has been left on an Isolation point, it shall be reported as per section 15.1

16.2

Equipment/Group Lock left on an Isolator/Lockbox or Group Isolation Board

Where an Equipment Lock is found left on an isolator that is not a current active isolation and the Responsible Manager or nominee needs to have that isolator returned to the normal operating position, the Responsible Manager shall attempt to contact the owner of the Equipment lock either on or off site and arrange to have it removed. In the case of group isolation this would be the Isolating Person. If the owner cannot be located the Responsible Manager may forcibly remove the Equipment Lock after verifying it is safe to do so using the same process applied for a Personal Lock, 16.1 above. Where an Isolating Person has failed to/cannot remove a Group Lock the Responsible Manager may forcibly remove the Group Lock after verifying it is safe to do so using the same process applied for a Personal Lock, 16.1 above.

17. Access Isolation and Immobilisation Access Isolation and Immobilisation refers to protection of workers from inadvertent plant movements (harmful sources of energy) whilst work is being conducted on or around such equipment. Such movements may occur by unwanted operation of the plant (e.g. Rolling stock, Heavy Vehicle, Forklift etc.) being worked on, or may result from the collision of some other plant with the item being worked on (e.g. unintentional locomotive contact with other rolling stock in a yard). 14-MAN-002-COM

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Isolation and Lockout Operating Manual 17.1

Access Isolation

Access Isolation involves workers installing a physical barrier that could physically stop another piece of plant from entering a “protected” area and colliding with the personnel or plant being worked on. For example, the placement of wagons between the desired work area boundaries and personnel with handbrakes wound on and handbrakes secured by a locking device would be considered a suitable barrier. When working within yards, facilities, sidings and workshops, this form of protection may be used in conjunction with the existing controls and local standard operating procedures. However, if these procedures are not available or applicable to the particular task, then prior to the commencement of the work, a STOP! Take Time and Switch On shall be conducted and assessed by the worker performing the task NOTE: When working within yards, facilities, sidings and workshops, the nominated “Person in Charge” shall be an accredited Isolation Planner to enable protection plans to be developed with reference to the Aurizon Isolation & Lockout principles to the greatest possible extent.

17.2

Immobilisation

Is the action taken to immobilise mobile equipment and plant such that people can work on it safely without inadvertent movement occurring. Not to be used for intrusive work where contact between an energy source and people may occur (i.e. repairs or maintenance activities). For example, it would be considered appropriate for daily maintenance checks on a light motor vehicle (as per the vehicle handbook) to be completed using immobilisation (i.e. handbrake applied and keys secured on the responsible person/driver performing the inspection). To conduct work on equipment that does not require full Isolation, but only requires Immobilisation, a procedure must document the process to ensure the proposed work can be conducted safely:   

Each situation requiring Immobilisation must be formally risk assessed which must include an assessment of the adequacy and redundancy associated with the controls Each situation will be formally approved by the Responsible Manager. Each work site/department must maintain a register of each situation where immobilisation will be utilised to make the equipment safe to work on.

18. Use of Tags Safety tags shall be applied to plant, structures and equipment, when it requires special operating procedures or special warnings. Safety tags do not protect workers, they should provide information relevant to the equipment they are attached to.

18.1

Use of “Out of Service” Tags

General 

When it is foreseen that the use, operation, or movement of any plant, structures or equipment could cause damage or extend an existing fault or malfunction, or expose any worker to the risk of injury, or cause damage or risk to any other plant or equipment, an “Out of Service” tag shall be used. The tag(s) shall be attached to the appropriate switch or control device of that

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Isolation and Lockout Operating Manual plant, structure or equipment, handbrake device or on the cord/hose near the supply connection of a portable appliance. 





 

The Supervisor/Plant Custodian may arrange for a qualified worker to inspect the plant, structure or equipment and give an opinion as to whether the suspected defective plant, structure or equipment may be operated. If doubt exists, the plant, structure or equipment shall be considered unsuitable for use and shall remain tagged out. Where the function of a plant, structure or equipment is defective, but can be safely operated without the use of that function, then an Out of Service tag may be placed on the function control. Before placing the tag, include details of the workers name, date, time of placing the tag, description of function tagged out and reason for isolating the function. Where the function is to be tagged out, then a qualified worker shall inspect the plant, structure or equipment to ensure that it can be safely operated with the function tagged out. Where there is a significant risk of an operator inadvertently operating the function control, then the worker shall disable the function completely. Operation of any plant, structure or equipment against the instructions detailed on the “Out of Service” tag will be treated as a serious breach – Refer to Section 15.2 Isolation Breaches Under no circumstances shall any plant, structure or equipment, which is unsafe to operate, be left without an “Out of Service” tag attached to it.

Placing “Out of Service” Tags 

 

Before placing an “Out of Service” tag in position, workers shall legibly print on it the workers name, date, time of placing the tag and the reason for attaching the tag (e.g. description of function tagged out and reason for isolating the function) Workers attaching “Out of Service” tags to equipment shall notify their supervisor of the placement as soon as possible before the end of the shift. Workers shall ensure the “Out of Service” tags are fastened securely to the appropriate switch or isolation point in a prominent position or near the supply connection of a portable appliance so that the tags will not become detached.

Removal of “Out of Service” Tags 



 

“Out of Service” tags may only be removed by:  The worker who placed the tag.  A supervisor of the worker who placed the tag.  A responsible worker after reference to, and following authorisation by a supervisor.  A maintenance worker responsible for the repair of the equipment. Before any removal of an “Out of Service” tag, the supervisor or the worker authorised to remove the tag shall ensure that the plant, structure or equipment is in proper working order and its operation will not cause injury or damage. Workers who remove an “Out of Service” tag under circumstances other than the above will be dealt with under Aurizon’s Code of Conduct – Refer to Section 15.2 Isolation Breaches If at the end of shift or job any plant, structures or equipment is still unserviceable, an “Out of Service” tag shall be placed before the yellow equipment lock is removed if part of a Team Isolation using a multi-lock device (as per Section 10) or Group Isolation (as per Section 12), or before the red personal lock is removed if part of an Isolating Person Working Alone isolation (as per Section 11)

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18.2

Test in Progress Tags

All Test in Progress tags shall be completed with details of the Isolating Person and task under the Test in Progress. Workers associated with the task shall be authorised to work on the plant, structure or equipment by the Isolating Person. Test in progress tags shall be used in conjunction with a testing program in the following situations:    

Attached to an isolation point which is energised; and Attached to barricading or other access control devices; and Attached to plant, structure and equipment used for control (e.g. a locomotive throttle, wagon break wheel). Attached to lockboxes

A Test in Progress tag shall not be used as part of an isolation to control de-energised plant, structures or equipment – this shall be isolated using equipment locks. Refer to section 20 Testing of Equipment SEE – APPENDIX A for details

18.3

Information Tags

Information tags are designed to be used in any circumstance to pass on general information. Circumstances may include:     

Minor faults that do not affect the safety or operation of the plant, structures or equipment, Labelling pneumatic lines, electrical wiring and water lines during maintenance or installation, or Attaching to barricading tape to explain the reason for the tape and the name of the contact worker. Identifying where yellow equipment locks are used in multiple isolations Identifying Group Isolation Board/Lockbox when there is no other means of identification.

Information tags shall not be used for worker protection or to identify plant, structures or equipment that is out of service. The Information Tag shall be filled out legibly and placed in a position that can be seen. Information shall include reason and contact details where required. SEE – APPENDIX A for details

19. Monitoring and Review Manual Review Review of this Manual will be periodically conducted by the SHE function and relevant subject matter experts. If appropriate a revision of this Manual will be undertaken as necessary to maintain its ongoing relevance in managing Aurizon’s Safety Management Systems.

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Isolation and Lockout Operating Manual Audits Responsible managers or nominees shall conduct regular 1 st party audits to confirm compliance with 14-STD-003-COM and this Manual. 1st Party audits for the purposes of operations Isolation & Lockout assurance should consist of:  Efficiency Testing (as per 07-STD-001-COM)  High Consequence Activity card inspections (as per 07-STD-002-COM and 07-STD-003-COM specifically HCA-013 Isolation & Lockout) Records Management Isolation Plans and associated documents such as SWMS, JSEAs and “Permit to Work” forms are required to be stored and maintained as per the Aurizon 'record classification and retention schedule" GEN/PRI/14/FORM 04.

20. Testing of Equipment General Testing is the activity of proving a piece of plant, structure or equipment is fit for operation or duty. There is often a need to test or conduct work with equipment in an energised state. In particular during testing and fault-finding or following the installation and commissioning, modification, change to operating circumstances or equipment maintenance, where harmful sources of energy may be present and positive isolation cannot be achieved (e.g. guarding removed, direction testing motors, function testing equipment, pressure testing pipelines etc.). Testing of equipment shall be performed under the control of an Isolating Person and an approved testing program that clearly details exclusion zones and other administrative controls used to prevent workers coming into contact with identified hazardous energy sources. Where exclusion zones and restricted zones shall be established as part of a Testing program, these zones should be marked with a suitable barrier and warning signs erected to prevent unauthorised entry. Where the size of the worksite/plant may be large, warning signs and supervision of site entries shall be in place and clearly communicated to workers to prevent unauthorised entry. Test in Progress tags shall be used in conjunction with testing of equipment as per section 18.2 of this document. NOTE: Only a qualified Electrical Worker with approval from their Responsible Manager is permitted to complete electrical isolations that require exposing potentially live components of a Low Voltage electrical circuit. Live electrical work shall be performed in accordance with the relevant regional Electrical Safety regulations (e.g. Part 3 of the Electrical Safety Regulation 2013 QLD). Testing Program requirements A risk assessment shall be conducted (as per 04-PRI-014) and implemented as part of developing a Testing program to provide a safe method to complete the testing. The risk assessment shall include evidence that other options were evaluated and the reasons why full energy isolation could not be achieved The Testing program shall be approved by a Responsible Manager prior to the task commences. The Testing program shall be provided by the Isolating Person. Testing programs shall contain an accurate description of:  Equipment to be tested. 14-MAN-002-COM

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Isolation and Lockout Operating Manual    

Reason for the test. Type of test. Sequence of Isolation points to be temporarily re-energised. Method for exclusion/separation of non-testing personnel from the testing area.

Testing Methodology Where testing is required, the following process will apply:  Isolating person needs to test equipment that has a potential energy source that constitutes a hazard (i.e. Non-Zero Energy state) 

Isolating person completes a risk assessment and develops a Testing Program to suit the desired testing activity (Note: The testing program must detail the energy sources to be energised and de-energised and the relevant isolators requiring the application of Test in Progress tags)



Isolating Person takes the completed Risk Assessment and Testing Program to the Responsible Manager to be authorised prior to the commencement of the testing activity.



Once approved, the Isolating Person shall: o Clear all personnel from the defined exclusion zone area (as defined in the risk assessment and would include the removal of red personnel locks from lockboxes, group isolation board, multi-lock device or single isolators) o Remove any Out of Service Tags if attached to plant/equipment and not part of an existing isolation. o Establish the Test in Progress Exclusion Zone by erecting bunting flags, tags, signs as required (Note: There must be only one point of entry to the Test in Progress Exclusion Zone unless defined in the risk assessment) o Place a copy of the authorised Risk Assessment and Testing Program at the entry point to the Exclusion Zone. o Remove any yellow equipment locks from isolators (if part of an existing isolation) and Re-energise each isolation point as identified in the Testing Program. o Complete/Fill in the Test in Progress tags required and attach to the primary isolation points of control (e.g. Locomotive throttle, circuit breaker etc.) o Direct all authorised workers required to be part of the testing activity to sign on to the Testing Program “sign on/off section” to acknowledge understanding of hazards within the defined Exclusion Zone and testing steps after a face to face induction has been delivered (Note: It would be considered a serious I&L breach if any person is inside an Exclusion Zone without being authorised by the Isolating Person and captured on the Testing Program “sign on/off section”)



Upon completion of the required testing activity, each authorised worker must inform the Isolating Person and sign off the Testing Program “sign on/off section”. The Isolating Person responsible for the Testing Program will then determine if the work is required to be completed under an isolation.

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Isolation and Lockout Operating Manual 

If an isolation is required:

YES

NO

Then, the Isolating Person removes the Exclusion Zone signs, flags, and Test in Progress tags and established/re-establishes the isolation as per the any relevant Isolation Plan (or as per section 10,11 or 12 of the I&L manual). The Isolating Person would then notify protected persons to place locks as required. And no further work is required, the Isolating Person removes the Exclusion Zone signs, flags, and Test in Progress tags, verifies the status of the plant/equipment to be in a safe, operable condition and notifies the relevant plant/equipment owner.

NOTE: The Isolating Person responsible for the Testing Program must be onsite and contactable for the duration of the testing activity.

21. Critical Equipment Isolations Where individual pieces of plant, structures or equipment that perform a critical safety function (personal safety or process safety) are to be isolated, the following process shall be followed:   

a procedure is to be written for the isolation (this may be a procedure specific or where warranted a generic procedure) the procedure shall include the alternative controls measure that shall be put in place to ensure the safety of workers the procedure and commencement of the job shall be approved by the relevant worksite manager (or their nominated delegate)

Examples of critical isolations include (but are not limited to):  instruments associated with critical alarms  emergency shutdown devices  fire and gas detection or suppression systems  safety eye wash/shower systems

22. Revision History Version No.

Section No.

Description of Change

Preparer (P) / Reviewer (R)

1.0

All

New document

Craig Bramble (P) Barry McCarthy (R)

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APPENDIX A – Tags/Signs

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Isolation and Lockout Operating Manual APPENDIX B - Personal Lock Investigation & Removal Report Details of Owner of Personal Lock(s) Intended to be Removed: Name: Section: Work Site: Date:

/

Time:

/

Worksite Location:

Reason and Physical Location the lock(s) were placed:

Reason for requiring removal of lock(s):

The following questions are required to be answered before removal of Personal lock(s):

Yes / No

Has the worker who placed the Lock definitely left the site?

Yes / No

Have comprehensive efforts been made to contact the worker?

Yes / No

Has a competent worker assessed the situation? (e.g. Area/Workshop owner or Isolation Planner)

Yes / No

Does the competent worker recommend the removal of the lock(s)?

Yes / No

Has a Responsible Manager or General Manager given their approval?

Yes / No

Removal of lock(s) is only to proceed if the answer to all of the above questions is “YES”. Was the Lock removed?

Yes / No

Date:

Was the worker able to be contacted?

Yes / No

Time:

Aurizon Co-ordinator

/

/

Competent Worker

Name:

Name:

Service no.:

Service No.:

Date:

Date:

Signature:

Signature:

Forward completed form to Responsible Manager and attach to the SHEM Event 14-MAN-002-COM

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Isolation and Lockout Operating Manual APPENDIX C – Management of Contractors and Visitors (Responsibilities)

1. Contractor Requirements: a) Contractors shall be trained and assessed in the Aurizon Isolation and Lockout requirements before starting work – Local Site inductions shall include reference to the work site rules in isolation and lockout (i.e. use of Protected Person red lock and undertaking Protected Person training). b) Contractor Personal Locks shall meet the requirements detailed in Section 9 – Identification of the contractor’s lock to be done via a personal lock through eyelet of an Information Tag (See Appendix A for tag details) c) The responsibilities of a contractor are no different to an Aurizon worker for different Isolation & Lockout roles (as per Section 5). d) If not trained, an unqualified Protected Person (e.g. a contractor will be undertaking a “one off” task/activity < 1 shift in duration) shall be fully supervised by an Isolation and Lockout competent person (i.e. the competent worker shall physically accompany and remain within arm’s length of the unqualified Protected Person for the duration of the task). NOTE: Aurizon supplied locks can be supplied on a temporary basis if the contractor locks do not meet the red lock requirements in section 9.3 of Manual. Local site lock registers shall be updated as required. 1. Visitors Requirements a) Visitors to work sites who will be undertaking a “one off” task/activity and who are not trained in the use of Personal Locks shall be fully supervised by an Isolation and Lockout competent person (i.e. shall physically accompany and remain within arm’s length of the unqualified Protected Person). b) If determined that the visitor needs to be part off or enter an isolation boundary, they shall be shown where to attach their Personal Lock as required by the work site representative responsible for the visitor after consultation with appropriate Isolation Planner or Isolating Person responsible for the isolation. c) Identification of the visitor’s lock to be done via a personal lock through eyelet of an Information Tag (See Appendix A for tag details). d) Visitors are to be issued with Aurizon red personnel locks and used as per Section 9.3 of this Manual. e) The responsibilities of a visitor are no different to an Aurizon worker or Protected Person (as per Section 5). 2. General Requirements a) Each site’s visitor / contractor management process shall include a step to check whether isolation and lockout requirements have been considered during the review of the contractor’s SWMS/JSEA (e.g. via a permit-to-work system). b) Each site shall have a process in place which includes the issue of personal locks to visitors and contractors as required. 3. Contractors shall follow the Aurizon Isolation and Lockout Manual unless: a) The contractor work is assessed by a Responsible Manager to be separate to any Aurizon work, and; b) The contractor procedures have been assessed by a Responsible Manager as being equal to, or better than Aurizon standards as required by this Manual, and; c) These assessments have been formally conducted and evidence of this recorded in a site register. 4. Aurizon workers working on a Contractor / Customer site may only use the isolation and lockout procedure for that site if it has been: a) Formally assessed by a Responsible Manager or nominee and evidence of that assessment has been recorded, and; b) Found to provide equal to, or greater protection required by 14-STD-003-COM

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Isolation and Lockout Operating Manual APPENDIX D – Isolation Decision Checklist Template

Isolation & Lockout Action/Decision Flow

Isolating Person

Protected Person

No

Check Multi-lock device for yellow lock

Job Scope

Use existing plan or create a new plan via S!TT&SO

Is it a Group or Lockbox Isolation?

Yes Checks Lockbox for equipment key

Seek permission to commence from Supervisor

Ensure green lock is attached to signify active I&L

Commences Isolation Plan

Checks lockbox isolation list

Attaches personal lock

Commences work

Confirms safe to de-isolate & no red personal locks are attached

Verifies Isolation & advises all

Detaches Personal Lock & advises all

Task Complete

De-isolate & verifies system normal

Isolation Planner

Job Scope

Responsible Manager

Complex or Simple Isolation

Supervisor

Simple

Supports Investigations

Complex

Isolation Planning Meeting

Use existing plan or complete a new Isolation Plan as per the I&L Manual

Scope isolation requirements technically & process-wise

Send Plan to Isolating Person

Supervisor advised of deisolation.

Permission granted to commence I&L

Ensures Training is current

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Isolation and Lockout Operating Manual APPENDIX E – Shift Handover of Isolation Isolated Task (Start)

No Work will continue next shift?

Yes

No

Will the isolation be deactivated?

Each worker removes personal red locks. Leave isolation locks & tags in place.

Same Isolating Person in Charge?

Departing Isolating Person physically shows incoming Isolating Person what equipment is isolated as per Section 12.3.1

Yes

No

Yes

Complete work and ensure tools/equipment are put away, each worker removes personal red locks.

Each worker leaves red personal locks in place. Also, Isolating Person leaves Isolation locks & tags in place.

Follow normal work practices for work on following shift(s).

If handover is not possible the isolation MUST be removed. Remove the isolation according to the sequence on the plan

Isolating Person confirms all workers have removed their personal red locks.

Remove any lockout devices & other safety equipment associated with the isolation according to the sequence on the plan as per Section 12.4

The incoming Isolating Person checks that the isolation is in place according to the isolation plan.

Departing Isolating Person & incoming Isolating Person complete Isolation Handover Sheet. Keys are handed over to the incoming Isolating Person.

Protected Person’s secure the isolation by attaching their red personal locks.

Remove personal red locks and make the Lockbox/Group Board securely covered (green lock remains in place) inactive as per Section 12.5

Isolated Task (Go back to Start)

Return equipment to normal service.

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Isolation and Lockout Operating Manual APPENDIX F – Harmful Sources of Energy and Precautions

Energy Source Hydraulic



Pneumatic

 

Water Compressed Air

   

Examples Of Hazards Raised Hydraulic or Pneumatic Equipment / Accumulators Multiple Pressure (Energy) Sources, Cross Connections, Alternate Supplies Stored or Residual Pressure Re-Accumulation of Harmful Pressure Leaking Valves Pump / Compressor / Blower supply still on-line

 

     

Steam

 

Electrical



 

All the above hazards AND Collapse of mains, vessels on steam systems Electric shock or arc blast and flash burn injuries.

   



Buried or hidden electrical cables

 



Working in the vicinity of live exposed conductors, overhead power lines, crane live rails, transformers, switchboards.



Hot or wet conditions Moving equipment Cramped conditions

 

  

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Precautions Depressurise / Lower the equipment or secure with pins, stands, etc. to support the load. Identify all pressure sources including: pressure supply, pilot supply, accumulators, air pilot supply, and electrical solenoid supply. Identify all Accumulators / Receivers / Pneumatic piping. Review circuit to identify all potential sources of trapped pressure. Identify if pressure is available upstream of isolation valve, prior to specifying verification steps. Identify if pressure will be present upstream of isolation valve whilst the job is in progress. Check bleeders or re-pressurisation. Isolate pumps, compressors, blowers and fans if practicable. All the above precautions AND Ensure adequate vent valves are open after depressurisation. Assume all electrical equipment to be live until proven otherwise Do not loiter around energised high voltage or high current low voltage electrical equipment Refer to appropriate electrical workers for preparation of plans For High Voltage (Greater than 1000V AC or 1500V DC) Contact local ECO Obtain an excavation permit. Check for electrical cables before penetrating (e.g. drilling, cutting, fastening, etc.) or demolishing walls, building cladding, ceilings, floors and other structures. Maintain safe working distances for people and equipment or isolate. For High Voltage (Greater than 1000V AC or 1500V DC) Contact local ECO Identify all hazards Use the appropriate PPE

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Isolation and Lockout Operating Manual Electrical



 

Out of date drawings

 

Auxiliary power supplies to plant equipment (e.g. motor field supply, supply to sensors, supply to brakes). Multiple feeds to control equipment (e.g. auxiliary interlocks, emergency backup power supplies) Mixed voltage systems (AC / DC). Stored energy sources (e.g. UPS, batteries, charged capacitors) Neutrals becoming live when disconnected. Induced voltages in cables Gas Plants De-dusting systems, Chemical vapour

 

 

Chemicals, Acids and Alkalis Fuel and oil

 

Stored Mechanical Energy Systems (Suspended Weights Unbalanced Systems, etc.)



Linked Process Equipment



Live or raised equipment such as:-pinch rolls, threading tables, raised work rolls, coil cars, lifts on cranes Dead weight accumulators Conveyor systems Material handling systems (e.g. hoppers, bins, bulkheads) Examples: Table rolls, cross transfers, transfer cars, crane runways, conveyor systems / hoppers, railway lines Hot foundry linings Radiation from hot / molten metal High humidity



  

Gases:Toxic / Flammable / Oxygen / Inert / Flue Chemicals

  

  

Heat

  

Uncontrolled Movement of Plant Electro Magnetic Radiation



Unsecured wagons, wheelsets, locomotives etc.



Transponder antennas

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



  

Test Before You Touch Always refer to up to date schematic diagrams and circuit diagrams when carrying out isolations· If unsure about validity of drawings, check against site conditions. Identify all power sources. Always refer to up to date schematic diagrams and circuit diagrams when carrying out isolations. Refer to appropriate electrical workers for preparation of plans.

If any of these gas systems fall within the isolation boundaries then all isolations for these services shall comply with local/site written Gas Procedures Check SDS register Refer to SHE /QES workers for further advice Isolate system, purge and flush Lower Mechanical protection – Secure by Pin or Block

  

As per hydraulic pressure Secure conveyor Empty system.



Understand isolation boundaries and equipment linkages. Take appropriate precautions.

         

Allow adequate time to cool. Provide ventilation, cooling air. Wear Protective Equipment. Heat causes increased potential for electrical hazards due to sweating. Identify appropriate controls. Chocking Derailers/Choke blocks Handbrake etc. Isolate circuit Establish clearance zones.

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Isolation and Lockout Operating Manual APPENDIX G – Linking Lockbox / Group Isolation Board examples

Example 1 - Isolation and Lockout Points Clipped and locked in normal. Yellow key placed in Mine Load Out Lockbox

Third Party Supervisor Lock

Mine Load Out Isolation and Lockout Lockbox

Key to Supervisor Lock

Positive Protection Lock Box

Stop Sign

Mine Load Out

Third Party Isolation and Lockout Lockbox procedure has been assessed by a Responsible Manager as being equal to, or better than Aurizon standards.

This Isolation and Lockout is in place PRIOR to the arrival of the Track Workgroup

Points Clipped and locked in normal. Yellow key placed in Track Workgroup Lockbox

Main Line

Example 2 - Isolation and Lockout

Lockbox

Stop Sign

1Stop Sign Track Workgroup Work Area

Workshop Derailer protecting Workshop

Mobile derailer protecting Track Workgroup Work Area

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Derailer protecting Workshop

Turnout Ladder for Yard

1

Lockbox

Because this Track Workgroup arrives after the Workshop Isolation is in place, the Isolating Person locks onto the Workshop lock box with a yellow equipment lock and verifies isolation, then places the key in the Track Workgroup lock box and locks Track Workgroup lockbox with green lock.

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