HES

Health, Environment and Safety

Standard Operating Procedure 10

Lockout and Tagout Procedures

Issued 1 February 1994

Revised 15 November 2003

Contents Page
1.0 INTRODUCTION.......................................................................................................2
2.0 DEFINITIONS ...........................................................................................................2
3.0 PERSONNEL ROLES AND RESPONSIBILITIES.....................................................4
4.0 DISCIPLINARY ACTION...........................................................................................5
5.0 LOCKOUT AND TAGOUT DEVICES........................................................................5
6.0 DOCUMENTATION ..................................................................................................6
7.0 PRE-JOB PLANNING ...............................................................................................7
8.0 MECHANICAL ISOLATION ......................................................................................7
9.0 ELECTRICAL ISOLATION ........................................................................................8
10.0 INITIAL LOCKOUT AND TAGOUT ...........................................................................9
11.0 MULTIPLE LOCKOUT AND TAGOUT PROCEDURES............................................9
12.0 REMOVAL OF LOCKS AND TAGS ..........................................................................9
13.0 VARIANCE PROCEDURE ......................................................................................10
ATTACHMENT A - APPROVED LOCKOUT AND TAGOUT TAG .....................................12
ATTACHMENT B - STANDARD DRAWING FOR SKILLETS/SPECTACLE BLINDS........ 13
ATTACHMENT C - LOCKOUT/TAGOUT VARIANCE APPROVAL FORM .......................14
ATTACHMENT D - FEEDER BREAKERS ADDENDUM ...................................................15
ATTACHMENT E - MAN ON LINE TAG ADDENDUM.......................................................16
SOP-10 Lockout and Tagout Procedures

1.0 INTRODUCTION

These Lockout and Tagout procedures must be followed during maintenance and repair
work on equipment connected to or containing mechanical, electrical or other energy
sources. The purpose of this procedure is to protect against accidental injury to personnel
and damage to company property that could occur if the equipment accidentally becomes
energized during such work.

1.1 Lockout and Tagout is generally accomplished by isolating the equipment to be

worked on from external energy sources, neutralizing internal energy sources, and
placing locks and warning tags on isolation devices to prevent accidental energy
release, or to prevent people from using it.

1.2 This SOP does not apply to normal operating activities such as running or
retrieving pigs, changing chokes, changing orifice plates, replacing pressure
gauges, collecting samples or conducting simple and routine operational equipment
checks and adjustments that do not endanger personnel or facilities.

1.3 When equipment is replaced, repaired, renovated or modified, or when new

equipment is installed, energy isolating devices for the equipment shall be designed
to accept lockout devices and/or spectacle blinds.

2.0 DEFINITIONS

2.1 Affected Personnel

People who may be affected by the isolation of a piece of equipment. This would
include, but may not be limited to, operators and maintenance personnel working in
the area or adjacent areas.

2.2 Authorized Group Representative

A person who represents a specific group (such as mechanics, electricians,

operators, etc.) and who has the authority to place a group lock.

2.3 Blinding

The installation of a blind flange or insertion of a solid steel plate between mating
flanges to prevent liquid, gas or vapors from passing through a pipeline or nozzle.
Block valves are not considered to be blinds.

2.4 Double Block and Bleed

The closing, locking and tagging of valves on either side of a bleeder that is locked
open and tagged. This may also be accomplished utilizing a double block and
bleed valve especially designed for this purpose.

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2.5 Energy Isolation Devices

Devices that physically prevent the transmission or release of energy. Examples

include: circuit breakers, disconnect switches, valves, blinds or similar devices.

2.6 Critical Equipment

Any equipment (such as gas compressor, turbine, etc) that requires energy isolation
devices, removing tubings or bypassing before maintenance or repair can be
conducted. An Lockout / Tagout checklist shall be filled for any critical equipment.

2.7 Lockout

Before starting maintenance or repair work on a piece of equipment, the power

source(s) must be de-energized or physically disconnected, locked, and properly
tagged in a safe position. The only exception is when simple equipment checks and
adjustments are made that will not endanger personnel.

2.8 Operator

The representative of the department or unit that has responsibility for operating
and/or supervising the facility or equipment.

2.9 Other Groups

Includes Mechanics, Electricians, Instrument Technicians, Facilities Engineering

personnel, and Contractors who may be involved with the maintenance or repair
work.

2.10 Person-in-Charge (PIC)

For daily routine work the PIC is the person responsible for on-site completion of
the work assignment. For non-routine or major jobs, the PIC is designated in writing
by the Section Supervisor responsible for the facility (e.g., Area Supervisor,
Terminal Supervisor, Municipal Services and Aviation (MS&A) Superintendent,
Telecommunications Supervisor, etc.).

A PIC may be anyone (i.e., Production Operations, Maintenance, Facilities, or a

third party contractor). However, the PIC is clearly identified for each task or project,
and must be knowledgeable and capable of the responsibilities of the PIC. The PIC
is responsible for pre-job planning, communication with all persons and
departments involved with the task or project, job-site inspection and coordination
with the facility Operator or Supervisor. The PIC insures that all applicable SOP's
are followed and has full authority to suspend work should problems develop that
may present a risk to personnel or the facility.

2.11 Tagout

A securely attached "Do Not Operate" tag is used to warn others that the control
position on a piece of equipment is not to be changed. These tags can also be
used to warn of an hazardous condition or defective piece of equipment. Tags

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attached to any equipment shall be “Readable.’’ A tag that is not readable should
be replaced.

2.12 Bar Clip

A device that is used to receive multiple locks.

3.0 PERSONNEL ROLES AND RESPONSIBILITIES

3.1 Supervisors

a. Supervisors are responsible for implementing these Lockout and Tagout

procedures in their respective operations.

b. Supervisors shall ensure that employees performing Lockout and Tagout are
trained and authorized to do the work.

c. Supervisors shall ensure that lockout and tagout devices (i.e. chains, locks,
tags, multi-clamps) are available and well maintained in their facilities. This
is critical for the implementation and success of lockout and tagout process.

d. Supervisors shall ensure that all tags attached to the equipment are
readable. Replace any tags that are not readable.

e. The Supervisor should ensure that all tags state the reasons for the tagout;
name of the person placed it, and date.

f. Supervisors shall carry out facility audits in a regular monthly basis.

g. Supervisors should address positive reinforcement on tasks well done and

encourage that pre-job safety meetings are held before starting lockout and
tagout on equipment.

3.2 Operators

a. Operators are responsible for following these procedures when performing

maintenance or repairs on equipment. They are also responsible for
controlling the Lockout and Tagout boxes in their platforms.

b. Operators shall maintain their key locks all the time while they are performing
maintenance or repairs on equipment involving lockout and tagout.

c. Lead Operators shall collect all the keys of locks installed on the equipment if
maintenance/repair works do not finish at the end of the day. The keys
should be placed inside the lockout and tagout boxes in their facilities.

d. Note: All keys should be identified according to their respective locks.

e. Operators shall maintain their lockout/tagout boxes with all necessary lockout
and tagout equipment (i.e. locks, tags, chains, etc.) as defined in section
4.0.

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f. Operators shall carry out a weekly inventory of lockout and tagout

equipment. Defective equipment shall be taken out of service.

g. Operators shall ensure that lockout and tagout log books are signed and
updated.

h. Lead Operators shall maintain a lockout and tagout preventive maintenance

checklist while critical equipment is being locked. Also P&ID are required to
be attached to the checklist.

3.3 Other Groups

a. Other groups are responsible for following these procedures when

performing maintenance or repairs on equipment.

b. Other groups shall carry their lockout and tagout devices during maintenance
or repair of equipment at unmanned facilities.

c. Other groups shall use lockout and tagout devices available in lockout and
tagout boxes on manned facilities where they are performing the tasks.

d. Other groups shall hand over their lock keys to the Lead Operator after
completion of the job or at the end of the day.

e. Other groups will need to have P&ID for marking up the location(s) where
lockout and tagout devices were applied for the work being carried on critical
equipment.

3.4 Support Departments

a. The HES Department is responsible for revising these procedures based on

recommendations from Operations Supervisors or any other concerned
party.

b. The CABGOC Learning and Development Center (CLDC) shall act as a

resource for training in lockout and tagout procedures.

4.0 DISCIPLINARY ACTION

Removing any lock or tag, or tampering with locked or tagged equipment is subject to
disciplinary action up to and including dismissal.

5.0 LOCKOUT AND TAGOUT DEVICES

5.1 All locks used for lockout will be keyed padlocks. The Lead Operator shall retain
spare keys of each lock assigned to the groups in the control room (Master Lock
Box). Locks and their keys should be individually numbered for identification
purposes.

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5.2 Locks should be coded:

Group Color Code Warehouse Symbol No.

Operators Yellow 555355790
Mechanics Blue 555355792
Electricians Red 555355794
Instrument Technicians Green 555355796
Facilities Engineering White 555355798
General none 555355800
(Key Blanks) 555355800

5.3 Depending on the facility (size and number of personnel), locks will be placed in a
lockout/tagout box so access can be controlled.

5.4 Every lock must be accompanied by a completed tag to identify the person who
applied the lock. Tags approved for Lockout and Tagout (Attachment A) are
available from the main Warehouse (Symbol no. 555100760). The tag reads
"Danger Do Not Operate". These tags are weather resistant and contain an eyelet
so they can be fastened to the equipment with a tie-wrap or wire.

5.5 Where multiple locks are required, bar clips shall be used (Warehouse Symbol no.
558101310).

5.6 If chain is needed to lockout valves or other equipment, yellow-coated safety chain
should be used (Warehouse Symbol no. 555350810).

6.0 DOCUMENTATION

6.1 Each major facility or area should maintain a lockout/tagout log book to document
lockout/tagout activities. All personnel authorized to lock and tag equipment should
enter the date and time that the lock and tag were installed, the name or initials of
the person who installed the lock and tag, the equipment description, the reason for
the lockout.

The person removing the lockout and tagout should sign his/her name, date, and
time that the lock/tag out were removed.

6.2 The log book should also contain a "blind list" to document instances where
mechanical equipment is isolated by other means, such as disconnecting lines and
using skillets, blind flanges or using double block and bleed. In these instances, the
same information required in paragraph 6.1 should be entered into the log book.

6.3 Log books should be color coded by section:

Yellow (top section of log book) Operations

Green Instrumentation
Red Electrical
Blue Maintenance
White Other or Construction
Orange (bottom section) Blind List

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6.4 Log books should be Acco-bounded so that the pages stay in place. Binders are
not recommended because it is easy to tear out or lose pages.

6.5 Grease boards may also be used to record lockout/tagout and blind list information,
but only in addition to a written log. If a grease board is used, entries should be
color coded to match the log book color codes.

7.0 PRE-JOB PLANNING

7.1 Prior to starting a Lockout and Tagout operation, a planning team shall review the
work to be performed and develop a Pre-Job Plan. As a minimum, the team should
consist of PIC and the Operator, with the participation of other involved groups as
necessary. The Pre-Job Plan may be an informal discussion with other groups
involved for minor jobs, or a formal written plan for major, non-routine jobs. Pre-Job
Plans should address:

7.1.1 Identification of all energy sources associated with the equipment to be

isolated.

7.1.2 Identification of energy isolation devices that will be used.

7.1.3 Identification of other Lockout and Tagout equipment that will be needed,
such as chains, blind flanges, skillets, spectacle blinds, etc.

7.1.4 Special hazards or considerations involved.

7.1.5 The possibility that energy may need to be released during the work, to test
or position equipment.

7.1.6 Notifications of all affected employees.

7.2 The planning team should walk the job, flag isolation points with red plastic tape,
and enter the isolation point in the lockout/tagout log or blind list, as well as marking
up the P&ID if critical equipment is locked and tagged.

8.0 MECHANICAL ISOLATION

8.1 The preferred method for mechanically isolating equipment from process lines is
disconnecting lines and installing blind flanges, skillets or spectacle blinds. Blind
flanges, skillets and spectacle blinds must be rated (working pressure and size) for
the lines where they will be used (see Attachment B - Standard Drawing for
Skillets / Spectacle Blinds).

8.2 Double block and bleed may also be used to isolate equipment from process lines.
Bleed lines should be carefully checked to ensure they are not plugged.

8.3 Isolation using a single block valve is not an acceptable alternative except in certain
specific situations where all the following conditions are met:

8.3.1 The isolation block valve closes tight, does not leak, and is locked closed;

8.3.2 The specific job activity is continuous and uninterrupted through to

completion, and is conducted during daylight hours;
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8.3.3 No confined space entry or hot work is involved; and

8.3.4 Approval from Area Superintendent is granted through the Lockout/Tagout

Variance Approval form procedure (Attachment C).

8.4 All valves used for mechanical isolation must be locked out, either on the valve
body or by use of a chain through the handle.

8.5 Mechanical isolation in preparation for confined space entry must be achieved by
installing blind flanges, skillets, or disconnecting and removing all associated lines.
(Note: Other requirements contained in SOP-5 “Confined Space Entry” Procedures
must also be met.)

8.6 Internal mechanical energy sources associated with equipment being worked on
(pressurized fluid, springs, elevated components, rotating equipment and gears)
must be neutralized or physically blocked out to prevent accidental release.
Examples:

• Bleeding down steam, air, or hydraulic lines and cylinders.

• Blocking out gears and other mechanisms.
• Placing blocks under raised dies, lifts, or any equipment that might descend,
slide, fall or roll.
• Releasing coiled springs and any spring-loaded devices.
• Chaining rotating equipment.
• Discharging large capacitors.

8.7 If mechanical isolation cannot be achieved as described in this section, an

approved variance must be obtained prior to commencing repairs and maintenance
on the equipment. The variance procedure is described in section 13.

9.0 ELECTRICAL ISOLATION

9.1 Equipment should be carefully reviewed to ensure that all electrical energy sources
have been identified.

9.2 Equipment must be isolated from electrical energy sources by opening and locking
all main power supplies. If the main power supply cannot be locked out, the
equipment must be physically disconnected from the power source by a qualified
electrician.

9.3 After the equipment has been isolated from the main power supply, local electrical
switches and start/stop stations should be activated to confirm that the isolation is
completed.

9.4 Lockout of electrical equipment is to be made at the main power supply. Lockout of
local switches may leave other portions of the equipment energized. Special
attention must be given to equipment connected to alternate power sources. In all
cases an attempt shall be made to start the equipment locally to ensure it is
properly isolated.

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9.5 If electrical isolation cannot be achieved as described in this section, an approved

variance must be obtained prior to commencing repairs and maintenance on the
equipment. The variance procedure is described in Section 13.

10.0 INITIAL LOCKOUT AND TAGOUT

The Person-in-Charge (PIC) and the Operator are responsible for the initial lockout and
tagout. Prior to commencing maintenance or repair work on equipment connected to or
containing energy sources, the PIC and the Operator shall:

10.1 Notify all affected personnel on the nature of the work to be performed.

10.2 Shut down the equipment by normal procedures.

10.3 Mechanically isolate and lockout the equipment as described in Section 8.

10.4 Electrically isolate and lockout the equipment as described in Section 9.

10.5 Apply a tag at each location where equipment has been altered for lockout and
tagout, including valves, flanges, skillets, spectacle blinds, switches, and blocking
devices. The tag should identify the person who applied it, the reason the tag has
been applied, and the date the tag was applied.

10.6 Notify affected employees that the initial lockout and tagout is completed.

10.7 If only the Operator will be performing the maintenance or repair, when the above
lockout and tagout is complete, the work may proceed. If Other Groups will be
performing work on the equipment, the Operator should advise and assist them with
the multiple lockout and tagout procedures described in Section 10.

11.0 MULTIPLE LOCKOUT AND TAGOUT PROCEDURES

If more than one group (Operators, Mechanics, Electricians, etc.) are involved in the
maintenance or repair work:

11.1 The Operator (or the Operator's designee) must apply a bar clip, and then install an
Operator lock and tag on the equipment.

11.2 One Authorized Representative from each Other Groups involved on the task must
place a lockout / tagout on the bar clip.

11.3 Each Group representative is responsible for all employees while work is being
performed.

11.4 Even in a group lockout situation, any employee working on the equipment may
elect to place his or her assigned lock and tag on the bar clip, if he or she feels it is
necessary. The individual employee's lock and tag must be removed when the
employee has completed his or her work or at the end of the workday.

12.0 REMOVAL OF LOCKS AND TAGS

Locks and tags used for lockout and tagout may only be removed as follows:

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12.1 Following the completion of maintenance and repairs,

12.1.1 The Operator shall perform a final check of the equipment to ensure it is
ready to be reactivated.

12.1.2 Authorized representatives shall remove any locks and tags installed by their
group.

12.1.3 The Operator shall be the last to remove his or her lock(s) and tag(s), and
then proceed to reactivate the equipment.

12.2 If lockout and tagout is in progress during crew or shift change, employees who
have installed locks and tags are responsible for turning over their keys to their
relief’s and explaining the nature of the work underway, including special hazards or
considerations involved.

The Operator is responsible for advising all, and including any in-coming personnel
involved on the work underway, and any significant aspects of the Pre-Job Plan,
including special hazards and considerations involved.

12.3 If the work being performed requires that energy be released to test or position
equipment, the following procedures shall be followed:

• Notify all affected personnel.

• Remove the lockout device(s).
• Only when safe to do so, energize and proceed with testing or positioning.
• Once testing or positioning is completed, de-energize and reinstall lockout
device(s), if applicable.

12.4 In an emergency, locks and tags may be removed by the Operator.

13.0 VARIANCE PROCEDURE

13.1 If it becomes necessary to vary from this SOP in unique situations, the Operator
and Other Group Representatives that will be directly involved in conducting the
work shall produce and obtain approval of a safe alternative procedure, using the
Lockout/Tagout Variance Approval form (Attachment C), prior to beginning the
work. This applies to any variance from these guidelines, even if the varied Lockout
and Tagout procedures are considered more stringent.

13.2 The proposed alternative procedure(s) shall be reviewed and signed by the
Operator and Other Group Representatives that will be directly involved in
conducting the work prior to submission for approval.

13.3 Each Variance Approval request shall be reviewed and approved, prior to starting
work, by a level of management equivalent to the Area Superintendent in the
department or unit that owns the equipment or facility involved.

13.4 A copy of the approved Variance Approval shall be maintained at the job. The
approved variance shall be distributed as follows:

Original Person approving the variance

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SOP-10 Lockout and Tagout Procedures

Copy Supervisor responsible for facility

Copy Job site
Copy Maintenance Supervisor (if applicable)

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SOP-10 Lockout and Tagout Procedures

ATTACHMENT A - APPROVED LOCKOUT AND TAGOUT TAG

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SOP-10 Lockout and Tagout Procedures

ATTACHMENT B - STANDARD DRAWING FOR SKILLETS/SPECTACLE BLINDS

The drawing is not available in the electronic version of the SOP. The drawing is available
in the gray Chevron Piping Manual, Volume 2, Specifications and Drawings. See the
tab Standard Drawings, drawing# GC-L31452-22. Gray manuals are housed in the
Facilities Engineering library.

http://techstds.chevron.com/document.asp?id=2320

http://techstds.chevron.com/tech_standards/Gray/PIM/dwgs/gc-l31452-22.pdf

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SOP-10 Lockout and Tagout Procedures

ATTACHMENT C - LOCKOUT/TAGOUT VARIANCE APPROVAL FORM

LOCKOUT / TAGOUT
VARIANCE APPROVAL

(Please Print)

Location: Date:

Equipment No. and/or equipment involved:

Section number(s) of this SOP that will not be followed:

Description of safe alternative procedure:

(Continue on the back if necessary)

The above variance from the preferred method of controlling energy as outlined in the Standard Operating
Procedure will not endanger Company employees, contractors, the general public, the environment, or
company property.

This variance is valid from (date): until (date):

(Print and sign names)

Person-in-Charge: Date:

Operator: Date:

Other Group Date:

Representatives:
Date:

Approved By* Date:

* Must be approved by a level of management equivalent to the Area Superintendent in the
department or unit that owns the equipment or facility involved prior to beginning the work. The
approved variance shall be distributed as follows:

Original Person approving the variance

Copy Job Site
Copy Supervisor responsible for facility
Copy Maintenance Supervisor (if applicable)

CABGOC - 02/94 Report Control No.:

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ATTACHMENT D - FEEDER BREAKERS ADDENDUM

Lock-Out Tag-Out for 5KV Feeder Breakers at Malongo Power Station

WARNING

THIS PROCEDURE MUST BE FOLLOWED TO PREVENT RECLOSING OF HIGH VOLTAGE

AERIAL LINES WHILE IN CONTACT WITH PEOPLE OR EQUIPMENT. BREAKERS MUST BE
RACKED OUT AND LOCKED.

MANPOWER REQUIREMENTS

1 POWER STATION OPERATOR, DESIGNATED “OPERATOR-IN-CHARGE”

1 QUALIFIED LINEMAN DESIGNATED “LINEMAN IN CHARGE”
1 POWER DISTRIBUTION FOREMAN OR DESIGNATED PIC

REQUIRED PREPLANNING

1. Outage is approved in advance and all materials and equipment are requisitioned and staged.
2. Line Crew / Power Station Operators “tailgate” meeting performed by “Lineman in Charge”. Work is
described in detail, visually identifying line.
3. Lineman in Charge to strictly coordinate commencement of and stoppage of line work.

PROCEDURE

1. Prior to line work proceeding, Lineman in Charge and Power Distribution Foreman fill in Section 1 of
the Man on Line tag, describing the work, naming the line to be de-energized and signs and dates.
2. Operator in Charge and Lineman in Charge identify line feeder breaker to be de-energized.
3. Operator in Charge and Lineman in Charge open line breaker and rack breaker from bus into the
disconnect position.
4. Operator in Charge and Lineman in Charge install locks and tags onto breaker.
5. Operator in Charge and Lineman in Charge attempt to re-close the breaker and verify that the
breaker can not be closed.
6. Operator in Charge fills in Section 2 of Man on Line tag verifying affected line is de-energized and
cannot be closed. Operator in Charge and Lineman in Charge sign and date Section 2.
7. Do Not Operate tag is placed on breaker control switch.
8. Man on Line tag is placed on breaker cubicle.
9. Line work may proceed as directed by the Lineman
10. At the completion of the line work, the Lineman in Charge fills in Section 3 stating that the line is
clear of all tools, shunts and people. Lineman in Charge signs and dates.
11. Operator in Charge, Lineman in Charge, and Power Distribution Foreman reconfirm that the line is
clear and ready to reenergize. Both Operator and Lineman in Charge, and Power Distribution
Foreman sign and date tag.
12. Operator and Lineman in Charge remove locks and tags from the breaker.
13. The breaker is racked into the bus and energized.

Note: The same Foreman in charge and the same Lineman in charge must both sign the MOL Tag in area
number 1 and number 3. If there is a change in personnel from the start of a job to its completion a
new MOL Tag shall be required.

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ATTACHMENT E - MAN ON LINE TAG ADDENDUM

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