This chapter describes minimum requirements for safely isolating energy sources and

managing associated hazards during maintenance, inspection and construction

activities, including facility modifications. This is applies to electrical sources of
energy as well as other sources of potentially stored energy.

Saudi Aramco (SA) General Instructions (GIs):

GI 2.100, Work Permit System

GI 6.012, Isolation, Lockout and Use of Hold Tags

SA Safety Handbook, Minimum Safety Rules

5.3.1 Isolation of energy sources shall be per GI 6.012.

5.3.2 During job planning, an isolation plan shall be developed that shall identify
all locations to be isolated, types of isolating devices to be used and
site/job-specific procedures for isolating the equipment.

5.3.3 The isolation plan shall include a blind list if blinds are to be used. The
blind list shall, at a minimum, include the following blind information:
blind number, blind rating, date of installation, location, installer name,
date of removal and remover name.

5.3.4 The isolation plan shall be reviewed and verified by relevant SA facility
management (e.g., the operations shift superintendent for the unit where
the isolation will occur) and contractor site management prior to the
isolation work being performed. In some cases, additional SA operations
shift superintendent(s) shall be required to also concur with the plan (e.g.,
where the isolation affects adjacent process units or other facilities). The
SA facility management shall specifically concur with the blind list where
plot/battery limit piping is involved.

5.3.5 All necessary isolation and blinding equipment/devices (locks, tags,

properly rated blinds, etc.) shall be made ready and inspected before
commencing work.

5.3.6 All forms of isolation (electrical, mechanical or otherwise) shall use the
Lock/Hold Tag (SA Form 525) at every isolation point. See Figures 5.1
and 5.2. The following information shall be provided on all tags:
 Plant number/location.
  Equipment name.
 Date and time of lockout.
 Name, badge number, organization, contact phone and signature of the
individual who installed the isolation device.
 The reason for the isolation.

5.3.7 Contractors shall establish an isolation, lockout and use of hold tag
program for grassroots projects that is compatible with GI 6.012 and this
chapter. For existing facilities, contractors are required to implement the
SA proponent organization’s isolation procedure.

5.4.1 Isolation shall be considered complete only when no associated control

device is capable of energizing the equipment.

5.4.2 In situations where it is not possible to lock out an isolating device,

isolation may be accomplished by removal of fuses, disconnection of
electrical cables, or physical removal of a component of the system
 supplying energy to the equipment. The point of physical interruption shall
be identified with a fully completed hold tag.

5.4.3 Each lock on a piece of equipment or on a multiple lockout clip shall be

identified with a subsequent hold tag. See Figure 5.3.

5.4.4 Each organization issuing locks shall have a system of uniquely identified
locks. Acceptable methods include color coding, stamping or engraving
locks appropriately.

5.4.5 Each lock shall be keyed separately, with no duplicate key, to ensure
removal only by the authorized user.

5.4.6 Operations representatives shall be the first to install their lock(s) and shall
be the last to remove them.

5.4.7 Maintenance personnel shall install their lock(s) at each corresponding

isolation point. Every individual worker shall have in place his personal
lock(s) at all lockout locations.

5.4.8 Work shall not be allowed to commence nor shall any maintenance
material/device be placed on the isolated equipment until a verification test
has been performed to ensure isolation has been correctly carried out and
that no residual energy exists within the equipment. “Clear” the area of all
potential hazards associated with an accidental start-up (e.g., tools,
materials, personnel at a hazardous location). Then a verification test (or
“Try”) shall be witnessed by all affected parties and shall be conducted for
each potential energy source for the equipment being isolated.

5.4.9 No padlock/lockout device shall be cut or forcefully removed without the

permission of the lock owner’s superintendent or operating shift
superintendent and such actions shall be in accordance with GI 6.012.

5.4.10 A “group lockout” procedure shall be implemented during maintenance

and construction activities involving large numbers of personnel, such as:
turnarounds and inspections (T&Is), facility expansions or compressor
 repairs. Personnel shall be afforded individual protection and the following
steps shall apply to group lockout:

A. An operations representative shall lock and tag each isolation point with
single-keyed locks per the requirements of this document or written
departmental isolation procedure/instructions.

B. The maintenance/construction supervisor shall also lock and tag each

isolation point.

C. The maintenance/construction supervisor’s key(s) to these locks shall be

placed in a group lockout box.

D. Multiple lock clips (hasps) shall then be attached on the closed group
lockout box, as required.

E. The operations representative shall install his lock and tag on the group
lockout box first. He shall maintain possession of his key(s) until the job is
complete.

F. Each member of the maintenance/construction crew shall then place his

lock and tag on the group lockout box (use a multiple lock clip (hasp) if
necessary) and maintain possession of his key(s) until the job is complete.

G. When a craft shift change occurs and work has not been completed, the
oncoming shift may either:

 Replace the previous shift’s locks and tags with their own locks and
tags, in which case the off-going shift shall remove their locks and
tags.

 Transfer keys between shifts. This transfer requires the craft

supervisors to conduct a detailed review of installed locks and tags.
Hold tags belonging to the original shift crew shall be signed by the
oncoming shift personnel, or entirely new tags shall be completed by
the oncoming shift and installed to replace the original shift’s hold
tags.

5.5.1 Piping or equipment shall be isolated and/or blinded and the contents
drained, vented or purged before any work is performed (inspections,
repairs, maintenance, modifications, etc.).

5.5.2 Operations or proponent organizations shall ensure that specific isolation,

lock and hold tag procedures are in place to protect personnel when such
activities are performed.

5.5.3 The levels of isolation are listed in Table 5.1 in the increasing order of
protection (first being the lowest and last being the highest) and shall be
applied accordingly depending on the nature of work.
5.5.4 If isolating by double block and bleed (DB&B), which involves locking
closed two isolation valves in series, and locking open a drain/vent valve
between the two isolation valves (see Figure 5.4), a hose or hard piping
shall be attached to the drain valve to ensure that any liquid that might pass
is carried away from the work site and all locks shall be tagged.

Single block valve Minimum Changing a gauge or sock filter,

swinging a blind (minimum routine
maintenance)

Double block and Medium Removing a control valve

bleed (DB&B)
Disconnection Maximum Long-term construction/maintenance
(removal/dropping of work
a spool piece)

Blinding Maximum Confined space entry/hot work

Notes:
 All means of isolation shall be locked and tagged accordingly.
 When using a single block valve, fluid shall be removed and valve tested for
leakage before commencing work.

5.5.5 In order for DB&B to be utilized, the subsequent bleed (vent/drain) valve
shall be adequately sized in order to handle the upstream pressure in the
event the first isolation valve fails/passes. Vents and drains shall be
verified to be clear of obstruction.

5.5.6 Single block valve and DB&B isolations shall not be used when equipment
or a piping containing hazardous materials is to be opened for confined
 space entry or hot work activities. This type of work activity requires
isolation by blinding.

5.5.7 Blinding involves inserting a slip blind or blind flange at a flanged joint or
a swinging (rolling) a spectacle blind if provided by design. See Figures
5.5, 5.6 and 5.7.

5.5.8 The rating, size and location of all blinds shall be verified prior to
installation and shall be reflected on the blind list. Each blind shall be
stamped with the corresponding pressure rating and installed with
matching gaskets.

5.5.9 Blind gaskets shall be inspected for damage prior to installing/swinging

blinds.

5.5.10 Written procedures shall be developed and implemented for major

equipment with multiple connections and several low points where
hazardous materials might remain trapped.

5.5.11 These written procedures shall include, but not be limited to:
 Drawings (P&IDs, isometric drawings, etc.) indicating all isolation
points, drains and vents.
 The blind list, to track installation (and later removal) of all blinds.
 The steps or sequence for depressurization, draining and purging of
equipment and associated piping before blinds are inserted.
 Site preparation steps (e.g., covering sewers).
 Proper sequence for installing blinds.
 Safe venting and disposal of any drained material.

5.5.12 Associated equipment and piping shall be isolated by closing block valves,
depressurization, draining and purging (for flammable/toxic service
piping). Valves shall be chain-lock closed and tagged before opening the
flange and shall remain so while any blinds are in place. Valve locks and
tags can be removed when the subsequent blinds are removed and the
flanged connection restored to its original condition.
5.5.13 Piping sections with valves on each end, drains at low points and vents at
high points shall be isolated, depressurized and drained prior to work.
Piping that has no drains or vents shall not be opened.

5.5.14 A Release Permit shall be issued before commencing any blinding activity.
Blind swinging/insertion shall be covered by a Hot or Cold Work Permit as
well, depending on the circumstances (using impact wrench with generator
vs. using hand tools).

5.5.15 Blinding shall be performed by loosening the bolts and cracking the
flanged connection at the “5 o’clock position” (down and away from the
person performing the work) to allow any potential gases or liquids to be
released away from personnel.

5.5.16 When equipment (e.g., pump, meter or filter) is removed from service for
long-term maintenance or construction activities, subsequent blinds shall
be required for associated piping.

5.5.17 Blinds shall be inserted only at the isolated side (i.e., downstream) of each
isolation valve that has been locked closed and tagged.

5.5.18 Blinds shall be accessible and scaffolding shall be provided where

necessary.

5.5.19 The first blind inserted shall be the last to be removed.

5.5.20 All bolt holes of the blind and corresponding flange connection shall be
used when installing blinds.

5.5.21 All slip blinds shall have tails as shown in Figure 5.5.

5.5.22 Safety precautions shall be taken (e.g., use of self-contained breathing

apparatus) for removing blinds since hazardous materials might have
accumulated between the blind and the corresponding isolated valve if the
valve was passing.

5.6.1 The SA Power Operations Department (POD) shall issue clearances as

required before work is performed on or near high-voltage electrical
equipment (e.g., that has been de-energized and isolated from the power
system in an approved manner). See Chapter III-3, Electrical Equipment,
of this manual.

5.6.2 Clearances shall be issued by POD dispatchers in addition to any work

permits that are required. See Chapter I-4, Work Permit System.

5.6.3 The proponent organization and contractors shall contact POD directly to
coordinate with the POD electric system operators for assistance.