5.

2 Isolation of Energy Sources

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Purpose: To protect personnel prior to and while performing work involving repair/alteration
on equipment in which the unexpected energization or start-up of the machines
or equipment, the release of energy or hazardous materials could cause injury.

Scope & The requirements of this standard are applicable to all facilities owned or
Applicability: operated by EQUATE including –

 Manufacturing plants,
 Pipelines,
 Maintenance shops,
 Laboratories
 Commercial pilot plants,
 R&D/laboratory pilot plants, and
 Office buildings.

Exceptions to this standard are listed in Appendix A.

Definitions:
Term Definitions

Active Master Card A Master Card becomes active after a Facility representative, first job
representative sign in section-3 and remains active until all work is completed,
and all job personnel have signed off in section-3 and section-4.

ECP Issuer A person authorized by department leader to issue Energy Control Plans.

Energy Control A documented plan used for safely preparing equipment for repair/alteration.
Plan (ECP)

Energy source Any source of energy that can be harmful to personnel. For example, but not
limited to: chemical, including engulfment and displacement of oxygen,
electrical, thermal, mechanical, pneumatic, hydraulic, pressure, gravity and
radiation.

Facility A person with knowledge of the facility operations that is trained to isolate and
representative Tag out the equipment.

Isolating Device A physical device that prevents the transmission or release of energy or
material. Examples include slide gates, slip blinds, air gaps, block valves, as
well as drain valves and vent valves used to protect personnel, physical
blocks, and electrical disconnects. Control circuits (i.e., PLC switches, DCS
switches, limit switches) are not Isolating Devices.

Isolation of Energy The use of Isolating Devices to control and restrain Energy sources and a
sources Master card system such that all person(s) doing work under the isolation have
control of all Isolating Devices and all Isolating Devices have been identified.

Job representative The person who performs repair/alteration work or who represents a group of
personnel performing repair/alteration. He is responsible for assessing the
Isolation of Energy sources from the perspective of the workers performing the
job.

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Lock-Box A fully enclosed and numbered lockable box used to secure keys to the Unit
Locks.

Lockout The utilization of a lock or bolting mechanism to physically secure an Isolating

Device to prevent it from energizing accidentally.

Master Card A document used to control an isolated system and provide information on the
Isolating Devices, location of tags and the people working under the isolation.

One-Plus The method or practice used to physically prevent inadvertent operation of an

Isolating Device. “One plus” means that two separate, unrelated actions must
occur to defeat the Isolating Device. The "One” refers to the Isolating Device
itself and the “plus” refers to the steps taken to prevent inadvertent operation
of the Isolating Device. An example of a “One-Plus” method is to remove the
handle of a quarter-turn valve that prevents inadvertent operation. Other
measures can be taken to prevent inadvertent operation of the Isolating
Device, such as:
1. Disconnecting the airlines to a spring loaded valve that will be
maintained in the safe position for the isolation by the spring,
2. Locating the Isolating Device such that a person would have to
use a ladder to access it,
3. Attaching locks, or
4. Using a wrench to tighten valves.

Personal lock An individual’s lock blue in color, identified with name, employee number and
department.

Personal Tag A red tag placed on the Isolating Device by the person performing the
repair/alteration work.

Physical Isolation The separation or interruption of process lines, utility services or Energy
sources. For example:
1. Installation of blinds in pipelines.
2. Disconnection of power cables, couplings, driver belts and pneumatic
and hydraulic powered drives.
3. The removal of a valve or spool from a pipeline.
4. Racking out and physically removing the breaker out of the cubicle for
equipment above 3.45KV or removal of fuses from the MCC for 433V
equipment.

Reconciliation It is the act of comparing the removed red tag number with the red tag number
on the location list to ensure all red tags are accounted for. When red tags and
locations are accounted for, then the Isolation of Energy sources has been
reconciled.

Red Tag The tag labeled “Do Not Operate”, traceable to a Master Card, used for
identifying each Isolating Device in use for the Isolation of Energy sources and
to warn people not to operate the Isolating Device.

Repair/Alteration Activities such as constructing, installing, adjusting, inspecting, modifying,

maintaining or servicing machines or equipment. Activities such as lubrication,
cleaning or un-jamming, and making adjustments or tool changes, where
employees may be exposed to the unexpected energization or startup of the

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equipment or release of energy.

Tag out The attachment of a Red Tag to an Isolating Device.

Temporary release The temporary removal of Red Tags to allow tests and checks on the
equipment. Only a job representative can initiate it.

Unit Lock A red lock installed by the Facility representative to lock the Isolating Device.

I. General Requirements:
A. Department Leader shall authorize and list personnel authorized as Facility representatives for the
facility. This list shall be maintained up-to-date.
Authorization may only be granted if:
1. He has received ‘working level’ training on the requirements of this standard.
2. He is knowledgeable of the facility operations, equipment to be isolated and is trained on the
Energy sources and associated hazards of the area/equipment and the safeguards to control
these hazards.
3. Department Leader is satisfied with his knowledge, skill and experience level to perform an
Isolation of Energy sources as per the requirements of this standard.
B. Energy Control Plan (ECP):
4. An ECP is required for each Repair/Alteration job that requires a Master Card.
5. The Department Leader issues a list of personnel who are authorized to provide an ECP. This list
shall be maintained up-to-date.
6. Energy Control Plans are developed as per Appendix -C. The ECPs shall be assigned unique
numbers for each job. Format for the unique number shall be “Unit – Area-Equipment ID – SR
number”.
(Example: UT-BFW- G210-001). For CSE, EPP system will add "CSE" to the ECP number.
7. The Energy Control Plan shall be attached to the Master Card.
8. For any unplanned jobs during silent hours, in the absence of any authorized ECP Issuers, the
Shift Activity Coordinator shall issue ECP with verbal approval from the concerned authorized
ECP Issuer.
9. Adding and deleting tags:
a) To modify an existing ECP, approval from the ECP Issuer (verbal approval, if not present on
site) is obtained and documented on the ECP location list for:
1) Adding Red Tags: Additional Red Tags are numbered and added to the location list of
ECP.
2) Deleting Red Tags: Red Tags listed in ECP can only be deleted before the Master Card
becomes active.
b) Master Card section-2 to be signed by Job representative and Facility representative as an
acknowledgment for the addition of Red Tags to an active Master Card.
C. Preparation of equipment for Repair/Alteration work:
10. Piping, vessel(s), mechanical, electrical equipment or instrument, removed from operation for
repair / alteration is isolated, de-energized and when appropriate, drained of contents and vented
before work begins.
11. Following actions, as applicable, shall be taken prior to the initial opening of lines/ equipment.
a) Isolate
b) Drain
c) Vent
d) Clean by one or more of the following methods:
1) Purge with an inert gas or steam.

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2) Displace the atmosphere with water.

3) Flush to remove hazardous chemicals.
e) Special cleaning or treatment or both shall be used as per departmental instructions to
ensure reactive substances (organic peroxides, oxidizers, pyrophoric materials, etc.) are
chemically changed, inhibited or neutralized to prevent uncontrolled decomposition.
Exceptions: Purging, flushing or displacement is not necessary if the material contained is
non-hazardous.
12. Delivery of equipment to a third party or RMD for repairs: Before an equipment is delivered to a
third party OR to RMD for repairs, the equipment shall be properly cleaned as mentioned in a) to
e) above and following information shall be provided along with the equipment using Appendix-
H:
1) Owning Department
2) Equipment ID/Tag.
3) Material last contained in the equipment
4) Cleaning method
5) Cleaned by, Name/Employee number/sign and date.
D. Prime Movers such as electric motors, internal combustion engines, steam turbines and pneumatic
drives shall be isolated from all Energy sources prior to the start of work.
Equipment shall be isolated from Energy sources and physically blocked from movement when the
work involves:
13. Internal driven machinery in confined spaces requiring an entry.
14. The insertion of any body parts into equipment.
Exception: Blocking device is not necessary when movement is required to service, test or
repair, (e.g. set tolerances, adjust baffles etc.,) provided:
a) Written instructions approved by the Department Leader are issued to ensure effective
controls to prevent personnel injury.
b) The Safe Work Permit conditions are followed as per EH&S 5.3.
E. Physical Isolation:
15. All slip-blinds used to physically isolate equipment shall have a 'T' handle or shall be of spectacle
type and meet the standards of Appendix -E for the pressure, temperature and material of
construction. (Note: Spacer shall not have a ‘T’ handle.)
Exception: Blinds of the appropriate materials of construction that do not meet the requirements
of Appendix-E may be used when pressure on the process side is controlled at atmospheric
conditions only, with the approval of Department Leader.
16. ECP Issuers shall issue blind / disconnect lists for each job as appropriate, complete with size,
thickness, material of construction and pressure rating.
17. The blind / disconnect lists along with a marked-up P&ID shall be attached to the Master Card.
18. The person installing the blinds or performing physical disconnects shall follow and comply with
the blind / disconnect list provided.
F. Master Card:
19. Common Requirements:
a) For any repair / alteration work a Master Card (Appendix-B) shall be used. All sections in the
Master Card are completed and, if not applicable, are marked “NA”.
b) Master Card numbers shall be unique. A unit prefix is added to the number. Example: PE–
1234, etc. For CSE master cards, EPP system will add "CSE" to the number.
c) Red Tag numbers shall be unique and shall correspond to the Master Card.
d) Red Tags shall include text that says "Danger, Do Not Operate ". They shall also document
the location of the tag (where it is placed), the required position of the Isolating Device to
which the tag is attached, name (or employee number) of the person who placed the tag and
the date and who (Facility representative or individual) can remove the tag. Red Tag shall
also indicate whether or not it is a Personal Tag.

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e) Red Tags shall have a predominantly red background, except where the text is entered,
which can have a white background. The entered text shall be in black or blue lettering.
f) Red Tags shall be clearly visible, designed to remain legible and adequately attached
(using curtain hooks or cable tie) to prevent inadvertent removal.
g) Red Tags shall be attached to each isolation device to indicate energy isolation and
document energy isolation. Red tags shall not be used for any other purpose such as for
labeling of inactive equipment
h) Each Lock-Box shall have a lock and key identified with the Lock-Box number. The
identifying numbers on the lock-boxes and their respective locks and keys shall be legible.
i) Master Cards shall be reviewed when the Isolation is in place for more than 90 days to
determine:
1) If the Isolation is still being used for energy control within the scope of this standard. If
not, the Red Tags shall be replaced with permanent devices or signs and the Master
Card shall be closed.
2) If the Red Tags are still intact or not. If not, the Red Tags shall be immediately replaced
with new Red Tags.
This review shall be documented in Appendix-I of this procedure and attached to the Active
Master Card until the Master Card becomes inactive.
j) Job safety is ensured by the following:
1) Accountabilities for Master Cards shall be transferred across shifts with job assignments
from one Facility representative to another.
2) Tagged devices shall not be operated, moved or manipulated while the Master Card is
active unless a Temporary release is obtained.
20. Section-1 of the Master Card is completed by Facility representative.
21. “Tag/lock No.” and “Tags placed columns” in location list of ECP shall be completed by facility rep
after the equipment is isolated, cleaned and made safe for work.
a) Unit Locks, along with Red Tags, are used to isolate electrical or radioactive Energy
sources. If an electrical Energy source cannot be locked, additional steps are taken to
reduce the possibility of operation.
Examples:
1) Fuses removed.
2) Wires disconnected.
3) 240 volt and less circuit switches may be secured in the off position with adhesive tape.
b) The keys to the Unit Locks shall be placed in a lock-box. The Lock-Box is locked with a lock
bearing the number of the Lock-Box and its key is placed at a location identified by the
facility. The Lock-Box number shall be written on the Master Card.
c) Unit Locks shall be removed only after Personal locks, if used, are removed.
d) One-Plus shall be applied where there is a potential for inadvertent operation of the Isolating
Devices.
22. Section 3 of the Master Card (Verification of Isolation):
a) Before the start of work, a Facility representative shall conduct a review of the energy
Isolation. This reviewer shall also verify that the conditions defined by the Energy Control
Plan have been met.
b) Electrical Check- The integrity of an electrical isolation must be demonstrated by doing the
following:
1) The local or remote start/stop switch must be operated prior to work on an electric
motor or the driven assembly.
2) De-energization of electrical wiring/components must be confirmed by conducting an
electrical test using electrical sensors (such as Tic-tracer, Multi-meter, Clamp meter, etc.
c) The Facility representative preparing the equipment is to sign and date “Equipment is
Prepared for Work Described Above” after reviewing all energy Isolation points and verifying
their effectiveness.

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d) Prior to the start of work a Facility representative and the first Job representative shall
review the energy Isolation points. When satisfied that the equipment is properly de-
energized and isolated both the Job representative and the Facility representative shall sign
and date “The equipment is safe for work to proceed and job rep reviewed the isolations”.
23. Section 4 of the Master Card (Repair/Alteration activity):
a) Before starting work, all personnel assigned to the job must print name in section-4 of the
Master Card, identify the skill code and enter date and time. If necessary, a supplemental
sheet (Section 4A) is to be used. A contractor supervisor may sign for the persons working
for him.
b) If desired, the Job representative or any person who performs work can place Personal Tags
on selected Isolating Devices. Personal Tags can only be applied if Red Tags are already
placed by Facility representative. All the Personal Tags shall be documented on Personal
Tag and lock location list which is the Appendix-G. This location list shall be attached to the
Master Card.
c) If isolation involves electrical or radioactive sources, personnel assigned to the job may
place Personal locks on these sources or on the Lock-Box using a multiple locking device.
Personal locks can only be applied if Unit Locks are already placed by Facility
representative. Personal locks shall be documented in the Personal Tag and lock location
list (Appendix-G).
NOTE: Personal locks/Personal Tags are removed when:
1) The person leaves the plant site.
2) The work is completed.
3) The person is shifted to another assignment, even if temporarily.
d) All personnel assigned to the job shall complete section-4 daily until the job is completed.
Contractor supervisor may sign on and off for personnel working for him.
e) Before removing equipment from a unit to the workshop, the Red Tags shall be removed
from the equipment and shall be attached to the Master Card. The equipment is re-tagged
when it is returned to the unit. This activity shall be completed by a Facility representative.
24. Section-5 of the Master Card (Temporary release):
a) Initiating a temporary release: The following sequential steps shall be completed prior to the
removal of tags:
1) The reason for each Temporary release is stated in section-5 on the Master Card.
2) The involved Facility representative and job representative(s) shall mutually agree on
the following:
(i) The need for the Temporary release and its effect on the safety of the work being
performed.
(ii) Tags to be removed to facilitate testing.
(iii) Work, if any, that may safely continue during the Temporary release period.
3) The facility Shift Activity Coordinator signs the Master Card authorizing the Temporary
release in section-5.
4) Each Job representative shall notify each person in his group and have them remove
the necessary Personal locks and Personal Tags. The Job representative requesting
the Temporary release shall ensure that sign-off is done in section-4 in the ‘Job not
complete’ column. The Job representative shall then sign in Master Card section-5
indicating that this is done. Notification to all individuals is required; but only the affected
individual(s) must stop work.
5) After all required signatures are complete, the Facility representative shall:
(i) Inspect work area to ensure it is safe to energize, and
(ii) Remove necessary tags, One-Plus, Unit Locks indicating date and time and sign.
b) Closing a temporary release: The following sequential steps are completed before resuming
work:
1) The Job representative notifies all individuals working under the Temporary release that
the testing is complete and prints his name in Master Card section-5

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“Close release” column.

2) The Job representative notifies Facility representative that the Temporary release may
be closed.
3) Facility representative reinstalls all Red Tags, one- plus, and Unit Locks, notes date and
time and signs “Tags reinstalled” column in section-5.
Exception: Tags, one- plus, and Unit Locks are not required to be reinstalled if the
equipment has passed the tests and no additional work or rework is required on the
equipment. Temporary release shall be closed and Master Card shall be signed-off as
“Work complete” in Master Card section-3.
4) All job personnel sign-on in section-4, reinstall Personal locks and Personal Tags, if
used, and return to work.
G. Closing Master Card (Work complete):
c) All Personal Tags shall be removed and reconciled in Personal Tag and lock location list(s).
Any missing Personal Tag is to be documented on this list and reported through AICR.
d) All job personnel shall sign-off in “Job complete” column in section-4.
e) If the person whose name is in section-4 (and may have applied Personal Tag or Personal
lock) is not available to sign-off (or remove Personal Tag/lock), the individual may be signed-
off (tag/lock removed) by a Job representative provided:
1) Job representative has verified that the person is not in the plant, and
2) Reasonable effort has been made to contact the person, and
3) The Maintenance Work Activity Coordinator (WAC) ensures that the person is notified
of the action before the person resumes work.
f) After actions 'a)' to 'c)' above are completed, the Job representative shall sign and date
“Work complete” in section-3 after ensuring proper housekeeping. The Master Card shall be
considered inactive now.
g) All electrical grounds used for isolation shall be removed before removing any Unit Locks
and Red Tags from electrical isolation devices.
Exception: For the Polypropylene Main Substation Medium Voltage Switch Gears, where
built-in lockable grounding switches are installed, the lock & red tag may be removed prior to
opening the grounding switch.
h) The Facility representative shall inspect the job site for housekeeping and shall remove
necessary tags for testing to confirm the completion of work. When the testing is completed
and no additional or rework is necessary, all the remaining tags, if any, shall be removed and
reconciled in the ECP location list by him. The Facility representative shall sign in section-3
for “Equipment tested, de-tagged, and ready for service”. The Master Card shall be
considered closed now.
i) Before energizing any equipment, all personnel in the immediate work area shall be notified.
j) The Facility representative shall investigate for any missing tags and shall print the date and
shall write “Missing” in the “Sign” column under “Tags removed” section of the ECP
“Location list” for each unaccounted tag. He must report the missing tags through AICR.
k) If after testing, additional work or rework is necessary:
1) Red Tags and Unit Locks shall be reinstalled.
2) The Facility representative reviews Isolation of Energy sources with job representative.
3) The Job representative signs again in section-3 against “Additional work”. The Master
Card becomes active here again.
H. Special Requirements:
25. Confined Space Entry:
a) Isolation of Energy sources shall be completed before:
1) Installation / removal of slip blinds, disconnects.
2) Reconnection of lines to prepare and to return equipment to service.
b) Following additional tagging is done:
1) Physical entry – All connections to the process are physically isolated using blinds and
disconnects. Tagging of the Physical Isolation points shall be done using Red Tags.

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These tags shall be listed in a separate Energy Control Plan which shall be attached to
a Master Card stamped “Confined space entry”.
2) If used for Physical Isolation, existing slip blinds shall be removed, inspected and
reinstalled before the attachment of Red Tags.
c) Isolation requirements as specified by EH&S 5.4 - "Confined Space Entry" shall also be
followed.
26. Welding or flame cutting: The following actions are taken prior to welding or flame cutting:
a) Procedure actions C.2.a through C.2.d of this standard shall be completed.
b) All connections to the process shall be physically isolated using blinds or physical
disconnects. Red Tags shall be installed on the Physical Isolation points.
Exception: Physical Isolation may not be necessary when the Department Leader approves
specific written instructions that include the following:
1) Valves or other methods employed to isolate lines / equipment from all connected
processes are secure and effective.
2) The atmosphere of the subject piping/equipment is tested with approved and calibrated
flammable gas meter.
27. Line Openings for Flammables and Combustibles: For all line or equipment openings that
contain a flammable material or a combustible liquid, grounding continuity shall be ensured for:
a) Flammable systems which are not purged prior to opening or are still in service.
b) Opening of any piping/equipment containing flammables that cannot be drained and vented
(for example: dead legs or dead ends).
c) Systems that contain solids that could trap flammable liquids or vapors.
d) Openings where there is a history of flammables remaining in the system even after purging.
28. Isolation of radiation sources: If the line or equipment to be opened is fitted with instrumentation
containing a radiation source (such as for monitoring level or density), the shutter shall be locked
and Red Tagged in the closed position when the line or equipment is prepared for opening and
shall be confirmed closed.
29. Entry into Sequence Batch Reactors (SBR) in Waste water system: The entry into SBR without
completely draining and blinding is allowed with all the following additional precautionary
measures:
a) Confined space entry permit shall be used for entry into tank and the worker shall stay in
man-basket or on the floating platform during maintenance.
b) Harness shall be used during the entire period of entry.
c) Procedure, approved by the Department Leader, specific for this job shall be provided which
includes details of Isolation, potential hazards, methods to mitigate hazards and PPE
required.
30. Entry into excavation pits (Confined space entry) for the repair of underground fire water lines is
allowed with single isolation where it is not feasible to insert a blind or disconnect a spool when
the isolation method adopted is One-plus and there is no leakage of fire water inside the pit.
31. Sawing or Cutting lines: Each side of the cut shall be identified by the placement of red tape or
red ribbon.
32. Double Isolation Requirements:
a) Double Isolation is required for isolation against process materials, when all the following
conditions occur:
1) The equipment contains a highly flammable or Class III Toxic Chemical as given in
Appendix F.
2) Line size is greater than 3/4 inch.
3) Potential release quantity is greater than 2200 kg. for highly flammable chemical or
greater than 230kg for a Class III toxic chemical.
b) Acceptable double isolation methods include:
1) Valve and blind flange or slip blind. The valve can be a remotely operated valve with a
mechanical means for holding the valve shut or manual valve.

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2) Two valves.
3) Double valve and vent.
Exception: Double isolation is not required if the only method to achieve double isolation is
the use of a blind flange or slip blind and the job will take less than two hours (nominal time
to install the blind flange or slip blind). This does not apply to isolation for Confined Space
Entry; this procedure has its own requirements.
33. Fire Protection, Deluge and Sprinkler Piping: A sketch of the piping removed is made to ensure
proper nozzle and piping location during reinstallation by the job representative.
34. If a job requires equipment in other units to be tagged, signature of the other unit Facility
representative must be documented in Master Card section-2 before placing tags.
35. Locks and tags defined in this standard shall not be used for any purpose other than what is
specified.
I. Self-Assessment: Each Facility shall conduct monthly self-Assessment using Appendix-D. The
person(s) conducting this self-assessment shall have the same level of training as a Facility
representative. Facility Shift EH&S Coordinator shall review the deficiencies with the individuals
involved.
J. EPP (Electronic Permitting Processing) System shall be primarily used for all master card related
activities.
II. Documentation requirements:
The following documentation shall be available:
1. Energy Control Plans
2. Documented list of people that are authorized to be Facility Representatives for the Facility.
3. Documented list of people that are authorized to be Job Representatives for the Facility.
4. 90-Day Master card review.
III. Record keeping requirements:
Records that are created and/or maintained in order to meet the requirements of this procedure shall meet
EQUATE's Record Retention Requirements. These records include, but are not limited to:
1. Master Cards: Inactive Master Cards are retained for a period of 7 days.
2. Red Tags: Red Tags associated with inactive Master Cards are not retained.
IV. Audit and Self-assessment:
Each Facility shall conduct monthly self-Assessment using Appendix-D. The person(s) conducting this self-
assessment shall have the same level of training as a Facility representative. Facility Shift EH&S
Coordinator shall review the deficiencies with the individuals involved.
V. Training Requirements:
A. Training shall be provided to following EQUATE employees:
36. Safe Work Permit issuers
37. ECP Issuers.
38. Facility representatives.
39. Job representatives.
40. Process Activity Coordinators
41. Maintenance Work Activity Coordinators
42. Other personnel as determined by Department Leader.
B. Contractor personnel who are required to act as job representatives shall receive training in this
procedure. All other contractor personnel shall receive overview of this procedure.
C. Training or overview shall be provided to all other EQUATE personnel as determined by their respective
Department Leaders.
D. Refresher training shall be provided every 3 years or when any major revisions take place in this
procedure.

VI. Roles and Responsibilities:

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Role Responsibilities

Department Leader 1. Delegates authority to, and documents the list of people authorized
as Facility representatives.
2. Ensures that Isolation of Energy sources is implemented for any
Repair/Alteration work.
3. Provides and maintains a list of persons authorized to issue an
ECP.
4. Ensures monthly self-assessments on this standard are carried out.

Facility 1. Ensures that an Isolation of Energy sources is implemented for all

Representative Repair/Alteration works.
2. Ensures that all persons doing work under the isolation have control
of all Isolating Devices and that all Isolating Devices are identified
and documented.
3. Isolates the Energy source s, documents the location of all Isolating
Devices, places Red Tags on the equipment and verifies the
isolation.
4. Ensures that all Personal Tags are removed and that all persons
doing work under the isolation have signed-off before removing and
reconciling the Red Tags from the Isolating Devices.
Job Representative 1. Ensures that an Isolation of Energy sources is implemented for all
Repair/Alteration works.
2. Evaluates the hazard potential for each job and communicates the
same to his group.
3. Reviews the Isolation of Energy sources with Facility representative.
Verifies isolation points as per location list (in ECP).
4. Places Personal Tags on isolation points, if desired by him.
5. Ensure that all Personal Tags and Personal locks are removed
before signing off section-3 as work completed

Reliability & 1. Provides training to contractor personnel as per the training

Maintenance requirements in this standard.
Department 2. Provides a means to identify the level of training received by the
contractor personnel going to different units.

VII. Implementation Guide: N/A

VIII. Practice & Guidance: See Frequently Asked Questions

 Document History
Approved by :   EH&S department leader.                               Date :  25-Aug-10
The following information documents at least the last 3 changes to this document, with all
changes listed for the last 3 months (most current is first).

ReviewActivity
Date by Activity

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Revise Date Activity by Activity

30-Mar-16 Bhanu Included requirements for marked-up

P&ID for physical isolations and modified
requirements for repair of underground
firewater lines.

MOC No: EHS-30Mar2016-29624

2-Aug-15 Bhanu Reviewed. No changes required.

3-Aug-10 Bhanu Added Appendix-I to document 90-day

master card reviews. Red tag
requirements modified.
MOC# EHS-21Aug2010-5027

13-Dec-09 Bhanu Changed to L3E format

APPENDIX-A
Exceptions to the scope: Requirements of this standard do not apply to the following:
A. Work on electrical components not feasible to isolate due to equipment design or nature of work (for
example, trouble shooting). Work on energized electrical equipment is covered by electrical hot work
procedures governed by EH&S 5.5.
B. Servicing of essential fire protection equipment such as fire alarms and deluge system, if an
appropriate alternate method protects workers from an unexpected release of hazardous energy. If
the service results in the loss of fire protection equipment function, the requirements apply.
C. Work on equipment which is de-energized by un-plugging or disconnection (examples: electrical or
pneumatic Energy sources), provided that:
1. The connection is under direct control of the person performing the work, and;
2. The disconnected Energy source is the only Energy source that needs to be isolated, and;
3. The user understands the hazards of the Energy sources and applies appropriate
safeguards.
D. Electrical equipment which is under the direct control of public utility provider.
E. Construction jobs which are completely isolated from process equipment and have no potential
hazards. The jobs need to be reviewed on a case-by-case basis with personal safety engineer.
F. In-service equipment work when there is a written procedure and all the following criteria are met:
1. Work by nature is minor, routine, repetitive and integral to process.
2. The equipment must be energized to perform work.
3. The removal of safety guard or safety device is not required.

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4. A person’s body part is not placed in an area where personnel could be injured by
energized equipment during Repair/Alteration activity.
G. When the person doing the work controls access to the energy Isolation Devices by remaining within
sight and arm’s reach of the Isolation Device(s). This exception applies when all of the following
criteria are met :
1. The equipment is prepared as per written instructions.
2. Do not exceed a maximum of 15 Isolation Devices.
3. The energy Isolation Devices are within sight and arm’s reach of a single person performing
the Repair/Alteration continuously through completion.
4. The energy Isolation Devices are designed and located so as to prevent accidental
operation or energization of equipment by a passerby or the person working on the
equipment (for example quick open valve or electric switch that could be bumped open or
switched ‘ON’).
5. The equipment is isolated by the worker performing the work or is isolated in his presence to
ensure the worker understands the Isolation boundaries.
6. The isolated equipment is not left unattended by the worker. If it becomes necessary for the
worker to leave the equipment, all requirements of this standard apply.
7. Job does not involve SRD deactivation. (Ref. EH&S 7.6 procedure).
H. Hot tapping (Ref. EH&S 5.8 procedure).
I. Inactive equipment that is permanently disconnected from Energy sources (Ref. HSE 7.4 standard)
J. Minor tool changes and adjustments (examples: changing drill bits, adjusting router heads, changing
saw blades, etc...), provided that:
1. They are routine, repetitive and integral to the use of the tool, and;
2. The Energy source (examples: electric or pneumatic) are under direct control of the person
performing the change or adjustment, and;
3. The user understands the hazards of the Energy sources and applies appropriate
safeguards.

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LINKS TO OTHER APPENDICES.

APPENDIX-B (MASTER CARD)
MCformat(App B).xls

APPENDIX-C (ECP)
ECP Form

APPENDIX-D (SELF ASSESSMENT)

Master Card SA

APPENDIX-E (BLIND SPECIFICATIONS)

Blind specifications (App E).doc

APPENDIX-F (CLASS III HIGHLY FLAMMABLE/TOXIC CHEMICALS)

Highly flammable chemicals App F.doc

APPENDIX-G (PERSONAL LOCK AND TAG LOCATION LIST)

Personal red tag and lock location list - App G.doc

APPENDIX-H (INFORMATION TO THIRD PARTY WHILE DELIVERING EQUIPMENT)

APPENDIX-I (90-DAY MASTER CARD REVIEW)

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