Aramco CS LOTO Awareness Course at Dhahran .pdf

Aramco CS LOTO Awareness Course

1. Saudi Aramco: Company General Use
Note to Dept: This presentation is intended to be adapted
to the Dept’s own LOTO process and arrangements
Note to Presenter:
❖Use the Speakers Notes
❖Go to ‘View’ & then ‘Notes Page’

2. Saudi Aramco: Company General Use

3. Saudi Aramco: Company General Use

4. Saudi Aramco: Company General Use
Objectives -What You Will Learn
1)Where to get further information
2)CS Training Requirements
3)Common CS Violations Noted
4)Aramco Standards & References
5)Definitions
6)Responsibilities
7)General Requirements (Equipment Isolation)
❑Proponent LOTO Procedures/Process
❑Isolation Plan
❑Lockout Devices & Equipment To Provide
8)Group lockout requirements
9)Emergency removal of lockout devices
10)Process piping & equipment isolation methods

5. Saudi Aramco: Company General Use
Where to get further
information?

6. Saudi Aramco: Company General Use
CS SharekWebpage
Community Services

7. Saudi Aramco: Company General Use
Where to get further info
❑Aramco Internet Websites (LP & EP)
❑CS Sharek
❑CS Departments
❑Safety Officers
❑CS Safety Coordinators

8. Saudi Aramco: Company General Use
The 11 SMS Elements

9. Saudi Aramco: Company General Use
CS Training
Requirements

10. Saudi Aramco: Company General Use
CS Training Matrix

11. Saudi Aramco: Company General Use
CS Training Requirements
❑All Electrical Engineers & Technicians must be trained, certified and
authorized to work in CS by Division Managers
❑They must complete the training stated on the CS Training Matrix
❑Names of Authorized Electrical Workers posted on plant rooms and
electrical room doors.
❑Checked by Facility Supervisor before allowed entry.
❑Not an Authorized Worker -then no entry allowed
❑Door key controlled as part of LOTO
❑Those working on, or near, above 240V must be trained and
certified as per Arc Flash GI

12. Saudi Aramco: Company General Use
Job Orientation
❑The employee mustreceive proper job orientation before he starts
work. Following this orientation you must receive site specific safety
orientationby your company.
❑Project Manager & Safety Officer
to action.

13. Saudi Aramco: Company General Use
Tool-Box Talk Meetings
❑Given by Foremen or Safety Officer
❑10-15 minute short safety talks,
❑Relating to ongoing work and hazards

14. Saudi Aramco: Company General Use
First Aid Training
❑Confirm that at least one (1) member of each crew has obtained
training and certification in first aid and basic life support (BLS) prior
to conducting electrical work.
❑Buddy system -No lone working

15. Saudi Aramco: Company General Use
Electrical Workers High Risk For
Death & Injury
❑Example -in USA, 31% of all job related deaths were electrical
workers (98% died from electrocution).
❑Each day you set off to work, youhave to actively plan your safety
or you can be injured for life, or die.

16. Saudi Aramco: Company General Use
1
st
Degree burns create red
or pink colored marks on the
skin. They are mildly painful
and will generally heal
without leaving a scar.
First Degree Burns

17. Saudi Aramco: Company General Use
2
nd
Degree burns form fluid
filled blisters. They are very
painful, require medical
treatment, can easily become
infected and may leave a
permanent scar.
Second Degree Burns

18. Saudi Aramco: Company General Use
❑Skin is often completely burned
away exposing flesh beneath.
These burns require long medical
treatment including skin grafts.
❑They are likely to become
infected, lead to other medical
problems and always leave
permanent scars
Third Degree Burns

19. Saudi Aramco: Company General Use
Video -Watch Out

20. Saudi Aramco: Company General Use
Stop Work & Right to Refuse Work Due
to Unsafe Conditions

21. Saudi Aramco: Company General Use
Common CS Violations Noted
A violation is a deliberate deviation from a rule or procedure and
usually happens because of a desire to carry out the job despite
barriers such as work or time pressures, lack of staff, unavailability of
the right equipment or tools, and/or extreme weather conditions.

22. Saudi Aramco: Company General Use
CS LOTO Violations Noted
❑Department Process Owner responsible to have Register of all
indoor and outdoor equipment subject to LOTO
❑Different CS Department Processes –workers not familiar
❑Areas with no LOTO with Locks & Tags missing

23. Saudi Aramco: Company General Use
CS LOTO Violations Noted
❑Facility Supervisors not inspecting and enforcing LOTO
❑No Register of who entered as the Authorized Workers
❑Lack of room key control -unlocked doors often seen
❑Not able to lock as no lever or clasp, or damaged (report it)

24. Saudi Aramco: Company General Use
Common Mistakes By Electrical
Workers
❑Ignorance of LOTO Procedure (not familiar with it).
❑Not following the Procedure.
❑Not using LOTO if job takes a short time.
❑Asking another worker to shut off equipment and to apply locks.
❑Just locking off the control circuit and not verifying the lock off of
main supply disconnect or switch.
❑Leaving keys in the Lock.

25. Saudi Aramco: Company General Use
Aramco Standards &
References

26. Saudi Aramco: Company General Use
Aramco Standards & References
❑Construction Safety Manual (CSM) Part I –Chapter 05
❑G.I. 6.012 (LOTO)
❑GI 2.100, Work Permit System
❑GI 2.600, Plant / Unit Acceptance after T & I Shutdown
❑G.I. 2.721 (Electrical Arc Flash Hazard Mitigation)
❑Safety Handbook 11-Electrical Safety, Pages 46-49

27. Saudi Aramco: Company General Use
Definitions

28. Saudi Aramco: Company General Use
GI 6.012 Definitions
Check the GI for the full list. Be familiar with these:
❑Authorized Personnel: Personnel who have the experience and
training in isolation, lockout and hold tag processes, and who apply
isolation and lockout devices and tags on equipment or operating
processes in order to perform servicing or maintenance.
❑Hold Tags: Warning devices affixed to energy isolating devices to
communicate the reason and authorization of the isolation.
❑Isolation: The process by which systems, equipment or machines
are removed from service and completely protected against the
release of energy and/or hazardous or injurious material from the
equipment/machine.

29. Saudi Aramco: Company General Use
GI 6.012 Definitions
❑Isolation Plan: A detailed and approved document that lists all
relevant energy isolations, their locations, the sequence in which
they are to be completed, and the steps / measures required to
safely complete the isolations.
❑Lockout: The placement of a lockable device on an energy
isolating device, in accordance with an established procedure, to
ensure that the energy isolating device and the equipment or
process being controlled cannot be operated until the lockable
device is removed.

30. Saudi Aramco: Company General Use
4 Step Process
This is a distinct 4-step process:
❖LOCK
❖TAG
❖CLEAR
❖TRY
To ensure that the equipment is properly isolated.

31. Saudi Aramco: Company General Use
Responsibilities

32. Saudi Aramco: Company General Use
CS Department Directors,
Division Managers & Supervisors
❑Develop isolation, lockout, and hold tag procedures for their
operations.
❑Develop a department specific isolation, lockout and hold tag
process that will satisfy the requirements of the GI.
❑Specific equipment/process isolation procedures shall be
incorporated into departmental instruction manuals, as necessary.

33. Saudi Aramco: Company General Use
CS Department Directors,
Division Managers & Contractor’s
Supervisors
❑Train relevant personnel in all elements of the organization’s
isolation, lockout, and use of hold tag program.
❑Before being allowed to conduct electrical work, ensure workers
pass the T&D Lockout Tagout Course (BET #40069962)
❑Ensure this T&D course has been successfully completed by all
Work Permit Issuers, Receivers and Designated Representatives as
required by GI. 2.100, Work Permit System.
❑Provide necessary lockout devices and equipment to employees.

34. Saudi Aramco: Company General Use
All Employees -You!
❑ImplementfullytheLOTOprocedures
❑Reportallincidents,nearmisses,andsafetyobservations(e.g.,
unsafeconditionsandunsafeacts)
❑Correctorreportunsafeactsorconditions.
❑Reportanyproblemsnotedwithunsecureplantroomdoors

35. Saudi Aramco: Company General Use
Refresh-Remind-Repeat
1)Where can you get information on LOTO?
2)What training is mandatory for electrical workers?
3)What are the common CS LOTO violations?
4)What are responsibilities of the contractor Supervisor?
5)What are the hazards to electrical workers if LOTO not
implemented?
6)What can you do if you do not have correct testing devices,
locks or tags provided?

36. Saudi Aramco: Company General Use
Refresh-Remind-Repeat
1)Where can you get information on LOTO?
•CS Sharek, Dept Safety Coordinators & Safety Officers
2) What training is mandatory for electrical workers?
•Work Permit Receiver training, this Course, 1 day T&D
Classroom LOTO Course
3)What are the common CS LOTO violations?
•Unlocked Plant Room doors, LOTO not implemented,
wrong procedure use, unauthorized or untrained
workers,

37. Saudi Aramco: Company General Use
Refresh-Remind-Repeat
4) What are responsibilities of the contractor Supervisor?
•Provide Isolation Plan, ensure staff all trained in LOTO,
provide testing devices, locks & tags
5) What are the hazards to electrical workers if LOTO not
implemented?
•Electric shock or burns. Death
6) What can you do if you do not have correct testing devices,
locks or tags provided?
•Stop Work -refuse to do the work until Supervisor
provides correct equipment.

38. Saudi Aramco: Company General Use
Break
Be Back On Time!

39. Saudi Aramco: Company General Use
General Requirements
(Equipment Isolation)
❑Proponent LOTO
Procedures/Process
❑Isolation Plan
❑Lockout Devices & Equipment
To Provide

40. Saudi Aramco: Company General Use
Exceptions to GI 6.012
This instruction does not apply to situations involving work on cord and
plug equipment when the cord is unplugged from the energy source and
under the exclusive control of the person performing the work.

41. Saudi Aramco: Company General Use
4 Steps: Lock -Tag -Clear -Try
This is a distinct 4-step process (LOCK, TAG, CLEAR & TRY) to
ensure that the equipment is properly isolated.
1)LOCK: Equipment shall be electrically isolated and lockout/lockable
devices installed
2)TAG: Hold tags installed for each lockout device (TAG).
3)CLEAR: Work area cleared of equipment and affected personnel
4)TRY:Test isolation of equipment to determine and verify the
effectiveness of the lockout device and that all residual energy has
been removed. Ensure controls cannot be moved to the “on” or
“open” position.

42. Saudi Aramco: Company General Use
Saudi Aramco LOTO Steps
Lock
Tag
Clear
Try
Prepare
Shutdown
Isolate
Apply

43. Saudi Aramco: Company General Use
Isolation Plan
❑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
❑All necessary isolation and blinding equipment/devices (locks, tags,
properly rated blinds, etc.) shall be made ready and inspected
before commencing work.

44. Saudi Aramco: Company General Use
Isolation Plan -Refer to CS Sharek

45. Saudi Aramco: Company General Use
❑Eachlockshallbekeyedseparately,withnoduplicatekey,to
ensureremovalonlybytheauthorizeduser.
❑Eachorganizationissuinglocksshallhaveasystemofuniquely
identifiedlocks.Acceptablemethodsincludecolorcoding,stamping
orengravinglocksappropriately.
❑Proponentorganizationsshallalwaysbethefirsttoinstallalock
andtagonapieceofequipmentandthelasttoremovethem.
❑Thislockandtagshallnotberemoveduntilproponentpersonnel
havecheckedandexaminedequipmenttoensureitcanbesafely
energized.
❑Nopadlock/lockoutdeviceshallbecutorforcefullyremoved,without
thepermissionofthelockowner'ssuperintendentortheoperations
shiftsuperintendent.
Lock

46. Saudi Aramco: Company General Use
LOTO
LOCKED ISOLATION SWITCH LOCKED CIRCUIT BREAKE R

47. Saudi Aramco: Company General Use
LOCKOUT EQUIPMENT
LOCKOUT CLIPS (HASPS)
CIRCUIT BREAKER
LOCKOUT

48. Saudi Aramco: Company General Use
COLOR CODED PADLOCKS
LOCKOUT KIT WITH
POUCH
LOCKOUT & TAG EQUIPMENT

49. Saudi Aramco: Company General Use
A tag (Saudi Aramco Form 525) shall be installed on each lock
indicating:
❑Plant number or location
❑Date and time of isolation
❑Equipment name
❑Reason for the lockout
❑Individual’s name, badge number, organization,
contact phone number and signature.
Tag

50. Saudi Aramco: Company General Use
Tags
All locked equipment shall be tagged using SA Form 525 as
below
LOCKOUT/HOLD TAGS
FRONT
BACK

51. Saudi Aramco: Company General Use
❑Work area cleared of equipment
❑Work area cleared of affected personnel
❑Ensure the normal workers are told that the equipment is to be
disconnected and not to try to reconnect it
❑Ensure the Plant Room door is kept locked when electrical workers
leave it (someone who comes in may try to switch the energy supply
back on again).
Clear

52. Saudi Aramco: Company General Use
Isolation
❑Isolation will have been completed only when no associated control
device, such as a push button, control interlock or automatic start-up
control circuit, has the capability of energizing the equipment.
❑In situations where it is not possible to apply a lockable device to an
isolating source, isolation may be accomplished by the removal of
fuses, disconnection of electrical cables, or physical removal of a
component of the system supplying energy to the equipment.

53. Saudi Aramco: Company General Use
Electrical Equipment Isolation
If lockout or chain and lock is not possible:
❑Remove fuses.
❑Disconnect electrical cables.
❑Physically remove a component.

54. Saudi Aramco: Company General Use
Isolation
❑The point of physical interruption shall be identified with a fully
completed hold tag.
❑When isolation has been completed the proponent organization
shall ensure the removal of any residual energy.
❑Proponent organizations shall identify if other departments / parties
may be affected by the electrical isolation(s) and seek their
concurrence on corresponding work permits.

55. Saudi Aramco: Company General Use
Energy or Substance Isolation
Examples of energy or substances that requires LOTO:
❑Electrical
❑Mechanical
❑Steam
❑Hydraulic
❑Pneumatic
❑Chemical

56. Saudi Aramco: Company General Use
LOTO Removal Procedure
Confirm equipment may
be safely
re-energized
Notify Affected Personnel
Remove Lock-out / Tag-
out devices

57. Saudi Aramco: Company General Use
Try
❑Eachenergyisolatingdevice,suchasadisconnectswitch,shallbe
physicallytestedbytheproponentorganizationbymovingits
operatingmechanismagainstthelockoutdevicetoconfirmthatit
cannotbeoperated.
❑Themaintenance/contractoremployee(s)performingservicingor
maintenanceshallverifythatisolationandde-energizationofthe
machineorequipmenthavebeenaccomplished

58. Saudi Aramco: Company General Use
Shift Change
Whenashiftchangeoccursandworkhasnotbeencompleted,the
oncomingshiftmayeither:
❑Replacethepreviousshift’slocksandtagswiththeirown,in
whichcasetheoff-goingshiftshallremovetheirs.
Or
❑Transferkeysbetweenshifts.RefertoGI6.012(6.7.2)for
specificrequirements.

59. Saudi Aramco: Company General Use
Electrical Test Equipment
❑High quality, calibrated electrical test equipment must be provided
and used.
❑Mandatory –if no Tester –Stop Work
❑Their purpose is to save your live, or prevent injury
❑They are your most important PPE

60. Saudi Aramco: Company General Use
Testing Devices
Anyelectricaltestingequipmentthatisdamaged,malfunctioning,orhasa
calibrationstickerthatisout-of-date,missingorcan’tbereadmustbe
removedfromserviceandrepairedorre-calibratedbeforeit’sused
again.

61. Saudi Aramco: Company General Use
Anytoolsortestequipmentusedmustberatedfordirectcontactat
thevoltageandenergylevelinvolvedandmustbeincludedinthe
approvedIsolationPlan.
Tools & Equipment

62. Saudi Aramco: Company General Use
Department LOTO Procedures
❑YoumustknowthespecificLOTOproceduresforwhereyouwork
❑YourSupervisorMUSTtrainyouinthosespecificprocedures
❑DifferentCSDepartmentshavetheirownprocedures
❑Example-ifyouworkinU&FSD,youmustalsobeshownthe
proceduresforOSDandCCSDifyouworkintheirfacilities.

63. Saudi Aramco: Company General Use
Work Permit Types
CS uses the following work permit types:
❑Hot Work Permit
❑Cold Work Permit
❑Confined Space Entry Permit
Refer: G.I. 2.100 (Work Permit System) & the Safety Handbook

64. Saudi Aramco: Company General Use
Work Permit Issuance
❑CSstaffwillissuethePermits(WorkPermitIssuers)
❑ContractorswillbetrainedasPermitReceivers
❑PermitReceiversmustremainonsiteifPermitisopen.
❑ForemenarenottosendtheirPermitReceiveroffsiteorthePermit
willhavetobecancelledandtheworkstopped.
❑ThePermitmustbefollowedcarefullyorsomeonecouldbeinjured,
ordie
❑ItisaserioussafetyviolationtonotfollowtheWorkPermit
requirements

65. Saudi Aramco: Company General Use
Work Permit Audits
❑Monitoring, audit and review enables an organization to confirm
that it actually does what it says it does, and that this is what it
should do.
❑Check the department’s specific LOTO procedure for that facility or
equipment
❑Is there an Isolation Plan?

66. Saudi Aramco: Company General Use
Group Lockout
Requirements

67. Saudi Aramco: Company General Use
Group Lockout
Whenlargenumbersofpersonnelareinvolvedinperforming
maintenanceorservicingactivities,agrouplockoutcanbeusedto
avoidlargenumbersoflocksandtagsonisolationpoints.
❑AProponentrepresentativeshalllockandtageachisolationpoint
withsingle-keyedlocks.
❑Themaintenance/constructionsupervisorshallalsolockandtag
eachisolationpoint.

68. Saudi Aramco: Company General Use
Group Lockout Box
❑The maintenance/construction supervisor’s key(s) shall be placed
in the “group lockout” box.
❑The Proponent representative shall install his lock and tag on the
group lockout box first and maintain possession of his key(s) until
the job is complete.
❑Each member of the maintenance/construction crew places his
lock & tag on the group lockout box. Each shall keep their key
until the job is complete

69. Saudi Aramco: Company General Use
Emergency Removal Of
Lockout Devices

70. Saudi Aramco: Company General Use
Emergency Removal of LOTO Devices
No lockout device shall be cut or forcefully removed without the
permission of the lock owner’s Proponent superintendent, or the
operations shift superintendent.

71. Saudi Aramco: Company General Use
Emergency Removal of LOTO Devices
The following steps shall be followed and documented:
1)The proponent organization superintendent / shift superintendent
will attempt to contact the individual who installed the lock, or his
supervisor, to confirm that the work is complete, that the employee
is safe and that the lock can be removed.
2)If the individual, his supervisor, or superintendent cannot be
contacted, the superintendent/ shift superintendent may remove the
lock and tag only after reviewing the equipment/process to be
energized, to ensure that personnel and facilities are safe from
injury or damage.

72. Saudi Aramco: Company General Use
3) The shift superintendent shall verbally advise the proponent
organization Division Manager of the action taken and record the
removal of the lockout device in the shift log book.
4) He will then document the incident in a written memo to the
proponent organization Division Manager explaining why the lockout
device was removed, the original purpose or the lockout device, and the
employee involved.
Emergency Removal of LOTO Devices

73. Saudi Aramco: Company General Use
Process Piping & Equipment
Isolation Methods

74. Saudi Aramco: Company General Use
Blocking
Single block valves:
❑Fully close the valve.
❑Attach chain, lock, and tag.
❑Safely drain fluid from pipe line.
❑Test the valve for leakage.

75. Saudi Aramco: Company General Use
Blocking
Double block & bleed:
❑Lock and tag the two consecutive valves on the same line.
❑Open drain valve, check for passing.
❑Not acceptable as isolation method for confined spaces.

76. Saudi Aramco: Company General Use
Blinding
❑A solid metal plate between two pipe flanges or on the end of a
disconnected pipe.
❑Blinds must be rated for potential internal pressures.
Three important criteria are:
❑Size.
❑Pressure Rating.
❑Location.

77. Saudi Aramco: Company General Use
Blinding
Blinds are used for piping and equipment isolation.
❑Individually identify blinds on a blind list.
❑Protect blind mating surfaces.
❑Only use matching gaskets.
❑Acceptable method for confined space entry.
Slip Blind Full face blind

78. Saudi Aramco: Company General Use
Disconnecting Or Removing Sections
Of Lines & Pipes
Disconnect:
❑Acceptable method for confined space entry.
❑Long term maintenance method.
❑Use if a fully rated blind cannot be fitted.
❑Drain and purge the line.
❑Check for hazardous materials leak.

79. Saudi Aramco: Company General Use
Refresh-Remind-Repeat
1)What is the most important PPE?
2)What is the main Aramco procedure for LOTO?
3)What are the 4 Steps?
4)What should be in the Isolation Plan?
5)What are the Lock rules?
6)Explain requirements for Try.
7)What are the rules for Test Equipment?
8)Whose LOTO Procedures should you use?

80. Saudi Aramco: Company General Use
Refresh-Remind-Repeat
1)What is the most important PPE?
•The correct Testing Device
2)What is the main Aramco procedure for LOTO?
•GI 6.012
3)What are the 4 Steps?
•Lock –Tag –Clear -Try
4)What should be in the Isolation Plan?
•Identify all locations to be isolated, types of isolating
devices to be used and site/job-specific procedures for
isolating the equipment

81. Saudi Aramco: Company General Use
Refresh-Remind-Repeat
5) What are the Lock rules?
•No duplicate key, unique marking on lock, proponent rep adds lock
first and removes it. Not cut off without permission of lock owner’s
Proponent superintendent, or the operations shift superintendent.
6) Explain requirements for Try.
•Disconnect switch physically tested by the proponent by moving its
operating mechanism against the lockout device to confirm that it
cannot be operated. Then use testing device.
7) What are the rules for Test Equipment?
•Must be correct device for voltage & energy levels, must not
malfunction, calibration in date
8) Whose LOTO Procedures should you use?
•Correct proponent’s for that building/facility

82. Saudi Aramco: Company General Use
Where to get further info
❑Aramco Internet Websites (LP & EP)
❑CS Sharek
❑CS Departments
❑Safety Officers
❑CS Safety Coordinators

83. Saudi Aramco: Company General Use
CS SharekWebpage
Community Services

84. Saudi Aramco: Company General Use