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M&C-M Procedure

PRO-4.5-0001-1-02
Energy Isolation
HSE Manager – Midstream, Network
Document Owner: Janelle Shackley
Solutions & OMS
HSE Manager – Midstream, Network
Approved By: Janelle Shackley
Solutions & OMS
HSE Specialist - Control of Work and
Prepared By: Adrian Connolly
Contractor Management
Document Status: Active Version 5
Approved Date: 15-Dec-23 Review By: 15-Dec-28

Purpose
Whenever BP conducts construction, maintenance, demolition, remediation and other similar work
that are typical of our industry, there is the potential for harm to people and the environment and for
damage to equipment. This document provides requirements for the isolation of energy systems in
support of PRO 4.5-0001-0-01 Control of Work. Energy Isolation is a key component of the system of
work that allows tasks to be completed safely and without unplanned loss of containment with the
potential to cause environmental damage or to damage a plant or equipment.

This procedure sets out a required approach to isolation of energy systems in accordance the Life
Saving Rules, and the requirements of GDP 4.5-0001 Control of Work.

Relevant OMS element(s)

OMS 4.5 (Control of Work

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Contents
Purpose .......................................................................................................................................... 1
Relevant OMS element(s) ........................................................................................................ 1
1. Scope .................................................................................................................................... 5
2. Methodology ........................................................................................................................ 5
2.1. General ............................................................................................................................ 5
2.2. Mechanical Isolation ....................................................................................................... 6
2.2.1. Positive Isolation 6
2.2.2. Valve Isolation 7
2.2.2.1. Double Block and Bleed 7
2.2.2.2. Single Valve 7
2.2.2.3. Valve Actuators 8
2.2.2.4. Isolation of other Energy Sources 8
2.2.3. Steps in Performing Mechanical Isolations 8
2.2.3.1. Identify 9
2.2.3.2. Isolate 9
2.2.3.3. Secure 9
2.2.3.4. Discharge 9
2.2.3.5. Test 9
2.3. Electrical Isolation ......................................................................................................... 10
2.3.1. Key Considerations 10
2.3.2. Steps Performing Electrical Isolation 10
2.3.2.1. Identify 10
2.3.2.2. Isolate 10
2.3.2.3. Secure 11
2.3.2.4. Discharge 12
2.3.2.5. Test 12
2.3.3. Interlocks and Automatic Starting of Equipment 12
2.3.4. ‘Try’ Step 13
2.3.5. Cutting of Electrical Cables 13
2.3.6. Opening of Enclosures 13
2.4. Working On or Near Live Electrical Equipment ........................................................... 14
2.4.1. Key Considerations 14
2.4.1.1. High Energy Installations 14
2.4.2. Safeguards 14
2.4.2.1. Assessment 14
2.4.2.2. Stand-by Person 15
2.4.2.3. Competency 15
2.4.2.4. Precautions 15
2.4.2.5. Safety Apparel (PPE) for Electrical Work 15
2.4.2.6. Earthing 16

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2.4.2.7. Neutral Connections 16

2.4.2.8. Barriers & Insulation Mediums 16
2.4.3. Fault Finding 16
2.4.4. Electrical Test Equipment 16
2.4.4.1. Key Considerations 16
2.4.4.2. Requirements for Electrical Test Equipment 17
2.4.4.3. Prohibited Electrical Testing Equipment 17
2.5. Powered Fixed Equipment Isolation ............................................................................ 18
2.6. Vehicles and Portable Equipment ................................................................................ 18
2.7. Application of Isolation ................................................................................................. 19
2.7.1. Area Isolation 19
2.7.2. Vessel Isolation (not for confined space entry) 19
2.7.3. Confined Space Entry Isolation (General) 19
2.7.4. Confined Space Entry Isolation (Tanks) 20
2.7.5. Confined Space Entry Isolation (valve chambers and tank turrets) 20
2.7.6. Confined Space Entry Isolation (vehicles) 20
2.8. Removal of Locks and Tags (De-isolation and Commissioning) ................................ 20
2.9. Commissioning ............................................................................................................. 21
3. Roles and Responsibilities ................................................................................................ 21
4. Terms, Definitions and Abbreviations .............................................................................. 22
5. Verification Processes associate with this Procedure ...................................................... 23
6. Associated Documents ...................................................................................................... 23
7. External References ........................................................................................................... 24
8. Version Summary. ............................................................................................................. 24
9. Disclaimer........................................................................................................................... 24
Annex A - Example LOTO Plan 25
Annex B - Typical Valve Isolation Integrity Tests 26
Annex C - Tagging 28

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List of Tables, Diagrams and Figures

Figure 1: Single Valve Isolation with Lock and Tag .................................................................... 8
Figure 2: Electrical Circuit Breaker with Multiple Lock hasp, Single Lock and Tag ................. 12
Figure 3: Neon Test Pencils - Prohibited for Use....................................................................... 18
Table 1: Roles and Responsibilities............................................................................................ 21
Table 2: Terms, Definitions and Abbreviations ......................................................................... 22
Table 3: Required References ..................................................................................................... 23
Table 4: Document Version Summary ....................................................................................... 24

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1. Scope

The requirement specified in this procedure applies equally to BP employees, contractors and visitors
engaged in the ANZ MC&M business.

Specific sites, areas and activities may have more detailed OMS requirements and where these exist the
requirements will be specified in local procedures, safe work instructions, manuals, handbooks or
specific standards.

2. Methodology

2.1. General

Isolations may be recorded on the Work Permit, Work Clearance, Lock out Tag out (LOTO) document or
other associated document for the work such the safe work procedure or risk assessment. Once
isolations have been performed, they shall be checked by the worker to confirm effectiveness before
commencing work.

Where capable of being locked, the lockout device is a lock with a tag to secure the isolation. If not
capable of being locked, tags only may be used along with other measures to provide an equivalent
protection to applying locks.

The general process for LOTO work is as follows:

• Prior to work being undertaken under the isolation:
a) Identify all potential energy sources or situations where a release of energy or product may
occur.
b) Identify all isolation points. Competent persons agree to the method of isolation. These can
be a valve, blind flange, circuit breaker, switch or fitting etc.
c) Include the isolation requirements on any Work Permits, Work Clearances, or procedure.
Identify and record isolations that are common to more than one Work Permit, Work
Clearance or procedure.
d) Obtain approval from the Site Representative to place tags and isolations and inform all
who may be affected. Locks and tags are able to withstand environmental conditions.
e) Place and install isolations as close to the worksite as possible to assist in security and ease
of monitoring.
f) Competent persons agree to the method by which stored energy will be discharged. A
responsible, competent person safely discharges stored energy, e.g. drain and depressurize
and / or discharge electrical or other sources of energy. It is critical that all bleeds, vents

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and drains are checked to be free from blockage during discharge of stored energy, and
prior to testing the isolation is effective.
g) Test conducted to confirm that equipment is isolated and that plant / equipment is de-
energized / depressurized and / or cannot be started.

• Whilst work is being undertaken under the isolation

h) Verifying the integrity of the isolations during the work by periodic testing and
monitoring. Monitoring and testing intervals are stipulated in the Work Permit, Work
Clearance, risk assessment, or procedure for the task.
i) If more than one group is working on the same item (including different trades) each
person from each group should have an individual tag but as a minimum one responsible
person from each group shall sign and date a “DANGER, DO NOT START”, or equivalent,
tag. See Annex C.

• When work is complete:

j) Check that all people involved in the work have finished.
k) Check system integrity, as applicable.
l) Drain and depressurize and / or de-energise and remove all blinds etc. and reinstate all
broken connections to same order as before application of LOTO. Care shall be taken
when removing these positive isolation devices as stored energy may develop between it
and the next isolation valve / point on the energized side of the plant.
m) Remove locks, tags and re-commission.
n) Sign off the LOTO Plan, as applicable.
o) Inform the Site Representative of the status of the work.

2.2. Mechanical Isolation

The method of isolation and discharge of stored energy shall be authorised in accordance with PRO4.5-
0001-1-01 Permit to Work (NZ) and WPCG-PRO-01 Worth Authorisation (Australia), and executed by the
responsible person(s).

2.2.1. Positive Isolation

Positive Isolation is regarded as the most secure method and should be considered in the development
of all LOTO Plans.
Positive isolation is defined as:
a) Spool removal - removal of a pipework section or spool piece and blanking the live end,
also called ‘air gapping’.
b) Blind isolation - insertion between flanges of a blind (spade); the swinging closed of a
spectacle blind (plate); or replacement of a spacer (slip-ring) with a line blind (spade).

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Where spool removal cannot be achieved, isolation by a valve and line rated spade provides the next
highest quality and security. The valve shall be locked and the spade inserted for that particular
isolation. The valve and spade shall be tagged in their secure position to prevent inadvertent operation
and removal.

Spectacle blinds, blank flanges, bolting, and gaskets shall be adequate thickness for the line rating. New,
correctly rated gaskets shall be installed and all correctly sized bolts shall be installed and tightened.

Positive isolation by spool removal or air gapping shall be considered as the minimum sole means of
isolation for Confined Space Entry - exception for the use of line rated blind only as authorised by the bp
engineering authority for the business. When a spool or valve is removed, (air gapped) the ‘live’
pipework side should be fitted with a blank flange. In most circumstances the isolated equipment (vessel
or pipe-work) flange should be left open to allow the vessel or pipe-work to "breathe". Positive isolation
by spool removal shall be performed for any positive isolation for confined space entry lasting longer
than one month.

Positive isolation is required for hot work on pipelines or equipment containing hydrocarbons (or other
flammable or combustible dangerous goods) that involves burning, welding, grinding, air arcing,
soldering, open flame or other similar type of activities. Isolation by valve and line rated spade is
acceptable for positive isolations involving this work. Positive isolation by spool removal shall be
performed for any positive isolation for hot work lasting longer than one month. Note that positive
isolation is not mandatory when performing hot taps, electrofusion welding of UPP, the Fitsafe technique
or other similar work.

2.2.2. Valve Isolation

2.2.2.1. Double Block and Bleed

Double block and bleed is the most secure form of valve isolation, but should only be used if the valve(s)
can provide a reliable seal under the particular conditions of service. The main valve shall be locked and
tagged closed and the bleed shall be wired and tagged open to prevent inadvertent operation.

Double block and bleed valve isolations may be considered as the minimum sole means of isolation for
routine short duration cold work for moderate and high pressures. This type of isolation shall only be
used if the duration of the work is short (less than 4 hours) and the immediate work site shall not be left
unattended.

2.2.2.2. Single Valve

In single valve isolations the integrity of the isolation is critically dependent upon the reliability of the seal
under the particular conditions of service and the security of the single valve operating stem.

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Isolation against a tested single valve may be used for the purpose of swinging a spectacle blind,
inserting a line rated spade or fitting a blind flange to achieve higher integrity isolation.

Single valve isolations may be considered as the sole means of isolation for routine, short duration, cold
work where pressures on the active side are less than 200 kPa g. The duration of work shall be short
(less than 4 hours) and the immediate work site shall not be left unattended.

Figure 1: Single Valve Isolation with Lock and Tag

2.2.2.3. Valve Actuators

When used for isolation:

a) Manually operated valves shall be locked and tagged to prevent unauthorized or
inadvertent operation.
b) Electrically actuated valves shall have the power supply positively isolated and any
manual override shall be manually locked.
c) Pneumatic and hydraulic operated valves which fail closed shall have the control lines
isolated and physically disconnected. Pneumatic and hydraulic operated valves which fail
open or fail as is shall not be used for isolation purposes.

2.2.2.4. Isolation of other Energy Sources

Other energy sources can include heat, gas, steam, gravity and pressure. These shall be isolated by a
physical break which is identified by a tag and secured by a lock or an equivalent mechanical means that
cannot be neutralized without the use of tools. Open ends shall be blanked or capped. Persons
performing the work shall test the operation of equipment before work commences to ensure effective
isolation.

2.2.3. Steps in Performing Mechanical Isolations

The following key steps shall be applied when making safe mechanical installations.

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a) Identify
b) Isolate
c) Secure
d) Discharge
e) Test

2.2.3.1. Identify

The equipment to be worked on and all isolation points shall be clearly identified. For Complex
Isolations, a copy of the plant P&ID’s should be marked showing which items are isolated and attached
to the LOTO plan.

2.2.3.2. Isolate

The equipment to be worked on shall be isolated from all sources of energy by the highest method of
isolation as reasonably practical and meeting the minimum isolation requirements of this procedure for
the type of work. Consideration should also be given to locking out and tagging any originating sources
of energy (e.g. pump motor circuit breakers) of the system.

2.2.3.3. Secure

All isolation points shall be locked out to ensure energy control devices, such as valves, are secured in a
safe position from inadvertent operation.

Appropriate warning tags shall be placed at all isolation points, which forbids the operation of the energy
control device and associated equipment, communicates the reason for lockout, the name of the person
who applied the tag and the date the tag was applied. Consideration should also be given to locking out
and tagging any originating sources of energy (e.g. pump motor circuit breakers) of the system.

2.2.3.4. Discharge

Once isolations have been made, all stored energy shall be discharged so far as is reasonably
practicable. Prior to breaking containment of a pipeline or piece of equipment (e.g. filter vessel), it shall
be de-pressurised to atmospheric pressure by means of a vent or drain to atmosphere. Any product or
contaminated water shall be captured. Product or contaminated water shall not be allowed to drain to
ground or be directed into open drains. It is critical that all bleeds, vents and drains are checked to be
free from blockage prior to testing.

2.2.3.5. Test

The energy control devices (e.g. valves,) as well as plant and equipment which is isolated, shall be tested
prior to conducting work to prove effective energy isolation

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2.3. Electrical Isolation

2.3.1. Key Considerations

Electrical equipment shall be considered to be energised (i.e. live) until proven de-energised.

2.3.2. Steps Performing Electrical Isolation

The following key steps shall be applied when making safe electrical installations.
a) Identify
b) Isolate
c) Secure
d) Discharge
e) Test

2.3.2.1. Identify

Electrical equipment to be worked on and the appropriate point of supply shall be clearly identified.
Identification of equipment should include labelling that is both consistent and clear at the equipment to
be worked on and all points of possible isolation, e.g. control isolator and main point of supply.

2.3.2.2. Isolate

The electrical equipment to be worked on shall be isolated from all sources of supply (e.g. mains,
generator, battery or solar) either by opening switches, removing fuses or switching circuit breaker /
RCD/ RCBO. Where isolation is performed at a removable or rack-out circuit breaker or combined fuse
switch or a removable fuse the device should be racked out or removed to provide a visible break for
isolation verification.
Where isolation is provided by the removal of fuses in a distribution board or motor starter the following
shall apply:
a) Removed fuses shall not be stored in the same panel as the fuse holder.
b) Fuses shall be tagged and stored in a secure location during the period in which
equipment is isolated.
c) Blank or empty fuse cartridges, preferably painted yellow and tagged ‘for isolation
purposes’ shall be inserted into the fuse holder to prevent inadvertent contact with
exposed conductors and to clearly identify that equipment is under isolation.
Confirmation shall be made that all required isolations are in place. For complex isolations, this
confirmation may be by a nominated second person if deemed necessary to manage the risk of incorrect
isolation.

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2.3.2.3. Secure

a) Tagging
Tags shall be placed at all points of switching, isolation or disconnection. Such tags shall be
clearly understandable and signed and dated by the person placing the tag or by the
supervisor in charge of the work party. Identification labels should also include warnings for
any abnormal hazards, e.g. multiple points of supply, etc.
b) Lock Out
Where a facility exists to lock an isolation point, it shall be used. All points of isolation for
the work (e.g. circuit breakers, switches and combined fuse switch units forming part of the
power or control circuit) should be locked out. Where locking facilities are not available,
temporary securing devices should be used. Securing devices shall be able to withstand any
disrupting environment, e.g. not become ineffective due to vibration.
If lock out facilities do not exist at the isolation point, other measures shall be implemented
to ensure the isolation is secure for the safety of personnel conducting the work. This may
include locking out the switchboard cabinet door, the room door, or a spotter to remain in
attendance. The need to implement alternative measure should be reported to the bp
representative.
Where fitted, all fuses in the power and control circuits requiring isolation for the work shall
be removed.
Where fitted, three phase field isolators in the power circuit requiring isolation for the work
shall be tagged in the off position and should be locked off.
Local field isolators for equipment shall be tagged in the off position and should be locked
out.
Where an isolation is secured (lock out) a padlock should be used and should be uniquely
keyed to prevent inadvertent removal by others. The use of a multi-lock device should be
employed where more than one person is to attach a personal lock to an isolator.
Figure 2 shows a typical method for tagging and locking out circuit breakers on a distribution
board.

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Figure 2: Electrical Circuit Breaker with Multiple Lock hasp, Single Lock and Tag

2.3.2.4. Discharge

Any stored energy shall be discharged e.g. capacitors.

2.3.2.5. Test

All electrical equipment, unless proven to be de-energised, shall be treated as live.

Voltage tests shall be carried out between all phase conductors and between all phase conductors and
earth.
The testing of equipment with an approved test meter for the purpose of confirming that the equipment
is isolated is not considered live work under this local practice. This position may vary from jurisdiction
to jurisdiction within Australia and New Zealand. Local requirements shall be applied.
Any voltage tests used to prove de-energization shall be conducted in the following sequence:
a) Test the voltage tester on a known voltage source for correct operation.
b) Test between all conductors and a known earth.
c) Test between all conductors.
d) Retest the voltage tester on a known voltage source for correct operation.

Only competent persons shall perform the tests.

2.3.3. Interlocks and Automatic Starting of Equipment

During the isolation consideration shall be given to the possibility of circuit wiring or electrical equipment
becoming live due to the operation of automatic control devices, e.g. thermostats, float switches, PLCs
and other interface and interlock devices.
To prevent the inadvertent or automatic starting of equipment from remote locations the respective
output from a PLC or DCS to equipment being isolated shall be disconnected as part of the isolation

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process. This includes connections to motor starters, valve solenoids, motorised valves, instrument
power etc.
Disconnection of the PLC/DCS output may be achieved by one of the following;
a) Physically disconnecting wiring at the output module,
b) Physically disconnecting wiring or removal of a fuse at a terminal strip in a wiring
enclosure,
c) Physically disconnecting wiring at the field device; or,
d) Through the use of a disconnect switch on the PLC/DCS or at the equipment.

2.3.4. ‘Try’ Step

Where practicable, persons performing the work shall try to start the equipment via the field isolator or
PLC once the isolations are in place. This step is sometimes referred to as the ‘try’ step.

2.3.5. Cutting of Electrical Cables

When carrying out work which involves cutting existing cables, the cable shall be treated as live until
positive tests proving the cable is de-energised can be made at the point where the cable is to be cut.

2.3.6. Opening of Enclosures

Opening of enclosures while circuits remain energised is often required to facilitate inspections,
troubleshooting and maintenance activities. However, consideration shall be given to the potential for
hazardous atmospheres. This shall be considered in the risk assessment for the task and a gas test shall
be conducted by a competent person for all such work in hazardous areas - as per WPCG-PRO-01 Work
Authorisation (Australia) and PRO4.5-0001-1-01 Permit to Work (NZ).

Opening of electrical enclosures or cabinets for purposes of troubleshooting, inspecting or investigation,

where the person is not coming into close proximity with exposed electrical circuits, is not considered
live electrical work under this local practice.

Opening of enclosures or cabinets where there is the presence of exposed voltage higher than 32Vac
shall only be permitted by qualified persons i.e. electrical engineer, electrical worker.

While there is low risk for a competent person when opening a panel to observe the status of wiring or to
inspect components as part of troubleshooting or maintenance activities, a safe approach distance of
500mm to exposed and live conductors shall be observed.

Placing hands or any part of the body within 500mm of live and exposed conductors shall be considered
live work and additional safeguards shall be in place to protect the person from direct or indirect contact
with energised conductors.

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2.4. Working On or Near Live Electrical Equipment

2.4.1. Key Considerations

Working on live electrical equipment shall only be considered as a last resort and when an adequate risk
process has been undertaken and documented in accordance with the risk assessment for the task.
The recommended safe guards, as listed in section 5.4.2, should be identified on risk assessment for the
task.
When working in the vicinity of live exposed electrical conductors consideration shall be given to the
potential arc flash hazards and level of PPE required.
Note: electrical work on switchboards with fully enclosed busbar chassis assemblies with integrated
isolation switch for each individual tee-off is permitted provided that:
a) All the spare poles are isolated at the busbar,
b) The circuit or tee-off which is being worked on is isolated at the busbar, and
c) The circuits immediately adjacent the circuit being worked on are isolated at the busbar.

2.4.1.1. High Energy Installations

When working, testing or fault finding on energised electrical equipment, a fault current of up to 20 times
the rated current of the supply transformer can flow for short duration during fault conditions. Arcs that
are produced under these conditions have the energy to cause an explosion and/or melt metallic
switchboard cubicles. Arcs can cause severe burns to the skin and/or flash burns to the face and eyes.
Inhaled hot gases and molten particles can cause serious internal burns to the throat and lungs. Injury
can also occur through the impact from flying debris and dislodged components. Overcurrent circuit
protection may not operate in such circumstances.

For installations rated above 800A or where the fault currents exceed 2000A special precautions are
required.

2.4.2. Safeguards

When working on live electrical equipment the safeguards outlined in 5.4.2.1 through 5.4.2.8 (inclusive)
shall apply.

2.4.2.1. Assessment

Prior to commencing any work on live electrical equipment an assessment of the associated risks shall
be undertaken. This assessment shall include a consideration to the available fault current and the
requirement for appropriate PPE based on the arc flash hazard.

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2.4.2.2. Stand-by Person

Where in the judgment of the person doing the work, it cannot be carried out safely without assistance or
a safety observer, that person shall be provided with the assistance required. If assistance is not
provided, work shall be delayed until isolation can be arranged.
When troubleshooting involves the use of approved test equipment and the measuring of voltages by
direct contact with exposed conductors exceeding 32Vac or 50Vdc the person undertaking the work shall
be supported by a safety observer of stand-by person.

2.4.2.3. Competency

Any persons undertaking work on live electrical equipment shall be skilled and competent in the work to
be carried out.

2.4.2.4. Precautions

The person responsible for authorising work to be carried out live shall specify any particular precautions
to be taken to eliminate hazards and to prevent injury.

2.4.2.5. Safety Apparel (PPE) for Electrical Work

Electrical workers and assisting personnel shall wear protective clothing suitable for the task when
working on, or in close proximity to, live (energised) electrical equipment.
a) PPE for Low Energy Installations:
1. The minimum PPE requirements that shall be followed for working in close
proximity to live low voltage exposed electrical equipment in low energy systems
are;
i. Safety glasses
ii. Long sleeve cotton shirt
iii. Long cotton pants
iv. Leather safety shoes
v. Leather gloves
Note: the above is the minimum PPE requirement for low voltage, low energy work.

b) PPE for High Energy Installations:

1. Where working on or in the vicinity of exposed conductors for installations rated
above 800A or where the fault currents exceed 2000A additional PPE requirements
apply.
2. PPE shall be suitable for the arc flash hazard.
3. For these installations consideration shall be given to the use of flame resistant and
non-synthetic clothing as well as insulating gloves and full face shield.

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2.4.2.6. Earthing

When working on live electrical equipment having earthed metal, precautions shall be taken to ensure
earthing continuity is maintained to any component part of the equipment at all times.

Bonding conductors may be required to be installed when removing electrical equipment from earthed
metal, e.g. live component part separated from its connected earthing medium. Bonding conductors
shall be rated to withstand the ‘let through’ energy of the primary protection without failing.

2.4.2.7. Neutral Connections

Particular care should be taken when removing neutral connections as tests may have indicated a de-
energised situation. However, when these connections are removed, a voltage may be present between
conductors or between conductors and earth.

2.4.2.8. Barriers & Insulation Mediums

Only conductors at one potential should be worked on at any one time and insulated barriers should be
utilised in the work area between conductors of different phases or voltage potentials.

Insulating mats or barriers should be used between electrical workers and conductors and between
electrical workers and earth including building structures such as concrete and steel which may be
earthed.

2.4.3. Fault Finding

Isolation of power shall always be the first choice when undertaking electrical work.

However consideration shall be given that there may be instances when fault finding, commissioning or
testing is only possible while equipment is live and in these instances other safety precautions are
required to be taken.

The electrical worker shall be competent in the work being undertaken and be familiar with the
equipment involved and the safeguards for requirements for working on live electrical equipment shall
be applied.

2.4.4. Electrical Test Equipment

2.4.4.1. Key Considerations

All test equipment, including leads and probes, shall be suitable for its intended purpose and periodically
inspected to ensure that it remains operational and safe.

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Before carrying out any tests, equipment shall be checked to ensure that it is correctly set, functional and
in good condition.

Testing equipment used for detecting a live (energised) source should undergo trial operation on a
known live circuit to prove that it is functioning correctly immediately before and after the test has taken
place.

2.4.4.2. Requirements for Electrical Test Equipment

Electrical test equipment (including test leads) used for direct contact on low voltage systems shall
comply with the requirements of AS 61010.1 or an equivalent standard and shall be a minimum of CAT
III 600V design.

Contact probes and leads shall be checked for damage to insulated parts, ensure continuity and verify
connections prior to use.

Insulation resistance testers shall be able to maintain a terminal voltage within +20% and -10% of the
nominal open-circuit terminal voltage, when measuring a resistance of 1 MOhm on the 500 V range or 10
MOhm on the1000 V range.

Voltage indicators such as high impedance volt meters shall only be used to verify the presence of a
voltage.

They shall not be used to verify the conductivity of a cable, as they will operate satisfactorily with high
resistances within the circuit under test.

Voltage indicating neon type devices shall not be used as the only means to verify the presence of a
voltage.
Test equipment that has the potential to generate a spark and is intended for use within a hazardous area
shall be certified for use within that hazardous area. If equipment is not hazardous area certified and has
a spark potential, the normal requirements of WPCG-PRO-01 Work Authorisation (in Australia) and PRO-
4.5-0001-1-01 Permit to Work (in New Zealand) shall be followed.

2.4.4.3. Prohibited Electrical Testing Equipment

Neon or LED test ‘pencil’ devices, similar to those shown in Figure 3 below, requiring the user to form
part of the test circuit shall not be used as electrical test devices.

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Figure 3: Neon Test Pencils - Prohibited for Use.

2.5. Powered Fixed Equipment Isolation

Prior to any work starting on powered equipment it shall be positively isolated.

Electrically powered equipment shall be isolated, locked and tagged out from its power supply in
accordance with the requirements of this local procedure.

Diesel driven equipment shall be positively isolated by removal and tagging out of ignition key, securing
of electrical isolation switch and consideration to disconnection of the battery, which has its own risks of
generating sparks and damage to circuit boards.

Steam, hydraulic or pneumatic equipment shall be positively isolated from its energy source by positive
isolation of its motive force. Further isolation will depend on the type of equipment and may include pipe
and additional physical isolation.
Persons performing the work shall test the operation of equipment before work commences to ensure
effective isolation.

2.6. Vehicles and Portable Equipment

The following procedure should be followed to lock out / tag out any vehicle to conduct work on the
vehicle or any equipment on the vehicle;
a) Park the vehicle safely; if possible at the maintenance workshop.
b) Turn off the vehicle ignition, remove the vehicle keys and turn the master battery isolation
switch OFF.
c) Install a lock out tag on the steering wheel, with the fleet number of the vehicle, the date
and time and name and signature. If possible install a lock out tag on the master battery
isolation switch.
d) Inform all who may be affected.
e) Follow the isolation requirement in this procedureError! Reference source not found. to
undertake the necessary repair works.

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f) The lock out tag shall only be removed by the maintenance fitter or the manager,
following repair work and test driving / operation has been conducted.

2.7. Application of Isolation

Plant isolations shall be approved by the Permit Officer (to approve the work as safe to do under the
isolation) and Site Representative (to approve any business operational impact) and executed by the
responsible person(s). All isolations shall be viewed and tested the isolations to confirm they are in
place prior to work under the isolation.

If the work is covered by a task breakdown the isolations shall be specified within the procedure.

2.7.1. Area Isolation

The work area shall be clearly identified and cordoned off to ensure that there is no risk from traffic,
personnel not associated with the work, or other external sources.

2.7.2. Vessel Isolation (not for confined space entry)

Isolation of the highest quality and security which is reasonably practicable shall always be used.
Positive isolation shall be provided for all work other than cold work. Vessel Isolations (e.g. filter
changes) for routine, short duration, cold work which are not positive isolation shall be subject to a risk
assessment. This shall only be allowed where the work duration is short (less than four hours) and the
immediate work site shall not be left unattended.

2.7.3. Confined Space Entry Isolation (General)

Given the specific hazards of Confined Space Entry, LOTO Plans shall be risk assessed.

Isolations shall be made to prevent the accidental introduction into the confined space of materials,
through equipment such as piping, ducts, vents, drains, conveyors, service pipes or firefighting systems.
The method of isolation shall be by Positive Isolation. The preferred method of isolation is air gapping.
Isolations should be made as near as possible to the Confined Space to be entered. Where isolation at
the vessel cannot be achieved due to the size of a piping connection, or where piping connections are
welded to the vessel / equipment, the isolation should be made at the nearest available place to the
vessel / equipment. The interconnecting piping between the vessel / equipment then becomes an
integral part of the Confined Space and shall be taken into account when preparing for entry and issuing
Confined Space Entry Permits.

Particularly important aspects that should be considered are:

a) The natural "chimney effect" of large vertical tower, vessels, pipework (e.g. overheads
lines),

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b) The effects of winds to create a low pressure area downwind of manways and other
openings which could result in an airflow and contaminants moving inside a vessel /
equipment in the reverse direction to that expected,
c) Connecting piping can contain harmful materials not removed from the systems during
purging and gas freeing, which can be subsequently released due to airflow and / or solar
heating, or Hot Work.

2.7.4. Confined Space Entry Isolation (Tanks)

Positive isolation of all sources of energy is mandatory for confined space entry into tanks. Valves and/or
sections of pipe from each connecting pipeline including foam pipelines (where installed) shall be
removed from as near to the shell as possible and the open end of the pipelines shall be sealed with an
appropriately line rated blank flange.

All electrical connections other than extra low voltage equipment complying with AS/NZS 3000 Electrical
installations (known as the Wiring Rules) shall be positively isolated.

Potential energy sources shall also be discharged e.g. floating suctions, by landing these onto solid
supports.

2.7.5. Confined Space Entry Isolation (valve chambers and tank turrets)

Positive isolation of all external sources of energy is often not practically achievable for pipeline valve
chambers and tank turrets. The highest level of isolation practically achievable shall be determined in
the risk assessment with appropriate controls and monitoring of isolation detailed and response to the
loss or containment detailed in emergency response plans.

2.7.6. Confined Space Entry Isolation (vehicles)

It is often not practically achievable to fully drain down and gas free pipework associated with aviation
refuelling vehicles. If entry into aviation vehicle compartments is required, pipework shall be
disconnected and isolated from compartments, pipework sealed and external vapour sources from
refuelling equipment controlled. The risk of vapour migration into vehicle confined spaces shall be
determined in the risk assessment with appropriate controls and monitoring of isolation detailed.

2.8. Removal of Locks and Tags (De-isolation and Commissioning)

Equipment that has been removed from service for maintenance (whether routine or non-routine) shall
on completion of maintenance, be tested in service to confirm the integrity of the system. If this is not
possible at the time the maintenance is completed, then maintenance shall be deemed incomplete and
the equipment shall remain locked out / tagged out until testing in service can be undertaken.

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On completion of the work, removal of locks and tags, de-isolation and recommissioning of the system
shall be performed with the same care as used during the isolation, locking and tagging. For example,
integrity testing of the point of isolation shall precede the removal of any blank flanges, swinging of
spectacle blinds or reinstatement of pipework to test for the presence of stored energy or product which
could be released.
Lockout locks and tags shall only be removed by the person who applied them.
Exceptions
Only under exceptional circumstances, locks and or tags may be removed by the site manager (authority
not to be delegated) according to the following procedure:
a) Verify that the person who placed the Lock and Tag is not on site.
b) Make all reasonable efforts to contact the person.
c) Ensure that the plant is in a safe and operable condition, by inspection by a competent
person.
d) Remove lockout and tag.
e) Re-commission plant.
f) Ensure that the person who applied the tag and lock is informed that the plant has been
returned to service and the documentation has been signed off by the site representative.

2.9. Commissioning

Equipment that has been removed from service for maintenance (whether routine or non-routine) shall
on completion of maintenance, be tested in service to confirm the integrity of the system. Pressure, leak
and functional testing of the reinstated system shall be performed as required for the equipment.
Particular care should be taken of electrically, pneumatically or hydraulically operated valves which may
open or close on reinstatement of the energy source. If this is not possible at the time the maintenance
is completed, then maintenance shall be deemed incomplete and the equipment shall remain locked out
/ tagged out until testing in service can be undertaken.

3. Roles and Responsibilities

The roles and responsibilities associated with this procedure are listed in the following table.

Table 1: Roles and Responsibilities

Planner The person responsible for planning the Energy Isolation shall ensure that
only accredited contractors are engaged to perform isolations (or
contractors engaged by an accredited contactor).

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Site Representative The Site Representative shall be the site manager or delegate, or if the
site is unmanned it may be the Permit Officer or Work Clearance Issuer.
The Site Representative is responsible for the overall safety of the site.
The Site Representative shall be aware of all planned operations of the
site that may interact with the work. Therefore no work shall be
undertaken before the Site Representative countersigns the work
authorisation. The Site Representative may stop or defer work at any
time.
Worker performing isolation Only performing isolations they are competent and authorised to
perform.
Completing isolations in accordance with bp and regulatory
requirements.

4. Terms, Definitions and Abbreviations

Table 2: Terms, Definitions and Abbreviations

Close Proximity Locations on installations, where deliberate, accidental or inadvertent
contact with electrical equipment is possible, either direct or indirect
through tools, long objects, drills, cutting blades, etc. For the purposes of
this practice ‘close proximity’ is taken to be 500mm.
Complex isolations These may include, but are not limited to, work requiring isolation of dual
energy sources, multiple sources of energy requiring isolation, isolations
required by multiple trades or organisations, and isolations required for
confined space entry. Consider all sources, not just electrical, when
assessing the complexity of isolations required to safely execute the
work.
De-energised (electrical) Disconnected from all sources of supply but not necessarily isolated,
earthed or out of commission.
Electrical Worker Person or persons engaged in the installation, maintenance, repair and
testing of electrical equipment.
Extra Low Voltage (ELV) Voltage not exceeding 50 V AC or 120 V ripple-free DC
Fault Finding (electrical) The process of taking measurements or carrying out tests on electrical
installations and equipment to locate faults or prove operability. It may
also include the process of applying testing instruments or devices to
various parts of the electrical installation.
High Energy Electrical System Electrical systems rated at 800A or where the fault current at the point of
the installation exceeds 2,000A.
Isolated (electrical) The state of equipment when disconnected from all sources of supply by
breaks of a length appropriate to the voltage and the insulating medium.
Isolation Plan A form to specify and record Lockout points for more complex plant
isolations. Also referred to as a LOTO Plan.
Isolator (electrical) A device which for reasons of safety, provides in the open position,
breaks appropriate to the voltage and the insulating medium.
Lockout The use of locks and / or locking devices (e.g. chains and locks, clasps and
locks) to ensure energy sources and energy control devices such as
electrical breakers and valves are secured in a safe position.
LOTO Lock Out Tag Out
Live (energised) A term applied to an object when a difference of potential exists between
conductors or would exist between it and earth under normal conditions
of operation.
Low Voltage Exceeding extra-low voltage, but not exceeding 1,000 V AC or 1,500 V DC

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On or near (electrical) A situation where an electrical worker is working on or near exposed

energized conductors or live conductive parts and there is a reasonable
possibility that the electrical worker’s body, or any conducting medium
the electrical worker may be carrying or touching during the course of the
work, may come closer to the exposed energized conductors or live
conductive parts than 500 mm. The term ‘on or near exposed energized
conductors or live conductive parts’ does not apply if the uninsulated and
energised part is safely and securely shielded by design, or segregated
and protected with barricades or insulated shrouding or insulating
material to prevent inadvertent or direct contact.
PLC Programmable Logic Controller that controls the operation of equipment
via software coding.
Positive isolation Positive isolation is defined as either:
a) Spool removal - removal of a pipework section or spool
piece and blanking the live end, also called ‘air gapping’.
b) Blind isolation - insertion between flanges of a blind
(spade); the swinging closed of a spectacle blind (plate); or
replacement of a spacer (slip-ring) with a line blind
(spade).
Site Representative The Site Representative is a person with responsibility for the overall
safety on a site, who has the ability to stop work at any time.
Tag out The attachment of prominent warning tags to locks and / or locking
devices that forbids the operation of energy control device and associated
equipment and communicates the reason for lockout. It bears the name
of the person who applied the tag and the date the tag was applied.
Testing (of LOTO) The act of confirmation that plant and equipment is isolated and de-
energised by checking the integrity of the local energy control devices
(e.g. valve, isolator), and that plant and equipment is de-energised (e.g.
by trying to start equipment or confirming de-pressurisation / drain down.
It is critical that all bleeds, vents and drains are checked to be free from
blockage prior to testing.

5. Verification Processes associate with this Procedure

The key process steps outlined in this procedure are included in a Self-Verification Programme.

6. Associated Documents

The following associated documents:

• Have been referenced in this procedure.
• Should be considered in understanding and applying the instructions provided in this procedure.

Table 3: Required References

Document Name Document No

Group Defined Practice - Control of Work GDP 4.5-0001

Permit to Work PRO-4.5-0001-1-01

WPCG Work Authorisation WPCG-PRO-01

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7. External References

This This procedure was prepared with reference to relevant legislation/regulations including but not
limited to, relevant Acts, Regulations, AS/NZ Standards and industry codes and practices.
Details of current legislation/regulations can be provided by the HSE Team on request.

8. Version Summary.

Table 4: Document Version Summary

Version Prepared by Description of Change Date MoC
1 Adrian Connolly Document created. Initial, replacing STP 35-20 LOTO 14 Nov 2014
2 Adrian Connolly Updates to document format and layout for readability. 06 Aug 2015 11233
Minor spelling and grammar corrections. Minor changes
to wording of clauses to improve clarity of requirements,
and to meet Standards requirements wording
(‘shall/should/may’). Some areas for further clarification
and documentation of existing practices.
3 Adrian Connolly No significant changes to actual requirements for Energy 23 Sep 2017 11374
Isolation above standard practices.
4 Adrian Connolly Updates to add clarity particularly with regards to LOTO 22 Aug 2018 11449
minimum requirements and working on live equipment.
5 Adrian Connolly Minor update for implementation of WPCG-PRO-01 Work 9 Oct 2023 11836
Authorisation

9. Disclaimer

Copyright © 2020 BP p.l.c. All rights reserved.

This document and any data or information generated from its use, are classified, as a minimum, BP Internal. Distribution is
intended for BP authorized recipients only. The information contained in this document is subject to the terms and conditions of the
agreement or contract under which this document was supplied to the recipient's organisation. None of the information contained in
this document shall be disclosed outside the recipient's own organisation, unless the terms of such agreement or contract expressly
allow, or unless disclosure is required by law.

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Annex A - Example LOTO Plan

LOTO PLAN LOTO Plan #

Lock Out / Tag Out

Page of
LOTO Plan Prepared by: Description of work:

Instructions
1 Review Site Procedure for the Isolation of Equipment (Lock Out / Tag Out).
2 Note lock out points in left column (attach P&ID or equipment drawing indicating isolation points).
3 Install Plant Locks at points outlined in left column.
4 Record lock number(s) beside corresponding lockout point.
5 Complete “Installed by” and “Date Installed”.
6 Confirm all isolations, locks and tags installed, and stored energy discharged.
7 Attach copies of LOTO PLAN to permit.
8 When locks are removed, complete “Removed by” and “Date Removed” columns.
9 Confirm all isolations, locks and tags removed and to confirm system integrity.
10 File completed copy of LOTO PLAN with completed Work Permit.
# Identification of Electrical Disconnect, Site lock Installed by: Date Removed Date
Valve, or other energy source to be Number: Installed: by: Removed:
Locked Out

All locks have been installed: ____________________________________ Date: ________________

(Signature)

All locks have been removed: ____________________________________ Date: ________________

(Signature)

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Annex B - Typical Valve Isolation Integrity Tests

B.1. Double Block and Bleed Isolation Integrity Test (2 Valves)

Diagram

Key V1 - First (upstream) isolation valve from live system.

M1 - Live side monitoring point (pressure gauge or vent/drain).
V2 - Second (downstream) isolation valve from live system.
M2 - Monitoring point between valves and break point (pressure gauge or vent/drain).
B - Bleed point between the isolation valves.
Procedure 1. If possible, ensure tapings at M1, M2 and B are not blocked and pressure gauges,
where installed, are operating.
2. Close downstream valve V2 and lock in closed position, tag out and record on LOTO
plan.
3. Record pressure at monitoring points M1 and M2.
4. Vent/drain section of line to be broken and monitor at M2 until the pressure is near
zero.
5. Close vent/drain at break point and monitor at M2 for a minimum of 10 minutes. No
pressure build-up at M2 indicates the integrity of the downstream valve V2.
6. Close upstream valve V1 and lock in closed position, tag out and record on LOTO
plan.
7. Record pressure at M1 and B.
8. Vent/drain between V1 and V2 (B) and monitor at B until pressure is near zero.
9. Close vent/drain (B) and monitor at M1 and B for a minimum of 10 minutes. (No
pressure build-up at B indicates integrity of upstream valve V1).
10. Open vent/drain (B) and lock in open position, tag out and record on LOTO plan.

Isolation Both block valves are now closed, the bleed valve is open and all three are secured. Any
Summary fluid passing via the upstream valve is vented through the intermediate bleed valve and
no pressure builds up against the downstream valve.

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B.2. Double Block and Bleed Isolation Integrity Test (1 Valve)

Diagram

Key M1 - Live (upstream) side monitoring point.

M2 - Monitoring point between valve and break point (downstream).
C - Cavity drain (between seals).
Procedure 1. If possible, ensure tapings at M1, M2 and C are not blocked and pressure gauges,
where installed, are operating.
2. Close isolation valve and lock in closed position, tag out and record on LOTO Plan.
3. Record pressure at M1, C (in cavity) and M2.
4. Vent/drain downstream section of line to be broken and monitor pressure at M2 until
pressure is near zero.
5. Close vent/drain at break point and monitor at M2 and C for a minimum of 10
minutes. (No pressure build-up at M2 and no pressure fall-off at C indicates integrity
of downstream seal.)
6. Record pressure at M1 and C.
7. Vent/drain off fluid in cavity (between seals) and monitor at C until the pressure is
near zero.
8. Close cavity vent/drain (C) and monitor at M1 and C for a minimum of 10 minutes.
(No pressure build-up at C indicates integrity of upstream seal).
9. Open cavity vent/drain (C) and lock in open position, tag out and record on LOTO
Plan.
Isolation The double sealed, single block valve is now closed, the cavity bleed valve is
Summary open and both are secured. Any fluid passing through the upstream seal is
vented through the intermediate cavity bleed valve and no pressure builds up
against the downstream seal.

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B.3. Single Valve Isolation Integrity Test

Diagram

Key M1 - Live (upstream) side monitoring point.

M2 - Monitoring point between valve and break point (downstream).
Procedure 1. Ensure tapings at M1 and M2 are not blocked and pressure gauges, where installed,
are operating.
2. Close isolation valve and lock in closed position, tag out and record on LOTO Plan.
3. Record pressure at M1 and M2.
4. Vent/drain downstream section of line to be broken into and monitor at M2 until
pressure is near zero.
5. Close downstream vent/drain and monitor at M2 for a minimum of 10 minutes. (No
pressure build-up at M2 indicates integrity of single valve.)
6. Open downstream vent/drain at break point and lock in open position, tag out and
record on LOTO Plan.
Isolation The single isolation valve is now closed, the downstream vent/drain is open and both are
Summary secured. Arrangements shall be made to monitor any fluid passing through the single
valve seal.

Annex C - Tagging
All energy control devices (e.g. valves,) as well as plant and equipment which is isolated, shall have an
identification tag attached. For Lock Out Tag Out, “DANGER - DO NOT OPERATE” or equivalent tags
shall be used. Additional “Out of Service” or “Information” tags may be attached to equipment, but
these tags do not form part of the isolation for the protection of workers performing work under the
isolation.

NOTE: AS1319 specifies requirements for the design and use of safety signs.

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End of Document

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