Control of Hazardous Energy (CHE)

Transcription

1 Document Number: RGP0005A Revision Date: 2015/09/01 Revision: 8 Control of Hazardous Energy (CHE) Procedure Facility: Regional Wood Buffalo Area: General FLOC: Table of Contents Purpose... 2 Scope... 2 Responsibilities... 2 References... 5 Prerequisites... 5 Violation of Procedure... 5 Definitions... 5 Procedure Operator Assist Receiver Performing Safing HEI Development Operations Safing and/or Coordinating Safing Valve Isolations Blind / Blank Installations Electrical and Instrumentation Isolations Nuclear Isolations Specialty Isolations Temporary Re-Energization of Isolated Equipment Blind and Blank Removal Lock Removal and HEI Closeout Appendices (Forms and Template Links) Appendix 1 Instructions for Completing the HEI Form Appendix 2 First Break Instructions Appendix 3 Lock Removal Form Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes Appendix 5 Specialty Isolation Devices and Single Isolation Methods Appendix 6 HEI Lockbox Compliance Monitoring Appendix 7 Process Flow Diagram Summary of Changes Revision Record Approved By: Derek Trapp, GM OEMS Integration Page 1 of 96

2 Purpose To define how hazardous energy sources will be isolated and controlled to ensure the safe execution of work in situations where workers are servicing, repairing, testing, adjusting, or inspecting systems, structures, or equipment. Scope This procedure applies to all work performed at Suncor Energy Inc. operating sites in the Wood Buffalo region including: Oil Sands and In Situ, East Tank Farm, and areas transitioned to operations at the Fort Hills site. Lodges will use LMS0036A. Responsibilities The following individuals and groups have the following defined responsibilities: Area Authority (Area Operator or Area Technician) Must install locks on Isolation Points as specified in this procedure. Must notify the Permit Issuer and Permit Receiver of changes in the work area according to procedure RGP0004A. Must communicate to incoming Operating personnel the status of HEI isolations, current conditions, hazards and operating limitations. The Area Authority can act as either the Installer or the Verifier. B/U Operations Managers Must ensure Control of Hazardous Energy procedures and protocols are monitored for quality and compliance and enforced. Identify to the CHEPTW Community of Practice document updates that may be needed. Should review and perform Lockbox Compliance Monitoring per Appendix 6. HEI Approver (Approver) Must be a competent individual for the mechanical or electrical isolations being approved. The individual can be the Permit Issuer, UL, SS, Electrical Supervisor or other individuals designated by the Operations or E&I department. This individual must not be the same as the HEI Author when creating a new sheet. Must review the HEI form according to Appendix 1 to ensure the specified isolations will make equipment safe to work on in the field for the Scope of Work. Must approve the HEI form before allowing Energy Isolation Points to be isolated in the field. Must sign the HEI form according to Appendix 1 signifying that the isolated components allow work to be performed on the equipment safely. Continued on next page Page 2 of 96

3 Responsibilities Continued HEI Author (Author) A competent individual for the system being isolated, who identifies the Energy Isolation Points to allow personnel to safely perform work. The individual can be the Area Authority, Permit Issuer, UL, SS, Electrical Supervisor, Shift Electrician or other individuals designated by the Operations or E&I department. This individual must not be the same as the HEI Approver when creating a new HEI form. If an existing lock-out package does not exist, will fill out the HEI form and identify Energy Isolation Points that need to be isolated in the field. Must fill out the HEI form according to Appendix 1. Must ensure that the components to be isolated will make equipment safe to work on in the field for the SOW. Must provide the HEI form to the HEI Approver for approval after completing the HEI form. File the HEI form in an electronic folder so it is convenient to locate for future users. Location of folder to be determined by Operations Management. Must sign the HEI form according to Appendix 1 signifying that the components to be isolated for the SOW allow work to be performed on the equipment safely. HEI Reviewer (Reviewer) Will obtain an existing HEI lock-out package from Livelink or the operations controlled department files to safely isolate the equipment to be worked on in the field for the scope of work. Must be a competent individual for the mechanical or electrical isolations being reviewed. The individual can be the Permit Issuer, UL, SS, Electrical Supervisor or other individuals designated by the Operations or E&I department. Can be the same person who originally authored or approved the HEI form. Will review existing HEI lock-out packages to assure the energy isolation points are correct for the SOW being performed in the field (for example, must ensure the components to be isolated will make equipment safe to work on in the field). Must sign the HEI form according to Appendix 1 signifying that it is acceptable for isolation activities to proceed. Continued on next page Page 3 of 96

4 Responsibilities Continued Installer Isolation Coordinator A competent person, knowledgeable in the system being isolated. Must ensure they isolate and confirm zero energy according to the HEI form. The person who isolates an energy isolation point will install a lock securing the position of the equipment. When initialling an isolation point on the HEI form, they signify that they have confirmed zero energy. Person (the Permit Issuer, UL or SS, or their designate) who coordinates the isolation activities. Must ensure HEI form is completed according to this procedure. Must ensure isolation tasks are assigned to competent installers and verifiers. Before sealing the lock box, must ensure all parts of the HEI form have been completed and keys for all isolation and verification locks are secured and visible, When signing the HEI form, the Isolation Coordinator signifies that all the isolation activities have been completed. The lock installers and verifiers retain accountability for the confirmation of zero energy. Note 1: The Isolation Coordinator can also perform the role of the HEI Author or HEI Approver. Note 2: The Isolation Coordinator can also perform the role of the Installer or the Verifier. Note 3: This role may transfer from one person to another as the isolation progresses. Permit Issuer Verifier Must ensure: HEI form is completed according to this procedure. All information on the HEI form is clearly stated, legible and complete in its entirety. All names on the HEI form are legibly printed, and complete with signatures. A seal is on the lock box as stated in this procedure, before authorizing a Safe Work Permit according to RGP0004A. A competent person, knowledgeable in the system being isolated. Must ensure that the installer isolated the correct points, confirm zero energy themselves according to the HEI form, and apply a verification lock to secure the isolation point. When initialling an isolation point on the HEI form, they signify that they have confirmed zero energy. Note: The person who performs the verification must not be the same person who initially isolated the system. Page 4 of 96

5 References MOC (Create CHE & PTW Procedures) CTS-0002 Corporate Technical Standard Deviation Notice / Non-Conformance RGP OEMS Element 15: Incident and Hazard Management LMS0035A Purging / Safing PMR0015A Insulators Occupational / Trade Specific Rules RGP0001A Drain Rodding RGP0004A Safe Work Permits RGP0006A Removing a Cap/Bull Plug and Opening a Drain RGP05001 Management of Change RGS0002A Permit Office Layout SUN Standard for Management of Change SUN Electrical Safety Risk Management Standard Prerequisites All personnel required to create, review, or authorize issuance of the HEI form must be trained on this procedure. All personnel required to isolate or coordinate isolation of equipment must be trained on this procedure. Violation of Procedure This procedure must be followed at all times. If an Operating Area needs to be exempted from complying with this procedure, the request must be documented using the MOC Process and approved by: General Manager, OEMS Integration Senior Vice President, Oil Sands Operations Senior Vice President, Maintenance and Reliability. Definitions The following terms and acronyms are used in this procedure: Asphyxiant B/U Car Seal Material capable of reducing the level of oxygen in the body to dangerous levels. Business Unit Refer to Seal Continued on next page Page 5 of 96

6 Definitions Continued Cascading or Satellite Lock Box Cross Boundary Lock Box Competent Worker Department Lock DCS E&I Energy Isolation Devices A secondary Lock Box used: To secure the keys for locks that have been placed on either cross boundary or master lock boxes To contain/secure the original HEI that ties the cascading lock box to the cross boundary or master lock boxes as applicable. The cascading or satellite lock boxes are typically located in the field (away from the master lock box). When a cascading lock box is used, workers will place their personal and department locks on the cascading lock box unless directed otherwise by Operations. Refer to Appendix 4 for additional information. A secondary lock box used when control of hazardous energy requires isolation in areas controlled by different Permit Offices. Cross boundary lock boxes will: Secure the keys for locks that have been placed on master lock boxes. Contain/secure the original HEI that ties the cross boundary lock box to the master lock boxes. Cross boundary lock boxes may be located in the field (away from the master lock box), or in the Permit Office. When a cross boundary lock box is used, workers will place their personal and department locks on the cross boundary lock box unless directed otherwise by Operations. Refer to Appendix 4 for additional information. A worker who: Is adequately qualified Is suitably trained Has sufficient experience to safely perform work without supervision, or with only a minimal degree of supervision. Locks which are common to individual work groups. They are most commonly used on lock boxes, but will also be used on isolation points during receiver safing. Used to control isolations across multiple shifts when work is not complete. Distributed Control System Electrical and Instrumentation A mechanical device that physically blocks, isolates, or dissipates the transmission or release of energy. Examples include, but are not limited to: A manually operated circuit breaker A disconnect switch A line valve A blank or blind Note: All energy isolation devices will be physically secured in place to ensure no inadvertent release or energization. Continued on next page Page 6 of 96

7 Definitions Continued Energy Isolation Point Equipment Exothermic First Break A specific location in a system or process where a system (or a portion of a system) is isolated. There may be multiple Isolation Points to isolate an entire system. Personnel should note that one side of an isolation point is energized, while the other side of the isolation point is de-energized. Mobile or stationary components within a system. Examples of equipment include: portable generators, switchgear, a pump tied to piping. Chemical reaction that produces heat. The initial action of disturbing any pressure or hazardous energy boundary, following the isolation of a system. This includes, but is not limited to, breaking into: flanges, welded or bolted process piping, equipment, vessels, pits, tubing, tanks and manhole covers. Once the boundary has been safely opened subsequent breaks within the same isolation are not considered first breaks. Blinding and Deblinding are First Break activities. Functional Location (FLOC) FLHA A code in SAP identifying where equipment is installed in the field. Field Level Hazard Assessment Note: The First Break FLHA used in this procedure is mandatory for all First Breaks outlined in this procedure and different than the FLHA outlined in Governing Document RGM Freeze Plug Hardwired Connection Hazardous Energy Hazardous Process A procedure used to temporarily isolate a section of a piping system in order to perform maintenance or repairs. When this is done, a section of the pipe is frozen to create a plug using the process fluid within the pipe. A direct connection from a control device (for example, switch or potentiometer), to an electrical isolation point. Wiring cannot pass through any other control device such as a PLC, DCS or interlock. Electrical, mechanical, hydraulic, pneumatic, chemical, nuclear, thermal, gravitational, or any other form of energy that could cause injury due to the unintended motion, energizing, start-up or release of such stored or residual energy in machinery, equipment, piping, pipelines or process systems. Any activity (such as manufacturing, handling, storing, or using hazardous substances), that can cause a release or ignition that can result in death or irreversible human health effects, significant property or environmental damage, or off-site impacts due to acute toxicity, flammability, explosiveness, corrosiveness, thermal instability, or latent heat. Continued on next page Page 7 of 96

8 Continued Responsibility Step Action Initial/Date HEI HEI Form Isolate LCD Lock-Out (Master) Lock Box Hazardous Energy Isolation A step-by-step checklist used to identify all the energy isolation points that are required to be locked and/or blinded, so that work can proceed on a specific piece of equipment in a safe manner. To separate, disconnect, de-energize or depressurize. Liquid Containment Device The performance of isolating equipment. Auxiliary lock-out device used: To secure the isolation and verification keys To secure and contain the original HEI Form used for hazardous energy isolation To control isolation points. Workers will place their personal and department locks on lock boxes as instructed in this procedure. Refer to Appendix 4 for additional information. Locksets Maintenance Management of Change (MOC) Operations Operator Assist Locks that are grouped in sets and are used to lock out Energy Isolation Points shown on the HEI form. Suncor or Contractor personnel engaged in field activities to support isolation or energizing equipment. Includes Mechanical and E&I, as applicable for the given activity. Defined in RGP The department having immediate responsibility for the operations affected by the Hazardous Energy Isolation. Operations must have direct control of the worksite. Only used when emergency work must proceed in order to protect people, equipment, property, or the environment. An SWP is not required during an Operator Assist. An ILP shall be generated according to RGP15001 for all Operator Assists. The ILP will document the reason for the Operator Assist. OSSA PCNG Oil Sands Safety Association Proximity Controlled Nuclear Gauge Continued on next page Page 8 of 96

9 Definitions Continued Perimeter Isolation Also known as Boundary or System Isolation. When preparing isolations for large systems, as occurs during turnarounds, a Perimeter Isolation can be created. The HEI Form and its lockbox can be used for all scopes of work within that isolation. Once the equipment located within the scope of the Perimeter Isolation has been confirmed at Zero energy, First Break Authorizations are no longer required. All supporting documentation must be attached to the HEI Form. Note 1: Specific HEI forms are still required for some scopes of work within the perimeter isolation, such as vessel blinding for confined space entries. Note 2: Re-introducing energy within a system from a separate or independent source, e.g. for hydrotesting or flushing, could require its own HEI form. Note 3: When creating perimeter isolations, careful planning will simplify the return to service; e.g. using master and cascading lockboxes instead of a large perimeter isolation lockbox can make it easier to re-commission systems or do rotation checks Permit Issuer (Issuer) Personal Lock P&ID PLC Pyrophoric Rack-Out/In Operations person (the UL or SS, or their designate) in the Permit Office who will sign SWPs allowing work to progress in the field. A lock used to protect a worker which is uniquely identified as belonging to that worker and keyed such that only the identified worker can open that lock. All personal locks must have the name of the person, their department or company name, and their Suncor Personnel (Badge) number. Piping and Instrumentation Drawing Programmable Logic Controller Spontaneously igniting in air. A common term used to describe the work of electrical isolation (Rack out) and equipment energization (Rack In). This work often includes the removal and insertion of low voltage and high voltage circuit breakers from their connected position to the disconnected position in their mounting rack. It is not intended to infer that a piece of fixed disconnect-able electrical equipment is to be removed or installed in an electrical equipment housing, switchgear or motor control centre. Continued on next page Page 9 of 96

10 Definitions Continued Receiver Safing Safing / Safed Seal Securing Devices For situations where Permit Receivers or Competent Workers are able to safely isolate hazardous energy or confirm isolation of hazardous energy, and where they can confirm the zero energy state by themselves. Lockout is performed by all workers by placing a department lock and their personal locks on all isolation points. Limited to three isolation points or less. Actions required to achieve isolation of equipment and/or an area by controlling sources of hazardous energy to a zero energy state. A tamper-indicating device designed to leave non-erasable, unambiguous evidence of entry or tampering. All seals at Suncor are to be uniquely numbered. Items used to physically secure energy isolation devices in place. Securing devices must be strong enough to withstand inadvertent opening or activation. Common examples include: Chains and locks Cable ties and locks Security seals Refer to Appendix 4 for methods to secure energy isolation devices. SLD SME SOL SOW SS SWP Tags UL W/N WR Zero Energy Single Line Diagram Subject Matter Expert Safe Operating Limit Scope of Work Shift Supervisor Safe Work Permit Used for informational purposes ONLY. For example, drains/vents that are not part of a hazardous energy isolation, may be tagged open/closed, with information such as Location, Lockbox Number and position of valve. Unit Leader Work Notification Work Request (type of W/N) A condition reached when all energy sources to or within equipment are isolated, blocked, or otherwise relieved, with no possibility of re-energizing. Equipment is not safe to work on until it is in a zero-energy state for the defined scope of work. Page 10 of 96

11 ! CAUTION Procedure IF YOU ARE IN DOUBT AT ANY TIME DURING THIS PROCEDURE, STOP AND ASK YOUR SUPERVISOR 1. Operator Assist Responsibility Step Action Permit Issuer 1.1 Use the information in the following table to determine your next action. Is Operator Assist being requested Yes then Obtain approval from the SS or Unit Leader to support Operator Assist. Note: A Safe Work Permit is not required during an Operator Assist. Go to Step 1.2. No Go to Step 2.1. SS or UL 1.2 Use the information in the following table to determine your next action. If Operator Assist is Approved Not Approved then Assign Operations personnel to work with the worker(s) to perform emergency actions. Note: Operations personnel must be physically present at the scene, or in constant radio communication with the worker, to ensure a clear line of communication until the task is completed or a Safe Work Permit can be issued. Go to Step 1.3. Have worker generate a Safe Work Permit according to RGP0004A or Direct worker on actions to take so Operator Assist is not required. SS or UL 1.3 Discuss with the worker(s) and Operator what equipment will be isolated or manipulated before allowing personnel to go into the field. SS or UL 1.4 After the emergency is under control, generate an ILP according to RGP Note 1: The ILP is to document the reason for the Operator Assist, and any corrective actions necessary to prevent similar emergencies in the future. Note 2: If work must continue, a Safe Work Permit must be generated according to RGP0004A. Page 11 of 96

12 2. Receiver Performing Safing Responsibility Step Action Permit Issuer 2.1 Use the information in the following table to determine your next action. Is Receiver Performing Safing? Yes then Ensure safing requirements and accountabilities are clearly understood by Area Authority and Permit Receiver. Note 1: A lot of Receiver Safing work is done without the requirement for a permit. Refer to RGP0004A for activities that do not require a permit; typically in workshops or laydowns. In this case, follow the applicable procedures for the safe isolation of the equipment being worked on. Note 2: Receiver Safing is limited to three isolation points or less. For example: mobile equipment maintenance (trucks, dozers, shovels), building maintenance (furnaces, air conditioners). Note 3: For work in plants, for example some process instrumentation, Receiver Safing is at the discretion of the Permit Issuer. Permit Issuers can request lock boxes be used on jobs requiring less than three isolation points if the Permit Issuer believes the isolation could have significant impact on the plant, equipment, site personnel, or for any other reason. Operating Areas can develop local Work Practices to define which work is allowed to be performed under Receiver Safing. Note 4: Where permits are not required, Workers are responsible for Steps 2.2 to 2.5. Note 5: For receiver safing, personnel are acting as Operations performing and verifying their own isolations. A first break authorization form is not required, however a first break FLHA must be completed. Go to Step 2.2. No Go to Step 3.1. Receiver or Competent Worker Receiver or Competent Worker Receiver or Competent Worker 2.2 De-energize equipment according to the Safe Work Permit, SOW, or appropriate procedure before performing any field activities. 2.3 Install personal locks, as well as department locks when they are required (see Appendix 4). 2.4 Perform field work as specified in the SWP, or SOW and applicable authorization forms. Note: All requirements for field activities under the SWP Procedure (RGP0004A), apply to workers who safe equipment. Continued on next page Page 12 of 96

13 Continued Responsibility Step Action Receiver or Competent Worker 2.5 Use the information in the following table to determine your next action. If field work is then Complete Remove personal and department locks. Go to Step 2.6. Not Complete Safe the area and equipment. Remove personal lock. Leave Department Lock installed until Job is complete. Communicate the status of the job with Supervisor and/or Operations if applicable. Note: If the job was performed under a Safe Work Permit ensure No is checked off under is the job complete. If Operations have concerns about leaving the Receivers isolation in place, generate an HEI and build a Lock Box. Go to Step 2.7. Receiver and/or Operations 2.6 Re-energize equipment as required. Note: Ensure that it is clearly understood between the Receiver and Operations on who will return equipment to service when job is complete. In some situations there will be a process impact that needs to be considered. Receiver 2.7 Return to Permit Office and close out Safe Work Permit if applicable. 3. HEI Development Responsibility Step Action Permit Issuer 3.1 Review Safe Work Permit to determine level of Operations support required. Note: Before carrying out work, all isolation points necessary to control sources of hazardous energy must be identified by designated personnel. Permit Issuer 3.2 Use the information in the following table to determine your next action. If Hazardous Energy Isolation is then Required Go to Step 3.3. Not Required Process Safe Work Permit per procedure RGP0004A. Exit this procedure. Continued on next page Page 13 of 96

14 Continued Responsibility Step Action Reviewer 3.3 Determine if an existing or established HEI lock-out package exists in Livelink or Operations controlled department files. If HEI Exists then Review HEI form to ensure the isolation points will isolate the proper equipment, and allow the scope of work to be performed safely in the field. Go to Step 3.4. Does Not Exist Go to Step 3.6. Reviewer 3.4 Use the information in the following table to determine your next action. If existing HEI is Acceptable then Authorize isolation of equipment specified on the HEI form by signing the HEI form cover page. Go to Step 3.5. Not Acceptable Modify HEI per Appendix 1. Go to Step 4.1 after HEI is corrected.. Reviewer 3.5 Give the HEI form to Isolation Coordinator to coordinate the isolation. Go to Step 4.1. Continued on next page Page 14 of 96

15 Continued Responsibility Step Action Author 3.6 Review SOW and create a new HEI form or modify the existing HEI using the instructions in Appendix 1 to allow personnel to safely work on the identified equipment. Fill out HEI form according to Appendix 1. Note 1: The preferred method to identify components that need to be de-energized is to show valve/breaker locations on P&IDs/SLDs and attach them to the HEI form. In the absence of P&IDs/SLDs, drawings / sketches should be attached to the HEI form to identify equipment locations in the field. Note 2: All sources of hazardous energy will be physically isolated using energy isolation devices. Note 3: For electrical isolations, the HEI form is to include the method of verification (for example, hardwire test bump or electrical test equipment). Note 4: If the Confined Space Entry box is checked in Part E of the SWP, one of the following must be performed: The confined space must have a blind or blank installed in areas needed to protect the worker (preferred method). The confined space must have a double block and bleed isolation configuration to protect the worker, if allowed by a valid technical deviation (CTS-0002). Note 5: A double block and bleed cannot be used if the destination of the bleed may result in the release of hazardous (toxic or combustible) material into the work area thereby introducing an uncontrolled hazard. The bleed line is to be vented to a safe location. Note 6: If it is not reasonably practicable to provide blanking, blinding, or double block and bleed isolation, an alternate means of isolation may be used providing it ensures adequate protection to workers within the confined space. See Appendix 5 for details on when a Professional Engineer has to approve before implementation. Note 7: In some situations, isolating hazardous energy may create a greater hazard and must be evaluated further. For example: Isolating Electric Heat Trace (EHT), for installation or removal of insulation, may create more hazards than leaving the EHT energized (i.e., systems may freeze). Need to evaluate if the EHT should be isolated. In such cases, a Risk Assessment must be conducted and approved by Operations Management to ensure the job can be done safety using another method or process i.e., Insulators Trade Specific Rules (PMR0015A). Author 3.7 Give HEI form to Approver for review and approval. Continued on next page Page 15 of 96

16 Continued Responsibility Step Action Approver 3.8 Review HEI form to ensure isolation is correct. If Isolation is Acceptable Not Acceptable then Authorize isolation of equipment specified on the HEI form by signing the HEI form cover page. Go to Step 3.9. Discuss needed changes with Author (continuous improvement). Go to Step 3.6. Approver 3.9 Give copy of approved HEI form to Isolation Coordinator for use in the field. Give original of approved HEI form to Author for filing in Livelink or Operations controlled department files according to Step Author or Designate 3.10 Scan original HEI form and file in Livelink or Operations controlled department files for future use. Note: Designate can be any individual who is able to scan and upload documents into Livelink or Operations controlled files. 4. Operations Safing and/or Coordinating Safing Note 1: Do not proceed with isolation activities without two signatures on new HEIs (Author and Approver), or three signatures on existing HEIs (Author, Approver, Reviewer) on the applicable HEI Authorization Sections. Responsibility Step Action Isolation Coordinator 4.1 Review HEI form and contact appropriate Supervisor for resources to perform isolations. Note 1: If multiple disciplines will be needed for the isolation, the HEI form can be copied and split into separate packages for each discipline. The master copy of the HEI form will be kept at the Permit Office. Note 2: Do not seal the lock box until all isolations are complete unless blinds/blanks will be installed. If installing blinds/blanks, the lock box will be sealed after E&I isolations and piping system valves are isolated. Note 3: If isolations cross into the next shift, keys and paperwork can either be kept in a secure location in the Permit Office (i.e. behind the desk), or a sign must be placed on the lock box stating Isolations and Verifications in Progress (per Appendix 4) and the lock box secured with a Green Department Lock. Continued on next page Page 16 of 96

17 Continued Responsibility Step Action Isolation Coordinator 4.2 Determine the type or types of isolations shown on the HEI. If Isolation is for then Valve Isolations Go to Section 5.0. Blinds/Blanks Go to Section 6.0 E&I Isolations Go to Section 7.0. Nuclear Isolations Go to Section 8.0. Specialty Isolations Go to Section 9.0. None of the above Discuss with SS or UL to determine how isolation will be performed, and how it will be documented or tracked. 5. Valve Isolations Responsibility Step Action Installer 5.1 Obtain red isolation locks and key from the Permit Office. Note: All personnel taking keys out of the Permit Office will attach the key to a lanyard to help prevent the key from being dropped or lost. Installer 5.2 Manipulate valves according to HEI form. After verifying and confirming that each component is de-energized, install a red isolation lock per Appendix 4. Note: For valves where position cannot be verified after isolation (for example, well head valves, globe valves) the verifier must accompany the installer during isolation activities. Installer 5.3 Use the information in the following table to determine your next action. If there is then A problem with isolation (component or HEI form) Go to Step 5.4. No problem with isolation Go to Step 5.7. Continued on next page Page 17 of 96

18 Continued Responsibility Step Action Installer 5.4 Use the information in the following table to determine your next action. If the problem is With isolation (for example, component will not isolate) Not with isolating components then Discuss with Isolation Coordinator and determine a path forward. Potential options include: Generate a WR to have the equipment repaired. Determine if there is another method to isolate the system so problem component will not need to be isolated. If so, modify the HEI form per Appendix 1. Go to Step 5.5. Discuss with Isolation Coordinator in Step 5.6. Isolation Coordinator Isolation Coordinator 5.5 Inform Operator of next actions based on decision with problem component. 5.6 Use the information in the following table to determine your next action. If there is A problem with the HEI form (isolation as specified will not protect workers) then Modify HEI per Appendix 1. Return to Step 4.1 to continue isolation activities after HEI is corrected. No problem, HEI form is correct Go to Step 5.2. Installer 5.7 Use the information in the following table to determine your next action. If valve isolations are then Complete Go to Step 5.8. Not Complete Go to Step 5.2. Installer 5.8 Return Installer keys to Permit Office and initial all points on the HEI form that have been isolated per Appendix 1. Installer 5.9 Give HEI form to Isolation Coordinator, or to Verifier to perform verification of isolations. Verifier 5.10 Obtain yellow verification locks and key from the Permit Office. Verifier 5.11 Confirm isolation points on HEI form. After verification that valve is in correct position, zero energy exists, and isolation lock is properly securing valve, install yellow verification lock. Continued on next page Page 18 of 96

19 Continued Responsibility Step Action Verifier 5.12 Use the information in the following table to determine your next action. If there is A problem with the HEI form (i.e., isolation as specified will not protect workers) then Go to Step No problem, HEI form is correct Go to Step Verifier 5.13 Discuss with installer to determine if HEI form needs to be modified. If HEI form is then Incorrect Discuss with Isolation Coordinator in Step 5.6. Correct Go to Step Verifier 5.14 Use the information in the following table to determine your next action. Are valves in correct position as specified on HEI form, and Isolation Locks installed correctly then Yes Go to Step No Go to Step Verifier 5.15 Discuss with Installer to determine if a mistake was made. Was an incorrect valve isolated, or lock installed incorrectly? Yes then Discuss with Operations Management to determine path forward. No Go to Step Verifier 5.16 Use the information in the following table to determine your next action. If all valve isolations on the HEI form are Completed then Return verifier keys to Permit Office and initial the HEI form on all points that have been isolated per Appendix 1. Go to Step Not completed Go to Step Verifier 5.17 Inform Isolation Coordinator that valves are isolated and HEI form has been returned to the Permit Office. Continued on next page Page 19 of 96

20 Continued Responsibility Step Action Isolation Coordinator 5.18 Use the information in the following table to determine your next action. Do blinds / blanks have to be installed? then Yes Record number of lock box seal on HEI form per instructions in Appendix 1. Make a copy of the HEI form for the outside of the lock box. Separate Part 2 of the HEI form. It is to remain in the control of the Isolation Coordinator until blinding and blanking activities have been completed. Place the remainder of the original HEI form in lock box with all appropriate signatures, supporting documents and isolation keys. Install seal on lock box, with a Blinding or Deblinding in Progress sign per Appendix 4. Go to Step 6.1. No Go to Step Blind / Blank Installations Note: If re-isolation will be required during De-Blanking activities, Operations must install the Re-Isolation Required for De-Blanking sign (per Appendix 4) on the Lock Box during the Blind/Blank process. This will serve as an aid to help remember that re-isolation will be required as part of De-Blanking/De-Blinding. Leave the sign on the Lock Box until ready to De-Blank. Responsibility Step Action Isolation Coordinator 6.1 Before allowing Maintenance to install blinds / blanks, confirm zero energy at the blind / blank location. If HEI form is Completed for blind / blank installations Not completed for blind / blank installations then Mark up a P&ID or appropriate drawing to show the blind/blank location in the field, where required. Have an SWP generated per RGP0004A for blinding/blanking activities. Enter First Break in the box marked Other, located in Part E of the Permit Form. Go to Step 6.2. Go to Step 4.1. Continued on next page Page 20 of 96

21 Continued Responsibility Step Action Isolation Coordinator Isolation Coordinator Isolation Coordinator 6.2 Identify blind / blank locations in the field using blank tags shown in Appendix 4. Note: Leave blind/blank tags at the blind location until after de-blind in Section 11 of this procedure. 6.3 Contact Maintenance to get resources to perform blinding / blanking activities. 6.4 Use the information in the following table to determine your next action. Is blind/blank part of plant operations (for example, normally closed blinds) then Yes Go to Step 6.5. No Go to Step 6.6. Isolation Coordinator 6.5 When Operations blind/blank is no longer required, remove blind/blank according to Section 11 of this procedure. Note 1: Note 2: Where a Department's Work Practices require that blinds/blanks be installed and locked for plant operations, a green Operations Department Lock must be used. These blinds/blanks are to be tracked using department work practices. The Lock Box is not required to remain active after the green lock is installed. Maintenance (Installer) 6.6 Obtain Safe Work Permit, red and yellow Isolation/Verification Locks, and key, if required, from the Permit Office for installation of blinds / blanks. Note: All personnel taking keys out of the Permit Office will attach the key to a lanyard to help prevent the key from being dropped or lost. Maintenance (Installer) 6.7 Install personal lock on Lock Box before installing blinds. Note 1: All personnel installing personal locks must remove their locks from the Lock Box and equipment in the field, before leaving the job site at the end of the shift. Note 2: Note 3: A Department Lock is not required because Maintenance is acting on behalf of Operations during blind/blank installation activities. Before installing personal lock, ensure the lockbox is sealed with a Blinding or Deblinding in Progress sign per Appendix 4. Continued on next page Page 21 of 96

22 Continued Responsibility Step Action Maintenance (Installer) 6.8 Install blind / blank at location designated on HEI form. Note 1: Installers are to confirm they are at the correct location by verifying that a blind/blank tag is at the location. Note 2: Note 3: If First Break is required, Operations is to be present at the work location before blind/blank installation activities. Perform First Breaks according to Appendix 2. The individual who will verify the installation (Operations or Maintenance) is not required to be present to witness installation of the blind/blank, and installation of the Installers Lock if the blind/blank is identified/stamped as a blind/blank or if it is a blind flange at the end of a pipe. If a blind/blank is not stamped and Operations is verifying installation, they shall be present to witness installation of the blind/blank and the minimum number of bolts to ensure that the blind/blank will not be removed. Operations can then leave and return to install yellow verifier lock after confirming red installer lock is applied. Maintenance (Installer) 6.9 Upon completion of blind/blank installation, install red Isolation Lock according to Appendix 4. Note: Isolation Lock signifies that the proper blind/blank has been installed. Maintenance or Operations (Verifier) Maintenance or Operations (Installer or verifier) 6.10 Confirm installation of the blind/blank on HEI form. After verification that the proper blind/blank has been installed correctly, at the right location, zero energy exists, and Isolation lock is installed, install yellow verification lock per Appendix Use the information in the following table to determine your next action. All blinds/blanks completed Yes then Return to Permit Office to sign-off SWP that was issued to install the blinds/blanks. Remove personal locks from lock box. Go to Step No Go to Step 6.8. Installer and Verifier 6.12 Initial each isolation point on Part 2 of the HEI Form, and add your name to the list of people who participated in the isolation, according to Appendix 1. Note: The installer is signifying proper installation of the blind/blank as indicated on the HEI form, and the verifier is signifying that the blind/blank has been verified as being correct according to the HEI form. Continued on next page Page 22 of 96

23 Continued Responsibility Step Action Isolation Coordinator 6.13 Use the information in the following table to determine your next action. Are all isolations on HEI form completed then Yes Break Lock Box seal, remove Blinding or De-Blinding Sign, and reunite all the sections of the HEI form. Record number of new lock box seal on HEI form according to Appendix 1. Make a copy of the HEI form for the outside of the lock box. Place original HEI form with all appropriate signatures in lock box with supporting documents and isolation keys. Install seal on lock box. Go to Step No Go to Step 4.1. Isolation Coordinator 6.14 Inform Permit Issuer that system has been safed and work under Safe Work Permit can proceed. Exit this procedure. Go to RGP0004A for processing of SWP. 7. Electrical and Instrumentation Isolations Note: Installer and Verifier for E&I Isolation Sources must be trained and competent on the test equipment. Responsibility Step Action Isolation Coordinator 7.1 Obtain resources to perform electrical isolation activities. Continued on next page Page 23 of 96

24 Continued Responsibility Step Action Installer 7.2 Obtain Safe Work Permit, locks and keys from Permit Office for installation on E&I isolation devices. Note 1: All personnel taking keys out of the Permit Office will attach the key to a lanyard to help prevent the key from being dropped or lost. Note 2: If Operations is not performing the verification function, they can accompany the Installer to verify the right equipment is isolated. Note 3: If it is not possible for a Verifier to confirm zero energy after equipment has been locked out, the Installer and Verifier will Go together. Note 4: When confirming zero energy through voltage testing, exposure to potentially energized systems can be minimized by conducting only one voltage test. If both competent workers are present and visually confirm the test was done properly, they can both act as the Installer and Verifier. Note 5: Transmission & Distribution personnel do not require a SWP as they are considered Operations personnel during performance of isolation activities. Note 6: Mining electrical personnel do not require an SWP as they are considered the Asset Owner during performance of isolation activities. Installer 7.3 Perform E&I isolations at locations designated on HEI form. Installer 7.4 Use the information in the following table to determine your next action. If there is then A problem with isolation (Component or HEI form) Go to Step 7.5. No problem with isolation Go to Step 7.8 Installer 7.5 Use the information in the following table to determine your next action. If the problem is With the isolation (for example, component will not isolate) Not with isolating components then Discuss with Isolation Coordinator and determine a path forward. Potential options include: Generate a WR to have the equipment repaired Determine if there is another method to isolate the system so the problem component will not need to be isolated. If so, modify the HEI form per Appendix 1. Go to Step 7.6. Discuss with Isolation Coordinator in Step 7.7. Continued on next page Page 24 of 96

25 Continued Responsibility Step Action Isolation Coordinator Isolation Coordinator 7.6 Inform Installer of next actions based on decision with problem component. 7.7 Use the information in the following table to determine your next action. If there is A problem with the HEI form (for example, isolation as specified will not protect workers) then Modify HEI per Appendix 1. Return to Step 4.1 to continue isolation activities after HEI is corrected. No problem, HEI form is correct Go to Step 7.3. Installer 7.8 Upon completion of E&I isolation, install Black Electrical Equipment Lock if equipment is greater than or equal to 480V and less than 13.8kV. Note: If an electrical device is not capable of receiving a lock (such as a fuse holder), open the device and perform one of the following: Install a security seal to block reclosing of the device. (Operations Manager Approval required See Appendix 4) If a seal cannot be applied to the device: 1. Remove an essential component of the device. 2. Place the essential component in a lockable container. 3. Lock and seal the container. 4. Place a tag on the container and refer to the isolation. 5. Store container in proximity of Isolation. If it is not possible to isolate using listed methods, then isolation is to be guaranteed by disconnection of the device after testing for absence of energy. When this is performed, the connection point is to be tagged. Installer 7.9 Install a red Isolation Lock, signifying that the E&I component has been de-energized and zero energy has been confirmed. See Note under Step 7.8. Installer 7.10 Use the information in the following table to determine your next action. If all E&I isolations are then Complete Go to Step Not complete Go to Step 7.3. Installer 7.11 Return Installer keys to Permit Office and initial the HEI form for all points that have been isolated per Appendix 1. Continued on next page Page 25 of 96

26 Continued Responsibility Step Action Installer 7.12 Give HEI form to Isolation Coordinator, or to Verifier to perform verification of isolations. Verifier 7.13 Obtain Safe Work Permit, or use Installer s Safe Work Permit, to confirm isolation of the E&I Isolation Points on HEI form. Note: Confirm isolation by hardwire test bump, visual means of disconnect, or by test equipment. Verifier 7.14 Upon verification that isolations have been properly installed, zero energy exists, and isolation lock is installed, install yellow verification lock per Appendix 4. See Note under Step 7.8. Verifier 7.15 Use the information in the following table to determine your next action. If there is A problem with the HEI form (for example, isolation as specified will not protect workers) then Go to Step No problem, HEI form is correct Go to Step Verifier 7.16 Discuss with Installer to determine if HEI form needs to be modified. If HEI form is then Incorrect Go to Step 7.7. Correct Go to Step Verifier 7.17 Use the information in the following table to determine your next action. Are E&I components in correct position as specified on HEI form, and isolation locks installed correctly? then Yes Go to Step No Go to Step Verifier 7.18 Discuss with Installer to determine if a mistake was made. Was incorrect component isolated, or lock installed incorrectly? Yes then Discuss with Operations Management to determine path forward. No Go to Step Continued on next page Page 26 of 96

27 Continued Responsibility Step Action Verifier 7.19 Use the information in the following table to determine your next action. Are all E&I isolations on the HEI form completed Yes then Return verifier keys to Isolation Coordinator and initial all points that have been isolated on the HEI form per Appendix 1. Go to Step No Go to Step Verifier 7.20 Inform Isolation Coordinator that E&I components are isolated and HEI form has been returned to the Permit Office. Isolation Coordinator 7.21 Use the information in the following table to determine your next action. All isolations on HEI form completed then Yes Record number of lock box seal on HEI form per instructions in Appendix 1. Make a copy of the HEI form for the outside of the lock box. Place original HEI form with all appropriate signatures, supporting documents and isolation keys in lock box. Install seal on lock box. Go to Step No Coordinate remainder of lock-out. Go to Step 4.1. Isolation Coordinator 7.22 Inform Permit Issuer that system has been safed and work under SWP can proceed. Exit this procedure. Go to RGP0004A, for processing of SWP. 8. Nuclear Isolations Note: Installer and Verifier for Nuclear Sources must be trained and competent on the test equipment. Responsibility Step Action Isolation Coordinator 8.1 Confirm Installer and Verifier qualifications for nuclear sources by reviewing E&I department database, discussing with Technicians Supervisor, certification provided by the Technicians, or other management approved method. Continued on next page Page 27 of 96

28 Continued Responsibility Step Action Isolation Coordinator 8.2 Ensure appropriate drawing is marked up to show the nuclear source location in the field where required. Note: Ensure SWP for isolation of nuclear sources is generated per RGP0004A Isolation Coordinator 8.3 Obtain resources to perform nuclear isolation activities. E&I 8.4 Obtain SWP, locks and keys from the Permit Office for installation on nuclear isolation devices. Note: All personnel taking keys out of the Permit Office will attach the key to a lanyard to help prevent the key from being dropped or lost. E&I 8.5 Install nuclear isolations at locations designated on HEI form. Installer 8.6 Use the information in the following table to determine your next action. If there is then A problem with isolation (Component or HEI form) Go to Step 8.7. No isolation problem Go to Step Installer 8.7 Use the information in the following table to determine your next action. If the problem is Component will not isolate then Discuss with Isolation Coordinator and determine a path forward. Potential options include: Generate a WR to have the equipment repaired. Determine another method to isolate the system so the problem component will not need to be isolated. If so, modify the HEI form per Appendix 1. Go to Step 8.8. Not with isolating components Discuss with Isolation Coordinator in Step 8.9. Isolation Coordinator 8.8 Inform Installer of next actions based on decision with problem component. Continued on next page Page 28 of 96

29 Continued Responsibility Step Action Isolation Coordinator 8.9 Use the information in the following table to determine your next action. If HEI form is then Incorrect (isolation as specified will not protect workers) Modify HEI per Appendix 1. Return to Step 4.1 to continue isolation activities after HEI is corrected. Correct Go to Step 8.5. Installer 8.10 Upon completion of nuclear isolation, install red isolation lock according to Appendix 4. Note: The red isolation lock signifies that the nuclear component is shielded. Installer 8.11 Install black common key equipment lock on isolated equipment. Installer 8.12 Use the information in the following table to determine your next action. If all nuclear isolations are then Complete Go to Step Not Complete Go to Step 8.5. Installer 8.13 Return installer keys to Permit Office and initial the HEI form for all points that have been isolated per Appendix 1. Installer 8.14 Give HEI form to Isolation Coordinator or to Verifier to perform verification of isolations. Verifier 8.15 Confirm isolation of the nuclear isolation points on HEI form. Note: Confirm zero energy by appropriate testing means (e.g., Geiger Counter) Verifier 8.16 Upon verification that: isolations have been properly installed, nuclear source is shielded, isolation lock is installed, install yellow verification lock per Appendix 4. Verifier 8.17 Use the information in the following table to determine your next action. If there is A problem with the HEI form (for example, isolation as specified will not protect workers) then Go to Step No problem, HEI form is correct Go to Step Continued on next page Page 29 of 96

30 Continued Responsibility Step Action Verifier 8.18 Discuss with Installer to determine if HEI form needs to be modified. If HEI form is then Incorrect Go to Step 8.9. Correct Go to Step Verifier 8.19 Use the information in the following table to determine your next action. Are nuclear components in correct position as specified on HEI form, and Isolation Locks installed correctly then Yes Go to Step No Go to Step Verifier 8.20 Discuss with Installer to determine if a mistake was made. Was a mistake made (for example, incorrect component was isolated, or lock was installed incorrectly)? Yes Then Discuss with Operations Management to determine path forward. No Go to Step Verifier 8.21 Use the information in the following table to determine your next action. If Nuclear isolations on the HEI form are Completed then Return verifier keys to Isolation Coordinator and initial all points that have been isolated on the HEI form per Appendix 1. Go to Step Not Completed Go to Step Verifier 8.22 Inform Isolation Coordinator that nuclear components are isolated and the HEI form has been returned to the Permit Office. Continued on next page Page 30 of 96

31 Continued Responsibility Step Action Isolation Coordinator 8.23 Use the information in the following table to determine your next action. Are all isolations on HEI form completed? then Yes Record number of lock box seal on HEI form per instructions in Appendix 1. Make a copy of the HEI form for the outside of the Lock Box. Place original HEI form in lock box with all appropriate signatures, supporting documents, and isolation keys. Install new seal on lock box. Go to Step No Coordinate rest of lock-out. Go to Step 4.1. Isolation Coordinator 8.24 Inform Permit Issuer that system has been safed and work under SWP can proceed. Exit this procedure. Go to RGP0004A for processing of SWP. 9. Specialty Isolations Responsibility Step Action Isolation Coordinator 9.1 Use the information in the following table to determine your next action. Are Specialty Isolation Devices on HEI form? then Yes Install as per instructions from Professional Engineer. Note: See Appendix 5 for information on Specialty Isolation Devices and Single Isolation Methods. Go to Step 8.23 No Go to Step Temporary Re-Energization of Isolated Equipment Responsibility Step Action Maintenance or Operations 10.1 Determine if need exists to manipulate the equipment currently isolated. Continued on next page Page 31 of 96

32 Continued Responsibility Step Action Permit Issuer 10.2 Review Safe Work Permits and HEI forms associated with equipment that needs to be manipulated. Determine if manipulating equipment will adversely affect other work on the system, or workers in the area where equipment will be manipulated. Note: During this activity, all other permits on this Lock Box are suspended. Maintenance and Operations Maintenance and Operations 10.3 Ensure Personal Locks are removed from the Lock Box Ensure Department Locks are removed from the Lock Box. Operations 10.5 Break Lock Box Seal and get keys for Isolation/Verification Locks. Permit Issuer 10.6 Fill out the Temporary Re-Energization of Isolated Equipment section of the HEI form for the components that need to be energized. Maintenance and Operations 10.7 Perform a risk assessment with workers who will be involved with equipment manipulation. Note: This Risk Assessment is mandatory and is to be performed according to RGP0004A. Operations 10.8 Record number of Lock Box Seal on HEI Form per instructions in Appendix 1. Operations 10.9 Take the original Temporary Re-Energization of Isolated Equipment page to the field for sign-offs per Appendix 1. Operations is to maintain control of the document during equipment manipulation activities. Make a copy of the Temporary Re-Energization of Isolated Equipment page of the HEI form for the outside of the Lock Box. Place remainder of the original signed HEI form in lock box. Operations Install new seal on lock box, with a Temporary Re-Energization In-Progress sign per Appendix 4. Operations Remove Isolation and Verification Locks on equipment in the field to allow manipulation of equipment. Note: Only remove locks for the equipment that needs to be manipulated. Operations Re-energize the equipment as specified in the Temporary Re-Energization of Isolated Equipment section of the HEI form. Continued on next page Page 32 of 96

33 Continued Responsibility Step Action Operations or Maintenance Maintenance and Operations Installer and Verifier Perform work activities on energized equipment as required. Note: As this is considered work on a live system, no Personal or Department Locks are required. However, if Maintenance is involved in the equipment manipulation, determine the need for a Safe Work Permit Upon completion of work activities, re-isolate equipment as specified in this procedure Install red and yellow locks when equipment has been re-isolated and zero energy confirmed. Note: The same methodologies used for initial isolation activities apply for re-isolation activities. Operations Return keys to Lock Box and remove Temporary Re-Energization In-Progress sign. Isolation Coordinator Record new seal number on HEI form and complete the section for Temporary Re-Energization of Isolated Equipment according to Appendix 1. Note: Make a copy of the HEI form for the outside of the Lock Box. Isolation Coordinator Install new seal on lock box. Maintenance Reinstall Department Lock on lock box. Maintenance Reinstall Personal Lock on Lock Box. Maintenance Return to work to complete activities under SWP package. 11. Blind and Blank Removal Responsibility Step Action Isolation Coordinator Maintenance and Operations Maintenance and Operations Isolation Coordinator 11.1 Determine if all Safe Work Permits that require the blinds/blanks have been completed and signed off Ensure personal locks are removed from the lock box. Note: If necessary, remove locks using Appendix Ensure department locks are removed from the lock box. Note: If necessary, remove locks using Appendix Break lock box seal and get keys for isolation/verification locks. Note: All personnel taking keys out of the Permit Office will attach the key to a lanyard to help prevent the key from being dropped or lost. Continued on next page Page 33 of 96

34 Continued Responsibility Step Action Operations 11.5 Verify Yellow Blind Tag is at the location. Remove isolation and verification locks on equipment in the field. Note: One person can remove both sets of locks. Return locks to Permit Office. If the lockset is complete, fill in the HEI Form and return the locks to storage. If not, place the locks on the padlock station below the lockbox. Initial each isolation point in the Lock Remover column and add your name in Part 2, to the list of people who participated in the isolation, as per Appendix 1. Isolation Coordinator 11.6 Use the information in the following table to determine your next action. Is the system safe for blind/blank removal then Yes Go to Step No Generate a new HEI form according to Step 3.1 in this procedure to safe system for blind/blank removal. Go to Step Isolation Coordinator Isolation Coordinator 11.7 Coordinate safing of system where blind/blank will be removed, and inform Permit Issuer that system has been safed and SWP can be issued for blind/blank removal Record number of new lock box seal on HEI form per instructions in Appendix 1. Make a copy of the HEI form for the outside of the lock box. Separate Part 2 of the HEI form. It is to remain in the control of the Isolation Coordinator until blinding and blanking activities have been completed. Place the remainder of the original signed HEI form in lock box with supporting documents and isolation keys. Install seal on lock box with Blinding or Deblinding in Progress sign.. Operator 11.9 Ensure appropriate drawing is marked up to show the blind/blank location in the field where required. Note: Ensure SWP per RGP0004A for blind/blank removal is generated. Maintenance Obtain Safe Work Permit. Install personal lock on lock box before removing blinds/blanks. Note 1: A department lock is not required because Maintenance is acting on behalf of Operations during blind/blank removal activities. Note 2: If First Break is required, Operations is to be present at the work location before blind/blank removal activities. Perform First Breaks according to Appendix 2. Continued on next page Page 34 of 96

35 Continued Responsibility Step Action Maintenance Remove blind/blank at location specified in SWP. Note: Removers are to confirm they are at the correct location by verifying that a blind/blank tag is at the location. (Reference Step 6.2 and 11.5). Maintenance Return to Permit Office and remove personal locks from lock box. Maintenance Sign off SWP issued for removal of blinds/blanks. Maintenance Initial Part 2 of the HEI form confirming removal of blind/blank at locations specified of SWP. Operations Obtain a copy of Part 2 of the HEI form and verify blind/blank removal in the field. Is there a problem with the blind/blank removal? Then Yes Go to Step No Confirm blind/blank has been removed according to the HEI Form and flanges are mated. Go to Step Operations Leave the blind/blank tag at location, return to Isolation Coordinator and discuss the problem with blind/blank removal. Isolation Coordinator will contact Supervisor Maintenance to determine path forward. Operations Remove the blind/blank tag at locations, and return tag to Permit Office. Initial Part 2 of the HEI form confirming removal of blind/blank from location. Isolation Coordinator When all deblinding / deblanking activities are completed: Break Lock box seal, remove Blinding or Deblinding in Progress sign and remove HEI form. Reunite all sections of the HEI form. Is Scope of Work requiring isolation complete? Then Yes Go to Step 12.1 No Go to Step Continued on next page Page 35 of 96

36 Continued Responsibility Step Action Isolation Coordinator Isolation Coordinator Record number of new Lock Box Seal on HEI Form per instructions in Appendix 1. Make copy of the HEI Form for the outside of the Lock Box. Place signed HEI Form, supporting documents and isolation keys in Lock Box. Install seal on Lock Box Inform Permit Issuer that system has been safed and work under Safe Work Permit can proceed. Exit this procedure. Go to RGP0004A for processing of SWP. 12. Lock Removal and HEI Closeout Note: A copy of the HEI form should be taken into the field and used when reversing an HEI (i.e., removing locks). Responsibility Step Action Operations 12.1 Determine if all SWPs that involve the HEI form have been completed and signed off. Note 1: Equipment or systems must not be returned to service, and sources of hazardous energy must not be re-energized until all work is safely completed. Note 2: All SWPs involving the HEI Form must be signed off before closing out the HEI. Operations 12.2 Ensure all locks are removed from the lock box. Note 1: If necessary, remove locks using Appendix 3. Note 2: Refer to Appendix 4, for department lock removal. Operations 12.3 Remove lock box seal and get keys for isolation/verification locks. Note: All personnel taking keys out of the Permit Office will attach the key to a lanyard to help prevent the key from being dropped or lost. WHEN REMOVING LOCKS, EQUIPMENT MUST BE LEFT IN A SAFE STATE. THIS COULD INCLUDE DRAINS AND VENTS BEING CLOSED AND CAPS/PLUGS FITTED Operations 12.4 Remove remaining isolation and verification locks on equipment in the field. Note 1: Operator can remove both sets of locks, or designate to E&I where applicable. Note 2: Do not remove black common keyed equipment locks. Operations 12.5 Return locks and keys to Permit Office storage area. Initial each isolation point in the Lock Remover column, and add your name to the list of people who participated in the isolation per Appendix 1. Isolation Coordinator 12.6 Sign off HEI Form per Appendix 1 and file HEI Form per Department procedures. Continued on next page Page 36 of 96

37 Continued Responsibility Step Action Operations 12.7 Use the information in the following table to determine your next action. Is a Black E&I Equipment Lock installed then Yes Go to Step 12.8 No Go to Step Isolation Coordinator 12.8 Request E&I or Competent Worker to remove black common keyed equipment locks as required to support plant line-ups. Note: When equipment is being returned to service, the black common keyed equipment locks are to be stored according to Area Department procedures. Operations 12.9 Before starting up the system, verify valve lineup according to department operating procedures. Note: HEIs are to be retained per RGP0004A Step 8.10 End of Procedure General Responsibilities The following individuals and groups have the following defined responsibilities: Community of Practice on CHEPTW Provides resolution of any interpretation issues associated with this procedure. Review requests for procedure changes from B/Us, and update this document if required regionally. General Manager OEMS Integration Ensures this document is reviewed according to the required revision cycle. Approved by: Derek Trapp, General Manager, OEMS Integration Page 37 of 96

38 Appendices (Forms and Template Links) *** Note: Forms and/or diagram with the symbol (***) in the table below can be found in Livelink using the following link: wtype=1 Appendix Description 1 Instructions for Completing the HEI Form, and HEI Form (***) 2 First Break Instructions, and First Break Authorization Form (***) 3 Instructions for Lock Removal, and Lock Removal Form (***) 4 Lock Descriptions, Lock-Out Devices and Lock Boxes 5 Specialty Isolation Devices and Single Isolation Methods, and Single Isolation Risk Assessment Form (***) 6 Lockbox Compliance Monitoring Form (***) 7 Control of Hazardous Energy Process Diagram (***) Page 38 of 96

39 Appendix 1 Instructions for Completing the HEI Form An HEI Form is generated to provide the necessary information for the efficient isolation of energy in a system to allow for maintenance work with no risk to employees, the environment or equipment. This Appendix describes how the HEI Form is to be completed so the parties involved in the HEI Form generation and approval process (for example, Author, Approver and Reviewer) understand the annotations on the form. Note 1: Note 2: Note 3: Note 4: Note 5: An HEI Form will aid in the identification and control of hazards, but will not by itself make the job safe. All personnel are expected to ensure the isolation points identified on the HEI form are the proper points to isolate the equipment in the field so work can safely be performed according to the Safe Work Permit and Scope of Work. Personnel are expected to follow applicable work procedures, and adhere to Journey to Zero principles to prevent and mitigate injury to workers or damage to equipment. In the following instructions, the text shown in bold is the same as printed on the HEI Form. All entries on an HEI Form can be done on a computer or by hand. If done by hand, all entries are to be printed (i.e. not hand written), unless noted otherwise (for example, signature or initials). An electronic version of the HEI form can be obtained using the link in the Appendices section of this procedure. A copy of the HEI form is located at the end of this Appendix. Refer to Appendix 6 for instructions on use of the Lockbox Compliance Monitoring (LCM) form. The objective of this form is to allow Business Areas to self-assess their compliance to the regional one-way program delineated in RGP0005A. It may be used to coach personnel working with lockboxes, and assist areas identify areas for improvement. Instructions: 1. HEI Cover Page Header 1.1 Enter the Equipment No (for example, the SAP FLOC for the asset that will be isolated). Examples: 85TM-4A, 04-SG-401C, etc. 1.2 Enter the Plant Number (for example, the number of the plant where the isolated asset is located). Business Units divide their assets into Plant numbers and assign equipment/areas to different CFTs. Examples: Mckay-754, EXT 300, etc. 1.3 Enter the Equipment Name (for example, a description of the asset that will be isolated). Examples: Feed Pump for Tailings Sump, HPSS B, etc. 1.4 Enter the Document Number (Optional). This field can be used by Operating Areas if they want to assign a unique or sequential number to HEIs. It may be useful for retrieval purposes for HEIs stored in the Operating Area controlled file. However, it is not required to be filled out. If used, the numbering system is to be determined by the Operating Area. 1. Top of First Page 1.5 Enter the total number of pages contained in the completed HEI. If additional pages are added at a later date, renumber the total number of pages by single line, initial/date. 1.6 Enter the Reason for Isolation (a description and/or reason the asset is being isolated and locked out.) Examples: Repack 3A pump or Maintenance on Steam Generator A, etc. Page 39 of 96

40 Appendix 1 Instructions for Completing the HEI form (Cont'd) Isolation Authorizations (Mechanical and Electrical) NOTE 1: There are times when one individual will not be qualified to authorize both mechanical and electrical authorizations, or one group wants to indicate they approve the Mechanical or Electrical section of the HEI. If a particular section is not required, check the Not Required box in the appropriate section. The instructions below apply to both the Mechanical and Electrical Authorization sections. NOTE 2: For Mechanical and Electrical sections of the HEI, the Author, Approver or Review of the HEI should enter any Special Precautions that Installers, Verifiers, or Lock Removers should be aware of during performance of the isolation activities. This section should provide information that Installers and Verifiers need to know before they start the lockout 1.7 Enter the name of the Author of the HEI Form (i.e., the individual who identified the Energy Isolation Points that will isolate the specified equipment and allow personnel to safely perform work). This should be a competent individual (e.g., the Permit Issuer, Area Authority, UL, Shift Supervisor or Electrical Supervisor, Shift Electrician or their designee). The Author cannot be the same person as the Approver. 1.8 Enter the name of the Approver of the HEI Form (i.e., the individual who approves the Energy Isolation Points specified by the Author). This must be a competent individual for the mechanical or electrical isolations being approved (e.g., the Permit Issuer, UL, Shift Supervisor, or Electrical Supervisor, or other individuals designated by the Operations or E&I Departments). The Approver cannot be the same person as the Author. Verify page numbers have been noted per Step For newly created HEI Forms, a reviewer signature is not required. Leave blank in this case. When using HEI forms previously approved according to 1.8, enter the name of the Reviewer (i.e., the individual that reviews the Energy Isolation Points and confirms they are still valid for the work to be performed). This must be a competent individual for the mechanical or electrical isolations specified on the HEI (e.g., the Permit Issuer, UL, Shift or Electrical Supervisor, or other individuals designated by the Operations or E&I Departments). The Reviewer can be the same person as the Author or Approver for previously approved HEI forms. If a P&ID or SLD was stored with the HEI form, the Reviewer must also ensure it is up to date. Specialty or Single Isolation determination and approval NOTE: The Shift Supervisor, or the Approver/Reviewer of the Mechanical Authorization section, will answer questions 1.10 through Answer the questions from the standpoint of the Worker who will be performing work after the Lock Box is sealed (see Reason for Isolation on HEI form) Answer Does this HEI contain Single Isolation approved per Appendix 5, section 4.2. Refer to Appendix 5 for types of devices and guidelines. Note 1: Note 2: Blinding done under single isolation (i.e., during blind installation) does not need further approval and should be checked No. If there is a situation where a blind is installed under single isolation, and another valve that is in the system that will not have a blind installed (i.e., worker performing work under single isolation), respond to the above question conservatively: check Yes. Check if Yes If the HEI form has single isolations that are approved per Appendix 5, section 4.2. Go to 1.11 No If the HEI form does not involve any single isolations that are approved per Appendix 5, section 4.2. Go to 1.11 Page 40 of 96

41 Appendix 1 Instructions for Completing the HEI form (Cont'd) 1.11 Answer Does this HEI contain Single Isolation per Appendix 5, section 4.3. Refer to Appendix 5 for types of devices and guidelines. Check if Yes If the HEI form has single isolations that are approved per Appendix 5, section 4.3. Go to 1.12 No If the HEI form does not involve any single isolations that are approved per Appendix 5, section 4.3. Go to Answer Does this HEI contain Specialty Isolation Devices. Refer to Appendix 5, sections 5 & 6 for types of devices and guidelines. Check Yes No if If the HEI form has Alternate Safing or Specialty Isolation Devices that are approved per Appendix 5, sections 5 or 6. Go to 1.13 If the HEI form does not involve any Alternate Safing or Specialty Isolation Devices that are approved per Appendix 5, sections 5 or 6. Go to 1.13 Note: 1.13 Review the answers to questions in 1.10 through 1.12 and answer the question Installation of Specialty or Single Isolation Devices Approved? If the answer is NO, progress no further. Find another way to complete the scope of work safely. If the answer is YES, the Approver/Reviewer or Shift Supervisor must sign as Approver. By signing, they confirm the following for each question that was checked YES: If Questions 1.10, 1.11 and 1.12 are all answered NO (i.e. there are no specialty of single isolation devices), then enter N/A in the "Approver" box under question 1.13 If Question Then confirmation indicates 1.10 is checked YES The work is approved under Appendix 5, section 4.2. Where zero energy could not be confirmed, the single isolation risk assessment section 1 and 6-9 has been completed, attached to the HEI, and approved by the shift supervisor is checked YES The work is approved under Appendix 5, section 4.3. A Professional Engineer has participated the risk assessment. The Single Isolation Risk Assessment has been attached to the HEI is checked YES The work is approved under Appendix 5, sections 5 or 6. A Professional Engineer, and appropriate level of approver depending on risk of installation (shown in section 5), has been recorded on the Single Isolation Risk Assessment. The Single Isolation Risk Assessment has been attached to the HEI. Page 41 of 96

42 Appendix 1 Instructions for Completing the HEI form (Cont'd) Seal and Lock Box Number 1.14 The Isolation Coordinator who seals the Lockbox will enter the following in the table at the bottom of Page 1: The seal number used to seal the Lockbox, Print their name, sign and date to indicate that they sealed the Lockbox. Enter the Lockbox Seal Number each time the Lockbox is sealed. Lockbox seals are uniquely numbered (for example, UP022498). Multiple lines have been provided in case more than one seal is required due to blind installations, or situations where temporary re-energization of isolated equipment is required. Attach additional copies of Page 1 to the HEI form if additional lines are needed. Note: When signing the HEI Form, the Isolation Coordinator signifies that all the isolation activities have been completed. The lock installers and verifiers retain the accountability for the confirmation of Zero Energy. Complete this section every time the lock box is re-opened The Isolation Coordinator will enter the Lock Box Number in which the HEI Form and isolation lock keys are stored on the bottom of Page 1. Each lockbox will be identified by a unique number (per Permit Office), and this number will be noted on the Safe Work Permit according to RGP0004A Safe Work Permits. 2. Lock, Lockbox Seals and Reason for Seal Installation 2.1 The Isolation Coordinator will enter the Lockset Number(s) used to isolate the components in the field. Each lockset contains Red Installer and Yellow Verifier locks. Multiple boxes have been provided in case more than one lockset is needed for an isolation. The lockset number is on each lock and on the keys for the locks. Note: It is recommended as best practice to match the red and yellow locksets used. Example: To isolate a system, 14 Energy Isolation Points are identified on the HEI form. Lockset #33 contains 10 red and 10 yellow locks, and lockset #14 contains 5 red and 5 yellow locks. The Installers and Verifiers use the 10 red and yellow locks from lockset #33, and 4 red and yellow locks from lockset #14 to isolate the system. When the isolation is completed, the Isolation Coordinator will record the lockset numbers on the HEI Form. The unused locks are locked under the Lock Box (towel rack). Page 42 of 96

43 Appendix 1 Instructions for Completing the HEI form (Cont'd) 2.2 The Isolation Coordinator will enter the Number of Locks on the Ring for each lockset specified in Step 2.1. This is the total number of locks originally on each of the rings. In our example, 10 and The Isolation Coordinator will enter the Number of Locks Installed for each lockset. In our example, 10 and The Isolation Coordinator will enter the Number of Locks Not Used for each lockset. In our example, 0 and If security seals (shown in Appendix 4 and approved by the Operations Manager) are used to lock equipment in the field, the Verifier will enter the Number of Isolation Seals Used. This can occur for electrical equipment where a lock cannot physically be installed. If the electrical portion of the HEI had 4 breakers that were confirmed open with 4 Red and 4 Yellow seals on each breaker, the field verifier would enter 4/4 for the number of isolation seals used. If no seals are installed in the field, the Isolation Coordinator should enter N/A in this box. 2.6 The Isolation Coordinator who seals the Lockbox will print their name, enter the Lockbox Seal Number, and provide the Reason for Installing the seal in the space provided in the table on Page 2. The reason for removing a seal is not required to be entered because the reinstallation note will address this. Example: New seal installed as part of temporary re-energization. 2.7 At any time during the isolation creation, installation or revision process, if additional space is needed to enter Notes or Comments, enter appropriate information in the space provided. 3. Electrical Isolation and Special Precautions NOTE 1: This section of the HEI should include electrical, instrumentation, and other non-mechanical isolations. If a discrepancy occurs as to where an isolation point should be recorded on the HEI form (i.e., mechanical or electrical), work with Operations management in the area to become consistent. NOTE 2: If this page is not needed as part of the HEI (i.e., there are no non-mechanical isolations), it is not required to be included with the HEI package. The Author is to complete Steps 3.1 through 3.6 below: 3.1 Enter the appropriate Page Number in the upper right hand corner of this page. 3.2 Enter the Point Number for each of the Isolation Points. The point numbers should be numbered sequentially. The number is assigned by the Author of the form. This number is also for Temporary Re-Energization of Isolated Equipment (Reference Step 5.2 of this Appendix). NOTE: If applicable, work with Operations to ensure the point numbers in the Mechanical section are not the same as the point numbers in the Electrical section. 3.3 Enter the Isolation Point and Description of Location. These are used by Installers/Verifiers to identify the physical piece of equipment to be manipulated as part of the isolation The isolation point is typically an alpha-numeric identifier used to specifically identify the equipment/ component in the field (e.g., 82GM-1B). It can be the FLOC number, equipment tag number, etc. If an equipment tag number does not exist (for example, if a breaker is not numbered on an SLD), describe the isolation point in terms that will make the location and identification of the component clear to competent Operators and/or other Installers/Verifiers E&I personnel (e.g., 82PA-13, Breaker 14). 3.4 Enter the Verification Method to be used by the Installer and Verifier to confirm zero energy. Typical methods include: VC = Visual Confirmation, TE = Test Equipment, HTB = Hardwire Test Bump). If another method is used, write the method in the space provided. Page 43 of 96

44 Appendix 1 Instructions for Completing the HEI form (Cont'd) 3.5 Enter the Isolation Position (i.e., the position the component must be left in to provide isolation). This is the position that the component will be manipulated to in the field). Examples include, but are not limited to the following: Breaker Indicate if it must be "De-Energized" or "Energized" upon completion of the HEI activities. Operations and E&I need to work together to determine which of the following codes will be used in a given area: O = Open or DE = De-Energized C = Closed or E = Energized Nuclear Indicate if it must be "shielded" or "unshielded" upon completion of the HEI activities. 3.6 The Author of the HEI should enter any Special Precautions that Installers, Verifiers, or Lock Removers should be aware of during performance of the isolation activities. This section should provide information that Installers and Verifiers need to know before they start the lockout. 3.7 The isolation installer will initial the Installer box for each isolation that they perform. The initials confirm that the individual placed the isolation point in the desired state, secured the isolation point with a red lock/seal and confirmed that the isolation has removed hazardous energy using the Verification Method indicated. 3.8 The isolation verifier will initial the Verifier box for each isolation that they verify. The initials confirm that the: Installer isolated the correct isolation point, Installer put the component in the desired state, Installer secured the isolation point with a red lock/seal, Isolation has removed hazardous energy, and Verifier has placed a yellow lock/seal on the isolation point. 3.9 Upon completion of the scope of work requiring the isolation, the individual removing the locks/seals will initial the Lock Remover column on each line for the relevant isolation point, to confirm that the lock/seal has been removed from that location. 4. Mechanical Isolation and Special Precautions NOTE 1: This section of the HEI should include mechanical isolations. If a discrepancy occurs as to where an isolation point should be recorded on the HEI form (e.g., instrumentation valves), work with Operations management in the area to become consistent. NOTE 2: If this page is not needed as part of the HEI (i.e., there are no mechanical isolations), it is not required to be included with the HEI package. The Author is to complete Steps 4.1 through 4.5 below: 4.1 Enter the appropriate Page Number in the upper right hand corner of this page. 4.2 Enter the Point Number for each of the Isolation Points. The point numbers should be numbered sequentially. The number is assigned by the Author of the form. This number is also used for Temporary Re-energization of Isolated Equipment (Reference Step 5.2 of this Appendix). NOTE: If applicable, work with E&I to ensure the point numbers in the Electrical section are not the same as the point numbers in the Mechanical section. Page 44 of 96

45 Appendix 1 Instructions for Completing the HEI form (Cont'd) 4.3 Enter the Isolation Point and Description of Location. These are used by Installers/Verifiers to identify the physical piece of equipment to be manipulated as part of the isolation The isolation point is typically an alpha-numeric identifier used to specifically identify the equipment/ component in the field (e.g., 85HV-3501). It can be the FLOC number, equipment tag number, etc. If an equipment tag number does not exist (for example, many valves have not been numbered on P&IDs), describe the isolation point in terms that will make the location and identification of the component clear to all competent Operators and/or other Installers/Verifiers. 4.4 Enter the Isolation Position (i.e., the position the component must be left in to provide isolation). This is the position that the component will be manipulated to in the field). Examples include, but are not limited to the following: Valve Indicate if it must be "open" or "closed" upon completion of the HEI activities. Operations personnel need determine if the following codes will be used in a given area: O = Open C = Closed Blinds / blanks are entered separately in Part 2 at the end of the HEI Form. 4.5 The Author of the HEI should enter any Special Precautions that Installers, Verifiers or Lock Removers should be aware of during performance of isolation activities. This section should provide information that Installers and Verifiers need to know before they start the lockout. 4.6 The isolation installer will initial the Installer box for each isolation that they perform. The initials confirm that the individual placed the isolation point in the desired state, secured the isolation point with a red lock and confirmed that the isolation has removed hazardous energy. 4.7 The isolation verifier will initial the Verifier box for each isolation that they verify. The initials confirm that the: Installer isolated the correct isolation point, Installer put the component in the desired state, Installer secured the isolation point with a red lock, Isolation has removed hazardous energy, and Verifier has placed a yellow lock on the isolation point. 4.8 Upon completion of the scope of work requiring the isolation, the individual removing the locks will initial the Lock Remover column on each line for the relevant isolation point, to confirm that the lock has been removed from that location. 5. Temporary Re-Energization of Isolated Equipment NOTE: If it is determined after the HEI has been approved, installed, etc., that equipment needs to be temporarily re-energized, this page can be added to the HEI package at a later time by Operations. 5.1 The person who removes the existing seal off of a Lockbox is to enter the Removed Seal Number. 5.2 Enter the Isolation Point (for example, FLOC or Tag number), of the equipment to be manipulated. If a FLOC or Tag number does not exist, use the Point Number for the component as described in Steps 3.2 or 4.2 of this Appendix. 5.3 In the Reason for Removal box, provide the rationale for opening the Lockbox, and/or the reason for having to manipulate the isolation in the field. Page 45 of 96

46 Appendix 1 Instructions for Completing the HEI form (Cont'd) 5.4 The person who removes the installer and verifier locks/seals in the field is to initial the Lock Remover box on the HEI form. 5.5 The person who re-isolates the Energy Isolation Point will initial the Installer Initials box. The initials confirm that the individual placed the isolation point in the desired state as specified on the HEI form, secured the isolation point with a red lock/seal and confirmed the isolation has removed hazardous energy. 5.6 The person who verifies re-isolation of the Energy Isolation Point will initial the Verifiers Initials box. The initials confirm that the: Installer re-isolated the correct isolation point Installer put the component in the desired state as specified on the HEI form Installer secured the isolation point with a red lock/seal Isolation has removed hazardous energy, and Verifier has placed a yellow lock/seal on the isolation point. 5.7 The Isolation Coordinator will enter the New Seal Number on the HEI form after re-isolation of the system, both on this page and page 2. The Isolation Coordinator makes a copy of the HEI Form, returns the original to the Lockbox and the new seal is affixed to the Lockbox. 5.8 If the work results in isolation points being added or removed, it must be updated on the Isolation Points Page and modified per section 10 of this Appendix. 6. Worker Identification Table 6.1 Every person who takes part in isolating equipment as part of an HEI, must enter their Initials, Worker Name, Company and Department, and Suncor Badge Number in the appropriate columns on this page. 6.2 Every person who initials an HEI form (e.g., as part of modifying an HEI), must enter their Initials, Worker Name, Company / Department, and Suncor Badge Number in the appropriate columns on this page. 7. Return of Locksets 7.1 When closing out the HEI form, enter the Lockset Number as locksets are returned to the Permit Office. 7.2 Document if locks and keys are returned with the lockset by circling either "yes" or "no". If the answer is "no", generate an ILP in accordance with RGP15001 to document the incident and initiate lock / key replacement process. 7.3 The Isolation Coordinator who enters the information in Steps 7.1 and 7.2 will Print, Sign and Date signifying that the information is true and correct. Add Comments as required, for example ILP number for lost locks. 8. Blind / Blank Section PART 2 of the HEI form The Author is to complete Steps 8.1 through 8.5 below: 8.1 Enter the Point Number for each of the HEI Points. The point numbers should be numbered sequentially, and continue from those used on the Mechanical Isolation page of the HEI form. The number is assigned by the author of the form. This number can be used on the Temporary Re-Energization section of the HEI form when a FLOC or Tag number does not exist (Reference Step 5.2 of this Appendix). Page 46 of 96

47 Appendix 1 Instructions for Completing the HEI form (Cont'd) 8.2 Enter Blind Tag Number for each of the HEI Points. This should be the number on the yellow blank tag used to identify the blind / blank location in the field required in Section 6 of the Procedure. 8.3 Enter the Isolation Point Description of Location and Comments. These are used by Installers/Verifiers to identify the blind / blank isolation location. 8.4 Enter Size, Rating and Type for the blind / blank to be used. 8.5 Enter the Isolation Position (i.e., the position the blind / blank should be left in to provide isolation). Examples include, but are not limited to the following: "installed", "removed", swing closed, swing open, etc. 8.6 The blind/blank Installer will initial the Installer box for each isolation that they perform. The initials confirm that the Installer: Placed the isolation point in the desired state Secured the isolation point with an Installer Energy Isolation Device (for example, lock, seal). Confirmed the isolation has removed hazardous energy. 8.7 The blind/blank Verifier will initial the Verifier box for each isolation that they verify. The initials confirm: The Installer isolated the correct isolation point, The Installer put the component in the desired state, The Installer secured the isolation point with an Installer Energy Isolation Device, The isolation has removed hazardous energy, and The Verifier has placed a Verifier Energy Isolation Device (e.g., lock, seal, etc.) on the isolation point. 8.8 Upon completion of the work requiring the isolation, the individual removing the locks shall initial the Lock Remover column on each line for the relevant isolation point, to confirm that the lock has been removed at that location. 8.9 The individual in Maintenance who returns the blind / blank to correct position shall initial the Remover column confirming they completed the task Operations shall initial the Verifier column confirming blind/blank is in correct position per HEI form, flanges are mated and they have retrieved the yellow blank tag for the field location. 9. Persons involved with Blind / Blank Section PART 2 of the HEI form 9.1 Every person who takes part in the blind / blank activities (i.e., initialled the blind / blank section on the HEI form), must enter their Initials, Worker Name, Company / Department, and Suncor Badge Number in the appropriate columns on this page Page 47 of 96

48 Appendix 1 Instructions for Completing the HEI form (Cont'd) 10. Changes / Modifications to an Existing HEI form 10.1 There are times when it will be discovered that equipment in the field does not perform its intended function (e.g., a closed valve passes). When this occurs it will be necessary to use another isolation point. This section is intended to show personnel how to identify the Isolation Points that need to be changed, deleted, or added to an existing approved HEI. NOTE: It is recommended that Appendix 1 changes to an existing HEI be used if only a few points have to be changed. If the number of points that need to be changed, added, or deleted, could result in the HEI being confusing to personnel performing Isolations/Verifications, it is recommended that a new HEI be created to avoid confusion in the field. Example: The existing HEI indicates to isolate Valve #1 (V1) to allow work on Pump A. However, before or during the isolation process it is discovered that V1 passes. The obvious choice is to go upstream, and isolate the next available valve(s). In this example, V2 and V3 would need to be isolated HEI Change Instructions: Note 1: In the following, a change means any change, addition or deletion to an HEI form. Note 2: In the following, the Author and Approver of the change take responsibility that the modified isolations still meet the intent of the original HEI Strike-out V1 on the HEI form. In this example, V1 should be in the Mechanical Isolation section of the HEI form. The individual making the change is to initial and date the change. Typically the individual is the person who is performing the isolation. Note 1: This person is the Author of the change. The Author of the change does not have to be the same as the Author of the HEI. Note 2: Strike-out means to draw a single line through the text being deleted. Do not scribble out, block out, or otherwise make the existing text unreadable Add valves V2 and V3 to the HEI form to indicate that they will need to be closed. In this example, they would be added to the Mechanical Isolation section of the HEI form. Initial and date next to the addition on the HEI form. Page 48 of 96

49 Appendix 1 Instructions for Completing the HEI form (Cont'd) Take the HEI form to obtain an independent review. This will typically be a Unit Leader, Senior Field Operator, or other HEI Author. The reviewer is to initial and date next to all changes and enter the reason for the change in the Precautions section. The reviewer s initials and date indicate that they agree to the change (i.e., the change does not create any additional risks to the plant, system, asset or personnel). The reviewer is only authorizing the specific changes, not the entire HEI form. Note: This person is the Approver of the change. The Approver of the change does not have to be the same as the Approver/Reviewer of the HEI Take the HEI form to the Shift Supervisor for approval to proceed. The Shift Supervisor is to initial and date next to all changes. The Shift Supervisor initials and date signify approval to proceed with isolations in the field as shown on the modified HEI. The Shift Supervisor is not approving the modifications All individuals who initialed the HEI are to record their initials and name in the Workers Identification table Continue to process the HEI form as outlined in RGP0005A. Page 49 of 96

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59 1. Purpose: This Appendix provides instruction to: Appendix 2 First Break Instructions Help protect employees from the unexpected release of hazardous materials during the initial opening of process piping or equipment Ensure the correct line or equipment is being opened. Ensure proper risk mitigation plans with respect to the personal safety of all employees are implemented. Minimize or eliminate any environmental impacts due to the release of contaminants during First Break activities. Note: The steps in this Appendix are extra safeguards which must be followed in addition to all regular risk mitigation processes, and will help ensure shared understanding between Operations and Maintenance when a First Break on equipment or process piping is performed. 2. Scope: This Appendix applies to all personnel involved in First Break activities. Note 1: The following are not required for Operations Normal First Break activities: Use of the First Break Authorization Form. Use of the First Break FLHA (unless required by Area Operations Management). Use of Safe Work Permit (unless required by Area Operations Management). Note 2: Work on the following systems is not within the scope of this Appendix: Instrument air lines Lines servicing buildings: potable water and sewer lines Fire water lines Electrical systems 3. Definitions / Examples: First Break: The initial action of disturbing any pressure or hazardous energy boundary following the isolation of a system. This includes breaking into flanges, welded or screwed process piping, equipment, vessels, pits, tubing, tanks and manhole covers, and opening drains or vents. Once the boundary has been safely opened and Zero Energy confirmed, subsequent breaks within the same Isolation are generally not considered First Breaks. Note 1: Need for the First Break authorization form will be made by the Permit Office Note 2: Blinding and Deblinding are First Break Activities. First Break Authorization Form: A form used to: Identify the location of the First Break Authorize performance of First Break activities Document that the Area Authority and Permit Receiver have met in the field at the correct location of the intended First Break and confirmed Zero Energy where possible Document completion of the First Break. A copy of the First Break Authorization Form is attached to this Appendix. Continued on next page Page 59 of 96

60 Appendix 2 First Break Instructions (Cont'd) Definitions Maintenance First Break: Performed by competent Maintenance personnel using specified tools and equipment to break the pressure boundary of a piping system or vessel for the purpose of blanking/blinding or other work activities, and the confirmation of zero energy. Operations personnel will be present before the start of First Break activities to confirm Zero Energy where possible and to prevent a First Break from being performed at the wrong location. Examples of Maintenance First Breaks include: Opening process piping Opening vessels or equipment that is part of a process stream Packing certain pumps depending on the risk and potential of hazardous material that may be involved. For example, packing vacuum pumps in Extraction Plant 16 would be considered a First Break due to high levels of H 2 S. Operations Normal First Break: Performed by competent Operations personnel who are knowledgeable of the hazards and risk mitigation in their respective area, and who have been trained on the execution of their daily tasks. Examples of Operations Normal First Breaks include: Opening drains or vents Changing filters 4. Prerequisites: Note: All first break activities, whether performed by Operations or other work groups, must follow basic procedures and incorporate all necessary PPE to ensure personal safety is not compromised. Basic procedures (items) to consider include: Stable footing Safe access to equipment to be worked on Safe body position for control of tools used when loosening bolts Unobstructed escape route for emergency egress Preferred direction of any potential fluids released when the seal is broken on a flange (line of fire) Position of capture systems for any potential fluid releases Wind direction and potential exposure to gases, fumes, or mist. 4.1 Personnel should always assume the system could be energized. This could be due to valves passing, plugged vents or drains, etc. Before performing maintenance First Breaks, zero energy needs to be confirmed as stated in this Appendix. 4.2 Equipment identification and verification complete the First Break Authorization Form for Maintenance First Breaks. 4.3 Conduct a First Break FLHA for all maintenance First Breaks. The First Break FLHA form is attached to this Appendix. Note: For receiver safing, personnel are acting as Operations performing and verifying their own isolations. A first break authorization form is not required, however a first break FLHA must be completed. Continued on next page Page 60 of 96

61 Appendix 2 First Break Instructions (Cont'd) 4.4 Work area isolation and control Warning tape, barriers and/or signage must: Designate and isolate the First Break work zone Have signed tags stating when and why the area has been barricaded Be large enough to prevent exposure if there is a release of product Prevent unauthorized personnel and equipment from entering the work zone Be easily removable to allow emergency access if required. 4.5 All personnel must review all MSDS for products contained within equipment for potential material hazards including: Direct hazards associated with the product Potential effects created by interaction with other agents Emergency First Aid procedures. 4.6 All personnel must use mandatory and specialized PPE identified in the MSDS or Safe Work Permit. 4.7 Worker training and skills confirmation All workers engaged in First Break must: Be knowledgeable, trained and competent in the First Break Procedure Be knowledgeable in the inspection and use of any specialized PPE required Have current SCBA/SABA training (if applicable). 4.8 All workers engaged in First Break must use the proper tools and equipment for the specified work. 4.9 The following steps must be taken for management of gases/fluids expelled during the draining/venting processes: Ensure outlet vent or drains discharge to safe location Ensure first break material is directed to a predetermined safe place Consider use of drain hoses or hard piping in the absence of engineered drains Ensure grounding of all parts of a tank vent line attached to a purge hose Verify and test for safe air quality as required.! CAUTION WITH THE EXCEPTION OF INSTRUMENT AIR/UTILITY LINES, AND POTABLE WATER, FIRE AND UTILITY LINES, THE PRODUCT INSIDE THE PIPING MUST BE IDENTIFIED AND THE POTENTIAL PRESSURE, TEMPERATURE AND TOXICITY ASSESSED BEFORE ANY FIRST BREAK ACTIVITY. IF THERE IS A POSSIBILITY THAT TRAPPED HAZARDOUS GASES MAY BE PRESENT, SCBA OR SABA MUST BE WORN. THE SYSTEM MUST BE PROVEN BEYOND DOUBT TO BE SAFE FROM GAS HAZARDS TO WORK WITHOUT A SUPPLIED AIR SYSTEM. EMERGENCY RESPONSE PLANS MUST BE COMPLETED AND PERSONNEL MUST BE STANDING-BY AS REQUIRED.! CAUTION IF YOU ARE IN DOUBT AT ANY TIME DURING THE USE OF THIS PROCEDURE, STOP AND ASK YOUR SUPERVISOR. 5. General First Break Instructions: 5.1 Obtain a Safe Work Permit according to RGP0004A for any maintenance First Break activities. Also obtain First Break Authorization Form showing location where First Break is to be performed. Note: The Area Authority and Permit Receiver must meet in the field before any First Break activities are started to verify the absence of pressure in the system. Continued on next page Page 61 of 96

62 Appendix 2 First Break Instructions (Cont'd) 5.2 The Area Authority and Permit Receiver are to sign the First Break Authorization Form at the work location signifying that the location is correct and that it is acceptable for the First Break to be performed. 5.3 Verify all required isolation procedures have been completed. 5.4 Complete a First Break FLHA before starting the First Break. During the FLHA, review applicable MSDS with the work crew to ensure all required precautions are taken. Operations personnel will participate in the FLHA if required by the Permit Issuer. 5.5 Operations personnel must be present to gas test and monitor the First Break for residual pressure and product, if applicable. 5.6 If drains or vents are present and part of the First Break activity, Operations personnel must verify that required drains or vents are opened and clear. See RGP0006A Removing a Cap, Bull Plug or Blank from a Drain or Vent. 5.7 Flag off the First Break work zone and clear non-essential personnel from the area if the fluid or gas being drained is identified as hazardous. The First Break work zone needs to consider areas above, below and around the work area. 5.8 Perform First Break in accordance with Section 6.0 of this Appendix. 5.9 When First Break is completed, perform the following: Sign First Break Authorization Form signifying that First Break has been completed Deliver First Break Authorization Form and Safe Work Permit to the Permit Office. If needed, sign off SWP in accordance with RGP0004A Safe Work Permits Operations should make two (2) copies of the First Break Authorization Form: One copy is to be filed in a location determined by the Permit Office One copy is to be filed with the copy of the applicable HEI form. 6. Specific First Break Instructions: 6.1 System Verified: (i.e., Positive Verification of Depressurization and Isolation Exists) If depressurization of the piping system cannot be verified, immediately halt work and use the Alternate Safing / Isolation Methods section in Appendix 5. If zero energy has been verified, use the following protocols for the First Break methods listed: Bolted System Line Break:! CAUTION BOLTED CONNECTIONS WHICH MAY RELEASE HAZARDOUS GASES (H 2S, SO 2, CO), MUST NOT BE OPENED UNLESS A SELF CONTAINED BREATHING APPARATUS (SCBA) OR SUPPLIED AIR BREATHING APPARATUS (SABA) IS WORN BY PERSON(S) WITHIN THE AFFECTED AREA.! CAUTION ON SYSTEMS THAT MAY RELEASE HAZARDOUS GASES, PNEUMATIC OR ELECTRIC POWER TOOLS: CANNOT BE USED FOR THE FIRST BREAK PROCEDURE UNLESS APPROVED OTHERWISE BY A RISK ASSESSMENT CANNOT BE USED UNTIL THE FLANGE IS BROKEN AND GAS TESTING VERIFIES A SAFE ATMOSPHERE Where possible, ensure workers are positioned upwind of any gas or liquid release that may occur when the bolted connection is broken. Continued on next page Page 62 of 96

63 Appendix 2 First Break Instructions (Cont'd) Ensure a stable and neutral body position is adopted when loosening the bolted connection If pressure/liquid comes out of the piping when the flange is broken, move away and observe to determine if the release is subsiding in pressure or volume. If release is subsiding go to Step when release stops. If release does not subside but can be contained Retighten flange and contact Permit Issuer for further instructions. If the release of pressure or liquid volume cannot be contained: Evacuate upwind of the emissions and go to the pre-determined Emergency Assembly Point Notify Operations to take remedial actions Do not return to the work area until Permit Issuer confirms that it is safe to do so, or if required to perform an emergency intervention When the flow has stopped, approach the flange and confirm it is still open (i.e., not clogged with debris or product) If the flange is open, proceed with disassembly or other work as required Notify Operations the work is complete per Step 5.9. Continued on next page Page 63 of 96

64 Appendix 2 First Break Instructions (Cont'd) FIRST BREAK AUTHORIZATION FORM THIS FORM IS TO BE USED FOR ALL FIRST BREAKS PERFORMED BY NON-OPERATIONS PERSONNEL. Date & Time SWP Number Location (Equipment # or Asset Description) Area / Plant Location & Description of Agreed Upon Break-In Point: Please sign below to indicate that the Area Authority and the Permit Receiver (or Maintenance person actively involved in the First Break task), have met in the field at the location of the break-in point, have mutually agreed on the location and have confirmed Zero Energy or agreed to an alternative plan. Area Authority Date Permit Receiver or Mtce Date Please sign below to indicate that the work authorized by this form has been completed. Return this form to the Permit Office. Permit Receiver or Maintenance Date Page 64 of 96

65 Appendix 2 First Break Instructions (Cont'd) Page 65 of 96

66 Appendix 2 First Break Instructions (Cont'd) Page 66 of 96

67 1. Purpose: Appendix 3 Lock Removal Form To cut locks from isolation points or lockboxes without jeopardizing the safety of personnel or equipment. To remove a lock from an isolation point or lockbox when the key cannot be located, lock is inoperable, or key is damaged and it is proven safe to remove. 2. Instructions: 2.1 Removal of personal locks or department locks from lock box or equipment isolation point: Determine the status of the work, using Safe Work Permits or Work Orders Review the lock label/identification, to see who the lock belongs to. Make every effort to contact the lock owner or the supervisor of the worker. The following are some possible ways to do that Check the area or plant SIGN IN/OUT log to determine if the individual is still on site Try to contact the lock owner s supervisor to obtain status of job and location / contact information of the lock owner Try to contact the person at home If the worker cannot be contacted: Inspect the equipment / system that has to be de-isolated, to confirm that the equipment / system is safe to be de-isolated Complete the Lock Removal Form Contact the Area Manager, or On-Call Manager, for final approval to remove the lock Remove the lock using the following steps: If a cable or scissor lock is present, cut the cable or scissor first. If this is not possible, cut the lock hasp Retain locks/tags for future follow-up or investigation Generate an ILP according to RGP15001 to document that a lock had to be removed. The title of the ILP should be Lock removed per Procedure RGP0005A When the employee returns to site, inform them that their Personal Lock had to be removed. 2.2 Removal of isolation or verification locks from lock box or equipment in the field: If the location of the isolation / verification key is known: Contact the individual and have the key returned to site If the individual cannot be contacted, and the affected locks can be removed upon the individual's return, wait for the individual to return and remove the Isolation / Verification Locks at that time If the individual cannot be contacted, and the affected locks must be removed before the individual returns to site: Complete the Lock Removal Form. Contact the Area Manager, or On-Call Manager, for final approval to remove the lock. Obtain the spare key from the secured location. Take the lockset out of service until the employee returns the key to the Permit Office. Continued on next page Page 67 of 96

68 Appendix 3 Lock Removal Form (Cont'd) If an isolation / verification key: Is lost and the location of the key is known, but cannot be retrieved (e.g., a key falls into a pond) Is damaged and will no longer open the associated locks Obtain the spare key from the secured location and remove the locks Contact the lock vendor to obtain a new key. Take the lockset out of service until the new key arrives on site If an isolation / verification key is lost and the location of the key is not known (i.e., it could be found at a later date and used by unauthorized personnel): Obtain the spare key from the secured location and remove the locks Send the lockset to the lock vendor and have the locks re-keyed, or discard entire lockset If an isolation / verification lock is damaged and will no longer open: Remove the damaged lock using bolt cutters. Obtain a replacement lock with the same key configuration from the lock vendor. Take the lockset out of service until the new lock arrives on site Convert the lockset to the next smaller size lockset (i.e., a 10-lock lockset can be changed to a 5-lock lockset). Note: For all of the above conditions, generate an ILP according to RGP15001 to document that the condition that occurred, why the condition occurred, and actions taken to prevent recurrence. Page 68 of 96

69 Appendix 3 Lock Removal Form (Cont'd) Page 69 of 96

70 1. Purpose: Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes To provide a visual aid of the various locks, lock-out devices and lock boxes referenced in this procedure. 2. Scope: This Appendix applies to all personnel involved in lock out activities at Suncor s Wood Buffalo facilities, including vendors and contractors. 3. Locks: 3.1 The following lock colors are used for Isolation and Verification Locks: Red Isolation Yellow Verification Isolation and verification locks are not to be used for any application other than isolation and verification activities An isolation/verification lockset consists of both red and yellow locks. The lockset number will be engraved on each lock. Isolation locks will use the same key for each lock in the lockset. Verification locks will use the same key for each lock in the lockset, but this key will be different than the isolation key in the lockset. Locksets are not to be keyed the same Store unused isolation and verification locks and keys as determined by Operations Permit Offices A spare key for isolation and verification locks can be kept in a secure location controlled by the Operations Manager. For example, the spare keys could be retained in a lock box in the manager's office, and be sealed with a lock box seal. The spare key will only be used if the other key is lost or damaged. If a lock needs to be removed, generate a Lock Removal Form and ILP according to Appendix The following lock colors are for Department Locks: Purple Orange Brown Green Mechanical E & I Projects Operations Page 70 of 96

71 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) Department locks represent a Scope of Work, typically performed by Maintenance. They allow the group who is performing the Scope of Work to remain in control of the isolation until they are ready to return the equipment to service, even while no workers are present on the job A Department Lock is not used for the following tasks, where the person does not impact the mechanical state of the equipment. For example (not inclusive): Fuelling of equipment Operator inspection checks on a haul truck A Process Engineer entering a vessel to perform an inspection Note: All of the above examples require the use of a personal lock in order to ensure components to control hazardous energy remain isolated Department locks are to be commonly keyed according to department requirements. For example, a mechanical department may want to have all mechanical locks keyed the same, or they may decide to have various mechanical groups within the department keyed differently. Area Management can have a set of Department Locks to use during shutdowns, when controlling the activities of multiple contractors Store unused department locks and keys as determined by the applicable department Mechanical, E&I and Project locks must be clearly identified with the trade type. Operations locks can be engraved with "Critical" when Operations is isolating critical valves. Identify by attaching a tag to the lock or by labelling the lock The work group supervisor is to verify that all work has been completed and it is acceptable to return the equipment to service. Upon completion of this verification, the work group supervisor or designate, will remove the Department Lock from the Lock Box. 3.3 The black lock is used by E&I or Competent Worker when: isolating nuclear, or electrical equipment is greater than or equal to 480V, and when electrical equipment is less than 13.8kV: Black E&I Common Key Equipment Lock These locks will be common keyed so all competent individuals within the E&I department (or other Competent Worker) can install or remove the locks Store locks adjacent to equipment in the field, or as determined by the E&I department (or Competent Worker). Keys are to be stored as determined by the E&I department (or Competent Worker) It is recommended that once the lock is installed in the field, it is identified with the equipment number. Identification can be provided by attaching a tag to the lock or by labelling the lock. Page 71 of 96

72 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) 3.4 The following lock colors are to be used for Personal Locks: Blue Suncor Personal Silver Contractor Personal Suncor personnel and long term contractors with Suncor will use BLUE locks. All other contractors will use SILVER locks All personal locks need to be clearly identified with: Person s name Company / department Suncor employee (Badge) number. Note: This is a minimum. Lock tags with additional information, such as pictures and phone numbers, are allowed Identification can be provided by attaching a tag to the lock or by labelling the lock All personal locks are to be uniquely keyed by individual, but are to be keyed differently than other personal locks on site. For example, if individual #1 has 3 personal locks, these will be keyed the same. Individual #2 may also have 3 personal locks, but will not use the same key as Individual # Unused locks and keys are to be retained by the individual who owns the lock, or as specified by department management If a personal lock is lost, notify department management to obtain a new lock. Department management must monitor lost locks through the ILP system and take steps as required to prevent abuse of the lock system. 4. Blinds and Blanks: 4.1 Blinds and blanks shall be constructed to the following drawings: Spectacle blinds: DD00-L (See link below) h&nodeid= Bleeder blinds: DD00-L (See link below) h&nodeid= Lock blinds and blanks using one of the following methods: Note 1: Blinds/blanks are only required to be locked in place if they are considered an Energy Isolation Point as defined in this procedure. Otherwise it is recommended that they are locked by an Operations department lock. Note 2: Other blind/blank locking methods are acceptable as long as they prevent inadvertent blind/blank removal, and allow multiple locks to be attached to the isolation point. Page 72 of 96

73 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) Install a lockable bolt through the flanges (see picture below): Install a lockable nut cover over a stud. In the following diagram, two (2) nut covers are shown for clarity. Only one (1) nut cover is required to lock a flange. Page 73 of 96

74 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) Lock a stud in place with washer and chains: Lock blind in place with cable lock: 4.3 Example of Blind / Blank Location Tag: Page 74 of 96

75 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) 5. Lock-Out Hasps (Scissors): 5.1 The following is a selection of the various lock-out hasps and scissors that can be used in the field: 6. Lock Boxes: 6.1 Lock Box (master or cascading): Page 75 of 96

76 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) 6.2 Signs/Tags for Lock Boxes: Blind/Deblinding (Section 6 & 11) Required sign during blinding/deblinding Typically only installers Personal Locks are on lockbox however there may be other Department and Personal locks installed (such as E&I) to allow certain scopes of work to be performed. Contact Permit Office. Lock Box is sealed with security seal by Operations Sign removed after blinding/deblinding completed Temporary Re-Energization of Isolated Equipment (Section 10) Required sign during Temporary Re-Energization Personal Locks and Department Locks are removed from the Lock Box All SWP s are suspended while Temporary Re- Energization is in-progress No locks allowed on Lock Box during Temporary Re- Energization including Workers Personnel Locks Lock Box is sealed with security seal by Operations Sign removed after Temporary Re-Energization completed Re-Isolation Required for De-Blanking Required sign if re-isolation will be performed during De-Blanking activities, Operations must install the Re-Isolation Required for De-Blanking sign on the Lock Box during the Blind/Blank process. This will serve as an aid to help remember that reisolation will be required as part of De-Blanking/De- Blinding. Department & Personal Locks can be on Lock Box while this sign is installed Leave the sign on the Lock Box until ready to De- Blank. Isolations and Verifications in Progress Required sign if keys and paperwork are stored in the Lock Box during the isolation process If sign is installed on Lock Box, it will be locked closed with a Green Department Lock Remove sign when isolations are being performed in the field, or after all isolations have been completed No Personal Locks or Department Locks are on Lock Box when this sign is installed. Sign is not required if keys and paperwork are stored in a secure location in the Permit Office (outside of Lock Box) Page 76 of 96

77 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) 6.3 Cascading (satellite) and cross boundary lock boxes: Cascading and cross boundary lock boxes may be used in the following situations (this list is not all inclusive): Cascading Lock Boxes can be used to tie multiple isolations into a larger isolation; Cascading Lock Boxes can be used to reduce the traffic in a Permit Office. In this situation the Cascading Lock Box is installed near the work location, and personnel hang their personal lock on the Cascading Lock Box instead of the Master Lock Box (See Diagram 1 below); Cross Boundary Lock Boxes are used when isolations involve more than one Permit Office area (See Diagram 2 below). 6.4 Instructions for Creating a Cascading Lock Box: Isolate equipment in the field as specified on the HEI form. Make 2 copies of the HEI form: One copy is to be attached to the Master Lock Box, and the other copy will be attached to the Cascading Lock Box. The copies will be placed outside of both lock boxes for easy viewing Cascading Lock Boxes are typically installed in the field but can be installed in the Permit Office if deemed appropriate by Operations to tie multiple isolations together Operations personnel are to put the original HEI form from Step and keys for the locks that isolated and verified equipment in the field, in the Master Lock Box. Operations personnel will seal the Master Lock Box using a uniquely numbered seal as specified in this procedure. Note: The Master Lock Box is the lock box containing the original paperwork and keys that isolate the equipment in the field Operations generate a cascading HEI form for the Cascading Lock Box. This cascading HEI form must indicate the number of the Master Lock Box and what it is isolating A lock installer will install a RED Isolation lock on the Master Lock Box at the Permit Office. A verifier will then install a YELLOW Verifier lock. These locks will be from an unused set of locks (they cannot be from the same lockset as was used for isolation/verification of equipment in the field) The Installer and Verifier will place the keys for Isolation and Verification locks installed in Step in the Cascading Lock Box and sign the HEI form Place the cascading HEI form in the Cascading Lock Box. Attach the copy of the HEI form from the Master Lock Box to the Cascading Lock Box Operations personnel will seal the Cascading Lock Box using a uniquely numbered seal as specified in this procedure Workers place their Personal Locks and Department Locks on the Cascading Lock Box when they are working on equipment that is safed. The Master Lock Box can still have Personal and Department Locks applied to it when deemed acceptable by Operations The location of the Cascading Lock Box must be identified in the Permit Office and on each Safe Work Permit that is protected by the original HEI From in Step Field personnel are protected because the equipment isolation and verification keys for the locks on equipment isolations in the field cannot be removed from the Master Lock Box until the Cascading Lock Box is opened, and the Cascading Lock Box cannot be opened until all Personal and Department Locks are removed from the Cascading Lock Box. Page 77 of 96

78 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) DIAGRAM 1 (Cascading Lock Box) 6.5 Instructions for removal of a cascading lock box: Workers remove their Personal Locks from the Cascading Lock Box When the work specified in the SWP or SOW is completed, remove the Department Lock. If work appears to be complete and a Department Lock is still installed on either the Cascading or Master Lock Boxes, Operations will request the work group supervisor to verify that all work has been completed and remove the Department Lock. The work group supervisor, or designate, will verify that work has been completed and it is acceptable to return the equipment to service. Upon completion of this verification, the work group supervisor or designate, will remove the Department Lock from the Master Lock Box or Cascading Lock Box Operations personnel can now break the seal on the Cascading Lock Box, retrieve the keys/paperwork, and return the Cascading Lock Box (if necessary), keys and paperwork to the Permit Office Operations will remove the RED Installer lock, and YELLOW Verifier lock from the Master Lock Box. If there are no other locks on the Master Lock Box, break the seal on the Master Lock Box, obtain the keys and original HEI form, and remove isolations per this procedure Return all locksets and keys to the Permit Office for storage. Sign the HEI form according to this procedure. 6.6 Instructions for Creating a Cross Boundary Lock Box: Isolate equipment in the field as specified on the HEI form. Make 2 copies of the HEI form: Attach one copy to the Master Lock Box, and the other copy to the Cross Boundary Lock Box. Place copies outside of both Lock Boxes for easy viewing. Page 78 of 96

79 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) Cross Boundary Lock Boxes are typically installed in the Permit Office but can be installed in the field if deemed appropriate by Operations Operations personnel put the original HEI form from Step and keys for the locks that isolated and verified equipment in the field in the Master Lock Box. The Master Lock Box is then sealed by Operations personnel. Note: The Master Lock Box is the Lock Box that will contain the keys and original paperwork that isolates the equipment in the field Operations personnel generate a cross boundary HEI form for the Cross Boundary Lock Box. This cross boundary HEI form is to indicate the number of the Master Lock Box and what the HEI form in Step is isolating A lock installer will install a RED Isolation lock on the Master Lock Box at the Permit Office. A Verifier will then install a YELLOW Verifier lock. These locks will be from an unused set of locks (they cannot be from the same lockset as was used for isolation/verification of equipment in the field). Cover unused Lock Box holes with tape, or other method, and post signage at Lockbox to prevent workers from installing Personal and Department Locks on the Master Lock Boxes Place the keys for Isolation and Verification locks installed in Step in the Cross Boundary Lock Box Place the cross boundary HEI form in the Cross Boundary Lock Box. The copy of the master HEI form from Step is also attached to the Cross Boundary Lock Box Operations personnel are to seal the Cross Boundary Lock Box using a uniquely numbered seal as specified in this procedure Workers will place their Personal Locks and Department Locks on the Cross Boundary Lock Box when working on equipment that is safed under Step For Cross Boundary Isolations, Personal and Department Locks are not to be put on the Master Lock Boxes. This is to prevent re-energizing the system while personnel are working on the cross boundary isolation The location of the Cross Boundary Lock Box must be identified in the Permit Office and on each Safe Work Permit that is protected by the Master HEI in Step Page 79 of 96

80 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) DIAGRAM 2 (Cross Boundary Lock Box) 6.7 Instructions for removal of a cross boundary lock box: Personnel are to remove their Personal Locks from the Cross Boundary Lock Box Once the work specified in the SWP or SOW is completed, remove the Department Lock. If work appears to be complete and a Department Lock is still installed on the Cross Boundary Lock Box, Operations will request the work group supervisor to verify that all work has been completed and remove the Department Lock. The work group supervisor, or designate, needs to verify that all work has been completed and if it is acceptable to return the equipment to service. Upon completion of this verification, the work group supervisor or designate, will remove the Department Lock from the Cross Boundary Lock Box Operations personnel will break the seal on the Cross Boundary Lock Box, retrieve the keys/paperwork, and return the Cross Boundary Lock Box (if necessary), keys and paperwork to the Permit Office Operations will remove both the RED Installer lock, and YELLOW Verifier lock from the Master Lock Box. If there are no other locks on the Master Lock Box, break the seal on the Master Lock Box, obtain the keys and original HEI form, and remove isolations according to this procedure Return all locksets and keys to the Permit Office for storage. Sign off the HEI form according to this procedure. Page 80 of 96

81 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) 7 Security Seals: Security Seals are used to seal lock boxes. In rare occasions, to be approved by Operations Managers, Black, Red and Yellow Security Seals can be used for some specific isolation points, but only if it is physically impossible to use padlocks, by themselves or with hasps or cable locks. The seal numbers (unique) are recorded on the HEI form. 7.1 Example of Security Seals 8. Lanyards: 8.1 Example of key carabineer: Page 81 of 96

82 Appendix 4 Lock Descriptions, Lock-Out Devices and Lock Boxes (Cont'd) SAP Ordering Information Note: The materials listed in this Appendix can be ordered through SAP Material masters. When looking for materials, refer to the list below, or search in the Material Description field with: *,CHE,* When ordering locks or replacement keys, enter the engraving information in the engraving form found here. Material Master Description BOX,LOCK,CHE,CLEARLID CABLE,LOCKOUT,CHE,ADJUSTABLE,15 FT FORM, CHE, FIRST BREAK AUTHORIZATION HASP, CHE, STEEL, 1-3/4X4-1/2 IN LABEL,PADLOCK,CHE,50 PACK LANYARD, KEY, CHE, GREEN LANYARD,KEY,CHE,BLUE LANYARD,KEY,CHE,RED LANYARD,KEY,CHE,YELLOW PADLOCK,CHE,CONTRACTOR,SILVER,GENERIC PADLOCK,CHE,ELEC,INST,DEPT,ORANGE,ENGRAVED PADLOCK,CHE,ELECTRICAL,BLACK,ENGRAVED (with chain) PADLOCK,CHE,ELECTRICAL,BLACK,ENGRAVED (with no chain) PADLOCK,CHE,MECHANICAL,DEPT,PURPLE,ENGRAVED PADLOCK,CHE,OPERATIONS,DEPT,GREEN,ENGRAVED PADLOCK,CHE,PERSONAL,BLUE,ENGRAVED PADLOCK,CHE,PERSONAL,BLUE,GENERIC PADLOCK,CHE,PROJECTS,DEPT,BROWN,ENGRAVED PADLOCK,CHE,RED,ISOLATION,ENGRAVED PADLOCK,CHE,YELLOW,VERIFICATION,ENGRAVED RING,CHE,ROUND BAR,7IN DIA,3/8IN CR RING,CHE,ROUND BAR,9IN DIA,3/8IN CR SEAL, CHE, WHITE, PAIR, CHAINS INSTALLED SEAL,CHE,BLACK SEAL,CHE,BLUE SEAL,CHE,RED SEAL,CHE,YELLOW STATION, PADLOCK, CHE, 6 LOCKS TAG, CHE, BLINDING, DEBLINDING, RED TAG,BLANK,CHE,6X6 IN,LAMACOID TAG,DEBLANKING,CHE,6X6 IN,BLACK/RED TAG,FIELD,LOCATION,CHE,4 IN X 6 IN,PE TRAY, DOCUMENT, CHE, WALL MOUNT TAG, CHE, RE-ISO for DE-BLANK, 6x6, BLACK ON YELLOW TAG, CHE, TEMP RE-ENERG, 6x6, BLACK ON ORANGE TAG, CHE, ISO & VER IN PROG, 6x6, BLACK ON WHITE Page 82 of 96

83 1. Purpose: Appendix 5 Specialty Isolation Devices and Single Isolation Methods To establish a minimum standard for the isolation and lockout of hazardous energy and fluid associated with equipment prepared for maintenance or construction activities. The procedure is intended to ensure compliance with Part 15 of the Alberta Occupational Health & Safety Code, CSA Z460: Control of Hazardous Energy and Suncor Corporate Technical Standard 0201 (Piping Design and Plant Layout). 2. Definitions for Appendix 5: Term Positive Isolation For Equipment Removal or Service Definition Blank or blind, where the blank remains in place when removable spools are separated Or Double block valve complete with bleed installed between the two to ensure the closed valves are not passing. For Confined Space Entry Suitable blanks or blinds shall be used at equipment nozzles to achieve positive isolation. Double Block and Bleed (DBB) Single Isolation Use of two closed block valves with a bleed valve in between to confirm Zero energy and the integrity of the closed valves. The block valves must be located as close together as possible to reduce the chance of build-up of debris that could plug the bleed. The use of a single mechanical device (i.e., valve) to provide isolation of a portion of the system. P. Eng Professional Engineer registered with APEGA 3. Blinding Requirements: 3.1 The following criteria shall be adhered to when installing a blind or blank: Primary isolation and confirmation of Zero energy shall be proven and witnessed before issuing any work permit Work under Single Isolation shall be stated on the Safe Work Permit First Break Instructions (Appendix 2) shall be used to complete the positive isolation tasks Blinds should be installed at flange nearest the work being carried out Page 83 of 96

84 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) When it is impractical to use the closest flange, blinds should be installed at an alternate flange if BOTH of the following conditions are met: - There are no traps, pockets, or connecting lines between the flanges, e.g. instrument impulse lines which cannot themselves be blinded. - The line is tested and verified to be free from hazard between the work and the blind. If blinds are required to be installed where the above two conditions cannot be met, a written detailed procedure providing sufficient protection to workers shall be developed and approved by Operations and Maintenance Managers When blinding equipment or piping, consider the possibility of thermal expansion of contained liquids. Provision must be made to relieve any pressure resulting from such expansions, e.g. thermal relief, open vents, etc A bleeder blind should be used where piping does not have a vent or drain to enable depressurizing; and where valves pass and there is no means of depressurizing. Work shall proceed continuously until complete. 3.2 For Confined Space Entry positive isolation shall be achieved by blinding or blanking of all lines at the nozzle nearest to the vessel irrespective of their contents. If this is not possible, a technical deviation as per CTS-0002 Technical Deviation is required. 3.3 Whenever maintenance work is to be performed on a piece of equipment where the equipment will be removed and the piping ends left open and unattended, and/or work where leakage from an open connection may constitute a hazard, all open process systems shall be blinded once the equipment is removed. Note: Unattended means nobody there paying specific attention. If the job cannot proceed and the equipment is left unattended, you must either install blinds or blanks, or do a risk assessment. 4. Isolation by Valve for Equipment Removal for Maintenance Note 1: Although the OH&S Code allows the use Double Block & Bleed as a means of providing isolation of equipment for maintenance, Oil Sands and In-Situ facilities should use blinding/blanking. Note 2: Double Block & Bleed shall not be used as isolation method for Confined Space Entry unless there is a technical deviation is in place. Note 3: A double block and bleed cannot be used if the destination of the bleed may result in the release of hazardous (toxic or combustible) material into the work area thereby introducing an uncontrolled hazard. 4.1 Double Block & Bleed Requirements (DBB): Use of two closed block valves with a bleed valve in between to confirm zero energy and the integrity of the closed valves. The block valves shall be located as close together as possible to reduce the chance of build-up of debris that could plug the bleed. Page 84 of 96

85 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) 4.2 Single Valve Isolation Requirements: Provided that the equipment and piping system has been rendered to a state of Zero energy (i.e. secured isolation in place, system depressurized, drained), replacement equipment is close by and ready for immediate installation and the open process piping is not left unattended; some tasks can be completed under single isolation and still meet the intent of Occupational Health and Safety Code Part 15 - Section Isolating Piping. In these circumstances Single Isolation is authorized without further approval for any one of the bullets (i.e. independent of one another) listed below: Installing / removing blanks/blinds or orifice plates Repairs, modifications and maintenance on piping systems which do not contain hazardous energy and/or substances Disconnection / removal of a pipe section which can be drained/vented to an adequate location Piping, control valve and PSV removal (blind after removal) and reinstallation Instrumentation removal downstream of a root valve (plug/cap after removal) Steam tracing and trap servicing Servicing of furnace burners Water and condensate systems that are less than 50 C (120 F), air services and utility nitrogen Lube/seal oil service (lube/seal pump de-energized and locked out) Low hazard strainers (Single Isolation design carrying low hazard material)* Note 1: Low hazard material can be assessed by referencing MSDS Note 2: The following shall be performed for single valve isolation activities: A pre-job meeting shall be conducted with assigned personnel to review task steps involved with the execution of the task A conditional plan for subsequent isolation in the event of emergency shall be in place. Element change out or work will proceed continuously until complete If zero energy cannot be confirmed for the single isolations as noted above in paragraph 4.2, complete the Single Isolation Risk Assessment form (Sections 1 and 6-9) to assess if the work can be completed safely. P. Eng approval is not required in these situations. The approval is valid for a single instance only. The Shift Supervisor is the approver of the Single Isolation Risk Assessment. Attach the documentation to the HEI Form and Permits associated with the lockbox 4.3 Blinding and/or blanking is the preferred method and double block and bleed is an accepted alternative isolation method for services other than those listed in 4.2. Single isolation may be approved when it is not reasonably practicable to provide blinds or double block and bleed, and single isolation provides adequate protection to workers, certified as appropriate and safe by a P. Eng. In these instances, the engineer shall participate in the risk assessment. The participants in the Single Isolation Risk Assessment, one of whom must be a Professional Engineer, then become the Approver(s) of the work to be done under Single Isolation. Their name(s) are recorded on the Risk Assessment which is attached to the HEI Form and Permits associated with it. Page 85 of 96

86 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) The Single Isolation Risk Assessment form (Sections 1 9) shall be used to authorize single isolation. Participants in the Single Isolation Risk Assessment shall include area team members, a professional engineer, the permit issuer, the workers involved and any other necessary expertise (refer to the Single Isolation Risk Assessment form section 9 for required participants). The approval is valid for a single instance only. Single isolation can also be acceptable when the risks of performing the work under single isolation are the same as or less than the risks involved in installing necessary blinds, as determined by the professional engineer. In each of these cases: Isolation and de-pressuring of equipment shall be proven before issuing a Safe Work Permit Isolation points shall be isolated and secured A pre-job meeting shall be conducted with assigned personnel to review task steps involved with the execution of the task A conditional plan for subsequent isolation in the event of emergency shall be in place. Work will proceed continuously until complete If a satisfactory safe work plan cannot be agreed upon by all participants, refer to Section 5 Alternate Safing / Isolation Methods. 5. Alternate Safing / Specialty Isolation Devices: 5.1 This section applies to systems and equipment where isolation cannot be achieved as per: Blinding Requirements Section Double Block and Bleed Section Single Isolation Section Such techniques may include shutting down additional process systems or equipment upstream of the single isolation. 5.3 All Alternate Isolation must be approved by a professional engineer registered with APEGA 5.4 For Alternate Isolation the results of the risk assessment determine the level of approval * Residual RR1 - VP Maintenance & Reliability Integration Residual RR2 - Engineering Dir/GMs (Reliability or PE) Residual RR3 - Engineering Manager (Reliability or PE) Residual RR4 - Area Engineer (Reliability or Contact) Use of hot tap procedures Use of stopple procedures Use of freeze plug procedures Use of shear plugs Use of non-permanent pipe plugs Pinching or crimping off of lines Chemical gel plugs Engineered leak containment devices Plugging of open lines with pressure resistant expansion plugs Note: All freeze plugs require VP M&R Integration approval regardless of risk rank Page 86 of 96

87 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) 6. Alternative Isolation When additional process system or equipment shutdown is not feasible, and alternative isolation has to be considered, the Operations GM/Director (or designee) shall be informed and has approval or authority for any production losses resulting from shutting down additional process equipment before proceeding with the scope of work. 6.1 Operations Area Management, in consultation with Maintenance Area Management and/or other required resources (Engineering, H&S, Emergency Services and Contracted Services representatives), shall initiate a review of options to achieve isolation by alternate means. The options selected shall adhere to the following: Ensure that all alternate isolation methods are approved by a professional engineer Ensure safe work procedure is reviewed with employees doing the work and the permit issuers at a pre job meeting Ensure the procedure contains an emergency "abort" plan to evacuate employees and control hazardous material releases Advise appropriate (based on Risk Rank) Business Area Management of the intention to implement and use an alternative isolation procedure before doing so. 7. Approval of Appendix 5 Reviewed by: G. Jansen GM, Reliability Engineering 2014/04/30 Reviewed by: H. Tran, GM, Process Engineering 2014/04/30 Reviewed by: C.Ellerbeck, Director, T&R Integration 2014/04/30 Page 87 of 96

88 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) Diagram 1 -Single Isolation Decision Matrix Proceed with Blind/Blank or DBB YES Can Blind/Blank or DBB be confirmed? NO YES Can Single Isolation be used? Does system fall under 4.2 YES NO Complete Single Isolation Risk Assessment P.Eng required NO Refer to Section 6 Alternate Safing and Specialty Isolation Devices Will there be hazards and/or unconfirmed Zero Energy? YES Complete Single Isolation Risk Assessment Section 1, 6-9 P. Eng not required NO Proceed without further approval Is residual risk acceptable once controls are in place AND Is proposed safe work plan acceptable to the workers involved? NO YES Can alternate safing method be used (Subject to Risk Assessment)? NO YES Proceed with Work as per Single Isolation Risk Assessment and Safe Work Permitting Unit Outage required to safely isolate / render system nonhazardous Page 88 of 96

89 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) Single Isolation Risk Assessment Department: 1 Equipment Name: Oil Sands & In Situ Equipment No: SWP or HEI No.: Location of Work: Job Description: Trades Involved Estimated Duration (hrs) Total Time Involved Describe Alternatives to, and Justification for working under single isolation: 3 Complete and Attach Zero Energy Isolation / Lockout List (HEI Form) 4 Valve Information: Type of Valve: Valve Size: Valve Orientation: Horizontal Vertical Fouling Effects? Identify any Sealing/Seating or Stem Leakage Issues (deposits, etc.) 5 Methods to be used to verify/test integrity of the single isolation: (continuous watch may be appropriate) Example: Monitor drains/vents for 15 minutes minimum and check for plugging. Page 89 of 96

90 Appendix 5 Specialty Isolation Devices and Single Isolation Methods (Cont'd) 6 Toxicity: Corrositivity: Solids / Deposits: Other: Single Isolation Risk Assessment (continued) Fluid Properties to be isolated by Single Isolation: Fluid Name: Fluid Pressure: Fluid Temperature (C or F): Flammability: Flash Temperature = Auto Ignition Temp = Fluid Type: Liquid Vapor Slurry 7 If Valve Passes, Describe Mitigation Steps: 8 Precautions for First Break and Ongoing Work: Chemical Protection: (suits, gloves, face, etc) Respiratory Protection: Eye Protection: Line of Fire: Method of Egress: Location of Shower/Eye Wash: Fire Equipment/Crew Required at Worksite: (if yes, specify) Other: Yes NO 9 Acceptable Risk: The undersigned agree that work under the single isolation described on this form provides adequate protection to the workers, and the job can proceed safely. POSITION Maintenance Coordinator / Supervisor (not required if off shift Engineer (See section 4.3) PRINT NAME SIGN NAME DATE UL / Ops Coordinator / SS Permit Issuer Permit Receiver Page 90 of 96

91 Appendix 6 HEI Lockbox Compliance Monitoring Purpose: This Appendix provides instructions on use of the HEI Lockbox Compliance Monitoring (LCM) form. The objective of this form is to allow Business Areas to self-assess their compliance to the regional one-way program delineated in RGP0005A. It may be used to coach personnel working with lockboxes, and assist areas identify areas for improvement. It is not an auditable form. Note 1: The instructions for the HEI LCM form, and the current HEI LCM form, are based on Revision 8 of RGP0005A. Note 2: Anybody can complete the LCM form. Where possible, the LCM form should be completed with the involvement of the Isolation Coordinator and Unit Leader or Shift Supervisor. This interaction is important both as an opportunity to coach and correct any minor deficiencies, and to also give the Isolation Coordinator / Unit Leader/Shift Supervisor a chance to raise any issues they are experiencing with RGP0005A compliance. Header: 1. The individual filling out the HEI LCM form is to provide the information listed in the top section of the HEI LCM form. Form Questions: 2. Review the HEI, Lockbox, and field configuration (as appropriate) and answer questions on the form. The following guidelines should be used/considered when answering the questions: Answer to Question Yes No N/A Action to be Performed Question is correct No additional action required. There may be a problem on the HEI form, with the lockbox, or with locks in the field. Discuss with the appropriate individual(s) if possible to ascertain why the condition exists. The question is not applicable No additional action required. NOTE: During the monitoring process, if it is discovered that a situation is unsafe, stop the work and discuss with the Workers at a minimum. The Business Area is to determine if escalation to Operations Management is required. 3. Provide additional comments as appropriate in the sections provided. Questions answered no should have additional information describing why the condition occurred, and what was done to fix the condition (if required). 4. After completion of the LCM, it is recommended that the results be discussed with the Shift Supervisors. Completed forms should be retained by the Business Area and reviewed periodically to determine if any adverse trends are occurring. If so, these should be communicated to the Workers as a group to improve performance. 5. Consider retaining completed forms in an Operations controlled folder, or other location as specified by the Business Area. Page 91 of 96

92 Appendix 6 HEI Lockbox Compliance Monitoring Continued Page 92 of 96

93 Appendix 6 HEI Lockbox Compliance Monitoring Continued Page 93 of 96