Isolation and Tagging Procedure PR – M002 - Pilbara · PDF filePHPA ISOLATION AND...

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Port Hedland Port Authority Isolation and Tagging Procedure PR – M002

Transcript of Isolation and Tagging Procedure PR – M002 - Pilbara · PDF filePHPA ISOLATION AND...

Port Hedland Port Authority

Isolation and Tagging Procedure

PR – M002

PHPA ISOLATION AND TAGGING PROCEDURE: PR – M002

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TABLE OF CONTENTS

1 OBJECTIVE ................................................................................................................... 6

2 SCOPE ............................................................................................................................. 6

3 ASSOCIATED DOCUMENTS ........................................................................................... 7

4 ASSOCIATED REFERENCES .......................................................................................... 7

6 DEFINITIONS ................................................................................................................... 8

7 GENERAL SAFETY ........................................................................................................ 12

7.1 Competency to Perform Isolations.......................................................................... 13

7.2 High Voltage Isolations for Electrical Access .......................................................... 13

8 LOCKS AND USERS ...................................................................................................... 14

8.1 General Requirements ........................................................................................... 14

8.2 Lock Identification .................................................................................................. 14

8.3 Registers ................................................................................................................ 14

8.3.1 Lock/Key Register ......................................................................................... 14

8.4 Isolation Officers .................................................................................................... 14

8.5 Personal Lock Holders (Red Personal Isolation Locks) .......................................... 15

8.6 Yellow Isolation Locks ............................................................................................ 15

8.7 Visitor Locks & Tags .............................................................................................. 15

8.8 Record Keeping ..................................................................................................... 16

9 TAGS .............................................................................................................................. 17

9.1 Personal Danger Tags ........................................................................................... 17

9.1.1 Contractor Personnel .................................................................................... 17

9.1.2 Attaching the Tag .......................................................................................... 18

9.1.3 Removing the Tag ......................................................................................... 19

9.2 Isolation Tags ......................................................................................................... 20

9.2.1 Attaching the Tag .......................................................................................... 20

9.3 Out of Service Tags ............................................................................................... 22

9.3.1 Attaching the tag ........................................................................................... 23

9.4 Information Tag ...................................................................................................... 24

9.4.1 Attaching the tag ........................................................................................... 24

9.4.2 Removal of Information Tag: ......................................................................... 25

10 HASPS & LOCKBOXES .................................................................................................. 26

10.1.1 6 hole hasp ............................................................................................... 26

10.1.2 D HASP .................................................................................................... 26

10.1.3 12 hole hasp ............................................................................................. 26

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10.2 Lockboxes .............................................................................................................. 27

10.3 Maintenance Shift Log ............................................................................................ 27

10.4 Isolation Numbering / Isolation Register ................................................................. 27

11 TYPES OF ISOLATIONS ................................................................................................ 28

11.1 Approval to Remove Equipment from Service for the purpose of Isolation ............. 28

11.2 Minor Isolation ........................................................................................................ 28

11.2.1 Raising a Minor Isolation ........................................................................... 29

11.2.2 Closing a Minor Isolation ........................................................................... 29

11.2.3 Locking onto a Minor Isolation .................................................................. 30

11.2.4 Locking Off a Minor Isolation ..................................................................... 30

11.3 Multi-Point Isolation ................................................................................................ 31

11.4 Major Isolation ........................................................................................................ 31

11.5 Multi-Point & Major Isolation Permit System ........................................................... 32

11.5.1 Raising an Isolation Permit (for Multi-Point or Major Isolations)................. 32

11.5.2 Issuing an Isolation Permit ........................................................................ 32

11.5.3 Transfer of Isolation Permit to new Permit Holder ..................................... 33

11.5.4 Task Supervisor Actions: Sign On the Isolation Permit ............................. 33

11.5.5 Task Supervisor Actions: Sign Off the Isolation Permit ............................. 33

11.5.6 Task Supervisor Actions: Task handover to another Task Supervisor: ...... 34

11.5.7 Task Supervisor Actions: Work is complete and the equipment is safe to use ................................................................................................................ 34

11.5.8 Task Supervisor Actions: Work is not complete ........................................ 34

11.6 Locking and Tagging On/Off an Isolation Permit .................................................... 34

11.6.1 Personnel Locking On the Isolation Permit ............................................... 34

11.6.2 Personnel Locking Off the Isolation Permit ............................................... 35

11.7 Additional Isolation Permit ...................................................................................... 35

11.8 Changes to the Isolation Points of an Isolation Statement ...................................... 35

11.9 Closing an Isolation Permit ..................................................................................... 35

11.10 Emergency or Cyclone Preparation ........................................................................ 36

12 METHODS OF ISOLATION ............................................................................................ 37

12.1 Electrical Isolation Devices: General ...................................................................... 37

12.1.1 Electrical Isolating Devices with a Visible Physical Break ......................... 37

12.1.2 Electrical Isolating Devices with Phase Indicator Lights ............................ 38

12.1.3 Electrical Isolation Devices that do not have a Visible Physical Break or Phase Indicator Lights ................................................................................... 38

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12.1.4 Electrical Isolating Devices that have no means of determining if Load Side Electrical Energy has been disconnected ...................................................... 38

12.2 De-Contactor .......................................................................................................... 39

12.3 Circuit Breakers ...................................................................................................... 39

12.4 Electrical Isolating Devices that cannot be locked .................................................. 40

12.5 High Voltage (HV) Isolation: General ...................................................................... 40

12.5.1 High Voltage Access Permits .................................................................... 40

12.5.2 Isolation of High Voltage Motors where there is no potential for contact with High Voltage Apparatus ................................................................................ 41

12.6 Heavy Mobile Equipment (HME), Light Vehicles & Other Mobile Equipment .......... 41

12.6.1 Heavy Mobile Equipment .......................................................................... 41

12.6.2 Light Vehicles & Other Mobile equipment ................................................. 41

12.7 Mechanical Isolations ............................................................................................. 42

12.7.1 Valves & Process Lines/Vessels (Water, Fire Systems, Diesel, Oil, Slurry Water, Air, Sewerage) ................................................................................... 42

13 ISOLATION ERROR OR VIOLATION ............................................................................. 43

13.1 Failure to Remove a Lock or Tag ........................................................................... 43

13.2 Failure to transfer or incorrectly sign off on a Permit document as Task Supervisor or Permit Holder ..................................................................................................... 43

13.3 Completed Tag found on floor or ground ................................................................ 44

13.4 Tag Missing from a locked Isolation Point .............................................................. 44

13.5 Inability to lock an Isolation Point ........................................................................... 45

13.6 Key Misplaced or Missing ....................................................................................... 45

13.7 Key Found .............................................................................................................. 45

13.8 Lock Misplaced or Missing ..................................................................................... 45

13.9 Lock Found ............................................................................................................ 45

13.10 Unexpected movement of stored energy ................................................................ 45

14 RESPONSIBILITIES ....................................................................................................... 46

14.1 Registered Mine Manager ...................................................................................... 46

14.2 Nominated Person ................................................................................................. 46

14.3 Isolation Officer ...................................................................................................... 46

14.4 Authorising Officer .................................................................................................. 47

14.5 Task Supervisor ..................................................................................................... 47

14.6 Permit Holder ......................................................................................................... 47

14.7 High Voltage Operator ............................................................................................ 48

14.8 High Voltage Assistant ........................................................................................... 48

14.9 Work Group ............................................................................................................ 48

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14.10 Substation Entry ..................................................................................................... 48

14.10.1 Utah Bulk Loading Facility & Eastern Harbour ........................................ 48

14.10.2 Motor Control Centre (MCC) Access ....................................................... 49

15 LEVELS OF AUTHORITY FOR ISOLATIONS ................................................................. 49

16 EMERGENCY CONTACTS ............................................................................................. 49

17 PROCESS OWNER ........................................................................................................ 50

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1 OBJECTIVE

The purpose of the PHPA Isolation & Tagging Procedure is to ensure the safety of all personnel on the PHPA sites from injury caused by an uncontrolled release of energy. The procedures are designed to comply with Statutory Regulations and with PHPA Health and Safety Standards. This purpose shall be achieved by ensuring that where practicable Positive Isolation is used for the protection of personnel working under a system of isolation on PHPA sites. Where positive isolation is not practicable, operational controls that permit controlled movement when a positive isolation is not in place must be included within a Detailed Work Instruction (DWI) or Safe Work Method Statement (SWMS). This shall be approved in writing from the Registered Mine Manager for that specific task. Should a DWI or SWMS not exist for that task, a Job Hazard Analysis (JHA) shall be written and approved by the Registered Mine Manager or deputy before commencing that task.

2 SCOPE

The PHPA Isolation & Tagging Procedures apply to all operations on PHPA work sites that involve work tasks with a risk of a hazardous release of energy (e.g. electrical, mechanical, chemical energy). This includes all in-loading and out-loading conveyor systems at Utah Bulk Loading Facility and Berth 01. This procedure outlines the methods to be used when performing isolations on plant and equipment to prevent accidental release of energy sources whilst personnel are performing work on plant and equipment. A key requirement in preventing accidental energy release is to ensure that where practicable all isolation points are positively isolated. This will be achieved by ensuring that: • Electrical equipment is proven to be de-energised and the isolation points locked. • Mechanical Isolations are proven de-energised, systems bled, pressure released

and locked in the case of valves and restraining devices and an air gap provided or the use of spades or blanks in the case of pipelines.

The system will require: • Training and assessment to ensure personnel are competent to carry out the tasks

required by these procedures. • The use of padlocks to maintain the integrity of the isolation/s at the specified

isolation point/s. • The use of tags with padlocks to identify ownership and control. Notes: Where guards are not fitted, the lanyard pull cable is the limit at which any part of the body or implement in contact with the body can approach the conveyor, whether moving idle, unless the conveyor has been positively isolated. Isolations involving High Voltage shall only be carried out by appointed persons, and may require specifically designed switching procedures which differ from the procedures referred to in this and related documents. Please refer to PHPA PR – M003 High Voltage Access Procedure.

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3 ASSOCIATED DOCUMENTS

• DOC – M001 PHPA General Guidelines on Maintenance Work, Contractor and Operational Activities within PHPA Jurisdiction

• DOC – HS002 PHPA OHS Management Plan • PR – C001 Contractor Management • FM – M003 Request for Isolation Permit • FM – M004 Isolation Statement • FM – M005 Isolation Permit • FM – M006 Forced Lock Removal Form • PHPA Detailed Work Instructions (DWI) • PHPA Safe Work Method Statements (SWMS) • PR – M003 High Voltage Access Procedure • High Voltage Switching Procedures • QUBE Safe Work Method Statements (SWMS) • QUBE Detailed Work Instructions (DWI)

4 ASSOCIATED REFERENCES

• Occupational Safety and Health Act 1984 • Occupational Safety and Health Regulations 1996 • Mines Safety and Inspection Act 1994 • Mines Safety and Inspection Regulations 1995

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6 DEFINITIONS

Term Definition ALARP As Low as Reasonably Practicable [ALARP] defines that wherever

there is a risk present to people it must be balanced against the sacrifice needed to eliminate or reduce the risk. In any assessment as to whether risks have been reduced ALARP, measures to reduce risk can be ruled out only if the sacrifice involved in taking them would be grossly disproportionate to the benefits of the risk reduction

Area Owner The Area Owner is the person responsible for the equipment or process at the time of isolation (usually the direct supervisor of the equipment operator)

Authority

A written permission given by the Registered Mine Manager or delegate on matters relating to the PHPA Isolation and Tagging Procedure.

Authorising Officer A person who is trained and deemed competent and is appointed in writing by the Nominated Person to undertake the duties of Authorising Officer in accordance with PHPA Isolation & Tagging Procedure; this person shall undertake the duties of Authorising Officer under an Isolation Permit.

Competent Person A person who has, to the satisfaction of the Nominated Person, acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to be deemed competent to perform specific tasks safely and correctly.

Contractor Any firm or any person not an employee of PHPA engaged / commissioned to do work on any PHPA site

Contractor Supervisor The competent person nominated to PHPA by a Contractor to accept responsibility for ensuring all Contractor’s personnel follow this Isolation and Tagging Procedure, PHPA procedures and policies, including procedures related to permits.

Cyclone Tie-Down Coordinator

A person delegated as the coordinator as per PR – M005 Eastern Harbour Cyclone Preparation and PR – M006 Utah Cyclone Preparation Procedures.

Cyclone Recovery Coordinator

A person delegated as the coordinator as per PR – M005 Eastern Harbour Cyclone Preparation and PR – M006 Utah Cyclone Preparation Procedures.

De-Isolate / Re-energise Reconnect or enable an energy source to equipment. DWI A PHPA Detailed Work Instruction document. Emergency An emergency is an abnormal occurrence that can pose a threat to

the safety or health of employees, contractors, local communities, customers, or which can cause significant damage to assets or the environment

Extra-Low Voltage Not Exceeding 50 V a.c. or 120 V ripple-free d.c. (AS 3000: 2007 1.4.98)

D Hasp A device used to allow multiple locks to be attached to a Single Isolation Point, with space available for locks to be attached.

6 Hole Hasp A device used to allow multiple locks to be attached to a Single Isolation Point, with up to 6 holes available for locks

12 Hole Hasp A device used to allow multiple locks to be attached to a Single Isolation Point, with up to 12 holes available for locks

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Term Definition HV – High Voltage Voltage in excess of 1000 v a.c. or 1500 v d.c. (AS 3000: 2007

1.4.98) High Voltage Access Permit A printed form generated under these Regulations which authorizes

access to Isolated and Earthed (Dead) High Voltage Electrical Apparatus

HV Isolation Assistant An individual trained and assessed as a competent High Voltage (HV) Isolation Assistant and authorised in writing by the RMM.

HV Operator An individual trained & assessed as competent in the operation of High Voltage (HV) apparatus for the purpose of isolation and authorised in writing by the RMM

Information Tag A printed tag used to communicate a message about the conditions of entry, status of equipment or any other relevant information.

Isolation A means of preventing the transmission, build-up or unintentional release of pressure/energy/power by whatever means necessary to ensure that the plant or equipment is safe to work on.

Isolation Incident Any non-compliance with the Isolation and Tagging Procedure. Isolation Lock (Yellow) A yellow lock used for security to lockout for the purpose of isolation Isolation Officer A person who is trained and deemed competent and is appointed in

writing by the RMM to undertake the duties of Isolation Officer in accordance with PHPA Isolation & Tagging Procedure.

Isolation Statement A detailed plan of the isolation points needed to effectively de-energise or make a piece of plant safe.

Isolation Permit A control and assessment system used to ensure the safety of all personnel on the PHPA sites from injury caused by an uncontrolled release of energy whilst performing work on plant and equipment.

Isolation Point An approved mechanism/device which controls the energy source for the purpose of isolating or de-isolating a piece of plant or system of plant. Note: Devices such as emergency stops, pull wire switches or any other devices associated with control systems shall not be used as primary approved isolation points unless authorised by the RMM.

Isolation Register An electronic file register which contains all isolation information based on the request, statement and permit requirements for isolations to be carried out. The Isolation Register shall generate the number for all isolations. This shall be handed over upon shift change to the next shift via the Maintenance Shift Log.

Isolation Tag

A printed tag which is attached to all Isolation Points identifying the type of isolation by isolation number and lock box number where applicable.

JHA Job Hazard Analysis (can also been known as Job Safety Analysis) Lock Box A lockable box that shall be used in conjunction with Multi-Point or

Major Isolations for personnel to lock onto: • Lock Box – used for less than 15 personnel • Master Lock Box – used for less than 30 personnel

LV – Low Voltage Exceeding extra-low voltage, but not exceeding 1000 v a.c. or 1500V d.c. (AS 3000: 2007 1.4.98)

Maintenance Shift Log An electronic register of occurrences during each shift period that is handed over to the following shift upon change over for information and actions if required.

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Term Definition Major Isolation A Major Isolation should generally be used for:

• Complex jobs where a greater degree of control is required • Where the number of people working on a job exceeds 12

and/or • The number of isolation points required exceeds 15

Major Isolation Officer An individual authorised to place red personal isolation lock, blue isolation locks and yellow isolation locks, plus Personal Danger Tag and Isolation Tags on multiple isolation points for the intention of isolating the plant or equipment for complex jobs or jobs exceeding 5 personnel (Multi-Point & Major Isolation types); this person shall undertake the duties of Major Isolation Officer under an Isolation Permit.

Minor Isolation An Isolation where: • There is one (1) isolation point • There are five (5) or less personnel required to work

under the isolation • The person raising the isolation & performing the work is

a Minor Isolation Officer and authorised for that piece of equipment.

Minor Isolation Officer An individual authorised to place a red personal isolation lock and Personal Danger Tag, plus a yellow isolation lock and Isolation Tag on a single isolation point for the intention of isolating the plant or equipment for less than 5 personnel.

Multi-Point Isolation An Isolation where: • There is more than one (1) isolation point, but no more

than fifteen (15) isolation points • There are twelve (12) or less personnel required to work

under the isolation • The person raising the isolation & performing the work is

a Multi-Point Isolation Officer and authorised for that piece of equipment.

Nominated Person A person who has, to the satisfaction of the Registered Mine Manager, acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly and has been is appointed in writing to act as Nominated Person. The Nominated Person shall be responsible for appointing and authorising Isolation Officers, Authorising Officers & Competent Persons.

Out of Service Tag A tag used to identify equipment which is faulty and/or dangerous and shall not to be used or operated.

Permit Holder A person who has acquired through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly in that specific area; this person shall undertake the duties of Permit Holder under an Isolation Permit.

Personal Danger Locks and Tag

A lock and tag applied by a person with the primary objective to provide personal protection to an individual working on plant and equipment. Must be removed at the end of each job or shift.

Personal Lock Holder An individual competent and authorised to place a personal lock on a

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Term Definition piece of equipment or lock box for the intention of working on that equipment / system. They shall be trained in this procedure and assessed as competent.

PHPA Port Hedland Port Authority Point Isolation Locks (Blue) Common keyed locks placed by an authorised Isolation Officer,

placed on an individual isolation points for the purpose of isolating a piece of plant or system of plant; usually Blue.

Positive Isolation An isolation where physical barriers have been put in place to isolate all forms of energy irrespective of changes in conditions.

Refresher Training

Refresher training on the Isolation and Tagging Procedure and systems to be undertaken annually or at a relevant time designated by the RMM or Nominated Person.

Registered Mine Manager The individual registered with the Mines Act as being the Accountable person for mine site.

Request for Isolation Permit A detailed request form indicating the area, equipment and isolation points needed to effectively de-energise or make a piece of plant safe. The Isolation Statement is compiled from the information contained within the Request for Isolation Permit.

Shall Indicates the requirement is mandatory Should Indicates the requirement is recommended SWMS Safe Work Method Statement document. Task Supervisor A person who has acquired through a combination of training,

education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly in that specific area; typically a tradesperson, team leader or supervisor. The Task Supervisor is responsible for the safe execution and completion of the work.

Visitor A person not intending to perform work. Visitors must be supervised at all times by a PHPA personnel member trained in Isolation & Tagging Procedures.

Yellow Isolation Pocket The Isolation Permit is displayed at the lock box and is retained inside the Yellow Isolation Pocket, which as affixed to the lockbox using the Yellow Padlock.

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7 GENERAL SAFETY

The primary objective is to provide personal protection to persons working on plant and equipment. A secondary consideration is the prevention of damage to equipment and environment. The procedure applies equally to servicing, repairs, inspections, testing and adjustments, cleaning and pre-start checks. In all of these instances the PHPA Isolation and Tagging Procedure shall be followed. REMEMBER: FAILURE TO FOLLOW THE PROCEDURE COULD RESULT IN DEATH, DISABLEMENT, PERSONAL INJURY OR DAMAGE. FOR THAT REASON, UNAUTHORISED REMOVAL OF TAGS OR OTHER VIOLATIONS OF THE ISOLATION AND TAGGING PROCEDURE MAY RESULT IN DISCIPLINARY ACTION. This procedure is required to protect individuals or groups of personnel from physical injury or through contact with or exposure to the following types of energies: • Chemical (corrosives, gases, toxic materials) • Electricity • Radiation (induction sources, lasers) • Mechanical (e.g. kinetic) • Pressure • Gravitational • Thermal • Stored Energy This procedure is to be applied in circumstances where: • Personnel are required to work on or within contact distance of any of the above

energies • Where there is a potential for contact and harm to people, equipment or the

environment. The PHPA Isolation and Tagging Procedure applies to all mobile and fixed plant and equipment at all operations. Once the equipment has been isolated, the equipment SHALL not be attempted to be started until: • Each individual has removed their own “Personal Danger” tags and locks from all

isolation points, lockbox or lockout stations. • The isolation locks and tags have been removed by an authorised person. • The isolation switch has been moved to the on position. Only authorised personnel will be allowed to isolate plant and equipment, a minimum competency of Minor Isolation Officer will enable personnel to isolate mobile or fixed plant.

Isolation of energies may be established using the following methods: • Breaking electrical circuits by using one of these three methods stated in

section 12.

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Note: Devices such as emergency stops, pull wire switches or any other devices associated with control systems shall not be used as primary approved isolation points. • Closing valves in flow or delivery systems carrying pressure, gas, liquids, slurry,

steam or venting to atmosphere to release stored pressure. • Open valves in flow or delivery systems carrying pressure, gas, liquids, slurry,

steam or venting to atmosphere to release stored pressure. • Physically securing an object to control gravitational forces using pins, slings or

chocks, belt clamps.

7.1 Competency to Perform Isolations

Only persons, who have completed Isolation Officer Level of Isolation and Tagging training and have been assessed, deemed competent and authorised are able to perform isolations. Once trained, assessed and deemed competent, they shall be appointed in writing by the Nominated Person to undertake the duties of Isolation Officer in accordance with the PHPA Isolation & Tagging Procedure.

7.2 High Voltage Isolations for Electrical Access

Refer to PR – M003 High Voltage Access Procedure. No person shall make personal contact, either directly or through any conducting object with any high voltage conductor believed to be dead, unless the conductor has been effectively earthed and short-circuited and is complying with all the requirements of the High Voltage Switching Procedure. High Voltage apparatus, which is to be earthed and short-circuited, shall be proven to be dead and safe for earthing and short-circuited by use of equipment specifically designed for the purpose and used in accordance with the manufacturer’s instructions.

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8 LOCKS AND USERS

8.1 General Requirements

Locks shall be of a type approved by the Registered Mine Manager.

8.2 Lock Identification

• Red Lock Personal Danger Locks shall be a set of one to six locks per person, and shall be clearly marked with individually stamped number on the lock for identification

• Yellow Lock Used to secure isolation points for Minor Isolations and lock box for group isolations (Multipoint and Major Isolations)

• Blue Lock Clearly marked with lock box number and used on isolation points for group isolations (Multipoint and Major Isolations)

• (set of 15 each) Used for HV Access Isolations – refer to PR – M003 High Voltage Access Procedure

8.3 Registers

The following Registers shall be kept by PHPA in the Myosh system. The Registers shall be audited by the PHPA Safety Department on a regular basis:

8.3.1 Lock/Key Register

The following registers outlining the authorised people who have been issued with locks and keys shall be maintained • Isolation Officers • Personal Lock Holders This Register shall have the Name of the Person, Date of Examination, Name of Examiner, and Level of Authority (i.e. type of isolation, area of authority, voltage levels) Expiry Date and Lock Number.

8.4 Isolation Officers

The Registered Mine Manager shall nominate a person in each operational area who will be responsible for approving and authorising Isolation Officers. • Personnel who are to be deemed an Isolation Officer shall first be trained in

the Isolation and Tagging procedure, hold relevant experience in the plant and pass the relevant competencies

• The Isolation Officer’s will be authorised to carry and place “Isolation Locks”. • The Isolation Officer training (for the equipment specified) shall clearly identify

the types of isolations that they are allowed to complete (Radiation, Electrical, Mechanical)

• Only authorised, trained and competent personnel shall be allowed to carry out Isolations on specific plant and equipment.

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8.5 Personal Lock Holders (Red Personal Isolation Locks)

Personnel who are Personal Lock Holders shall be trained and deemed competent in the PHPA Isolation & Tagging Procedure. PHPA personnel that are to be issued with a personal lockset and key shall first be trained in the Isolation and Tagging Procedure and pass the competencies for Minor Isolations at minimum. Personal Locks and Keys shall be issued to personnel by their Supervisor. • A minimum of one personal lock to be issued to each person. A maximum of a

lock set of 6 is required to be issued to personnel authorised to conduct Minor Isolations as per section 11.2

• A person shall not use another person’s lock(s) and key. • No person shall place another person’s lock • No person shall remove another person’s lock unless authorised. Refer

section 11 • All the locks on a lock set shall use the same key • Only one key to be issued per lockset • Personal locks and key shall be marked with a unique identification number • A personal lock holder shall gain permission by making positive contact with

Permit Holder or Isolation officer prior to attaching their personal lock and tag to isolation points.

• A personal lock holder shall not isolate plant and/or equipment, except for appointed Minor Isolation Officers as per section 11.2

• A record of Personal Lock Holders shall be maintained in Training database and displayed in Maintenance Department.

• Records shall be kept with cross reference to the engraved identification code and the name of the person to whom the lockset was issued.

8.6 Yellow Isolation Locks

Yellow Group Isolation Locks are used to lock the blue lock keys in the lockbox or lockout station under a Multi-Point or Major Isolation. • One isolation key will be issued to each Isolation Officer. • All isolation locks shall use the same key. • Isolation lock key shall be marked with a unique identification number. • Spare locks and keys shall be kept at a central location at each site.

8.7 Visitor Locks & Tags

Visitor Locks and Tags may be issued where: • A person who has not completed PHPA Isolation & Tagging training (visitor)

and is required to lock onto an isolation point as a visitor. • A personal lock holder that does not have possession of, or has not been

issued their own lock, is required to lock onto an isolation point. Visitor locks shall be supplied by PHPA out of the visitor lock station and shall be issued to a visitor when deemed necessary by the Electrical Supervisor or Maintenance Superintendent. The visitor name, company, and contact number shall be recorded for return.

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Visitors must be supervised by a person trained in the Isolation & Tagging Procedures. The supervisor of the visitor must witness the signature of the visitor’s Personal Danger Tag and also be locked on to same point.

8.8 Record Keeping

The following records pertaining this procedure are to be maintained at each site / location: • Request for Isolation • Isolation Statement • Isolation Permit • HV Switching Procedures used for isolation of plant Records are to be retained as per the PHPA PR – ICT002 Recordkeeping Procedure. The following records pertaining to authorised personnel are to be maintained in the Mines Record Book: • Statutory Letters of Appointment detailing site authorisation of Isolation

Officers • Statutory Letters of Appointment detailing site authorisation of High Voltage

Operators / Assistants for the purpose of isolations The following records are to be kept in the PHPA safety management & training system (MYOSH): • Record of all incidents and accidents related to the use of the Isolation and

Tagging Procedure • Training competencies and completion date

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9 TAGS

The use of tags is considered an administrative control and as such only provides limited protection to people and plant; therefore in all cases a physical isolation must be used in conjunction with a tag to prevent the accidental activation of an isolation point.

9.1 Personal Danger Tags

Any person required to work on the equipment must place their clearly identified personal lock and tag on a hasp located on the isolation point or lock box. Remember, the main isolation point Shall Be turned and locked to the off position. The isolation should be tested and proven prior to the commencement of work by testing for absence of electrical power or stored energy. A Personal Danger Tag is for single use only and must be destroyed on completion of task. Do not assume that it is isolated - Confirm that it is isolated! The Personal Danger Tag and lock are designed to give personal protection and to highlight that the employee/s whose name appears on the Personal Danger Tag are engaged in carrying out tasks to the tagged equipment and could be at risk if the machine were to be started or moved.

9.1.1 Contractor Personnel

All contractors and visitors working on PHPA sites shall conduct isolations in accordance with this procedure. Personnel shall also follow this procedure in relation to tag use. All contract personnel must place their personal lock and Personnel Danger Tag on the isolation point whilst in the presence of the Task Supervisor. All Personal Danger Tag Reminder stubs found on the bottom section of the tag shall be handed to the Task Supervisor for that task/work group prior to commencing task/work. This will confirm that contractor personnel have: 1. Completed the Personal Danger Tag correctly 2. Locked on to the correct lockbox and associated Isolation Permit for the

task 3. Ensured confirmation of task completion during the lock off process Where a contractor or visitor has any queries or uncertainty when undertaking tasks within this procedure, they shall refer to their Task Supervisor or delegate from PHPA.

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9.1.2 Attaching the Tag

The person attaching the tag must completely fill the tag with the following information: • Name & company of person placing tag • The classification/department the person works for • The date that the tag was placed • The equipment / plant the tag was placed on • Contact number • Work order / job number if applicable • Signature

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It is important to clearly identify the exact piece of equipment that the tag and lock was placed on to allow identification of those personnel working on the plant. NOTE: Each and every person working on the job must place their own Personal Danger Tag / Personal Lock before the job commences only after the isolation has been tested and proven effective. Once placed it must remain in place for the duration that the person is on the job.

9.1.3 Removing the Tag

No person shall remove another person’s Personal Danger Tag. Only the person who signs and attaches the Personal Danger Tag can remove it. If a Personal Danger Tag has been left on the equipment at the end of the shift then that person will be contacted to return to site in their own time to remove their Personal Danger Tag. If that person cannot be contacted or is in an unfit state to return to site or is off on R/R then the approved tag removal procedure will be instigated (as per section 11.1). YOUR Personal Danger tag and lock are to be removed from the equipment by only you on completion of the task or at the end of the shift.

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9.2 Isolation Tags

The Isolation Tag Indicates equipment has been isolated by an Isolation Officer. Any item of equipment or machinery marked with an Isolation Tag shall not be operated. The equipment must be in an “Isolated” position, thereby removing energy from the circuit. A hasp is to be placed on the isolation point and a completed Isolation Tag with an Isolation Lock shall be placed on the hasp.

9.2.1 Attaching the Tag

The Isolation Officer must print the following information on the tag: • Isolation number • Lockbox • The date that the tag was placed • How the isolation was confirmed

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The equipment owner or area supervisor must be notified as soon as possible if the equipment has been fixed to ensure that the tag can be removed and the plant reinstated. NOTE: Anyone conducting repairs on plant or equipment will be required to place their own Personal Danger tag and lock on the hasp or corresponding lock box before commencing work. If the repair is not complete within the shift or they are called away, they must remove their Personal Danger tag/lock. The Permit Holder shall ensure the Isolation Tag & lock remains and if repairs are not complete, an Out of Service tag shall be attached to the isolation point and plant equipment controls.

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9.3 Out of Service Tags

The Out of Service Tag allows for faulty, unsafe or permanently disabled equipment to be taken out of service to prevent further use or damage to the equipment. Any item of equipment or machinery marked with an Out of Service Tag shall not be operated or used except for the direct purpose of repair by an authorised person. The isolation switch on the equipment must be switched to the off position, thereby removing power to the circuit. A completed yellow Out of Service Tag must then be placed on the isolation point. If it is a power tool or other hand tools or apparatus or equipment that is not energised, the Out of Service Tag should be securely attached to the defective device.

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9.3.1 Attaching the tag

The following information shall be printed on the tag: • Equipment name • Name of person placing tag • Classification of fault/reason for out of service • The date that the tag was placed It is important to clearly identify the exact reason for placing the tag to allow proper analysis and rectification of the problem. The equipment owner or area supervisor must be notified as soon as possible of the condition and the reason it has been placed Out of Service. Once a piece of equipment has been tagged Out of Service to conduct repairs, the equipment must be isolated in accordance with this procedure. An Out Of Service Tag shall REMAIN attached to the device or main isolation point of the equipment during the time that the repairs or servicing and inspection are being carried out. This ensures that even when left unattended, the unsafe condition of the equipment is communicated readily to any person. Anyone can place an Out of Service Tag on faulty plant/equipment; however only authorised personnel or an authorised delegate can remove it. Only a qualified person in the maintenance or repair of that piece of equipment may then remove the tag once repairs are complete.

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9.4 Information Tag

In some instances instruction needs to be given about a specific piece of equipment, barricading of a designated area. In these instances an information tag shall be used. The tag shall be placed by personnel to communicate a message about the conditions of entry, status of equipment or any other relevant information. In the event an Information Tag has been placed all personnel shall read the information.

9.4.1 Attaching the tag

The person attaching the tag must completely fill out the tag with the following information: • Print their name • The department the person works for • The date and the time that the tag was placed • The equipment / plant the tag was placed on

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9.4.2 Removal of Information Tag:

• Removal of Information Tags shall only occur once the information is no longer relevant

• Prior to removal of tag contact the area owner • Any person may remove the tag once the steps above are completed

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10 HASPS & LOCKBOXES

Hasps are used to allow multiple locks to be placed on an Isolation point.

10.1.1 6 hole hasp

This is used for Minor Isolations when requirement is 5 or less personnel to lock on.

10.1.2 D HASP

This is used for Minor Isolations when requirement 5 or less personnel to lock on.

10.1.3 12 hole hasp

This is used for Isolations when requirement 12 or less personnel to lock on.

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10.2 Lockboxes

PHPA has 4 different types of Lock Box which are used as follows; • Master Lockbox

For use with a Major Isolation Involving greater than twelve (12) people Involving more than fifteen (15) locks

• Blue Lock Box For use with Multi-Point and Major Isolations For use with up to twelve (12) people per lockbox For use with up to fifteen (15) locks

• Red Lock Box For use with Isolations that require HV Access

10.3 Maintenance Shift Log

The electronic log used by Maintenance team for recording all isolation and de-isolations. This is for all isolations except Minor Isolations.

10.4 Isolation Numbering / Isolation Register

The numbering of Isolations placed on the permit will be sourced from the Isolation Register. The register is to be filled in showing: • Date • Lockbox number • Isolation number • Equipment to be isolated • Requestor Name • Isolation Officer

No Isolation and Isolation permit are to begin until all information is completed on the Isolation Register.

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11 TYPES OF ISOLATIONS

Three (3) types of isolation are used on all PHPA sites: • Minor Isolation • Multipoint Isolation • Major Isolation

11.1 Approval to Remove Equipment from Service for the purpose of Isolation

Prior to performing the isolation, approval should be gained from the area owner or the person responsible for its operation. The Area Owner is the person responsible for the equipment or process at the time of isolation (usually the direct supervisor of the equipment). The person responsible for the equipment’s operation is usually the equipment operator. To remove equipment from service, the following process should occur: a. At a suitable time prior to performing the isolation, the Task Supervisor or

Isolation Officer should seek verbal approval from the Area Owner to remove equipment from service. This approval should be recorded in the relevant maintenance or plant log.

b. Immediately prior to performing the isolation, the Isolation Officer should seek agreement from the equipment operator that the equipment will be removed from service.

c. The equipment operator should prepare the equipment / process for isolation (e.g. run product off conveyor belts and stop the plant).

d. The equipment operator should advise the Isolation Officer that the equipment is ready for isolation and records the event in the relevant plant log book.

e. The Isolation Officer performs the isolation.

11.2 Minor Isolation

Minor Isolations shall be used in situations where: • There is one (1) isolation point • There are five (5) or less personnel required to work under the isolation • The person raising the isolation and performing the work is a Minor Isolation

Officer and authorised for that piece of equipment Controls used with a Minor Isolation are:

• JHA, DWI or SWMS • Personal Locks (Red) • Personal Danger Tags • Yellow Isolation Lock • Blue Isolation Tag • Six (6) Hole Hasp or D Hasp • Electrical personnel may perform Minor Isolations utilising any approved

isolation point • Non-electrical personnel shall perform the isolation by means of a local

isolator and shall be confirmed by the use of phase indicator lights

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• Alternatively, if no phase indicator lights are present (i.e. a hand valve) then the person shall confirm that the power has been disconnected from the load side of the isolating device, through testing by attempting to start the machine from the local control station and confirm that the machine did not start.

• Other local isolations may be performed by means of a de-contactor, valve etc.

Typically a Minor Isolation may be used for:

• Isolations that can be carried out by means of a local isolator situated in the field

This may include such tasks as: • Low voltage isolations • Mechanical isolations • Mobile Plant isolations

11.2.1 Raising a Minor Isolation

a. The Minor Isolation Officer shall receive approval to take the equipment out of service from the equipment owner or person responsible for its operation.

b. The Minor Isolation Officer shall identify the isolation point for the equipment and complete the risk assessment (JHA), recording the isolation point on the JHA.

c. If an existing generic DWI or SWMS exists for that equipment, it may be used provided that the Minor Isolation Officer ensures that the generic DWI or SWMS is suitable for the scope of work to be performed.

d. The Minor Isolation Officer shall operate the isolation device and place a hasp on the isolation point and secure it with a Yellow Isolation Lock and Isolation Tag.

e. The Minor Isolation Officer is to place his / her Personal Lock, Personal Danger Tag and Isolation Tag on the isolation point.

f. The Minor Isolation Officer shall confirm the isolation as per the risk assessment, DWI or SWMS.

g. The work/task may commence.

11.2.2 Closing a Minor Isolation

The Minor Isolation Officer or Task Supervisor shall inspect the work area and ensure that the work is complete, the equipment is assembled and safe to operate.

Work is complete & equipment is safe to operate If the work is complete and the equipment is safe to operate the Minor Isolation Officer shall: a. Ensure all Personal Danger tags (if Applicable) are removed b. Remove his / her Personal Lock, Personal Danger Tag, Isolation Tag,

Yellow Isolation Lock and hasp and from the isolation point. c. Operate the isolation point to the in service position if applicable. d. Attach Isolation Tag to JHA and work order for isolation confirmation and

records

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e. Destroy the Personal Danger Tag(s) by tearing into at least 2 pieces and dispose of the tag.

f. Notify the equipment owner or person responsible for its operation that the equipment may be returned to service.

Work is not complete and equipment is not safe to operate If the work is not complete and / or the equipment is not safe to operate the Minor Isolation Officer shall: a. Ensure all Personal Danger tags (if Applicable) are removed)Attach Out

of Service Tags to the equipment isolation and / or control points b. Remove his / her Personal Lock and Isolation Tag from the isolation

point. c. Destroy the Personal Danger Tag by tearing them into at least 2 pieces

and dispose of the tags. d. Attach Isolation Tag to JHA and work order for isolation confirmation and

records. e. Notify the equipment owner or person responsible for its operation that

the equipment is not safe for return to service. f. Complete and attach Out of Service tag to the equipment. g. Advise the appropriate maintenance personnel of the equipment status.

11.2.3 Locking onto a Minor Isolation

Personnel requiring the Minor Isolation for protection shall: a. Obtain the permission of the Minor Isolation Officer, to place their

personal lock and danger tag on the isolation b. Demonstrate a satisfactory understanding of the safe area of work

covered under the isolation. c. Complete a Personal Danger Tag with their name, date, company,

contact details and job / work area. d. Confirm isolation point with the Minor Isolation Officer. e. Place their Personal Lock and Personal Danger Tag on hasp attached to

the isolation point in the presence of the Minor Isolation Officer. Should there be insufficient holes left on the hasp, the isolation must be changed to a Multi-Point Isolation. The attachment to another lock or hasp is not permitted.

11.2.4 Locking Off a Minor Isolation

When their work is complete, or when they leave site, or as directed by the Minor Isolation Officer, the lock holder shall: a. Remove their Personal Lock and Personal Danger Tag from the hasp. b. Destroy the Personal Danger Tag by tearing it into at least 2 pieces and

disposing of the tag.

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11.3 Multi-Point Isolation

Multi-Point Isolations shall be used in situations where: • There is more than one (1) isolation point, but no more than fifteen (15)

isolation points. • There are less than twelve (12) personnel required to work under the isolation. • The personnel raising the isolation are Major Isolation Officer/s and authorised

for that piece of equipment. Controls used with Multi-Point Isolations are: • Request for Isolation Permit form • Isolation Statement • Isolation Register • JHA, DWI or SWMS • Isolation Permit • Lockbox (Blue) • Personal Locks (Red) • Personal Danger Tags • Yellow Isolation Locks • Blue Isolation Locks • Blue Isolation Tag • Maintenance Shift Log • Hasp

11.4 Major Isolation

A Major Isolation shall be used in situations where: • The job is complex and a greater degree of control is required • There are up to or exceeding twelve (12) personnel required to work under the

isolation and / or • There are up to or exceeding fifteen (15) isolation points • The personnel raising the isolation are Major Isolation Officer/s and authorised

for that piece of equipment. • High Voltage Equipment Controls used with a Major Isolations are: • Request for Isolation Permit form • Isolation Statement • Isolation Register • JHA, DWI or SWMS • Isolation Permit • Lockbox (Blue or Master) • Personal Locks (Red) • Personal Danger Tags • Yellow Isolation Locks • Blue Isolation Locks • Blue Isolation Tag • Maintenance Shift Log • Hasp

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11.5 Multi-Point & Major Isolation Permit System

11.5.1 Raising an Isolation Permit (for Multi-Point or Major Isolations)

a. A Request for Isolation Permit form is completed by the person requesting access for the work.

b. A Major Isolation Officer identifies all isolation points and compiles the Isolation Statement, based on the information supplied on the Request for Isolation Permit.

c. The Major Isolation Officer obtains approval to take the equipment out of service from the equipment operator.

d. The Major Isolation Officer enters the Isolation Number and Lockbox Number in the Isolation Register.

11.5.2 Issuing an Isolation Permit

a. The Major Isolation Officer identifies the Isolation Type (Multi-Point or Major), Isolation Number, Lockbox Number, Date and Time on the Isolation Permit.

b. The Major Isolation Officer writes the reason for the isolation from the Request for Isolation on the Isolation Statement and Permit

c. The Major Isolation Officer lists the equipment to be isolated under the Isolation Permit.

d. The Major Isolation Officer performs the isolation and places the locks and tags in accordance with the Isolation Statement. Blue Isolation locks and Isolation Tags are attached to the isolation points. The Isolation Number is recorded on each Isolation Tag.

e. The Major Isolation Officer confirms the number of locks placed. The key to the isolation locks are locked inside the lockbox by placing yellow isolation lock on the lockbox. An isolation tag is placed on the isolation lock. The Isolation Number is recorded on the Isolation Tag.

f. The Major Isolation Officer signs the Isolation Permit. g. The Authorising Officer checks that the isolations are in place and are in

accordance with the Isolation Request and Statement. The isolation points are confirmed locked and tagged with the Isolation Number and date recorded on each isolation tag.

h. The Authorising Officer signs the Isolation Permit as verification that the isolation is in place

i. The Permit Holder must ensure that: • The isolations are in accordance with the Request for Isolation,

either via the Isolation Statement or by viewing the physical isolation points.

• All Task Supervisors are aware of the isolations in place and confirm they cover the tasks being undertaken.

• The isolation number is recorded on the isolation tags and permits. j. The Permit Holder confirms and signs the Isolation Permit. k. The Isolation Permit is placed in either the Yellow Isolation Pocket,

attached to the lockbox, or to the master lockbox. Ensure that the front page of the Isolation Permit is clearly shown and all signatories to the permit are clearly visible.

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11.5.3 Transfer of Isolation Permit to new Permit Holder

a. When the Permit Holder leaves site for any reason and work is to continue under the permit, the Isolation Permit must be transferred to a new Permit Holder.

b. The current Permit Holder shall advise the new Permit Holder of any special circumstances pertaining to the permit in person.

c. The current Permit Holder shall sign the Transfer of Permit Holder section of the Isolation Permit to relinquish control of the permit, with date and time.

d. The new Permit Holder shall sign on to the Transfer of Permit Holder section of the Isolation Permit to accept responsibility for the permit, with date and time accepted.

Personnel already locked on are not required to lock off during this process. Additional personnel are not permitted to lock on during this process.

11.5.4 Task Supervisor Actions: Sign On the Isolation Permit

The Task Supervisor is the person who is responsible for: • The safe execution and completion of each specific job covered by the

Isolation Permit. • Ensuring that members of the work party read and sign on to the JHA

pertaining to their work. • Ensuring that members of the work party read and understand the safe

areas of work covered by the Isolation Permit. a. The Task Supervisor reads the Permit Isolation and checks the

equipment listed as isolated. They ensure the Isolation Permit covers the scope of work for the specific job for the work group. Clarification may be sought from Permit Holder or Isolation Officer.

b. The Task Supervisor then receives permission from the Permit Holder to sign on to the Isolation Permit.

c. The Task Supervisor shall demonstrate a thorough understanding of the areas / equipment covered under the Isolation Permit

d. The Task Supervisor signs onto the Isolation Permit by: • Entering the work order or other reference number, if applicable • Enters the equipment to be worked on • Writes his / her name, company and contact details • Enters the date and time that they are signing on to the permit • Enters his / her signature to complete sign on

e. The Task Supervisor enters the Isolation Number on to the JHA pertaining to the work.

11.5.5 Task Supervisor Actions: Sign Off the Isolation Permit

If the Task Supervisor does not change for the duration of the Isolation Permit, the Task Supervisor does not have to sign off until the job is complete, or the end of the shift, the Isolation Permit is closed or as required by the Permit Holder.

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11.5.6 Task Supervisor Actions: Task handover to another Task Supervisor:

If the Task Supervisor is required to change during the duration of the Isolation Permit, the Task Supervisor shall sign off the Isolation Permit and hand over task and/or work group in person to the new Task Supervisor as follows: a. Ensure the new Task Supervisor is aware of the equipment, work group

and work status. This can be done in person or in writing. b. Enters his / her signature, date and time on the Isolation Permit and

mark the Task Complete as Y for Yes or N for No.

11.5.7 Task Supervisor Actions: Work is complete and the equipment is safe to use

When work is complete and equipment safe to use, the Task Supervisor shall: a. Inspect the work and check that the work is complete, equipment is

assembled, guards are installed where applicable and equipment is safe to reinstate, and housekeeping has been addressed.

b. Ensure all members of the work group have removed their Personal Locks and Personal Danger Tags from the lockbox.

c. Enters his / her signature, date and time on the Isolation Permit and mark the Task Complete as Y for Yes.

c. Advise the Permit Holder that the work is complete and all members of the work group have locked off the Isolation Permit.

11.5.8 Task Supervisor Actions: Work is not complete

When work is not complete, the Task Supervisor shall: a. Ensure all members of the work group have removed their Personal

Locks and Personal Danger Tags from the lockbox. b. Advise the Permit Holder that the work is incomplete and members of

the work party have locked off the Isolation Permit. c. Place Out of Service tags on the plant equipment controls. d. Enters his / her signature, date and time on the Isolation Permit and

mark the Task Complete as N for No.

11.6 Locking and Tagging On/Off an Isolation Permit

11.6.1 Personnel Locking On the Isolation Permit

Personnel who use the Isolation Permit to protect themselves shall: a. Read the Isolation Permit and check the equipment listed as isolated on

the Isolation Permit covers the scope of work for the specific task they intend to do.

b. Obtain the permission of their Task Supervisor, to place their personal lock and danger tag.

c. Demonstrate to the Task Supervisor a satisfactory understanding of the safe area of work covered under the permit.

d. Check that the isolation lock keys are locked inside the lock box and a yellow isolation lock is in place.

e. Complete a Personal Danger Tag with their name, date, company, contact details and job / work area.

f. Place their Personal Lock and Personal Danger Tag on the lockout station.

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g. Contract personnel must place their Personal Lock and Personal Danger Tag on the lockout station in the presence of the Task Supervisor.

In the case of a Major Isolation utilising a Master Lockbox: Should there be insufficient holes on the lockout station, a D hasp may be placed in one of the holes and locks placed directly on the hasp. The attachment to another lock is not permitted.

11.6.2 Personnel Locking Off the Isolation Permit

When their work is complete, or when personnel leave site, or as directed by the Task Supervisor, the personnel are to lock off the Isolation Permit. To lock off an Isolation Permit, personnel shall: a. Remove their Personal Lock and Personal Danger Tag from the lock out

station. b. Destroy the Personal Danger Tag by tearing it into at least 2 pieces and

disposing of the tag.

11.7 Additional Isolation Permit

Additional Isolation Permits may be issued only under circumstances where the additional task/s fall under the existing Isolation Statement and the existing Isolation Points do not change. a. A Request for Isolation Permit form is completed by the person requesting

access for the work. b. The Major Isolation Officer confirms the suitability of the additional task/s

against the Isolation Statement for the existing permit. c. If suitable, the Major Isolation Officer compiles the additional Isolation Permit.

The numbering for additional permits shall be the existing Isolation Number followed by a slash ( / ) and the number 1 e.g. 009/1; if more than one permit is added, then consecutive numbering shall follow i.e. 009/1, 009/2, 009/3 etc.

d. The Major Isolation Officer records the issue of the additional Isolation Permit in the Isolation Register against the existing permit listing.

e. The Major Isolation Officer, Authorising Officer and Permit Holder all sign and confirm the issue of the additional permit and task/s, as per section 11.5.2.

f. The Major Isolation Officer shall securely attach the approved additional Request for Isolation form with corresponding Isolation Permit to the existing Isolation Permit.

11.8 Changes to the Isolation Points of an Isolation Statement

If there are changes to the Isolation Points on the Isolation Statement section of a permit, the Isolation Permit shall be cancelled and a new Isolation Permit issued as applicable.

11.9 Closing an Isolation Permit

a. The Task Supervisor shall check the work areas for housekeeping and establish that all nominated equipment on the Isolation Permit is complete, safe and ready for de-isolation.

b. The Task Supervisor shall check that personnel are clear of any plant or equipment and are aware of an impending start up.

c. The Task Supervisor enters his / her signature, date and time on the Isolation Permit and mark the Task Complete as Y for Yes or N for No.

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d. The Permit Holder shall confirm that all Task Supervisors have signed off the Isolation Permit with the status of the plant understood and Out of Service tags placed where necessary.

e. The Permit Holder shall verify that all Personal Locks and Personal Danger Tags have been removed from the lockout station, and marks and signs the appropriate box on in the Permit Completion section of the Isolation Permit.

f. To close the Isolation Permit, the Authorising Officer marks and signs the completion box in the Permit Completion section of the Isolation Permit.

g. The Permit Holder returns the closed Isolation Permit to the Isolation Officer.

11.10 Emergency or Cyclone Preparation

Refer to PR – MO002 Staff Cyclone Procedures, PR – M005 Eastern Harbour Cyclone Preparation and PR – M006 Utah Cyclone Preparation. Isolation of plant and equipment for cyclone preparation shall be conducted in accordance with this procedure. Once instructed to evacuate site, all lockboxes, permits and keys shall remain in the site security office until the All Clear notice is given to return to site. When directed by the Site Cyclone Coordinator, personnel shall conduct a risk assessment of each plant area, ensuring the equipment is complete and safe to de-isolate. If equipment is found to be damaged, faulty or repairs are required, the isolation shall remain in place and an Out of Service Tag shall be placed, as per section 9.3

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12 METHODS OF ISOLATION

12.1 Electrical Isolation Devices: General

Electrical Isolations shall only be performed by authorised Isolation Officers. Electrical Isolations shall be performed in accordance with relevant statutory regulations. Any PHPA Electrical or Mechanical personnel member can be trained as an authorised Isolation Officer to carry out Minor Isolations on specific items of plant/equipment. If there are any issues experienced whilst following the Minor Isolation process, they must stop work and the isolation immediately and contact a PHPA Electrician and have the Isolation verified. Non Electrical qualified personnel may perform Electrical Isolations utilising LV isolators, provided: • They are authorised Isolation Officers for that equipment • Phase Indicator Lights are installed on the load side of the isolating device • There is a Visible Physical Break • The level of isolation is a Minor Isolation When locks are attached to an isolator the panel door shall not be opened. Electrical isolation devices shall be checked to be in the off position prior to attaching the isolation tag; some devices have the ability to be locked in the on position. Disconnection of electrical power supply should always be proven before commencing work. There are three ways to confirm a positive electrical isolation: • Phase indication lights • Physical separation • Electrically testing (test for dead)

12.1.1 Electrical Isolating Devices with a Visible Physical Break

Some electrical isolating devices have provision to inspect for a visible air gap between the feed and load sides of the isolating device. A visible air gap may be used to determine that electrical power has been disconnected from the plant. To use an electrical isolating device with a visible break, the Isolation Officer shall: • Identify the isolating device as per the Isolation Statement • Operate the isolating device to the “off” position • Inspect the visible physical air gap in the each phase of the electrical

conductors and confirm that there is an air gap on each phase between the feed and the load sides of the isolating device.

• Lock the isolating device in the “off” position • Place an isolation tag on the isolator. • Sign the step in the Isolation Statement or HV Switching Instruction

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12.1.2 Electrical Isolating Devices with Phase Indicator Lights

Phase indicator lights indicate that there is electrical power supply on an electrical conductor. Phase indicator lights may be installed on each phase of the load side of the electrical isolating device. To operate an isolating device fitted with phase indicator lights, the Isolation Officer shall: • Identify the device by means of the work order and/or suitable JHA/DWI

or SWMS • Be trained, assessed and deemed competent in Minor Isolations at

minimum on that particular piece of plant/equipment • Inspect and confirm that the phase indicator light on each phase is on,

indicating that power is supplied to the load side of the isolating device • Operate the isolating device to the “off” position • Inspect and confirm that the phase indicator light on each phase is off,

indicating that power is disconnected from the load side of the isolating device

• Lock the isolating device in the “off” position • Complete and place an Isolation Tag on the Isolation point

12.1.3 Electrical Isolation Devices that do not have a Visible Physical Break or Phase Indicator Lights

Some electrical isolating devices do not have provision for a visible air gap or phase indicator lights. For electrical isolating devices that do not have a visible air gap or phase indicator lights the Isolation Officer shall: • Identify the device by means of the work order and/or suitable JHA/DWI

or SWMS • Be trained, assessed and deemed competent in Minor Isolations on that

particular piece of plant/equipment • Operate the isolating device to the “off” position • Confirm that the power has been disconnected from the load side of the

isolating device, through testing o with an appropriate metering device by a Qualified

Electrician/Electrical Engineer o by attempting to start the machine from the local control station and

confirm that the machine did not start • Lock the isolating device in the “off” position • Place an isolation tag on the isolator

12.1.4 Electrical Isolating Devices that have no means of determining if Load Side Electrical Energy has been disconnected

Some electrical isolating devices may not have provision for physical inspection or testing with a meter. For these isolating devices the following procedure shall apply. A formal Risk Assessment shall be conducted by a team comprising of as a minimum:

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• Isolation Officer • Task Supervisor • Authorising Officer (in the case of a Multi-Point & Major Isolations)

The Risk Assessment shall specifically address how it will be confirmed that electrical energy has been disconnected to the plant to be worked on, according to the scope of work. At least one member of the Risk Assessment team is to be a Qualified Electrician/Electrical Engineer. If the Risk Assessment indicates that the residual risk of proceeding is low, the task may proceed. For situations where the residual risks of proceeding are high or extreme, the site Superintendent or the Registered Mine Manager shall be contacted prior to proceeding. The Isolation Officer shall report the Isolating Device in question, so it may be modified.

12.2 De-Contactor

De- contactors may be used as electrical isolating devices. To use a de-contactor as an electrical isolating device, the Isolation Officer shall: • Identify the device by means of the work order and/or suitable JHA/DWI or

SWMS • Be trained, assessed and deemed competent in Minor Isolations on that

particular piece of plant/equipment • Activate the e-stop for the equipment • Remove the de-contactor from its socket • Cover the de-contactor with a lockable device • Place an Isolation Locks and Isolation Tags on the de-contactor cover

12.3 Circuit Breakers

If no other means is available, circuit breakers may be used as electrical isolating devices as a last resort. These may only be operated by a Qualified Electrician/Electrical Engineer To use a circuit breaker as an isolating device the Isolation Officer shall: • Identify the correct circuit breaker by means of the work order and/or suitable

JHA/DWI or SWMS • Be trained, assessed and deemed competent in Minor Isolations at minimum • Switch the circuit breaker to the off position • Test the load side of the circuit breaker to ensure electrical energy has been

disconnected • Place an Isolation Lock and Isolation Tag on the lock out device

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12.4 Electrical Isolating Devices that cannot be locked

Some electrical isolating devices may not have provision for locking them in the “off” position. These may only be conducted by a Qualified Electrician/Electrical Engineer For isolating devices that cannot be locked the Isolation Officer shall: • Identify the isolating device by means of the work order and/or suitable

JHA/DWI or SWMS • Be trained, assessed and deemed competent in Minor Isolations at minimum • Operate the isolating device to the “off” position • Confirm that electrical energy has been disconnected from the plant using

suitable method, as per section 12.1 • Place an isolation tag on the isolator • Report that the Isolating Device was unable to be locked so it can be modified

12.5 High Voltage (HV) Isolation: General

Only Western Australian Licensed Electricians authorised as HV Operators are to conduct an isolation requiring the operation of a HV device. Personnel trained and assessed as competent HV Isolation Assistants may participate in the Isolation of HV Motors for mechanical work and cleaning (for example Utah Conveyors).

12.5.1 High Voltage Access Permits

A High Voltage Access Permit is required in all cases where work is to be performed on, or in close proximity to, High Voltage Electrical Apparatus where the Safe Working Distance cannot be maintained. If a High Voltage Access Permit is required, the process as outlined in the PR – M003 High Voltage Access Procedure shall be followed.

Circuit Breaker Lock Out Devices

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High Voltage Access, Work in the Vicinity of High Voltage Apparatus and High Voltage Testing are not covered under this procedure. For further detail refer to the PR – M003 High Voltage Access Procedure.

12.5.2 Isolation of High Voltage Motors where there is no potential for contact with High Voltage Apparatus

For circumstances where a high voltage motor is isolated to conduct mechanical work or cleaning on non-electrical components (for example mechanical work or cleaning of Utah conveyors), a High Voltage Access Permit is not required. Such isolations are to be conducted as per the PHPA Isolation and Tagging Procedure.

12.6 Heavy Mobile Equipment (HME), Light Vehicles & Other Mobile Equipment

All mobile plant and equipment at PHPA operations shall be isolated for the purpose of conducting prestart inspection or maintenance activities as per the PHPA Isolation and Tagging Procedure to the level of isolation required as identified as per section 11.

12.6.1 Heavy Mobile Equipment

Heavy Mobile Equipment (HME) as a minimum shall be fitted with an appropriate isolating device that disconnects power (electrical or pneumatic) to the vehicles starting system.

The isolation required for HME shall be the same as that for Minor Isolations (refer section 11.2) with the following specific requirements pertaining to that equipment:

a. Park the HME on a flat sturdy surface b. Engage suitable gear to hold the machine via the transmission c. Switch off and lock the power from starting battery to the HME starting

device (usually the main battery isolator) d. Apply locks and tags as per Minor Isolations e. If pneumatic starts are installed, follow manufacturer’s procedure to isolation

and discharge starting air devices f. Physically prevent the vehicle from movement by a means as determined

appropriate via a risk assessment (e.g. wheel chocks, windrow)

12.6.2 Light Vehicles & Other Mobile equipment

The isolation required for light vehicles and other mobile equipment shall be as follows:

a. Vehicle is to be parked fundamentally stable (use of wheel chocks to be considered)

b. Engine shut down, transmission selected in an appropriate gear, with hand brake engaged

c. Ignition Keys are to be removed d. Attach Out of Service Tag to vehicle steering wheel

Note: This basic isolation does not remove the need to consider other levels of control, such those required to control exposure to mechanical and stored energy. Controls should be applied according to the Take 5 risk assessment or JHA.

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For maintenance tasks which involve equipment to be running, personnel shall: a. Have wheel chocks in place b. Ensure gear box is in neutral c. Ensure hand break is engaged d. Additional controls where practicable (i.e. barricading, signage)

12.7 Mechanical Isolations

The below list is not inclusive of all forms of mechanical isolations. From time to time other devices may be required to be used as isolation points; this shall require approval from the Registered Mine Manager. Approved Devices may include, but not limited to:

• Valves • Blank plates • Drains • Belt clamps • Shuttle pins

12.7.1 Valves & Process Lines/Vessels (Water, Fire Systems, Diesel, Oil, Slurry Water, Air, Sewerage)

Isolations involving valves need to be proven by releasing the pressure and material from process lines. Note: Visual confirmation of this discharge or pressure and material needs to be obtained. Any valves used to de-pressurise the system should be locked out in the appropriate position where practicable.

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13 ISOLATION ERROR OR VIOLATION

An isolation error or violation is considered a serious event as there is potential that either: • Someone is working on a piece of plant that has not been effectively isolated • A piece of plant that is no longer being worked on has not been de-isolated. When an isolation error occurs the following process shall occur: • Ensure there is no risk to personnel or equipment and contact supervision. • The person involved in or observing the suspected error or violation shall initiate a

standard PHPA Incident Report in Myosh, documenting the Incident Type as an Isolation Incident.

• The Incident shall be investigated using the standard processes applicable to the PHPA Incident Reporting and Investigation.

Examples of potential Isolation Errors are as follows:

13.1 Failure to Remove a Lock or Tag

Refer to FM – M006 Forced Lock Removal Form in all instances where a person fails to remove their Personal Lock when de-isolation is required. The following process shall be followed: • The Isolation Officer shall conduct a full inspection of the isolated equipment,

and use tag, permit or lock register to identify lock holder and/or lock number. • Contact the lock holder or lock holder’s supervisor and they shall use all

reasonable means to attempt to locate the person. • If the person is contacted and has left the work area, then they shall return to

the work area and shall remove their Personal Lock and Tag. The Isolation Officer shall complete a Myosh report.

• If the person cannot be located, cannot return to the work area due to having left the site or has Fitness for Work issues, then the Registered Mine Manager or delegate shall be contacted and advised that the lock holder is unable to remove their lock via the appropriate means.

• The Isolation Officer shall gain verbal approval and confirmation from the Registered Mine Manager to remove the lock.

• The lock and tag shall then be removed, equipment de-isolated and the work area left in a safe condition.

• The relevant Supervisor or Manager shall raise an Incident Report in Myosh. Ensure the completed Forced Lock Removal Form is attached to the Myosh report notification.

• The associated lock and all matching keys shall be handed to the Registered Mine Manager for disposal at the earliest possible time.

13.2 Failure to transfer or incorrectly sign off on a Permit document as Task Supervisor or Permit Holder

Task Supervisor • The person’s Supervisor shall be contacted and shall use all reasonable

means to attempt to locate the person. • If the person is contactable and is able to return to the work area they shall do

so and complete the sign off of the Isolation Permit. • If the person is unable to return to the work area but can be contacted they

shall be thoroughly questioned on the job ensuring that all tasks undertaken

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have been completed. Visual inspections of the work area shall be undertaken by the new Permit Holder and Task Supervisor before being satisfied that the tasks are completed and able to be signed off. The new Permit Holder will then sign off the task and/or Isolation Permit as complete.

• If the person is not contactable then their immediate Supervisor should be notified. That Supervisor must also make reasonable attempt to contact that person. If still no contact can be made then that persons Supervisor and the new Permit Holder are to carry out a visual inspection of the workplace to ensure all tasks have been completed. The relevant Superintendent is then to be contacted and informed about the situation and the outcome of the inspection. If satisfied, they can then grant permission for the Isolation Permit to be signed off on that person's behalf.

• Incident Report shall be raised in Myosh.

13.3 Completed Tag found on floor or ground

Any completed Tag found unattached to a piece of equipment is an Error within this procedure. If this occurs: • The Person named on the Tag and his/her Supervisor shall be contacted. • The status of the equipment shall be determined and if the Tag Owner and

Permit Holder are satisfied the Tag shall be reattached or destroyed and new Tag attached.

• An Incident Report shall be raised in Myosh

13.4 Tag Missing from a locked Isolation Point

A persons tag may become detached for a number of reasons. These reasons include: • Accidental removal by another person • Damaged due to external influences e.g. weather If it is known which lock/person the tag belongs to, the following shall occur: 1. Attach a Danger tag stating that “This tag replaces the Danger tag of (enter

person’s name) whose tag has been accidentally removed”. 2. Include contact details of the person attaching substitute tag. 3. Attempt to contact the person who’s tag was removed and arrange for them to

attach a new tag 4. Remove the substitute tag after the new tag has been replaced. If it is not known which lock/person the tag belonged to, the following shall occur: 1. Attach a Danger tag stating that “This tag replaces the Danger tag of

unknown person whose tag has been accidentally removed and is placed by (enter your own name).”

2. Include contact details of the person attaching substitute tag. 3. Contact each of the Task supervisors to confirm that each member of their

team is correctly tagged on. By process of elimination, you should be able to identify the missing tag holder.

4. When removing their lock, the lock owner shall contact the owner of the substitute tag and have them remove the tag before removing the lock.

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13.5 Inability to lock an Isolation Point

• When the lockout mechanism on an isolation point is found to be broken or missing, where possible the mechanism shall be repaired or replaced immediately. The mechanism must be made safe.

• If the isolation point is unable to be repaired or replaced immediately, other upstream isolation points shall be considered.

13.6 Key Misplaced or Missing

• Conduct a thorough search of the working area to attempt to recover the lock key

• If the key is unable to be found, refer to FM – M006 Forced Lock Removal Form

• If the key cannot be found ALL ASSOCIATED locks shall be destroyed and a new set made available with a new key

13.7 Key Found

• Any person finding a Personal Lock Key, Isolation Lock Box Key or Isolation Lock Key shall immediately return the key to the Personal Lock Holder, Isolation Officer or Task Supervisor.

13.8 Lock Misplaced or Missing

• The loss of a lock shall be reported as soon as practical to the Task Supervisor

• Conduct a thorough search of the work area to attempt to recover the lock • If the lock cannot be found ALL ASSOCIATED locks shall be destroyed and a

new set made available with a new key.

13.9 Lock Found

• Any person finding a Personal Lock or Isolation Lock shall immediately return the lock to the Personal Lock Holder, Isolation Officer or Task Supervisor

13.10 Unexpected movement of stored energy

• Unexpected movement of stored energy, such as belt movement of isolated plant

• Stop all work immediately and ensure personnel are clear of area • Report to Task supervisor for further investigation and action

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14 RESPONSIBILITIES

Registered Mine Manager Responsible for Safety on the mine site according to Mines Safety and Inspection Act 1994 and the Mines Safety and Inspection Regulations 1995 (MSIA & MSIR).

Line Managers Responsible for ensuring their personnel are trained and competent in this procedure; responsible for enforcement of this procedure.

All Personnel Responsible for ensuring they conduct their work in accordance with this procedure.

14.1 Registered Mine Manager

The Registered Mine Manager shall, in writing: • Nominate a person in each operational area who will be responsible for

appointing and authorising Isolation Officers, Authorising Officers & Competent Persons.

• Appoint a sufficient number of personnel as High Voltage Operators to enable High Voltage Isolations to be undertaken as required.

• Appoint High Voltage Assistants where required.

14.2 Nominated Person

A person who is appointed in writing by the Registered Mine Manager for each operational area that is responsible for appointing: • Isolation Officers • Authorising Officers • Competent Persons

14.3 Isolation Officer

The Isolation Officer shall: • Design the Isolation Statement as per job requirements ensuring electrical and

mechanical energies as well as potentially stored, kinetic and other forms of energy identified according to the scope of work.

• Review and sign off Isolation Permits in accordance with the scope of work. • Accept isolation requests and plans and ensure the documentation has been

completed and signed off in accordance with this Isolation and Tagging Procedure

• Complete tags by entering appropriate information as contained in the appropriate JHA or Isolation Statement section of a permit.

• Contact relevant parties (e.g. operations, contractors, proponents, and other supervisors) to inform of the intent to isolate.

• The Isolation Officer identifies isolation points as per Isolation Statement and performs physical isolation and attaches locks, hasps and tags to correct isolation points and signs Isolation documentation in accordance with this Isolation & Tagging Procedure.

• Hand isolation list to Authorising Officer and move away from physical location of isolations to allow uninterrupted verification of isolations.

• Notify relevant parties if required (e.g. operations, contractors, proponents, and other supervisors) to enable equipment to be put in such state as to confirm and conduct a mandatory try step test in the field.

• Ensure lockbox and paper work where task is being completed in a safe place.

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• De-isolate the plant as per the Isolation Statement section once work has been completed or when instructed by an Authorising Officer and all relevant paperwork is returned.

• Contact relevant parties (e.g. operations, contractors, proponents, and other supervisors) to inform the equipment has been de-isolated.

• Destroy isolation/lockbox tags on completion of task. • De-isolate plant or equipment if instructed to do so by an Authorising Officer

14.4 Authorising Officer

An Authorising Officer shall: • Ensure that the isolations are in place and are in accordance with the Isolation

Request and Statement. The isolation points are confirmed locked and tagged with the Isolation Number and date recorded on each isolation tag.

• Sign Isolation Permits as verification that the isolation are in place • Close the Isolation Permit by marking and signing the completion box on in the

Permit Completion section of the Isolation Permit.

14.5 Task Supervisor

A Task Supervisor shall • Manage the work group and provide onsite supervision to a work group for the

task/s • Verify and confirm against the JHA or Isolation Statement section of a permit if

isolation points are correct and isolated correctly, tags are completed correctly and correspond to isolation points.

• Inspect the work and establish that all nominated equipment on the Isolation Permit is complete, equipment is assembled, guards are installed where applicable, equipment is safe to reinstate and ready for de-isolation, and housekeeping has been addressed.

• Ensure all members of the work group remove Personal Locks and Personal Danger Tags from the lockbox.

• The Task Supervisor shall check that personnel are clear of any plant or equipment and are aware of an impending start up.

• Place Out of Service tags on the equipment controls if required. • Ensure that if a change of Task Supervisor is to occur during the duration of

the Isolation Permit, sign off the Isolation Permit and hand over task and/or work group in person to the new Task Supervisor.

14.6 Permit Holder

A Permit Holder shall: • Have site, plant and task specific knowledge to enable them to check that the

permit and isolation conforms to the isolation request and that the equipment locked out is correct as per the isolation statement.

• Ensure that the isolations are in accordance with the Request for Isolation, either via the Isolation Statement or by viewing physical isolation points.

• Ensure that all Task Supervisors are aware of the isolations in place and confirm they cover the task being undertaken, and ensures the Isolation Number is recorded on the Isolation Tags and on the permit.

• Confirms and signs Isolation Permits

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• Confirm that all Task Supervisors have signed off the Isolation Permit with the status of the plant understood and Out of Service tags placed where necessary.

• Verify that all Personal Locks and Personal Danger Tags have been removed from the lockout station, and marks and signs the appropriate box on in the Permit Completion section of the Isolation Permit.

14.7 High Voltage Operator

To become eligible for authorisation, a person shall be a qualified Electrician or Electrical Engineer. A person’s site specific competency shall be determined through practical training and assessment. The person shall also: • Produce documentation certifying satisfactory completion of a recognised

training course in High Voltage Operations and; • Be appointed in writing by the Registered Mine Manager.

14.8 High Voltage Assistant

An individual trained and assessed as a competent High Voltage (HV) Isolation Assistant and authorised in writing by the Registered Mine Manager. A High Voltage Assistant can assist in HV switching operations of isolating devices for mechanical work and clean downs of the Outloading Conveyor systems.

14.9 Work Group

The Work Group Shall: • Make contact with Permit Holder before applying lock and tag • Place their Personal Lock and Personal Danger Tag on the isolation point(s)

as appropriate • Remove their Personal Lock and Personal Danger Tag upon completion of

work • Remove their Personal Lock and Personal Danger Tag at the end of shift • Remove their Personal Lock and Personal Danger Tag if removed from the

task • Destroy Personal Danger Tag on completion of task • Not remove another person’s Personal Danger Tag or Lock • Follow all instructions outlined on the JHA and/or Isolation Statement • Sign on and/or lock on to the JHA and Isolation Permit to indicate that they will

be working under it. • Sign off and/or lock off on the JHA and Isolation Permit to indicate that they

will no longer be working under it.

14.10 Substation Entry

14.10.1 Utah Bulk Loading Facility & Eastern Harbour

Conditions of entry: • Two (2) person entry for switching or live electrical testing, one (1) of which

must be a qualified Electrician/Electrical Engineer (low voltage only). • One (1) qualified Electrician/Electrical Engineer entry for VSD reset or

substation inspections

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• As a minimum requirement stand by person shall be trained in LV rescue and basic life support

• Any third party requiring access into substation shall be escorted by a PHPA qualified Electrician/Electrical Engineer at all times.

• HV switching requires two (2) authorised HV Electricians/Electrical Engineers or standby person that has been trained a HV assistant.

14.10.2 Motor Control Centre (MCC) Access

Conditions of entry: • Two (2) person entry for switching or live electrical testing, one (1) of which

must be a qualified Electrician/Electrical Engineer. • Other personnel entry shall be authorised by the site Maintenance

Superintendent.

15 LEVELS OF AUTHORITY FOR ISOLATIONS

The level of authority shall be clearly defined and recorded on the individual’s training record (as shown on the training matrix in Myosh) and shall clearly show the following information: • Type of Isolation level

o Personal Lock Holder o Minor Isolations o Major Isolations

• Minor or Major Isolation Officer • Authorised Voltage Switching Level (LV, HV) • Completion and Expiry Date A record of authorised personnel shall be kept by the Registered Mine Manager or delegate.

16 EMERGENCY CONTACTS

In case of emergency, contact the Shipping Control Tower on (08) 9173 0030, or VHF CH 12 or 16.

For Utah, UHF CH 20 to contact Control Tower and Security:

Registered Mine Manager: 0417 903592

Maintenance Manager: 0417 290972

Maintenance Superintendent East: 0429 295896

Maintenance Superintendent Utah: 0417 848641

Electrical Supervisor Utah: 0409 677030

Health and Safety Manager: 0419 048894

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17 PROCESS OWNER

The Maintenance Manager has overall responsibility for this procedure. Date approved: 26 NOVEMBER 2012 Approved by: GMO RMM & MM

Version: 2 Document ID: PR – M002