Energy Isolation

The following completed documents must be submitted to the Asset Owner for approval prior to working on any live asset (when in the line of fire):

• Permit and Risk Assessment
• Isolation Plan or a Standard Isolation process

3.1.1   Risk Assessment

Lock out and/or tag out of assets for routine inspections, repairs, maintenance, assessments, adjustments or cleaning should not be undertaken until a risk assessment is completed by the team comprising both the work party as well as the asset owner, operators and relevant subject matter experts.

The risk assessment will be conducted using the risk assessment template as part of an Isolation Plan or a Standard Isolation Process.

A documented risk assessment must be completed to determine:

• What stored energy sources are present
• What risks are associated with known hazards or stored energy sources
• What controls are implemented to remove all harmful sources of stored energy to make it safe
• To Identify the isolation points required for the task/job to be undertaken safety

When the risk assessment identifies stored energy sources, the Hierarchy of Control must be used in conjunction with GMW Hierarchy of Isolation to ensure the task/job can be undertaken safely.

3.1.1.1 Hierarchy of Control

The hierarchy of control is a system for determining, designing and applying risk controls to activities in the workplace:

• Elimination - Highest level of protection and most effective control
  • Eliminating the hazard and the risk it creates is the most effective control measure
• Substitution
  • Substitute the risks with lesser risks
• Isolation
  • Isolate people from the risks
• Engineering
  • Reduce the risks through engineering changes or changes to systems of work
• Administration
  • Administrative controls / actions to minimise exposure to hazards and to reduce the level of harm
• Personal Protective equipment (PPE)
  • Personal protective equipment (PPE) to protect people from harm

3.1.1.2   GMW Hierarchy of Isolation

GMW’s preferred isolation method is Double Isolation and test for dead. Where this cannot be achieved, the below GMW Hierarchy of Isolation must be adopted.

• Double Isolation
  • 2 x Isolations applied and system tested for dead
  • Permit application will include an Isolation Plan or a Standard Isolation process
• 1 x Isolation and 1x Control
  • 1 x Isolation applied and system tested for dead
  • Permit application will include an Isolation Plan or a Standard Isolation process
• 1 x Isolation
  • 1 x Isolation applied and system tested for dead
• 2 x Controls 
  • Permit application will include an Isolation Plan or a Standard Isolation process
• 1 x Control = Live work
  • Permit application will include an Isolation plan or a Standard Isolation process
  • Risk assessment, requires written approval from the General Manager of the Division responsible for conducting the works via the LOTO Approval Form A4892865 and will require an emergency / rescue plan.

All isolations and controls must be deemed appropriate and effective and tested for dead prior to work commencing.

3.1.1.3   Isolation versus Control

An isolation involves the physical interruption of the stored energy source and applying a Lock and Tag.

A control involves a process for monitoring the stored energy source to ensure that it does not pose a risk. 

Where a control is to be applied, there must be an allowance for adequate time between the control being triggered and the activity that is required from the working group (i.e. vacating the worksite). 

Where only one control can be achieved, the work is to be considered “ Live work”.

Note: No live work will be conducted without the approval of the General Manager of the Division conducting the works until all documentation has been submitted for assessment / evaluation to ensure all other options have been exhausted.  (Live Works form must be completed)

3.1.1.3.1 Live Work

Prior to any live work being conducted the permits should be accompanied by:

• A risk assessment of the live work activity in consultation with any HSRs or contractors who will be undertaking the “Live Work”
• Confirmation that training, information and supervision has / will be provided to all workers either conducting or that are exposed to the live work prior to the live works being conducted
• Safe work instructions / SWMS relevant to the activities relating to live work have been reviewed
• Written approval from the General Manager of the Division responsible for conducting the works via the LOTO Approval Form A4892865
• Where the risk level associated with the “live work” is determined to be medium or high, a copy of an emergency / rescue plan must also be approved by the responsible General Manager.

Any testing or monitoring of equipment in an energised state required for maintenance purposes including but not limited to commissioning must only be conducted by a suitably qualified person and have as a minimum a safe work instruction and risk assessment for the activity.    An Electrical Safety Procedure is scheduled to be developed to further clarify the testing and monitoring expectations.

3.1.2   Isolation Plan

An isolation plan is a set of steps to be followed to keep assets from being set in motion or to prevent the release of any form of stored energy while work is being completed. Isolation plans are to be developed by the workgroup with responsibility for the asset (in most instances, this will be the asset owner).

When developing Isolation Plans, consultation with relevant subject matter experts must be undertaken to ensure that the process is robust and considers all possible scenarios for the inadvertent release of stored energy.

The effectiveness of an isolation plan relies on:

• Having the isolation plan documented and accessible to the relevant people in the workplace
• Ensuring that the appropriate SME’s from all relevant parties are involved in the development of the isolation
• Ensuring that Third Party Organisations (where applicable) are involved in the development of the isolation (in regard to their asset only)
• Providing information, instruction and training to workers involved with the isolation and/or scope of work
• Appointing a person as a Site Works Supervisor (Permit Owner) to make sure the workplace strictly follows isolation plan
• Walking the isolation to ensure that all sources of energy have been identified, controlled and that the isolation will be effective

GMW documented isolation plans must contain:

• All isolation steps required to safely remove the asset, from service
• Any points where work should pause and be assessed by all relevant parties. E.g. Specific stages of a projects

Isolation Plans must:

• Be peer reviewed before being carried out
• Be communicated with all relevant parties involved including contractors
• Available at the worksite for the duration of the activity
• Have the correct approvals

3.1.3   Standard Isolation Process (SIP)

A Standard Isolation Process is a plan that has been developed to perform an isolation that is routinely completed. It is a set of steps to be followed to prevent assets from being operated or to prevent the release of any form stored energy while work is being completed. Standard Isolation Processes are to be developed by the workgroup with responsibility for the asset (in most instances, this will be the asset owner).

When developing Standard Isolation Processes, consultation with relevant subject matter experts (SME’s) must be undertaken to ensure that the process is robust and considers all possible scenarios for the inadvertent release of energy.

The effectiveness of Standard Isolation Process relies on:

• Having the SIP documented and accessible to the relevant people in the workplace
• Ensuring that the appropriate SME’s for all relevant parties are involved in the development of the isolation
• Ensuring that Third Party Organisations (where applicable) are involved in the development of the isolation (in regards to their asset only)
• Providing information, instruction and training to workers involved with the asset,
• Appointing a person as a supervisor (Permit Owner) to make sure the activity strictly follows SIP
• Conducting a review to ensure that the SIP is relevant to the scope of work
• Walking the isolation to ensure that it will be effective

GMW documented Standard Isolation Processes must contain:

• All isolation steps required to safely remove the asset from service
• Any points where work should pause and be assessed by all relevant parties

SIP’s must be:

• Peer reviewed before being carried out
• Communicated with all relevant parties including contractors
• Reviewed every two years at a minimum or where there has been a change to the design of the asset that is being isolated, there is a change to the scope of work or there has been a change to the process
• Signed off by the appropriate GM once all SME’s have agreed on the process.

3.1.4   Permit

The permit process ensures that GMW’s isolations meet the ‘Principles of Isolation’. The permit can represent a standalone isolation or it can represent a master isolation with secondary isolations that are associated. The permit identifies the isolation process which is as follows:

• The scope of work and the assets involved
• The stakeholders
• Identification of all energy sources
• Identification of all isolation points; and/or
• Documented controls

Where energy sources are identified, all works must have a corresponding permit and include an Isolation Plan or a Standard Isolation Process. The permit covers:

• Isolate all energy sources
• De-energise all stored energies (Test for dead)
• Lock and Tag all isolation points
• One person per lock/one key per lock,
• Multiple Isolations (More than one energy source)
• Tagging
• Testing of Isolation Procedures
• Re-energising and re-instating

Where control(s) are used within the Isolation Plan, they must also be:

• Inspected for implementation
• Regularly inspected for effectiveness during works
• Removed / checked before re-energizing and re-instating  

Where only one control can be achieved, the work is to be considered “Live work”.

An isolation permit must include an expiration date. If the works are not completed within the original allocated timeframe, a new permit will be required. A new permit will also be required where there is a change of the scope of works from what was originally proposed.

3.1.4.1 Locking Single & Multiple Isolation Points for One Isolation Permit

Asset Owner

• Apply Isolation Point Lock(s) and ‘Out of service’ tag(s) to each Isolation Point
• Retain any key(s) to the noted Isolation(s)
• Inspect all the isolation points with locks and verify isolations are effective

Site Works Supervisor

• Apply Isolation Point Lock(s) and ‘Danger – Do Not Operate’ tag(s) to each Isolation Point
• Select required isolation equipment required to satisfy the Isolation Plan; this may include:
• Lock Box
• Hasps
• A number of personal locks
• Place the Isolation Point Lock key(s) (Permit Owner’s) in the Lock Box and closes box
• Attach a SWS lock to the Lock Box and retains the key
• Inspect all the isolation points with locks and verify isolations are effective
• Shows the Work Party Members all of the isolation points with locks
• Lock on and lock off daily or when moving to another job

Work Party Members

• Sign on to the Isolation Permit and attaches their Personal Safety Lock and tag to the group isolation point
• Lock on and lock off daily or when moving to another job

3.1.4.2 Locking Isolation Points Shared Across Isolation Permits

Asset Owner

• Apply Isolation Point Lock(s) and ‘Out of Service’ tag(s) to each Isolation Point
• Retains any key(s) to the noted Isolation(s)
• Inspect all the isolation points with locks and verify isolations are effective

Site Works Supervisor

• Identify the Master Isolation Permit and associated Lock Box which contains the isolation points required for any secondary Isolation Permits
• Apply Isolation Point Lock(s) and ‘Danger – Do Not Operate’ tag(s) to each Isolation Point
• Select required isolation equipment required to satisfy the Isolation Plan; this may include:

• • Lock Box
  • Hasps
  • A number of personal locks
• Locks Cascade Lock onto the primary Isolation Permit Lock Box and places the key into the Lock Box for any secondary Isolation Permits along with Isolation Point Locks key(s) (SWS) in the Lock Box and closes box
• Attach a SWS lock to the Lock Box and retains the key
• Inspect all the isolation points with locks and verify isolations are effective
• Shows the Work Party Members all of the isolation points with locks
• Lock on and lock off daily or when moving to another job

Work Party Members

• Sign on to the Isolation Permit and attaches their Personal Safety Lock and tag to the group isolation point
• Lock on and lock off daily or when moving to another job

3.1.5   Workshop Maintenance

Where vehicles, plant and equipment are subject to repairs, maintenance or servicing, the workshop technicians will remove the keys from the equipment and they will be secured to prevent unauthorised access. Prior to work being undertaken, all sources of stored energy will be identified and appropriately controlled or dissipated.

Once work is completed, the keys can be returned to the equipment provided the responsible technician has verified that all systems/components of the equipment are safe to operate.

3.2 Locks and Tags

*Note: Personal Isolation Locks must never be keyed alike

Lock type	Description	Image of Locks	Image of tags
3.2.1 Black Locks - (Asset Owner)	Asset Owner Locks are BLACK and: Will only be issued to asset owners who have completed GMW level 2 training on energy Isolation, They are the first and last lock to be added to or removed to an asset isolation An “out of service” tag is also to be fitted with the asset owners isolation lock The asset owner’s lock can be an individual lock or a team lock; this is to be specified on the Isolation Permit (Asset Owner Sign Off Section) Where an asset lock is individual, a handover process must be conducted and tags/information changed if the individual changes Must be implemented if work is being performed by the same Division Where a lock is a team lock, the tag should be marked as such May be implemented if work is being performed by a different Division or Contractor Any member of a Black Lock Team interacting with an isolation must be familiar with that specific isolation **  The person who places the asset owners lock cannot also assume the role of the Supervisor
3.2.2 Site Works Supervisor / Permit Owner (SWS/PO) Lock	Site Works Supervisors/Permit Owner (SWS/PO) Lock is blue Will only be issued to workers who have completed GMW level 2 training on energy Isolation, Can be used by the SWS/Permit Owner in replacement of their personal Red Lock Can remain in place over the course of the permit or as an overnight lock One person, one lock One lock, one key Must be installed/removed by SWS/Permit Owner Is to be fitted with “Danger, do not operate tag Changing of Locks/Tags When work is occurring, there must always be an SWS lock and Tag on the asset. Where work is being conducted over multiple shifts, the SWS /Permit Owner must conduct a physical handover with the incoming SWS/Permit Owner at the location of the SWS/PO Lock The incoming SWS lock must be placed before the outgoing lock is removed.		Tag used while Workers are in the line of Fire
3.2.3 Red Locks -   Personal Safety Lock (PSL	Personal Safety Locks (PSLs) Personal Safety Locks are RED and: Will only be issued to workers who have completed GMW training on energy Isolation, Are individually keyed Every individual working on the asset must place their own personal red lock and a “Danger, do not operate” tag. Locks and tags		Tag used while Workers are in the line of Fire
3.2.4 Yellow Locks - Maintenance Lock	Maintenance Locks are YELLOW and: Will only be issued to workers who have completed GMW training on energy Isolation, Will be locked onto isolation points to keep assets in an isolated state when it is under maintenance. An “out of service” tag is also to be fitted with the asset maintenance lock. Is to be fitted to an asset along with the red personal locks of each person working on the asset. Can be used to secure an asset overnight but personal locks must be removed to indicate that there is no individual in the line of fire.

 Collection of Locks & Tags

The store (Cussen St) will hold energy isolation equipment for business units, groups, or individuals to collect. Training will be required prior to being issued with locks & tags.

Requirements when collecting LOTO equipment from the store

Where a worker has been requested to collect multiple items of LOTO equipment for employees on behalf of a manager/supervisor, the Equipment Release Form (A4872943) must be signed as authorisation that the manager/supervisor will be taking responsibility for distributing the locks and tags etc. to the workers who have completed required/relevant ELMO LOTO modules.

 Specialised LOTO equipment

Under certain circumstances, specialised equipment may be required to effectively perform an isolation. The type of equipment required may be determined based on specific risks such as high voltage/electrical, the presence of non-lockable valves, the absence of appropriate locking mechanisms on cabinets etc.

No work on an asset will be undertaken until the isolation has been verified and all stored energy sources are “tested for dead”. Verification steps must include but are not limited to the following:

• Confirm no identification errors were made (correct isolation points),
• Confirm isolation points are in the safe position
• Ensure all stored energy is dissipated or controlled
• Test for dead

In the event of a test demonstrating that the isolation has not been achieved, work must not proceed. The Permit Owner and the Asset Owner shall be contacted to investigate and design and approve a new isolation.

The Persons completing the isolation are responsible for ensuring isolations are effective at appropriate intervals. These checks are to be documented and available for inspection.

All Principal Contractors must have and adhere to the requirements of their (Contractors) Safety Management System concerning energy isolation.

Where GMW performs the isolation of an asset for the purposes of  controlling stored energy prior to handing over to a principal contractor, the principal contractor must nominate an individual to place a lock on the GMW group isolation prior to work commencing. This lock will remain in situ until the works are completed at which time, the principal contractors nominee will notify GMW and remove their lock from the GMW group isolation.  

Where GMW performs the isolation of an asset for the purposes of controlling stored energy prior to handing over to a third-party organisation, the third-party organisation must nominate an individual to place a physical isolation lock on the GMW Group Isolation prior to work commencing.  This lock will remain in situ until the works are completed at which time, the third-party organisations nominee will notify GMW and remove their lock from the GMW group isolation.

Where a third-party organisation performs the isolation of an asset for the purposes of controlling stored energy prior to handing over to GMW, GMW must nominate an individual to place a physical isolation lock on the third party’s Isolation locking device prior to work commencing.  This lock will remain in situ until the works are completed at which time GMW nominee will notify the third-party organisation and arrange to remove their lock from the third-party’s isolation locking device.  

To remove the isolation from the asset these steps shall be followed:

1. Check to ensure no one is at risk (no one is in the line of fire)
2. Ensure asset is safe to operate (any maintenance or construction works are completed)
3. Remove your red personal lock and/or yellow maintenance lock tags.
4. Where appropriate, notify the job supervisor who will then remove the Master lock
5. Where required, notify the Asset owner of the works completion. The Asset owner will remove the black asset owners lock

Asset can be reinstated

In situations where a person has left a job and failed to remove their lock (red personal lock, yellow maintenance lock) or where the key to a lock has been misplaced, the SLT representative, will make the decision to have that lock removed once the following steps have been documented and completed:

• In the case of a lock accidentally left on, all practical efforts have been made to contact the person to return and remove their lock
• In the case of misplaced key, the person who placed the lock has been identified and is physically present at the location of the lock

The LOTO Lock Removal Checklist has been completed identifying:

• A confirmation that all workers have been cleared from the line of fire
• The General Manager of the team concerned has been contacted
• The Asset Owner has been contacted
• That competent and suitably qualified people have checked that the equipment is safe to operate
• The Asset Owner and Permit Owner have completed the LOTO Lock removal checklist, signed and agreed it is safe to remove the lock
  • This has then been reviewed and signed off by the appropriate General Manager

In the case of a lock that has been accidentally left on, the person shall be advised as soon as practicable that their lock has been removed and their isolation is no longer in place.  

An incident report in IRIS must be raised and an investigation (or contractor’s specific investigation method) is conducted to determine why the lock was left on/keys misplaced. Once the investigation is completed, it will be presented to the General Manager for review.

All permits are to be registered in Objective and held in folders relevant to the Division authorising the permit

Process flowcharts and high level principles can be found as follows:

• Appendix B - GMW Energy Isolation Process Flow Chart
• Appendix C - Water Efficiency Project (WEP) Process Flow Chart

• Overseeing and ensure the implementation of the requirements of this procedure within the respective functional area
• Ensure Standard Isolation Plans are suitably risk assessed and that appropriate controls are implemented to prevent the risk of injury or harm to workers
• Any Live Work risk assessment / evaluation, including any documentation required as per this procedure has been undertaken in a comprehensive manner and all other safer options for undertaking the work have been exhausted
• Completion of the LOTO Approval Form A4892865 as required
• Lock removal LOTO Lock removal checklist have been comprehensively completed and satisfied that the lock removal can proceed without injury or damage of those in the line of fire.

• Establish a training plan to ensure that all relevant employees are trained in theory and practical components of LOTO activities
• Ensure that records are maintained of training activities
• Equipment used is in accordance with regulations and service records are maintained
• Ensure that time and budgets are made available for appropriate training and LOTO equipment
• Ensure the implementation of this procedure in their area of control and that supervision of persons in the workplace is in place to provide compliance

• Conduct workplace inspections on a frequent basis to ensure compliance and adequacy of LOTO practices in their area of control
• Ensure that when LOTO has not been able to be applied, the issue is escalated to the Manager
• Conduct a regular review of the safety controls on work sites
• Ensure that resources are available to support the implementation of this procedure
• Ensure regular Occupational Health & Safety local inspections are conducted

• Monitor and ensure that the requirements listed in this procedure are being adhered to while carrying out their work activities
• Report hazards or incidents to the Supervisor
• Where LOTO has not been able to be applied for a work activity requiring LOTO, do not undertake the work activity until the issue is escalated to the Supervisor
• Participate in activities and investigations designed to improve safety

• Is responsible for ensuring the isolation plan and permit conditions are in place over the duration of the permit
• Verifies and approves the method of isolation documented on the Isolation Permit (and Plan) for the isolation of equipment
• Attaches his or her personal lock (Master Lock) and danger tag to a group lock box(or hasp)  to control an isolation
• Has consulted with the person in charge of the equipment (asset owner) in relation to the isolation required
• Arranges for the handover of control of the isolation to another Permit Owner or to the person in control of the equipment

• Conduct regular reviews of this procedure to ensure currency
• Provide technical oversight of the Energy Isolation/LOTO process
• Support GMW in implementing these requirements.