1. System Lock Out/Tag Out and Line Breaking GSS24

2. System Lock Out/Tag Out
SCOPE
Used to isolate an entire process or a large portion of a process and involves the use of multiple tags and isolation points with multiple crews and will be extended for several work shifts or days. System Tag Outs are commonly used for turnarounds and require additional administrative controls.

3. System Lock Out/Tag Out Flow Chart
Owning Dept. determines a System
Tag Out will be used for Servicing and/or Maintenance activity
System is isolated, prepped, and tagged out by Owning Department (Operations)
Once system is deemed acceptable/safe,
Owning Dept. issues first yellow copy of
System Tag Out Sheet to Designated Work Crew Rep.
NOTE: At this point, the system “belongs” to the Work Crew, not the Owning Dept.
System is “walked” by
Owning Dept. and Designated
Work Crew Representative
Once all individual job tasks are confirmed complete, System Tag Out Sheet is final released by the Work Crew Rep.
NOTE: System now “belongs” to the Owning Dept. System Tag Out is complete.
All individual job tasks to be completed within the system are performed using Safe Work Permits and referencing the System Tag Out Sheets

4. (Non-System Lock Out/Tag Out and Line Breaking procedure would apply)
Administrative Controls Required:
Owning department (operations) personnel are assigned to track work activities.
Daily/nightly maintenance scheduling meetings for duration of System Tag Out.
Detailed job plans are reviewed between the Work Crew and the owning department.
Isometric drawings or P&ID indicating all Red Tag locations.
A list of jobs to be done within the System Tag Out is tracked (this will be done on a visual boards for 2016 VTAR)
ALL ADMINSTRATIVE CONTROLS ARE REQUIRED OR PROCEDURE MAY NOT BE IMPLEMENTED
(Non-System Lock Out/Tag Out and Line Breaking procedure would apply)

5. System Lock Out/Tag Out and Line Breaking
System LOTO differs from Non-System LOTO, in that:
Procedure strives to make paperwork more efficient without sacrificing safety.
Job planning and tracking is paramount.
The isolation plan shall be agreed upon and every tag walked together between the Owning Department Rep. and the Designated Work Crew Rep. The System is then issued to the Work Crew Rep. At that point, the Work Crew “owns” the tagged out System.
Other work groups / companies who will be performing work under the System LOTO shall be invited to participate in the system walk.
Any work group can then request copies of the tag out from the Work Crew Rep.

6. System Lock Out/Tag Out and Line Breaking
System LOTO PERMITTING differs from Non-System LOTO, in that:
Pre-printed permits are acceptable more than 1 shift in advance
Jobs within the System Tag Out can be permitted 2 possible ways:
With a Safe Work Permit Referencing the “System Tag Out #” in Section 1
Individual Tag Out Sheets (Same as) issued with Safe Work Permits, as we normally do
There is an option to use a vessel entry system LOTO, which saves on some paperwork, but vessel entry prep up to and including initial entry is done in accordance with GSS-2, Entering and Working Within a Confined Space.

7. System Lock Out/Tag Out and Line Breaking
General Requirements
There are two acceptable methods for permitting jobs within the System Tag Out, after the Work Crew Representative has been issued the System:
Option #1: A Safe Work Permit only, with Section I referencing the System Tag Out number; or
Option #2: A Safe Work Permit & Tag Out Sheet issued

8. System Lock Out/Tag Out and Line Breaking
In Option #1, the Safe Work Permit is the Tracking tool.
The Safe Work Permit references the System Tag Out Sheet(s) in Section I
The Permit tracks the job by Work order and steps of the job..
Advantage for this option: LOTO does not need to be filled out for each job step.

9. System Lock Out/Tag Out and Line Breaking
In Option #2, the System Tag Out Sheets are issued
Sheets of the “same as” LOTO are issued per job similarly to normal use of the Non-System LOTO

10. System Lock Out/Tag Out and Line Breaking
Owning department prepares the equipment (isolating, decontaminating, purging and red tag sources), same as with Non-System Lock Out.
When the isolation/decontamination of the system is completed, the Tag Out Sheet shall be signed indicating the system is ready for Servicing and/ or Maintenance, same as with Non-System Lock Out.

11. System Lock Out/Tag Out and Line Breaking
4 Eyes Review applies, as per normal
One-Plus Isolation applies, as per normal
Electrical verification of interlocked equipment and electric tracing applies, as per normal
Minimum Line Breaking requirements, isolation of energy sources, and process blind tracking also apply

12. System Lock Out/Tag Out and Line Breaking
The designated Work Crew Representative and the Owning Department Representative shall review the system (verify switchgear, valves, tracing, etc.) before any jobs on the system are started (System Walk).
The first yellow copies (sheet #1) of the System Tag Out are issued to the Designated Work Crew Representatives and are not re-issued each day.
Each job within the System Tag Out is issued a Safe Work Permit. The System Tag Out Sheet shall not be signed off for final release until all Safe Work Permits within the system have been released/finalized.
There may be additional jobs on the Safe Work Permit (Section 1) that do not involve Line Breaking or Confined Space. Those jobs will follow GSS3, Safe Work Permit Procedure.

13. System Lock Out/Tag Out and Line Breaking
The Owning Department shall maintain a system job list to keep track of all jobs within each system (this will be tracked on a visual board for the 2016 VTAR).
Basic requirements of GSS3 (Safe Work Permits) apply.
The Safe Work Permit may be printed well in advance, with gray sections completed
The Safe Work Permit must be issued (signed) by an Owning Department Representative who is qualified in the area of the work.
Note: A person who is not qualified in the area of work can manage the permitting desk, however only one who is qualified in the area of the work can perform the Four-eyes review and sign and issue the Safe Work Permit.

14. System Lock Out/Tag Out and Line Breaking
Basic requirements of GSS1 (Non-System Lock Out/Tag Out) as it relates to Tag Out Sheet (LOTO) apply.
The exception:
On the LOTO, “Reason for Tag Out” shall be filled out with “System Tag Out”
Only the first yellow copy of the LOTO will be issued to the Designated Work Crew Representative - He can make copies and distribute to applicable work crews who desire to see the LOTO.
When returned for testing, the LOTO will be signed “released for testing” and work crew yellow tag pulled until testing is completed.
It is important to remember that isolating a system and issuing it to the Work Crew does not mean that it is necessarily safe for all possible work. Each job within the System is subject to a Four-Eyes review between the work crew and the permit issuer just before issuing the permit.

15. System Lock Out/Tag Out and Line Breaking
“Beyond System Red Tags” - when additional red tags are required besides the red tags listed for the System Tag Out, a Safe Work Permit and individual Tag Out Sheet (TOS) listing the isolation points is required.
All Yellow Tags will be hung in the same location as designated on the System Tag Out Sheet or Safe Work Permit. Work Crews will label their Yellow Tag with the applicable work order number.
For individual jobs within a system that require isolation of electrical energy, additional Yellow Tags shall be hung on each electrical isolation device. The work order number shall be on each Safe Work Permit or Tag Out Sheet.
All paperwork (Tag Out Sheets & Permits) must be maintained for at least the duration of the System Tag Out to ensure all jobs within the system have been signed off (and then retained in the permit file drawer for 30 days).
When there is a job within the system which requires extra tags (like double isolation for hot work in flammable service), another individual LOTO sheet can be added to that permit, but do not add the tags to the existing, issued, System LOTO. That individual LOTO can be cleared when that work is done without affecting the System LOTO.

16. System Lock Out/Tag Out and Line Breaking
Operations Interaction with a System Owned by Maintenance
Note: In this section, “Operations” is intended to be the operations personnel and not the Equipment Owner, because Maintenance becomes the Equipment Owner once the System is released to Maintenance.
There are times when operation activities must take place within a system. The following are the only allowed activities :
With the blinds still in place, it is permissible to:
steaming/washing a line for work such as welding can take place.
Leak checking/drying a line or exchanger after work crew finishes their work
Drying a vessel after entry work is completed
Operations preparing equipment for vessel entry.
All other activities require the system to be turned back over to operations

17. System Lock Out/Tag Out and Line Breaking
Operations Interaction with a System Owned by Maintenance
If it is impractical to withdraw the System Tag Out for Operation activities, the Tag Out Sheet signature roles are reversed since the Work Crew Representative “owns” the system.
A new Safe Work Permit must be issued for each job Operations does. Operations will write themselves a Safe Work Permit and Tag Out Sheet referencing the System Tag Out and identify the activity to be performed.
Operations gets a yellow copy of the Tag Out Sheet. The white copy and all other copies will remain with the Work Crew Representative.
Operations will hang a (blue/yellow) Operations Tag, describing the activity, at the System Tag Out maintenance tag location.
When the operations activity is completed, the Work Crew Rep will return the white copy of the permit to operations so they can sign off for final release.
The Tag Out Sheet will remain with the Owning department for filing.

18. System Lock Out/Tag Out and Line Breaking
Changing the System Tag Out Sheet
There may be times when the System Tag Out Sheet needs to be modified to add or relocate a tag. When this is necessary, the following should apply:
The Designated Work Crew Rep will release the system paperwork (Released for testing or Final; Meaning all work within the system stops)
The Owning dept. will modify the sheets and the modifications shall be inspected by Owner and Designated Work Crew Rep (System Walk)
If Released for testing, Sheet #1 will be “reissued” to the Designated Work Crew Rep
If Final released, Sheet #2 will be “issued” to the Designated Work Crew Rep
No changes will be made unless there is joint approval between the Owning Dept. and the Designated Work Crew Rep.

19. System Lock Out/Tag Out and Line Breaking
Changing The System Tag Out Sheet
There may be times when it is impractical to withdraw the System Tag Out Sheet. In this case, the following should apply:
The Designated Work Crew Rep and the Operations Supervisor shall evaluate the proposed change to ensure it does not affect the integrity of the LOTO isolation
Red tags eligible to be considered are those no longer isolating any energy sources (e.g., bleeder valve needs to be removed with piping). This exception cannot be applied when the proposed change includes removing a tag from a valve which is isolating an active energy source.
The evaluation should consider any impact to any work scope, including future work scopes until the completion of all System work
These changes can be made only when there is joint approval between the Owning dept. and the Designated Work Crew Rep.

20. System Lock Out/Tag Out and Line Breaking
Performing Maintenance on a System Tagged Valve
System tagged valves are typically valves that define the boundaries of 2 adjacent systems and are Red Tagged.
If maintenance work is required on the valve:
Owning Dept. notifies the Designated Work Crew Rep. that the job involves a System tagged valve.
The Safe Work permit for the work shall reference both Systems.
The owning department pulls the Red Tag and attaches it to the white copy of the System Tag Out Sheets.
When the job is completed, the tags are reinstalled and the system treated as two separate systems.

21. System Lock Out/Tag Out and Line Breaking
Questions/Concerns?