MALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION COPY Title: Energy Isolation and Lock out/Tag Document: QW-PR-35 ‘out Procedure Revision: 1 1.0 2.0 3.0 4.0 Originated 7 Reviewed and Approved by: | Reviewed by : Reviewed by: OMS Committee Head of Department Date: 01 APR 2018 Expiry Date: Until Superseded Page 1 of 13 Purpose This procedure establishes minimum requirements for securing, locking and tagging out energy - isolating devices, and for the protection of workers from the unexpected release of hazardous energy during installation, maintenance, service and repair activities involving hazardous energy sources Scope This procedure shall apply to all MSCIK operated equipment, facilities and all MSCIK | employees | References 3.1. HSE Lockout and Tagout Procedure (HSE — BKB - 009) 3.2 OSHA Standard (29 CFR 1910.147) | Definition 4.1 Energy ~ all energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, stored energy, gravitational or other energy 4.2 Lockout — the placement of a lock on an energy-isolating device, in accordance with an established procedure, ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the locking device is removed. 4.3 Tagout — the placement of a tagout device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed. i} 4.4 Personal lock - a uniquely keyed lock issued to an employee to install his personal Padlock on the single lockout device of the equipment. Riu? [MALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 WORK INSTRUCTION UNCONTROLLED coPY Title: Energy Isolation and Lock out/Tag Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 2 of 13 5.0 Responsibility 5.1 Authorized Permit Approval (APA) 5.1.1 Approving Permit to Work, PTW for modification, servicing or maintenance work on equipment or system 5.1.2 Identified the hazard associated with the work and recommend control ‘measure including the need of implementing the suitable LOTO devices 5.1.3. Ensure only trained and competent personnel perform the preparation and isolation activities 5.2, Permit Receiver (PR) / Work leader 5.2.1 Ensure that the system or equipment being worked on has been safely isolated and disabled with proper lockout and tags 5.2.2 Responsible for carrying out maintenance works 5.3. Area Owner (AO) or Process Supervisor (PS) 5.3.1. Appointed by the APA to prepare and isolate the system and equipment involve for modification, servicing and maintenance work 5.3.2 Apply and install any lockout devices and tags under the supervision of APA 5.3.3. Shall be competent to operate the equipment and understand the process or system being isolated 6.4 Charge man 5.4.1 Responsible for prepare and isolate the electrical system and equipment involve for modification, servicing and maintenance work 5.4.2 Apply and install electrical lockout devices and tags on electrical circuit breaker involved 5.5 LOTO coordinator/HSE personnel 5.5.1 Understand how this procedure applies to personnel in their area of * responsibilty 5.5.2 Ensure employees have training, skills, knowledge and understanding to comply with this procedure, Originated / Reviewed and Approved by: | Reviewed by : Reviewed by: OMS Commies Head of Department Bes AMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant — lant 2 UNCONTROLLED WORK INSTRUCTION coPY Title: Energy Isolation and Lock out/Tag — Document: QW-PR-35 ‘out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 3 of 13 5.53 Provide equipment needed to complete lockouttagout (e.g., locks, tags, chains, and ete). 6.0 Procedure Step | Person In ‘Action Charge (PIC) * Standardize and manage lockouttagout equipment foray for the facility or area in MSCIK ‘+ Issue lockoutftagout devices to individuals upon 6.1.1 | coordinator / ; : HSE personnel | Successful completion of required training. + To carry out a random audit on maintenance or servicing work related to LOTO procedure. ~* Lockout and tagout devices will be located at each Plant Area workstation respectively. (Appendix 1) 6.12 | Owner/ Charge | » Responsible to maintain control of the lockout and man tagout devices + Inform any defective of LOTO devices Step | Person In ‘Action Charge (PIC) + Request @ modification, servicing and maintenance Ge eee work through Work Order system * Apply permit to work eae Permit Receiver | | Detailing the work to be carried out * Identify the hazardihazardous activites to the work stated (Section 2 on PTW) 2 Sis. | ABA + State the precaution steps to be taken and appropriate PPE to be used ( Section 384 on PTW) Originated / Reviewed and Approved Head of Department Reviewed bj jeviewed by: OMS Committee Rav lMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION ‘COPY Title: Energy Isolation and Lock out/Tag _ Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 4 of 13 * Complete any additional certificate required for PTW 6.24 APA & PR such as hot work permit, confine space permit and supporting certificate. (Section 586 on PTW ) [SE Eneipy Rotation and LOTO Procetire” RS RT| Notify AO & PS the work that to be carry out 6.3.1 APA ‘+ Plan and brief the suitable isolation procedure to atea owner of process supervisor ‘* Carry out energy isolation (except electrical energy) Which required equipment isolation and release the stored energy to achieve a zero energy state following the method as in Appendix 2 ‘+ Affix appropriate lockout devices and “Do not operate” tag on each isolation point. (Appendix 3) ‘* Fill the energy isolation information in Section 3 on ‘Supporting Certificate (Attachment 1) ‘+ Place the used safety padlock key in the key station provided at Control Room ‘+ Document the LOTO devices used in LOTO log sheet (Attachment 2) ‘* Perform electrical energy isolation upon request by PS or APA following the method as in Appendix 2 ‘+ Affix appropriate lockout devices and “Do not operate” tag on each isolation point (Appendix 3) ‘+ Fill the energy isolation information in Section 2 on ‘Supporting Certificate (Attachment 1) ‘+ Place the used safety padlock key in the key station provided at Control Room ‘+ Document the LOTO devices used in LOTO log sheet (Attachment 2) p PEP ‘© Verify all the related documents, ‘+ Approve the PTW * Perform de-energized test on the equipment before start work. Area Owner / 6.32 Process ‘Supervisor 6.3.3 ‘Charge man 6.4 | Permit Apr 41 "| APA 642 PR Originated / Reviewed and Approved by: | Reviewed by : Reviewed by: QMS Committee Head of Department Awl [MALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION COPY Title: Energy Isolation and Lock out/Tag Document: QW-PR-35, out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 5 of 13 ‘+ Proceed to service or maintenance work. * Inspect the work area to ensure that unnecessary tools have been removed, guards have been es! BR reinstalled and the equipment’s components are operationally intact. + Verify work is complete and restore the equipment to normal condition. AO [Process | * Remove lock out devices and "Do not operate” tag 6.52 eee from the isolation points * Fill de-isolation information in Section 5 on supporting certificate (Attachment 1) + Notify to APA that equipment is ready for use ‘* Remove lockout device and “Do not operate” on related circuit breaker upon request by AO/Process Supervisor. * Re-energized the equipment. ‘+ Fill de-isolation information in Section 5 on supporting certificate (Attachment 1) 653 Charge man 6.6.1 PR Hand back permit to APA 7.0 Documentation 7.1 Procedure Review and Revision Review of Energy Isolation and Lock out/Tag out procedure must be carried out at least when changes required as per QP-01. Mechanical, electrical and process department will ensure the requirements of the procedure are being followed, Originated / Reviewed and Approved by: | Reviewed by : Reviewed by: QMS Committee Head of Department RowMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION COPY Title: Energy Isolation and Lock out / Tag out Procedure Document: QW-PR-35 Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 6 of 13 7.2 Training years. 7.3 Records All documentation related to certificate (Permit), training ai for a period of next revision. All personnel involved in Energy Isolation and Lock-out/Tag-out procedure must be trained and refresher training to be conducted at least once in two Energy Isolation and Lock-out/Tag-out activities, Ind procedure should be kept by HSE department Originated / Reviewed and Approved by: Head of Department Reviewed by : Reviewed by: OMS Committee A awMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) UNCONTROLLED. Kemaman Plant - Plant 2 WORK INSTRUCTION COPY Title: Energy Isolation and Lock out/Tag Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 7 of 13 8.0 Appendices APPENDIX 1 MSCIK Plant Section and LOTO devices allocation Remark: Colour code is set for safety padlock to differentiate each section Area omer | —Staton/ Section Becton cover Colour BineMan | Binerenoteroom | Bine Mart 1&2 IETS and ypo Plt = Calcom Man | Gatroom house | Garcon Pat 18 2, Evaporon Pt anaiciP1 | Yelow Evap Man P2_ | BRBMOIP2TEMOI® | novevap pa nacven | Cnvoamn soa | GE amet 1 PCW a Pcs Baer &, Darin Wa, Cosi owe and ; Baier Man | Boer howe Soler 72 Oe ing ; soar ioems = Fling _| Fira san (i ling and Loading bay a Charge Man | chargenan com | A NGC oom APPENDIX 2 TOTO devises section eae) TagOut viBi2 v-cp4 | stationbox | Cable Padlock sere | 3 : : 7 7 cal Roan 2 s : : 7 7 eaphGiPe | 6 a ima eae i a ed 2 : : i 7 Botarraase | 8 3 aan nae i 7 Ficg peat | 6 3 : 2 7 7 Grarganan | 6 3 7 : Remark: LOTO devices allocation to each section. Head of Department Originated / Reviewed and Approved by: Reviewed by : Reviewed by: OMS Committee QW) (MALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION COPY Title: Energy Isolation and Lock out/Tag Document. QW-PR-35 ] out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 8 of 13, 9.0 Hazardous Energy Isolation method 1. Equipment Shutdown If the system is operating it should be shutdown in its normal manner. Use manufacturer instructions or in-house work instructions. Equipment shutdown involves verifying that all moving Parts such as flywheels, gears, and spindles have come to a complete stop. 2. Physical isolation ‘The method of isolation and discharge of stored energy shall be approved by and be executed by the responsible person. Isolation of the highest quality and security which is reasonably practicable shall be prioritising, This method is applicable for most of the hazardous energy involve including flammable gasiliquids, hazardous chemicals, hydraulic, steam, stored potential and pneumatic energy except electrical energy a) Positive Isolation Positive Isolation is considered as the most secure and preferred method. Complete separation of the plantequipment to be worked on from other parts of the system. These techniques can include use of valves, blinds and bleeders. Type Method Ilustrative example spoolreneval Physical sconnecton | Double bloc, bleed and spade iE} Bind isolation ‘Single block and bleed and spade | Originated 7 Reviewed and Approved by: | Reviewed by : Reviewed by: OMS Committee Head of Department Rw [MALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant — Plant 2 UNCONTROLLED WORK INSTRUCTION COPY Title: Energy Isolation and Lock out/Tag _ Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 9 of 13 Situation requiring for positive isolation as per below: I. For confine space entry II. For hot or cold work on a unit which is part of a system containing eneray source: + High temperature + High pressure + Asphyxiant + Toxic gas | * Corrosive IIL For hot or cold work on a unt which is part of a system containing combustible or explosive material b) Valve Isolation ‘Should only be used if the valves can be operate and provide a reliable seal (not passing) | Under the particular conditions of service. Effectiveness of valve closure can be confirmed via vent/bleed points before intrusive work commences. Type Method Illustrative example Double block, bleed and spade Valve isolation ‘Single block and bleed and spade fra Live system iE; Equipment / process sytem to be isolated P| Manual vatve (closed position) Originated / Reviewed and Approved by: | Reviewed by : Reviewed by: OMS Committee Head of Department rw [ WiMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION COPY Title: Energy Isolation and Lock out/Tag Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 10 of 13 3. Stored Energy Isolation Non-operate equipment may still contain stored energy. This energy should be removed or placed in a controlled state that will not change whilst the defined work is being carried out. This particularly applies to spring mechanisms, pneumatic and hydraulic systems. The situations where stored energy may be encountered by: i Draining ii Venting Purging iv. Flushing 4, Electrical isolation Electrical equipment shall be considered to be energised (ie. live) until proven de-energised, ‘Switch electrical breaker to the off position. Visually verify that the breaker connections are in the off position and install lock out device with a proper tagging Figure 1: Electrical lockout Originated 7 Reviewed and Approved by: | Reviewed by : Reviewed by: QMS Committee Head of Department aMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 WORK INSTRUCTION { Title: Energy Isolation and Lock out /Tag out Procedure UNCONTROLLED COPY Document: QW-PR-35 Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 11 of 13 APPENDIX 3 Approved LOTO devices to be used in MSCIK plant Do not operate tag (Ot. INFORMATION OPERATE EQUIPMENT TEER ‘EQUIPMENT LocK-OUT Safety Padiock Originated 7 Reviewed and Approved by: Head of Department ie Reviewed by : Reviewed by: OMS Committee |MALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION ‘COPY Title: Energy Isolation and Lock out/Tag _ Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 12 of 13 10.0 Attachment ATTACHMENT 1 Supporting certificate for physical and electrical isolation ‘SUPPORTING CERTIFICATE FOR PTW merorimieaee” Cts nanan ne eee ae rerenineerete Oi fea! Daneman Originated / Reviewed and Approved by: | Reviewed by : Reviewed by: OMS Committee Head of Department aifMALAY-SINO CHEMICAL INDUSTRIES SDN. BHD. (Company No.: 16055-T) Kemaman Plant - Plant 2 UNCONTROLLED WORK INSTRUCTION ‘COPY Title: Energy Isolation and Lock out/Tag Document: QW-PR-35 out Procedure Revision: 1 Date: 01 APR 2018 Expiry Date: Until Superseded Page 13 of 13 ATTACHMENT 2 Lockout and tagout log sheet Tockout] Tagout released Time Lockout/ Tagout applied ig Originated / Reviewed and Approved by: | Reviewed by : Reviewed by: OMS Committee Head of Department Rw (K