Professional Documents
Culture Documents
Page 2 of 35
TABLE OF CONTENTS
1. PURPOSE
2. SCOPE
5. PROCEDURE
7. CONTROL OF RECORD
8. COMPETENCY
9. CONTINUAL IMPROVEMENT
11. ATTACHMENTS
Classification: Internal Use
Page 3 of 35
1. PURPOSE:
2. SCOPE:
GLOSSARY DEFINITION
An inquiry raised to Global Assurance via a controlled form in order to
Clarification
provide explanation on the intent of OMS standard requirements.
EHSS Environment Health Safety Security
eSHEM Incident Reporting System
This means that the authorized employee has the authority to and is
continuously in a position to prevent (exclude) other individuals from
re-energizing the machine or equipment during the servicing or
maintenance activity. For instance, where the exposure to hazardous
energy is controlled completely by unplugging the equipment from an
Exclusive Control
electric outlet. This applies only if electricity is the only form of
hazardous energy to which employees may be exposed and work is
being performed only by the person in control of the plug. This
exception can encompass many portable hand tools and some cord
and plug connected machinery and equipment.
Classification: Internal Use
Page 4 of 35
GLOSSARY DEFINITION
This is the physical test to start the equipment/process and open
valves to check for the absence of hazardous energy and to verify the
Try-out
equipment is properly locked/tagged out and the LOTO devices stays
fixed and secure.
This is the location where the affected personal can witness and verify
the secure state of the locked equipment. The affected person does
not perform the verification. Indicated in drawings as VP (Verification
Verification point Point). Verification points are (i.e. low point drains, high point vents,
pressure/temperature gauges, MCC Electrical Switch (cabinets), or
plant main-steam feed) which will be verified periodically when LOTO
work will continue to establish that a zero
FSR Field Safety Representative
HCIS High Commission for industrials Security, Ministry of Interior
JQP Job Qualification Procedure
JSA Job Safety Analysis
KPI Performance Indicators
Obligations imposed on an organization, including those that are
Legal Requirements
statutory or regulatory.
Line Management Supervisors, Managers, and Senior Managers.
LOTO Lock Out / Tag Out
Management Detailed procedures or policies that explain the implementation
System methodology to meet the requirement of SABIC OMS standard.
OMS Operations Management System.
OMS Champion A senior level individual from the Senior Management Team and senior
managers who demonstrate knowledge to implement, review and
update Petrokemya management system.
The percentage of actual adoption in terms of documentation and
OMS Compliance
implementation, against the applicable Management system
Rate
requirements in OMS.
OMS Document
Petrokemya Management System document issuers / authors.
Developers
A document that mainly enlists a set of Management system
OMS Element requirements developed to outline what needs to be done in order to
achieve operational excellence for a specific business aspect.
OMS Element A subject matter expert who is accountable for the internalization of
Leader applicable requirements for specific OMS Management system, usually
within the line management roles of the organization.
OMS Performance A measure to define the successful achievement of expected outcome
that resulted from implementing the Management system
Classification: Internal Use
Page 5 of 35
GLOSSARY DEFINITION
requirements for one or a group of OMS elements. It represents the
percentage of achieved results versus the expected results.
An individual responsible for the coordination of OMS development
OMS Specialist and implementation, who interfaces with OMS element owners and
management.
OMS Sponsor A senior level individual from the Senior Management Team who
provides direction, secure resources, and inspires a successful
development and implementation of OMS in his organization.
OMS Sub-Element A subject matter expert who is accountable for the internalization of
Leader applicable requirements for specific Sub OMS Management system,
usually within the line management roles of the organization.
OSHA Occupational Safety and Health Administration
P&ID Piping & Instrumentation Diagram
PMT Plant Management Team
PPE Personal Protective Equipment
R&R Roles and Responsibilities
SAFER SABIC Assurance Program for EHSS Risks
Senior Management Leader of a department who is Senior Manager position.
Shall The term 'shall' as used in this document is intended to describe a
mandatory requirement.
The term 'Should' as used in this document is intended to describe a
Should
highly recommended, but not mandatory requirement.
SME Subject Matter Expert.
SMP Standard Maintenance Procedure
SMT Site Management Team (director) and/or president.
SOP Standard Operating Procedure
SDS Safety Data Sheet
Table 2 Glossary, Formulae & Definitions
Page 6 of 35
Sub-element
EHSS Senior
Coordinator
Operations
Employees
Authorized
Supervisor
Managers
Element /
SMT
Manager
Affected
SN Activity description
Isolator
Leader
Person
Person
Owner
Owner
Senior
LOTO
LOTO
LOTO
Develop, review and
4.1 approve management A R C/I C I I I I I
system.
Periodic Compliance
4.3
Assessments / Inspections.
A R R I R R R R R
Effective implementation of
4.4 this Sub-element in area of A C R C R R R R R
responsibility.
Validate knowledge /
4.5 training for this Standard in A C R R I I I I I
the area of responsibility.
Validate knowledge/training
4.8 for LOTO authorized A I R I I I I I I
employees
Perform periodic inspections
to verify ongoing
4.9 compliance with regulatory A I R I R R R R I
and internal requirements
relating to this sub-element
Table-3 Roles and Responsibility
5. PROCEDURE
Page 7 of 35
5.1.1.3 Shall be responsible for the LOTO program for their area of
responsibility (e.g. Site, unit, plant)
5.1.1.4 Is responsible for maintaining the integrity of the LOTO program
for their area of responsibility (Plant/Unit/..).
5.1.1.5 Is responsible for record LOTO used in LOTO Certification
Control Sheet (Attachment-11) for their area of responsibility
(Plant/Unit).
5.1.1.6 Has received the same training as a LOTO Authorized employee
in accordance with Training Requirements (Attachment-3).
5.1.1.7 Manage the keys in the LOTO Coordinator cabinet in such a way
that no unauthorized persons can obtain any key as these keys
control the safety of all persons working under LOTO with
regards to isolated energy sources in the plant/unit.
5.1.1.8 Has a clear overview of all ongoing LOTO activities within his
area of responsibility.
5.1.1.9 Is responsible for proper hand over and received back of all
LOTO activities after his working hours (Sufficient time will need
to be set aside to have an adequate handover of ongoing work
between the off-going and incoming assigned LOTO Coordinator
or area Owner Supervisor) using the LOTO Cabinet Hand Over
(Attachment-7)
5.1.1.10 Periodically verifies the LOTO program in the field to meet the
expectations of this program.
5.1.1.11 Shall consult with LOTO authorized person to de-LOTO
equipment or system, when work is finished.
5.1.1.12 Report concerns of all kind of dangerous (unsafe) situation by
issuing eSHEM report and communicated to Owner supervisor
Page 8 of 35
Page 9 of 35
Page 10 of 35
5.2.4 Energy isolating device(s) shall be locked out using the PETROKEMYA
appropriate lock out device(s) that shall be properly affixed to the source
of energy (machinery or process equipment) identified for installation,
service or maintenance.
5.2.5 As per this management system, energy isolating devices are further
defined as mechanical devices that when applied to machinery or
process equipment will physically prevent the transmission or release of
all forms of energy associated with the machinery and or process
equipment. Energy isolation devices include but are not limited to:
5.2.5.1 A manually operated electrical circuit breaker (only if in
compliance with IEC 60947-3)
5.2.5.2 A disconnect switch breaker (only if in compliance with IEC
60947-3)
5.2.5.3 An electrical plug;
5.2.5.4 Manually operated switches by which the conductors of a circuit
can be disconnected from all ungrounded supply conductors,
and, in addition, no pole can be operated independently. Only
switches that clearly indicate the state of isolation by an
approved “fail-proof” indicator or by the visible separation of
contacts (both as per IEC 60947-3) may be used to validate that
“Zero energy” is in place (other means of providing Zero energy
need to be described).
5.2.5.5 Line valves, flanges and any similar device used to block or
isolate energy.
Classification: Internal Use
Page 11 of 35
Page 12 of 35
Page 13 of 35
Page 14 of 35
Page 15 of 35
Page 16 of 35
Page 17 of 35
area.
5.4.10.6 Use of correct standard of drain hose for service and ensure they
are secured at the drain point to prevent whipping under
pressure.
5.4.10.7 Always drain slowly when draining as high rates can cause static
sparking.
5.4.10.8 Never leave a drain open when unattended.
5.4.10.9 Any open end created or temporary hose fitted shall be
recorded in the appropriate register.
5.4.10.10 Inspect and verify that the equipment is de-energized after
draining is complete.
5.5 LOTO (Lock-Out/Tag-Out)
5.5.1 Whenever service or maintenance is performed on machinery or process
equipment it shall be done utilizing procedures that afford all employees
a level of protection equal to that provided by the implementation of
personal LOTO devices.
5.5.2 LOTO devices shall be used in accordance with the following steps:
5.5.2.1 The equipment\system qualified area owner shall put the owner
lock in the energy source (equipment/system) to isolate it.
5.5.2.2 The key of owner lock (Red Color) shall be maintained inside the
LOTO Lockbox (Movable or fixed).
5.5.2.3 The LOTO authorized (owner) shall verify that all LOTO
verification points are isolated as per LOTO specific procedure.
5.5.2.4 The LOTO authorized (owner) shall lock “Green” LOTO Lockbox
by the General lock.
Note: The above tasks can be handled by one person in case of qualified
area owner is LOTO authorized.
5.5.2.5 The key of General lock shall be maintained inside the LOTO Key
Cabinet (fixed). One LOTO Key Cabinet shall be provided for
LOTO Coordinator.
5.5.2.6 The LOTO Coordinator shall lock LOTO Key Cabinet by LOTO
Coordinator Lock. (Black color)
5.5.2.7 All LOTO affected persons shall lock LOTO Lockbox by their
personal locks (Yellow Color).
5.5.2.8 The satellite box can be utilized in additional to LOTO Lockbox if
there is extra group of workers from different disciplines work in
same isolated equipment or for workers work in the same group.
5.5.2.9 The LOTO Coordinator shall control and maintain the LOTO
Classification: Internal Use
Page 18 of 35
Lockbox.
5.5.2.10 The LOTO affected supervisor shall control and maintain the
satellite box.
5.5.2.11 The Lockbox number and satellite box number to be register in
LOTO Certificate (Attachment-5).
5.6 LOTO Exceptions
5.6.1 A combination of Lockout and Tag-Out shall always be applied when
work (maintenance, service...) with potentially hazardous energy sources
needs to be done unless one of the following conditions are applicable:
5.6.1.1 Exposure to hazardous energy is controlled completely by
unplugging the cord and plug connected equipment from an
electric outlet and where the person doing the service or
maintenance has exclusive control of the plug. This applies only if
electricity is the only form of hazardous energy to which persons
may be exposed when work is being performed by the person in
control of the plug (this exception encompasses many portable
hand tools and some cord and plug connected machinery and
equipment). Any activity, related materials, tools and equipment
are controlled by SHEM-08.10 requirements and controls.
5.6.1.2 Minor tool changes and adjustments, and other minor servicing
activities, which take place during normal production operations,
are not covered by this management system if they are routine,
repetitive, and integral to the use of the equipment for production,
provided that the work is performed using alternative control
measures that provide effective protection. These control
measures shall be prepared by person(s) familiar with the
equipment/process and reviewed and approved by LOTO
Authorized personnel or the department manager.
5.6.2 In situations where LOTO devices must be temporarily removed from the
energy isolating device and the machine or equipment temporarily
energized, e.g. for testing or positioning a machine, equipment,
installation or component thereof, the following sequence of actions
shall be followed:
a) Clear the machine and/or process equipment and adjacent
area of tools and materials by owner supervisor/ LOTO
authorized person.
b) Remove persons from the machine or equipment area by
owner supervisor/ LOTO authorized person.
c) Notify the area operations and affected personnel prior to the
temporary removal of locks/tags by owner supervisor/ LOTO
authorized person.
Classification: Internal Use
Page 19 of 35
5.7.1.2 Locks & gang lockout (multi-lock hasps) devices shall be strong
enough to prevent removal without use of excessive force or
unusual techniques, such as with the use of bolt cutters or other
metal cutting tools.
5.7.1.3 The LOTO certificate is only an authorization for LOTO/equipment
isolation; but to perform the job, work permit is required.
5.7.1.4 Tags shall meet the requirements in accordance with General
EHSS Rules procedure (SHEM-8.01).
5.7.1.5 LOTO locks shall be unique from all other locks in use; and one
lock is issued with only one key for each person authorized in
LOTO practices to work on and/or be exposed to hazardous
energy during work practices.
NO spare keys shall be allowed under any
circumstance.
5.7.1.6 Lockout devices and Tag-Out devices shall be the only devices(s)
used for controlling energy, and shall not be used for other
purposes and shall meet the following requirements:
Classification: Internal Use
Page 20 of 35
Page 21 of 35
Page 22 of 35
Page 23 of 35
Figure 1: Process isolation by physical disconnection in combination with double block and bleed
Figure 2: Process isolation by physical disconnection in combination with single block and bleed
5.8.5.1 Blinding/Blanking/Spading
Classification: Internal Use
Page 24 of 35
Figure 3 Examples of blinding devices (Blind, Spade and Spectacle Blind) and
the visible distinction between a spade and a spacer (a Spacer as shown above
is clearly NOT a blinding device). A Spade (or slip plate) and a Spectacle Blind
(or spectacle plate) applied correctly will form a positive barrier across the bore
of a pipe and are held between flanges of the pipe.
Classification: Internal Use
Page 25 of 35
Figure 4: Process isolation by a spade in combination with double block and bleed.
5.8.5.3 Double Block:
If double block with bleed isolation is not possible, double block
isolation only could be acceptable, with the required
precautions, if backed by the risk assessment. Keep in mind that
this might not give a true indication if a full successful isolation
has been made. SAFER (SHEM-02) process may be necessary to
identify and mitigate the remaining risk.
5.8.5.4 Single block (Isolation)
Classification: Internal Use
Page 26 of 35
Figure 5: Process isolation by a spade in combination with single block and bleed
Type of
No. Type of Process Material Minimum Type of Isolation
work/case
Confined
1 Any material Blind and/or physical disconnection
Space Entry
Page 27 of 35
Type of
No. Type of Process Material Minimum Type of Isolation
work/case
Other material
(Non-Hazards)
Double block and Bleed.
(Pressure >2kg/cm2 or temp.
>50oC)
Note: If above isolation methods cannot be strictly followed and implemented, then
Policy & Management System Development procedure (OMS-231) shall be followed to
raise exemption.
5.8.6 To be aligned with the forms, shall include an attachment of P&ID
drawing copy with all valves marked and numbered what to be opened
and what to be closed. Equipment isolation shall be reviewed and
approved by supervisor level for confined space entry isolation.
5.8.7 Equipment Isolation shall be the nearest isolation valve to the
equipment.
5.8.8 Equipment blinding shall be done as per approved Equipment/ system
blind list.
5.8.9 Issuer/Owner shall attach blind list markup drawing to the work permit
before issuing the work permit.
5.8.10 Ensure zero pressure in the system by assuring vents/drains are opened.
Classification: Internal Use
Page 28 of 35
Page 29 of 35
5.9.17 In case the operator leave the working area, the line break executers
shall stop the job till he return back.
All the local, regional, national and international regulation requirements applicable
to this management system, and to which Petrokemya subscribes, have been
identified and determined in accordance with Compliance, Assessments and
Evaluation Management System (OMS-232), and incorporated into the procedure or
otherwise referenced in Section 10, and provided below:
7. CONTROL OF RECORD
The following records are identified and described in the record control requirements
pertaining to this Management system in accordance with Documentation & Control
of Records Management system (OMS-234).
S. Retention
Document/Record Owner Location
No. Period
Owner Department LOTO Owner
1 LOTO Control Sheet 1 Year
Coordinator Department
3 months
Owner Department Owner
2 LOTO Certificate from the
Supervisor Department
closing date
Owner
3 LOTO Specific Procedure Owner Department 3 years
Department
Owner Department Owner
4 Cabinet handover sheet 1 Year
LOTO Coordinator Department
Owner
Owner Department
5 Lock cutting form Department 1 Year
WFD&CI Latest
6 SHEM-08.11 Hard copy OMS Specialist
Department version
ECM, SHEM-8.11
Latest
7 SHEM-08.11 Soft copy OMS Specialist Electronic folder
version
8 Inspection Report Owner Department Owner Department 2 Years
9 KPI Report Owner Department Owner Department 2 Years
Owner Department Sr. Owner
10 LOTO Authorization Manager Department 3 Years
Page 30 of 35
8. COMPETENCY
LOTO Authorized
Personnel Safety
Senior Managers/
Employees**
LOTO Affected
Coordinator*
Managers
Person**
Engineer
Manager
LOTO
Lead
Competency Type
Page 31 of 35
9. CONTINUAL IMPROVEMENT:
Page 32 of 35
10.1 References
SAF-02 Environmental, Health and Safety Management, HCIS, V2.0, 2017
SAF-13 Work Permits, Isolation of Energy, and Hazardous Work, HCIS, V2.0,
2017
Page 33 of 35
Page 34 of 35
11. ATTACHMENTS
1 LOTO Flowchart
Attachment 1
5 LOTO Certificate
Attachment 5
Page 35 of 35
Implementation Assessment
12 Checklist Attachment 12
Table 10 Attachments