VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
LOCK, TAG, TRY GUIDELINE
1.0 PURPOSE
To provide safeguards or barriers at those points where unwanted release of energy could result in injury and/or damage.
2.0 SCOPE
This guideline specifies lockout/tagout for both maintenance and refinery turnarounds and shall apply to all work performed by company or contract personnel on equipment to control electrical, mechanical, hydraulic, pneumatic, chemical, thermal, radiation and potential energy.
3.0 DEFINITIONS

Blinding - The absolute seal off of a pipe, duct, vessel, exchanger, or tower or other refinery equipment using a properly designed metal plate inserted between two flanges or bolted onto the end of a flanged pipe.

DCS Equipment Lockout - To disable the remote start/stop switch within the operating unit D istributive C ontrol S ystem.

Departmental Safety Locks - Common locks that are color coded to show the specific unit or department to which they are assigned. They do not take the place of a personal safety lock. Department safety locks will be keyed alike and are the
Department Supervisor's responsibility.
COLOR CODES
Millwrights
Complex I & Complex II
Pumping Department
Instrumentation and Electrical (I & E)
Pipefitters, Welders, Carpenters, Boilermakers,
Insulators, Equipment Operators
Environmental, Safety & Health Department
Blue
Green
Red
Yellow
Orange
Purple

Do Not Operate Tags - A weatherproof DANGER tag placed with each lock and as a tagout device on equipment energy sources that cannot be locked out. The tag contains the date and name of the individual who applies the tag and may contain specific information related to the job.
When used as a Tagout Device, it shall be attached by means of a non-reusable, self-locking, one-piece, all environmental cable tie, which will prevent inadvertent or accidental removal. A minimum unlocking strength of 50 pounds is required.

VALERO
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– KROTZ SPRINGS SHG #11
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Revised 12/20/01
Double Block and Bleed - The isolation of a pipe, line or duct using a drain or vent which is open to the atmosphere between two locked-closed valves.

Energy Source - Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, radiation or potential energy.

Equipment Lock - A lock used to secure a system, piece of equipment or circuit in conjunction with a lock box.

Equipment Lockout/Tagout Log - A written log maintained by the owning area of the equipment/system(s) locked out in their work area. An example is provided as Attachment 1.

Lock Box - A box in which the key to a group of padlocks (keyed alike) is locked to secure a system, piece of equipment or circuit. The red lock boxes contain 10 locks keyed alike. The red lock boxes with yellow stripes contain 20 locks keyed alike. The box is then secured with a single department lock onto a multiple lock hasp. Personnel working on the system place their personal safety lock on the multiple lock hasp while present at the location of the work. A lock box is not needed if a single isolation point will control all energy sources.

Multiple Lockout Adapter - A multi-"holed" hasp which is attached by the individual preparing the equipment/system for work.

Owning Area Supervisor - Management representative directly responsible for the work area where work is being performed.

Personal Safety Locks - Locks issued to individuals for equipment lockout.
Each individual will be responsible for its proper use for equipment lockout.
Personal safety locks will ONLY be used as part of the lockout process to ensure the isolation of potential energy sources as outlined in this guideline.

Zero Energy - The point at which all electrical, mechanical, hydraulic, pneumatic, chemical, thermal, radiation and potential energy within a piece of process equipment has been dissipated or controlled to prevent its unexpected or unwanted release during work activities.

VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
4.0 PROCESS EQUIPMENT ENERGY CONTROL
4.1 General Policies
A piece of equipment must be de-inventoried, de-energized and otherwise brought to a state of "zero" energy through a combination of lockout/tagout and/or blinding before it can be safely repaired, cleaned, inspected or tested. Where equipment or systems must be opened exposing process or utility fluids, they must normally be isolated from active refinery equipment by blinding or locking of valves where isolation can be verified.
Lockout/tagout is generally done for short-term maintenance and is also done as part of preparing to blind equipment.
4.2 Contractor Requirements
All contractors working on equipment will follow this Lock, Tag And Try Guideline.
Contractors will be required to provide all required locks for their personnel unless an exception is approved by refinery supervision. Contractor locks will be identified with the company name and individual worker name. Contractor supervision is responsible for instructing their employees working at this facility regarding the refinery's Lock, Tag and
Try Guideline. Questions regarding proper energy source control at a specific location within the refinery will be resolved with that area's Operations and refinery Safety personnel.

VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
5.0 RESPONSIBILITIES
Employee Group • Responsibilities
Owning Area Supervisor
• Assure compliance with the Lock, Tag and Try Guidelines.
• Provide necessary materials or equipment including lock boxes, tags, chains, information stickers, hasps, and other related items.
• Maintain the necessary items at the designated Lockout/Tagout
Lead Technician
Shift Supervisor
Operations Personnel
Maintenance / Contractor
Supervision
Maintenance / Contractor
Personnel
Stations.
• Implement and enforce proper Lock, Tag And Try Guidelines.
• Be thoroughly familiar with their equipment and proper equipment isolation.
• Make notifications and coordinate if a personal lock needs to be removed.
• Be thoroughly familiar with Lock, Tag And Try Guidelines and proper equipment isolation practices.
• Properly prepare equipment and safe work permits for the maintenance work about to be performed.
• Inform appropriate maintenance or contractor supervision of any special hazards involved and the precautions to be taken.
• Maintain control of the locks installed and removed on equipment within their area of control and keep records of equipment locked or tagged out (the Lockout/Tagout Log).
• Verify that locks and tags are installed in and removed from the proper location(s).
• Verify that DCS equipment start/stop switch is locked out.
• Return equipment to Lockout/Tagout Stations after use.
• Update the Lockout/Tagout Log.
• Assure that their personnel are properly trained in the refinery
Lock, Tag And Try Guideline.
• Ensure that the refinery Lock, Tag And Try Guideline is followed by their personnel.
• A Contract Supervisor may place his personal safety lock on a lockout device in the place of individual personal safety locks when it is deemed to be impractical for the entire work crew to maintain a lockout. This will require the approval of Maintenance and the
Owning Area Supervisor.
• Install individual locks and tags on lock boxes.
• Verify and test the adequacy of the lockout prior to starting work.
• Remove locks according to guidelines.
Safety Personnel • Assure that at least annual assessments of the facility lockout program are performed and properly documented.

VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
6.0 LOCKOUT/TAGOUT Procedures
6.1 OPERATIONS PERSONNEL

Identify all potential energy sources associated with the equipment to be isolated.

∙
∙
Isolate all identified potential energy sources and place an equipment lock and a
Do Not Operate Tag with the date and name of person attaching tag on each energy isolating device.
∙ Every lockout will have a tag with the date and the name of the person
∙ that applied the lock/tag. A permanent marker will be used to fill out necessary information on the tag. A new tag will be used for each job.
Tags will be discarded after use.
If only a single energy source is identified, additional information specific to the job shall be added to the tag at the lockout point.
∙ If more than one energy source is identified a lock box shall be used.
Place the key(s) to the equipment lock(s) used in a designated lock box and place a departmental safety lock and tag on the lock box. A lock box should only be used on one system at a time.
∙ Anytime a department lock is used, the information specific to the job shall be added to the tag.
∙ Valves will be locked with chains that are inserted through the valve yoke and wheel to assure the valve cannot be opened or moved. Tie wraps may be used where chains and locks are not feasible. If the valve handle cannot be secured, the valve handle will be removed and valve tagged.
Lock out any equipment associated in the DCS display.
Complete Lockout/Tagout Log.

Assure that any stored energy has been dissipated and equipment is at zero energy.

Verify that the equipment has been properly isolated by trying start/stop button, opening and clearing bleeder, and stroking valve, etc.

Tag non-energy source valves that must remain in a certain position with Do Not
Operate tags. These valves do not require locks. An example is a valve used to depressure equipment or verify isolation that must remain open.

Contact qualified I&E personnel when lockout of high voltage (13,800 volts) electrical equipment is required.

Maintain their departmental safety locks on the equipment until work is verified to be complete and the equipment is ready to be returned to service.

For a test run, coordinate the temporary removal of locks and DCS display lockout. Stand by during the test to assure that the lockout is revalidated at the end of the test. (Operations personnel must be present.)

VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
6.2 MAINTENANCE PERSONNEL

Place their personal lock on the lock box or single isolation point prior to beginning work and leave the lock in place until completion of their work, until the end of their shift, or until reassigned to another job, whichever occurs first. If all personal locks for a craft are removed before work is complete, a departmental lock and tag containing information specific to the job will be installed.

Clear the area and try the start/stop switch, check bleeders and/or check chains and locks on isolation valves to assure that a secure lockout has been achieved.

Inspect the area at the completion of the work to ensure that good housekeeping has been maintained and all equipment safe guards have been properly reinstalled.

Inform Operations personnel when removing personal or departmental locks regarding the present status of the equipment. Update lockout information tag.

Standby as requested by Operations during start up of equipment after completion of maintenance.
6.3 Tagout (DO NOT OPERATE Tag)
If any energy isolating device is not capable of being locked out, the placement of a tagout device on the energy isolating device, in accordance with this guideline, will indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
6.4 Trying
The person who installs the first personal safety lock will be responsible for, and assure that a lockout has been achieved. This will involve such things as trying the start button, checking a bleeder, checking placement of blinds, and checking chains and locks on isolation valves. An Operations representative must be present during this procedure.
NOTE: Be sure that personnel are clear of equipment before trying to energize.
6.5 Removing a Lockout


Once equipment has been released, the owning area will verify readiness, remove their locks and tags and update the lockout/tagout log to allow the equipment to be started.
Locks/chains will be saved and stored as appropriate and tags will be discarded.

VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
6.5.1 Exceptions

If for any reason locks are not removed by maintenance or contractor personnel and the equipment is ready to be returned to service, a reasonable attempt will be made to contact the individual(s) who have left their locks in place.

If the individual(s) can be reached, they will return to work and remove their lock(s). If they cannot be contacted, Operations Shift Supervisor and the individual’s supervisor, if available, will then be informed and coordinate a review of the particular piece of equipment to verify that the equipment is indeed ready to be returned to service. Before a personal lock will be removed the individual’s director or designee must be notified.

Once equipment readiness is verified, the Operations Shift Supervisor will remove the locks and tags and enable the DCS equipment control, if applicable, to allow the equipment to be started.

Locks removed will be returned to the affected employee at their next scheduled work period
6.6 Removal of Equipment from Service
Any equipment locked out of service indefinitely (3 months or longer) should be isolated by disconnecting the power supply on both ends, removing spool pieces, blind flanging piping, and if possible by removing the breaker. This equipment will not be locked or tagged after isolation is completed.
6.7 Training

Energy source control training will be provided to company employees affected by this Lock, Tag and Try Guideline upon:

∙
∙
∙
Initial employment;
Whenever a substantial change is made to these procedures; or
In conjunction with the operations and maintenance retraining done in response to Process Safety Management requirements.
Initial training will include an explanation of the recognition of hazardous energy sources, the type and magnitude of the energy available in the workplace, the methods and means necessary for energy isolation and control, and the purpose and use of the refinery Lock, Tag And Try Guideline.

Records of training will be kept which include the date of the training, the instructor's name, and a description of the program content.

VALERO – KROTZ SPRINGS SHG #11
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Revised 12/20/01
6.8 Internal Program Inspections

The refinery Safety Personnel will coordinate the implementation of an annual
Lock, Tag and Try Guideline inspection. Records of these inspections will include the machine(s) or equipment examined, the date of the inspection, the names of the employees included in the review, and the names of the individuals conducting the review. Any deficiencies identified during the review will also be documented, as well as, what follow-up action was taken to correct the problem and prevent its recurrence.

VALERO
– KROTZ SPRINGS
Lock
/Box
No.
Number of locks used
SHG #11
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Revised 12/20/01
ATTACHMENT 1
Equipment No./ Description/
Box Location
Date Out of Service
Operator
Initials
Date
Returned to
Service
Operator
Initials

VALERO
– KROTZ SPRINGS
SHG #11
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Revised 12/20/01
A TTACHMENT 2
L OCKOUT /T AGOUT A SSESSMENT
L
OCATION
:
I NSPECTORS :
E QUIPMENT B EING I NSPECTED :
E MPLOYEES I NTERVIEWED :
REQUIREMENT
1. Does the employee have knowledge and skills of the purpose and function of the energy control program?
Complies?
Yes No N/A
D
ATE
:
2. Is a record of lockouts being kept?
COMMENTS
3. Is the description/location adequate?
4. Are required initials/signatures entered?
5. Have all energy sources been addressed?
6. Are all personal safety locks in place?
7. Where a tagout is employed, does the DO
NOT OPERATE tag indicate the date and the identity of the employee applying the tagout?
8. Is the tagout located so that the location of the tagout will prevent energizing of the energy source, or in the case of a remote start/stop switch positioned so that maintenance can try to start the equipment before starting work?
9. Are individual maintenance/contractor locks present on the lock box multiple lock adapter?
10. Is there any equipment taken out of service indefinitely (90 days or more) that is still locked out? If so, is the equipment out of service indefinitely and in need of more secure removal from service than lockout/tagout?