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XSTRATA IRON ORE TOOLBOX NOTES PROVIDE SPEAKING POINTS FOR SUPERVISORS AND MANAGERS
TO EFFECTIVELY COMMUNICATE THE FATAL HAZARD PROTOCOLS TO XSTRATA IRON ORE TEAMS. JULY 2012

FATAL HAZARD PROTOCOLS #7

INADEQUATE ENERGY
ISOLATION
DISCUSSION TOPICS

- Fatal Hazard Protocols

The safety of our people is our first priority and our Iron Ore projects in Congo and
Mauritania are developed with a strong emphasis on safety. Our goal is to reach
mining stage and to produce Iron Ore with no fatality or injury and to ensure that all
employees, contractors, supervisors and managers understand the fatal hazards in
their workplace and know how to manage them.

In 2012, Xstrata Iron Ore is introducing a new series of communication tools at every
site, to enable us to focus on one fatal hazard per month – 12 months to cover 12
fatal hazards – and the Protocols that have been created to manage them.

Each month, managers and supervisors must work with their teams in pre-shift
briefings to workshop and understand if and where that month’s fatal hazard could
apply to their work place, and whether they have the necessary controls in place.

At the end of the briefing, it is expected that teams will have discussed and reviewed
the Protocol in detail.
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

What is the Intent of this Protocol?

The intent of this Protocol is to eliminate

or minimise potential fatalities, injuries
and incidents arising from risks
associated with inadequate isolation of
energy sources.

Link to XC HPRIs
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Mandatory Requirements
 A Risk Assessment must be conducted and documented to
identify the hazards and assess the risks associated with
interaction with uncontrolled energy sources.
 An Energy Isolation
Procedure and
Permit System must
be developed,
implemented and
maintained for
relevant energy
sources.
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Inadequate Energy Isolation Procedure & System - 1

As a minimum they must include:

a) The 12 step process for isolations (see previous slide);
b) Particular emphasis must be placed on:
 Identification and dissipation of relevant energy sources;
 Isolating and securing; and
 Verification of the isolation, i.e. test for dead/zero energy.
c) Procedures for:
 Individual isolations;
 Group isolations - involves the use of Permits; and
 High Voltage isolations - involves the use of Permits.
d) Use of locks in preference to danger and permit tags;
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Inadequate Energy Isolation Procedure & System – 2

e) Use of tags where locks cannot be used. Tags must be limited
to the following types:
 Personal Danger Tags;
 Permit Danger Tags;
 Out of Service Tags;
 Commissioning Tags; and
 Information Tags.
f) Provision of adequate numbers of isolation points on plant and
equipment, and in determining locations, give consideration to
practicality, accessibility and clear identification;
g) Isolation devices must (wherever possible) be lockable and
clearly labelled to identify the equipment that has or is to be
isolated, and to identify whether the isolation switch or power
switch is in the “on” or “off” position;
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Inadequate Energy Isolation Procedure & System - 3

h) For plant and equipment containing energy sources that
cannot currently be locked out, a risk-based and prioritised
action plan should be developed to address positive isolation
requirements;
i) Any person working on high voltage equipment (greater than
1200 volts AC or 1500 volts ripple free DC) that cannot be
isolated with basic isolation and cannot verify a break in the
electrical conductors must have permit in place that
incorporates a second competent electrical isolation verifier;
j) Provision of specific training for Authorised Isolators and
Permit Holders. The training and assessment will include
practical applications, and the competent person must be
appointed;
k) Procedures that control the risks associated with live testing or
approved “power on” maintenance activities;
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Inadequate Energy Isolation Procedure & System - 4

l) Procedure for the removal of isolation devices (locks and/or

tags) by persons other than the isolator in the event that the
isolator is unavailable to remove the lock and/or tag;
m) Documented processes for the maintenance of isolation
equipment;
n) Procedures for complex isolations;
o) Documented processes for the use of stands, chocks, locking
pins, clamps or other methods for securing objects from falling
or moving;
p) Motor Control Rooms, Electrical Sub-Stations, Transformer
Yards and Compounds, and Electrical Cabinets are to be
clearly labelled and signposted and kept locked to prevent
unauthorised access; and
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Inadequate Energy Isolation Procedure & System - 5

q) Identification of training needs and competency requirements

of relevant employees and contractors in relation to Energy
Isolation, and the provision of adequate training and
assessment to verify competency.
Further Considerations
Consider the use of interlocks to prevent access to energy sources
that have not been isolated;
Consider the use of displaying photographs and/or diagrams at the
various isolation point locations to more clearly demonstrate the
isolation requirements within each of the procedures; and
Consider awareness training for the entire workforce in energy
sources such as gravitational, stored, kinetic, pressure, hydraulic,
mechanical, electrical etc., to properly understand isolation
requirements.
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

What are the top 3

energy isolation
risks ?
 Failure to adequately
identify potentially
hazardous energy sources
(gravitational, stored, kinetic,
pressure, hydraulic, mechanical,
electrical, etc.).

 Failure to positively isolate,

secure or dissipate potential
hazardous energy sources.
 Failure to adequately verify
the effectiveness of an
isolation (test for dead /
zero energy).
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

What is your role in managing isolation of

energy sources?
 Adhere to the 12 step process for isolations to ensure effective
identification, dissipation and verification of isolation of energy
sources.
 Use of approved locks and tags on appropriate isolation
mechanisms.
 Ensuring you or other personnel are appropriately authorised to
conduct isolations on high voltage electrical sources or when
conducting live testing.
 Ensuring relevant permits and procedures are adhered to when
involved in complex isolations.
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

What training have you undertaken and is

it sufficient?
 Training and familiarisation in
the 12 step isolation process.
 Training in Isolation or Permit
Holder procedures.
 Trained or familiarised in the
identification of potentially
hazardous energy sources for
the work environment.
 Trained, competent and
authorised to conduct
complex isolations involving
permit systems.
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Can you list minimum requirements of the

protocol for energy isolation?
 An energy isolation procedure and permit system must be developed that
includes the 12 step isolation process, identification and dissipation of energy
sources, isolation and securing of energy sources and verification of the
effectiveness of energy isolation.
 Use of lock and/or tag mechanisms.
 Provision of adequate and suitable isolation points that are wherever possible
lockable and clearly labelled.
 Procedures and permit systems in place for isolation of high voltage
equipment: live testing and complex isolations.
 Clear labelling and locking of electrical cabinets, motor control rooms,
substations and switchyards.
 Identification of training needs and competency requirements in relation to
energy isolation, and the provision of adequate training and assessment to
verify competency.
PROTOCOL #7 – INADEQUATE ENERGY
ISOLATION

Can you rate from 1 – 5 (1 low, 5 high)

how you think your operation is complying
with this protocol

1 2 3 4 5
What actions do we need to take?