Annex-IV to PR No: O8005-080-E-K-6506 dtd-07.11.
2011
POSITIVE ISOLATION FEATURES / FACILITIES APPLICABLE
FOR DESIGN, ENGINEERING & MANUFACTURING OF
ELECTRICAL EQUIPMENT.
Basic Concept of Positive Isolation:
Providing Safety measures for the working personnel is the basic purpose of
Positive Isolation (P.I.) procedure.
P.I. can be achieved through:
1) Assurance of Correct Isolation
Energy Source Identification
Accreditation / Authorisation of Isolating Personnel
2) Assurance that Equipment cannot be energised till person has completed
the job:
Personal Locks
System Locks
The Isolating/disconnecting facilities, padlocking provision and provision of
Personal & System Locks of various colours wherever applicable are to be provided
by the Vendor / Manufacturer (Pls. Refer Annexure I).
All Electrical equipments shall be designed & manufactured considering the
following:
I) Low Voltage (LT Upto 650 Volts) Electrical Equipment
i. Low voltage electrical equipment/switchgear such as MCCB, ACB, and SFU
etc. shall have completely disconnecting, drawout type and padlocking
provision (in off position) on front door/in equipment off position/in
operating handle, so as to ensure the positive isolation of electrical energy.
The equipment/switchgear shall have proper indication about the
confirmation of isolation.
ii. The design of such equipment shall be suitable for positive isolation as
defined in IEC-60947 and IS: 13947. The equipment/switchgear shall be
designed in such a way that the pad-lock can be put easily and only in a
safe isolated condition.
iii. Equipment/switchgears like MCCB up to 440 volts not having drawout
features shall necessarily have the symbol [ ] which
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signifies the compliance of the positive isolation requirements. Apart from
this symbol, the equipment shall have provision for padlocking in isolated
condition.
iv. The padlocking facility for such equipments/switchgears shall be provided
such that the TATA STEEL’s specified padlocks can be put without any site
modifications. The dimensions of Tata Steel’s specified padlocks are as
indicated in the Annexure of this document.
Specification of Isolation Locks:
Specification of the locks used in Tata Steel for Positive Isolation. (To
be considered for designing the equipment)
DRAWING DETAILS OF ISOLATION LOCKS
v. Written safe work procedures for safe operation of switchgears must be
provided at the panels and shall be properly pasted. The switchgear shall
have pad-locking provision (at the position where it ensures positive
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isolation) to ensure that the switchgear cannot be made “ON” unless the
pad-lock is removed.
vi. Warning signs: All low voltage electrical equipments should have proper
provision/space to display the warning signs / indications.
vii. Identification of controls: Each electrical distribution switch, circuit
breaker and control must be clearly marked to indicate the equipment it
serves.
II) High Voltage (HT above 650 Volts) Electrical Equipment
i. High voltage electrical equipment/switchgear such as circuit breaker,
isolator etc. must have positive isolation (physical as well as electrical
isolation in both power & control circuit) and, grounding and pad-lock
provision in isolated condition. The switchgear shall have proper indication
about the confirmation of isolation. Equipment/switchgear shall be selected
in such a way that it ensures positive isolation of electrical energy with a
padlocking arrangement.
ii. The design of such equipment shall be suitable for positive isolation as
defined in IEC-60947 and IS: 13947. The equipment/switchgear shall be
designed in such a way that the pad-lock can be put easily and only in safe
isolated condition.
iii. The padlocking facility for such equipments/switchgears shall be provided
so that the TATA STEEL’s specified padlocks can be put without any on site
modifications.
iv. Written safe work procedures for safe operation of switchgears must be
provided at the panels for equipment/switchgear and shall be properly
pasted.
v. The equipment/switchgear shall be designed in such a way that the pad-
lock can be put easily and only in safe isolated condition. The design shall
ensure that the switchgear cannot be made “ON” unless the pad-lock is
removed.
vi. Warning Signs: All high voltage electrical equipment should have proper
provision/space to display the warning signs / indications.
III) Safety Guidelines For Control Systems To Be Considered At Design Stage
i. The control system must be designed in accordance to provide positive safety
to the operating and maintenance personnel through provision of proper
positive isolation scheme without hampering the operation and reliability of
the equipment.
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ii. The control system must be designed so that the controlled equipment
cannot be inadvertently activated (Pls. Refer Annexure I).
a. Hardwired emergency stop devices shall be provided at operator
stations to isolate the energy sources. The emergency stop system
shall be completely hardwired and shall not be routed through PLC or
other automation system.
b. Hardwired emergency stop actuation for the specified
equipment/group of equipment shall directly isolate the energy source
of the equipment.
c. Necessary indications for emergency actuations shall be properly
indicated on the HMI screens/local control panel’s at all relevant
locations.
d. The visual indication of emergency actuation must be visually
displayed at the respective work area (in form of warning lamp and
alarm).
e. All electrical appliances shall be provided with “Press to lock and turn
to release” type push-button station with moulded type transparent
enclosure to prevent accidental operation near all motors and
transformers. For roller tables, run-out tables similar type group
emergency stops shall be provided. Lockable local stop push-button
station shall be provided for individual motors of auxiliary/media
systems.
f. All equipment to conform to IEC 61508 and IEC61511 regarding
functional safety requirements.
iii. A control system must be designed to prevent automatic start-up after a
power interruption or low voltage occurrence, except for change over to
Emergency Power/duplicate source.
iv. The supplier shall provide written safe work procedures for the use of
equipment operated by a control system, including lockout procedures as
required for ensuring safety.
IV) Exclusion
i. The electrical work below and up to 250 Volt AC, 220V DC & lighting circuit
is not covered in this standard. However, the electrical equipments
controlling/ regulating other energy sources shall be included irrespective of
the voltage level e.g. 24V DC solenoid valve which may be used to control the
steam, gas, water, hydraulic valves etc.
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ii. Release of geological or structural energy that may be released by unforeseen
failure of slopes/structures.
iii. Release of energy associated with Loco Movement while idling on a gradient.
Example I :
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Drawings & Documents: (Applicable For turnkey projects only)
The energy sources or stored energy or both (as the case maybe) for each
independent equipment or module/component or part of large machinery or
stand-alone system shall be identified in a separate format as shown in item 8.
Such document shall be prepared by Vendor/Supplier and submitted to the
Purchaser along with other drawings & documents generally under “Information
Category”. However, the Purchaser reserves right to ask for additional
information or modifications, if in his opinion the same is required. The
Vendor/Supplier will comply with this additional information or modifications as
the case may be without demur.
In order to satisfy the above mentioned requirement, any other item not
specifically mentioned herein but required for safe, smooth and reliable isolation
of energy source or stored energy sources shall deemed to form part of the
design and manufacture of the equipment and the responsibility to ensure
completeness will solely rests with the Vendor/Supplier.
Isolation points shall be clearly labeled to identify the circuit or system over
which they have direct control. These labels shall be applied following a process
of pre-isolation identification using isolation list, marked drawing etc ( where
permanently applied, these labels shall be physically verified prior to the
isolation).All the energy or stored energy sources required to be isolated for each
equipment shall be clearly marked and identified by a unique number in the
Vendor’s/Supplier’s drawing. This unique number shall be provided as per the
following guidelines:-
The number shall have the format xxx / y /zzz/ nnnn. Here the x, y and z
shall be English alphabets while n shall be digits.
The “xxx” shall indicate Plant Like HSM, PH3, CRM for Hot strip Mill, Power
House-3 and Cold Rolling Mill etc.
The “y” shall indicate the Department name i.e. Electrical, Mechanical etc.
The “zzz” shall indicate the section in particular department. Like PPH, CTR
for pump house or Cooling Tower areas.
The “nnnn” shall be four digit numbers and this number shall be unique
across the particular Plant. There shall not be similar digital numbers for
any two equipments in a plant.
The provision made in the equipment to facilitate positive isolation and the
required positive isolation tool shall also be indicated in the drawing or in a
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separate document. The reference of such separate document shall be also
mentioned in the main drawing for ease in co-relating by the user.
The identified energy sources or stored energy which may require positive
isolation for any equipment shall also bear the same unique number as
indicated in the Vendor’s/Supplier’s drawing. This unique identification number
shall be either painted or marked prominently on the equipment subject to
approval from purchaser.
The format for energy source identification shall be as per the format given in
Item 8. The energy sources of the equipment shall form a part of the technical
specification /data.
Lock out points for providing isolation locks for each equipment in an
isolated/de-energized condition shall be clearly shown in the respective
drawings. It shall be ensured that any energisation of energy source or stored
energy source is effected only after the isolation lock is removed from its position
and isolating device thus released from locked position is restored to its normal
operation or energized position. The method of control stop shall be clearly
documented. However, control stop shall in no case be applicable to
equipments rated 1 KV and above.
Formats for energy source identification:-
Format for energy source identification (Having single type of energy
source)
Project Name: New Blast Furnace – I, Tata Steel Limited, Jamshedpur
Vendor Name:
Name of the Area & Equipment:
Equipment Details Type Details of Positive Isolation Remarks
of Job
Equipment Equipment Method Location of
Name No. of Isolation Locks
Isolation
Panel S/S or
No. / MCC
Valve Location
No. or Valve
Location
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Format for Controlled Stop
S.No. Equipment Details Job Isolation Details Control Remarks
description stop
procedure
Equipment Equipment No.
Name no.
Method Switch/Valve Location
of No.
isolation
1. Reference Picture for Isolation & Locks
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