WORK PERMIT

1
WORK PERMIT
A.K.SINGH, SAFETY MANAGER INDIANOIL CORPORATION
LTD. BARAUNI REFINERY, INDIA
2
ROAD MAP

• The session will include the following
• Presentation on BR Work Permit system followed by
  discussion
• Role of Issuing Executing Authority
• Exercise how to fill the permit
• Questionnaire/QUIZ

3
WHY WORK PERMIT?

• Petroleum Refinery handles Hydrocarbons and toxic
  materials - poses special risks.
• Maint. Personnel are not adequately familiar with
  process conditions.
• Operation will determine that it is safe to
  perform the designated job.
• Basic purpose of permit system is to prevent
  injuries to personnel.

4

• Protect property from damage
• Avoid fire
• Ensure that all work is carried out in safest
  possible manner.
• permit specifies the conditions and procedure for
  safe execution.

5
WORK PERMIT REQUIRMENT

• Permit is required for the following jobs
• Major Minor Maint. work.
• Inspection.
• Construction.
• Alteration.
• Process Equip. cleaning
• Entry into confined space.
• Excavation
• Vehicle entry into hazardous areas etc.

6
WORKS - PERMIT NOT REQUIRED

• Works carried out by Oprs. Dept. as a part of
  routine operation.
• FIRE STATION
• FIRE TRAINING GROUND

7
BLANKET PERMIT

• SIX MONTHS BASIS / MAX I YEAR
• WORK SHOP
• INSTRUMENT LAB/WORKSHOP
• LABORATORY
• INSPECTION

8
TYPES OF PERMITS

• 7 types of work permit with specific colors.
• HOT WORK VEHICLE ENTRY PERMIT (Pink, light
  green white)
  For use of or generates local source
  of ignition,vehicle engine operated equip.
  entry to hazardous areas.
• 
  BRFSFR1
• CLEARENCE COLD WORK PERMIT (YELLOW WHITE)
• BR FS FR2
• (For all general maint. works (no ignition
  source)
• DYKE CUTTING EXCAVATION PERMIT(PINK ,light
  green white)
• BR FSFR3
• ROAD CUTTING BLOCKAGE PERMIT (PINK , yellow
  light green)
• BR FSFR4
• VESSEL ENTRY/VESSEL BOX UP/EXCAVATION (yellow
  white)
• For personnel entry into confined space. BR
  FSFR14
• WORK AT HEIGHT PERMIT (yellow
  white) BRFSFR17
• RADIATION WORK PERMIT( PINK WHITE)
  BRFSFR18

9
FEATURES OF WORK PERMIT FORM

• Work Permit form generally consists of the
  following features
• THE ORIGINIAL AND COPIES
• Original is unmarked and belongs to Executing
  Authority-pink copy
• Printed serial number
• FORM NO. BR FSFR...

10

• Special instructions printed on the permit

11
PROCEDURE FOR WORK PERMIT SYSTEM(WPS)

• WPS OPERATE ON OWNER IN CHERGE CONCEPT(UNITS-CPNM,
  LAB-SQCM,TPS-CPUM, STORES-SMTM)
• PERMIT IN PRINTED FORM
• SEPARATE PERMIT FOR COLD HOT WORK
• PERMIT COLOUR CODED, SERIAL NUMBER
• DEPTL. OR CONTRACTOR JOBPERMIT RECEIVING BY
  MN/PJ/CONSTRN. SUPERVISOR OF IOCL.
• PERMIT INITIATION BY MN/PJ SUEPRVISOR.
• ALL PERMITS TO BE WRITTEN IN CAPITAL LETTERS
• WORK ORDER/LOA NO. TO BE MENTIONED ON PERMIT
• LOCATION DRAWING/SKETCH TO BE GIVEN ALONG WITH
  PERMIT.
• RISK EVALUATION CHECKLIST TO BE TICKED BY ISSUER
  (GSI(HOT WORK), SUPERVISOR. NOT BY EXECUTOR.

12
PROCEDURE FOR WORK PERMIT SYSTEM(WPS)

• HOT WORKPERMIT
• EXECUTOR TO INITIATE THE FIRE PERMIT-DUATION,LOCAT
  ION, EQUP.TAG NO., NATURE OF WORK, NAME
  SIGNATURE. ECECUTOR NOT LESS THAN A GRADE
  OFFICER
• GSI( B GRADE AND ABOVE)-CHECK THE PERMIT,
  EVALUATE THE RISK,TICK 30 ITEMS AS APPLICABLE,
  SPECIAL INSTRUCTION IN SPACE PROVIDED IN PERMIT
  TO PREPARE THE AREA /EQUIPMENT TO CARRY OUT THE
  HOT WORK.
• SHIFT IN CHRAGE IN E/N SHIFT TO FOLLOW UP
  DIRECT PREPARATIONS. N/SHIFT TO INSPECT THE AREA
  /EQUIPMENT JUST BEFORE THE SHIFT CHANGE AND LEAVE
  MESSAGE FOR FPS(C GRADE AND ABOVE)IN SHIFT LOG
  BOOK.

13
PROCEDURE FOR WORK PERMIT SYSTEM(WPS)

• HOT WORKPERMIT
• FPS AFTER GOING THROUGH LOG BOOK ,ACCOMPANIED BY
  GSI EXECUTOR INSPECT THE AREA, SATISFY HIMSELF
  WITH PREPARTIONS AND THEN SIGN THE PERMIT.
• PERMIT TO BE RECEIVED BY EXECUTOR BY SIGNING.
• REGISTRATION AT FIRE STATION.
• PINK COPY FOR EXECUTOR/ WHITE FOR ISSUER
• ISSUER REPRESENTATIVE-SHIFT PNE/SPNE/SPUE TO
  CARRY OUT GAS TEST, INSPECT THE AREA, ENSURE
  COMPLIANCE OF ALL SAFETY PRECAUTION GIVEN IN
  PERMIT , THEN ISSUE CLEARENCE CERTIFICATE TO
  START THE JOB.

14
VALIDITY OF HOT WORK PERMIT

• HOT WORK PERMIT
• NORMAL 8 HOURS( 8AM-5 PM). BEYOND 5 PM
• RENEWABLE AFTER AUTHORISATION FROM HOD.RENEW AT
  FIRE STATION ON EXTENSION.
• NORMAL HOT JOBS IN NIGHT SHIFT NOT ALLOWED UNLESS
  JOB IS URGENT, PERMISSION FROM HOD REQD.
• FOR EACH LOCATION/EQUIPMENT SEPARATE HOT WORK
  PERMIT REQUIRED IN PROCESS UNITS
• IN OFFSITEDISTANCE EXCEEDING 15 METERS, SEPARATE
  FIRE PERMIT.

15
WHO CAN SIGN A WORK PERMIT

• Personnel who are authorized to sign on the Work
  Permit shall have thorough knowledge of the work
  to be performed and the conditions under which
  the work will be performed.
• DGM(T) AUTHORISES GSI FPS AND LIST IS
  CIRCULATED.

16
ISSUING AUTHORITY OF WORK PERMIT

• Issuing authority is responsible for preparation
  and handing over of the equipment in safe
  condition to perform the work.
• Authority to issue all types of work permits is
  generally granted to shift supervisor(PNE/SPNE,
  UTE,ELE) level of OFFICERS and above.

17
EXECUTING AUTHORITY OF WORK PERMIT

• Request for a work permit by executing authority.
  He shall indicate types of tools and equipment
  necessary for performing the work.
• He shall also ensure his tools, equipment and
  accessories are in good condition and all his
  workers are provided with proper PPE.

18
PREPARATION OF THE EQUIPMENT

• Equipment electrically isolated
• Inspection tested(for cold hot job)
• Isolated from steam,air gas
• Depressurized
• Drained
• Positively isolated/blinded
• Steamed water flushed

19
PREPARATION OF EQUIP. CONTD.

• Ventilated gas freed
• Continuous inert gas flow / continuous adequate
  ventilation arranged.
• Vehicle/equipment in good condition with spark
  arrested
• Radiation source removed(Confined space entry)

20
RESIDUAL HAZARDS

• Lack of oxygen
• H2S and/or any other toxic gases
• Combustible gases
• Corrosive chemicals
• Steam / Condensate
• Pyrophoric iron
• High humidity

21
PROTECTION MEASURES

• Protective clothing
• Hearing protection
• Safety Harness
• Eye protection
• Face protection
• Respiratory protection
• Keep fire equipment stand-by

22
PROTECTIVE MEASURES CONTD.

• Barricade the area
• Remove flammable and combustible
• Cover with fire retardant tarpaulin
• Crane with basket stand-by
• Attendance with Airline set
• keep man ways open
• Allow minimum possible no. of persons inside
  confined space

23
PROTECTIVE MEASURESCONTD.

• To ensure positive isolation maintain it all
  through
• Ensure adequate ventilation all through
• Display copy of entry permit near entry manhole

24
GAS TEST FOR WORK PERMIT

• Why gas test is required ?
• Most of the gases are unwanted
• Hazards involved -
• Flammability(Fire Explosion)
• Toxicity(health hazard)
• Oxygen Deficiency

25
GAS TEST CONTD

• Common flammable gases/liquids in refinery are
  -
• All petroleum products,Crude and intermediates
• Hydrogen
• LPG
• Common toxic gases in refinery -
• H2S, CO,NH3,CL2, etc.

26
GAS TEST CONTD.

• COMMON TERMINOLOGIES
• For flammable substances
• Flash Point
• Minimum temp. at which a liquid gives off
  sufficient vapor to form an ignitable mix. It
  will give a flash, flame will not continue.
• Auto Ignition Temp.
• The lowest temp. to which a substance will
  ignite without a spark or flame.

27
GAS TEST CONTD.

• Explosive limit
• The concentration range of vapor in air when
  propagation of flame(ignition) occurs in presence
  of an ignition source.
• LEL (Lower Explosive Limit)
• The minimum concentration of vapor to air
  required to propagate(ignite) flame.

28
GAS TEST CONTD.

• UEL(Upper Explosive Limit)
• The maximum vapor to air conc.above which
  propagation of a flame will not occur(will not
  ignite).

29
GAS TEST CONTD.

• Material LEL UEL F Pt.(C)
  AIT(C)
• Hydrogen 4 75 Gas
  585
• Methane 5 15 Gas
  538
• Propane 2 9.5 - 104
  466
• Naphtha 1.1 5.9 - 18
  288
• ATK/ATF 0.7 5.0 35-50
  210
• Diesel 0.7 5.0 32-96
  256
• Fuel Oil 1 5.0 66
  262-407

30
GAS TEST CONTD.

• Toxic substances
• TLV (Threshold Limit Value / PEL(Permissible
  Exposure Limit)
• The maximum permissible conc. of a toxic
  substance to which exposure of a person will
  have no adverse effect on health for working 8
  hrs per day.
• STEL(Short Term Exposure Limit)
• Maximum conc. to which worker can be exposed
  for a period of 15 mins. without any adverse
  effect to health.

31
GAS TEST CONTD.

• IDLH(Immediate Danger to Life Health)
• A maximum conc. from which one can escape within
  30 mins. without irreversible health effect.
• HYDROGEN SULPHIDE (H2S)
• Highly toxic, combustible, colorless.
• Smells like rotten egg.

32
GAS TEST - H2S

• EFFECTS ON HUMAN BODY
• PHYSICAL EFFECT CONC.(PPM)
• Can be smelled as rotten egg 0.13
• TLV
  10
• STEL
  15
• Smelling sense will dry within 150 - 200
• 2 mins, burning sensation in
• eye throat
  

33
GAS TEST - H2S CONTD.

• PHYSICAL EFFECT CONC(PPM)
• IDLH(Loss of smelling sense, 300
• heavy breathing, dizziness,
• headache,and total collapse
• within 1 to 4 Hrs)
• Dizziness,headache,lungs 450
• problem and total collapse within 30 to
• 60 mins.

34
GAS TEST-H2S CONTD.

• PHYSICAL EFFECT CONC(PPM)
• Slow down of heart beats, 700
• heavy breathing with coughing,
• then death, if not rescued
• Fatal emergency over
  700
• Explosive limits 4.6 to 46, it gives blue
  flame when ignited.

35
GAS TEST-H2S CONTD.

• FIRST AID
• IF INHALED -
• Remove exposed person to fresh air and
  administer oxygen immediately.
• PROTECTION
• Use fresh air mask in case conc. exceeds 10
  PPM

36
TOXIC GAS - CO

• TOXIC AS WELL AS FLAMMABLE
• TLV - 50 PPM
• STEL - 400 PPM
• IDLH - 1500 PPM
• LEL - 12.5
• UEL - 74

37
GAS TEST - CO

• HEALTH HAZARDS
• CO combines with hemoglobin of blood and make
  it unable to carry oxygen.
• Symptoms Headache, dizziness to unconscious
  and ultimately death.
• First Aid
• Remove to fresh air and apply oxygen at the
  earliest.

38
OTHER TOXIC GASES

• TOXIC GAS TLV STEL IDLH
• NH3 25 35
  -
• SO2 2 5
  -
• CL2 0.5 1
  30

39
GAS TEST CONTD.

• For hot work the gas test results shall be
• Combustible - Below 1 LEL
• ( Preferably NIL)
• For confined space entry
• Oxygen - 19.5 minimum
• Combustible - 10 LEL Max.
• Toxic gases - below TLV

40
GAS TEST CONTD.

• Confined space With BA protection
• Combustible - 20 of LEL maximum
• H2S - Less than 100 PPM
• CO - Less than 500 PPM
• However, no hot job can be carried out inside the
  confined space at this condition.

41
WORKS NEED GAS TEST

• Gas tests are required for all hot work/vehicle
  entry and confined space entry permits some
  cold permits also.
• Issuing authority shall determine the requirement
  of gas test frequency of re-checking.
• Trained Gas tester only shall carry out the test.

42
RESPONSIBILIES OF GAS TESTING AUTHORITY

• To check confirm that the gas testing
  instrument is working in perfect condition before
  proceeding for the area/equipment
• To carry out gas test at all critical
  locations/positions
• To advise on safe method to work inside/at the
  location i.e., further gas freeing , use of PPE
  etc.

43
ELECTRICAL ISOLATION

• Before issuing a Work Permit, it is essential to
  ensure that the equipment / facility to be worked
  on is electrically safe and electrical power is
  isolated to the extent necessary for the safe
  conduct of the authorized work.
• Issuing, Executing authorities and Electrical
  Maintenance shall jointly decide the extent of
  isolation required.

44

• DO NOT OPERATE tag shall be used when
  isolation by local switch is decided as adequate
  protection.
• Multi-lock systems to be used when different
  crafts are involved.(this is towards best safety
  practices)

45

• SPECIAL REQUIREMENT FOR - WORKING WITH
  RADIOGRAPHY
• Risk assessment through checklist
• Barricade the area and provide adequate warning
  signs.
• Film badges and Dosimeters shall be worn by
  personnel handling radiography equip.
• job preferably during night time or with least or
  no person around.
• Continuous monitoring of cordoned off area

46
SPECIAL REQUIREMENTS FOR HOT WORK

• The person who authorizes the Hot Work Permit is
  responsible for ensuring that the site and the
  equipment are properly prepared to prevent the
  danger of fire explosion involving flammable
  material.
• The equipment shall be emptied and cleaned of
  flammable materials and isolated from sources of
  hydrocarbons by means of disconnection, blanking
  or insertion of blinds.

47

• Equipment and surrounding areas shall be checked
  to ensure that they are free from any combustible
  gas.Carry out gas test.
• Any heavy oil deposit, dried vegetation or other
  flammable / combustible materials within 8 m of a
  hot work site shall be cleared away.
• No hot work shall be allowed within a radius of
  15 m of any sample point, drain or relief valve
  outlet unless precautions have been taken to
  prevent the escape of flammable liquids and
  vapors.

48

• The outlet of all units drain seals within 15 m
  of the hot work shall be plugged.
• If welding or grinding is to be done at height,
  then precautions shall be taken to prevent the
  spread of sparks and molten metal to the
  surrounding of the work area with fire-resisting
  or flame-retarding tarpaulin.
• A hose capable of reaching up to the hot work
  point and connected to fire water main.
• Fire Station (333/5989) shall be informed of hot
  work.

49
VEHICLE ENTRY

• A Hot Work / Vehicle Entry Permit is required for
  entry of all vehicles in hazardous areas. Such
  areas shall be clearly demarcated with signs
  indicating No Entry without Vehicle Entry
  Permit and/or with removable chain.
• The signatory authorities shall ensure that all
  vehicles / equipment exhaust are equipped with
  spark arrestors of approved type.
• Entry shall only be allowed for loading and
  unloading of materials and not for passenger
  transport.

50
REQUIREMENTS FOR CONFINED SPACE ENTRY

• The process vessel / equipment is to be
  positively isolated by blinding.
• Shall be made safe for entry by depressurizing,
  venting, draining, steaming, washing and
  ventilating. Radiation sources ,if any, shall be
  removed.
• The atmosphere within the confined space shall be
  checked initially and periodically(gas test).

51
EXCAVATION AUTHORIZATION

• An excavation authorization is required for all
  excavations. Detail drawings of the underground
  facilities shall remain attached with the
  authorization if available.
• In addition to an Excavation Authorization a Cold
  / Hot work Permit is required to work.
• For excavations more than 1.2 meter deep confined
  space entry permit is required. Gas tests shall
  be done as per entry permit requirements.

52
SUSPENSION OF WORK PERMIT

• All work shall immediately stop when a fire or
  emergency alarm is sounded or accident of any
  kind occurs. Approval from the FS shall be
  obtained after necessary preliminary
  investigations, to resume such work.
• The Work Permit shall be revalidated to resume
  the work.

53

• Any responsible member of the PN.dept. or FS is
  authorized to suspend work and withdraw the Work
  Permit if, safety regulations are violated.
• If work is not started or is stopped for over two
  hours, the permit shall be revalidated by the
  issuing authority.

54
VALIDITY OF PERMIT

• Work permit shall be initially issued for a
  period of 8 hrs. and shall be renewed for one
  more shift .
• On need basis , permit can be given for max. 7
  days period.
• Clearance to be obtained every shift.
• Clearance to be given after physically checking
  the site.

55
CLOSING AND FILING OF USED WORK PERMITS

• Permit Closure Duly filled and signed by both
  executing issuing authority at completion of
  work
• Copies of the closed permits shall be properly
  filed and kept with the respective disciplines
  for at least one month from the date of
  issue/closure. Different types of permits shall
  be filed separately in chronological order in box
  files.

56
BASIC RESPONSIBILITIES OF ISSUING AUTHORITY

• To prepare the equipment and properly tick the
  checklist items
• To identify indicate any residual hazard
• To advise on protective measures mention
• To carry out gas test wherever reqd. and enter
  the result with sign,date time

57
RESPONSIBILITIES OF ISSUING AUTHORITY CONTD.

• To discuss explain with/to executing authority
• Carry out electrical isolation whenever reqd.
• Close the permit when the job is complete or end
  of permit duration, which one is earlier.
• To preserve the permit for next one month.

58
BASIC RESPONSIBILITIES OF EXECUTING AUTHORITY

• To clearly understand the conditions of the
  equipment and residual hazards
• To discuss the above with issuing authority and
  decide upon the protective measures.
• To describe the job and associated hazards to the
  workmen
• To ensure that safe procedure of execution are
  being followed

59
RESPONSIBILITIES OF EXECUTING AUTHORITY

• To check all the hand tools / devices /equipment
  and ensure that they are healthy
• To make the permit available at work site all the
  time
• To close the permit when the job is over or at
  the end of permit duration,which one is earlier.
• To preserve the closed permit for next one month

60
AUDITORS CHECK-LIST

• An Auditor shall check the following
• Whether the exact location of area/unit
  equipment has been mentioned clearly
• Detail description of work is properly written
• Fire station has been informed and properly
  ticked

61
AUDITORS CHECK- LIST

• Permit issued to which Dept., Div.,Section
  Craft - all mentioned
• Equipment preparation - Equipment has been
  properly prepared, all checklist items area
  properly checked ticked
• Residual Hazards - Identified and
  ticked/indicated
• Protective Measures- Requirements identified
  properly marked

62
AUDITORS CHECK-LIST

• Other details - like provision of continuous
  ventilation, additional precautions
• GAS TEST
• Test for all probable gases carried out and
  reading recorded with sign., date time etc.
• Frequency of rechecking identified and carried
  out

63
AUDITORS CHECK-LIST

• Electrical isolation was reqd., carried out and
  documented.
• Both issuing executing authority signed
  mentioning name signature, date time.

64
AUDITORS CHECK-LIST

• Permit has been closed by both issuing
  executing authority with date time
• Closed permits has been kept properly filed and
  being preserved for next one month

65
OPEN FIRE

• PERMISSION-WEST SIDE OF RD.1 OR OUTSIDE GATE.2
• NO OPEN CHULLA IN OMS,LPG RUNNING PROCESS UNIT
  INCLUDING ROAD SIDES.
• IN SHUT DOWN UNITS UNDER REVAMP, JOINT INSPECTION
  BY AREA IN CHARGE /FS RECOMMENDATION
  DGM(T) FOR ONE DAY

66
Clearence permit/certificate

• for hot /cold work
• issued against permit no.
• 14 checklist items to be critically evaluated and
  ticked
• issued for one shift maximum/renewed shift wise.
• Closure on job completion/ clearing the area,
  signed , date, time, return to issuer.
• Not meant for billing.

67
Road cutting blockage permit

• Request by executor(A grade and above) by filling
  all the entries and attaching sketch/indicating
  on reverse of permit form
• clearance from EL maint.
• Clearence from Civil
• Clearence from PN
• Clearence from IS dept.
• Clearence from FS
• Approved by DGM(T)
• Permit registered at Fire Station.
• On completion , permit return to Fire Station.

68
Excavation Dyke cutting

• Request by executor(A grade and above) by filling
  all the entries and attaching sketch/indicating
  on permit form
• clearance from EL maint./ Telecom.
• Clearence from FS
• Clearence from CL
• Clearence from PN/Area in charge
• Registered at Fire Station.
• Approved by GSI
• On completion , permit closure and return to Fire
  Station/ Area in charge.

69
Vessel Entry

• Request by executor(A grade and above) by filling
  all the entries clearance from EL maint./
  Telecom.
• Critical evaluation of 27 checklist
  items./ticking
• Approved by GSI
• Clearence from PN/Area in charge
• On completion , permit closure and return to Fire
  Station/ Area in charge.