TRAINING PROGRAM

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FIELD COPY

TRAINING PROGRAM ON PERMIT TO WORK PROCeDURE
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Objectives Of This Training

• Identify the purpose and the job requires
  Permit to work
• Train/Refresh employees on the Permit to Work
  system.
• Full commitment and compliance to Permit To
  Work procedure
• Enhance Safety Awareness

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What is a Work Permit

• A Work Permit is an Agreement which gives
  authorization for specific work activities to be
  undertaken ( Machine, Facility, Equipment or
  Structure ) the location and the time required to
  complete the assigned work
• It is an agreement between the Issuer receiver
  that the work to be done will be carried out in
  accordance with the provisions stated in the
  permit

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Why a Work Permit ?

• In the petrochemical industry, work must be done
  under controlled conditions to ensure the safety
  of workers and facilities. The Work Permit system
  was developed to provide safety in the workplace
  by controlling potential hazards inherent to the
  industry

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PURPOSE OF PERMIT SYSTEM

• Communication tool for understanding nature of
  the job and Identify related hazards
• Safety checklist that ensures proper
  procedures,equipment and precautions are in place
• Minimize risks to personnel and equipment

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Cancellation of Work Permit

• Plant Emergency Alarm sounds
• Safe Conditions Changes
• Scope of job changes
• Incident/Accident on the job
• Job exceeds the permit deadline

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Cold Work

• Work activity that does not produce a source of
  ignition for flammable mixtures
• Examples
• Any work which require opening vessels,
  pipes, manholes etc.
• Erection / Removal of scaffolds
• Insulation painting jobs
• Equipment greasing and lubrication
• Machinery monitoring including vibration
  instrument
• Cutting of lines ( hacksaw/cold cutting )

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Hot Work

• Work activity capable of supplying ignition
  source for flammable mixtures
• Examples
• Process of joining together two pieces of
  metal ( Welding, brazing )
• Breaking of metal into two pieces
• ( Cutting) by means of extreme heat
• Metal grinding
• Use of IC engines
• Sand Blasting
• Drilling, Chipping
• Photography
• Torches and other open flames

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Confined Space Entry

• Is large enough and configured so that an
  individual can bodily enter and perform assigned
  work
• Has limited or restricted means for entry or
  exit such as tanks, vessels, furnaces, boilers,
  excavations, pits, sumps, stacks, pipes etc.
• Is not designed for continuous employee
  occupancy
• May contain flammable, explosives, toxic or other
  harmful substance or oxygen deficient

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Excavation Work

• Use of Manual tools or mechanical excavator in
  digging a hole, pit, trench or any opening on the
  ground that is within the area covered and under
  the jurisdiction.

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Vehicle Equipment Entry

• Is the entry if Internal Combustion Engine
  vehicle or equipment in a designated hazardous
  area or at areas where there are potential
  presence of combustible or flammable gases or
  liquids, explosive dusts and other materials
  which are declared hazardous

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Electrical Work

• Any work which requires a worker to do job on a
  dead or live electrical equipment, system,network
  or facility.
• Electrical Works include
• Energization De-Energization
• Trouble shooting
• Preventive Corrective Maintenance
• Other such activities that are related
  to any source of electrical power

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Hot Tapping

• The work that applies to welding connection
  made to pipeline or a vessel under pressure or
  has de-pressurized but has not been cleared for
  conventional construction method.It is also to be
  used where it is impractical to take equipment
  out of service

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Definitions

• Gas Test An instrumentation test of an
  atmosphere to determine oxygen, flammable gas,
  and/or toxic substance ( Benzene, hydrogen
  sulphide, carbon dioxide ) concentrations. A
  properly calibrated direct reading monitor shall
  be used for gas testing
• Hazardous Atmosphere An atmsophere that may
  expose individuals to risk of harm from flammable
  gas or vapor Airborne combustible dust Toxic
  Gas or oxygen levels lt 19.5 or gt 23

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Definitions

• Hot Work Job activities that include
  welding, torch cutting, open flame and /or
  grinding, or any other activity in the operating
  area that could be an ignition source
• Operations In most cases operations are the
  owners and the Team Leader, Asst. Team Leader or
  operator will communicate with the lead worker
  about the job. All operators will be certified in
  work permit compliance training
• Exemptions The Maintenance workshop is exempted
  from the work permit requirements as they pertain
  to source of ignition. It is the responsibility
  of the Maintenance Supervisor to ensure the work
  is done safely

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Entry Authorization

• A personnel Vehicle entry/work authorization
  form will be located in each Field Information
  Centre ( FIC )_
• All personnel ( Other than operations staff )
  entering an operating area/process shall be
  identified in the entry log
• Personnel performing work under same order can be
  signed in by one person. Work orders associated
  with job assignments and brief description should
  be included in the sign-in.
• The operator will inform worker(s) if additional
  work permit is required or if there are any
  active permits associated with or relevant to
  work to be done.

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Entry Authorization

• The operator will assign a vehicle pass number (
  if needed )
• Sign out is required when departing due to work
  completion.

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Obtaining Work Permit

• Work permits are initiated by the department
  performing the job then authorized and approved
  by operations of the unit.
• Operations is always the issuing authority and
  responsible for ensuring the plant/area is safe
  for the work to proceed
• The work permit issued by operations releases
  equipment control from operations to those
  performing the work
• Issuer and Receiver cannot be the same person

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Work Permit Section A

• Filled in by Lead Worker and Maintenance
  Supervisor prior to work permit approval
• Type of permit ( Hot or Cold )
• Date
• Work Order Number
• Unit/Area
• Equipment Number/Location
• Description of work

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Work Permit- Initiator of Permit ( Section B )

• Filled in by Maintenance Supervisor prior to work
  permit approval
• Permit initiated by
• Signature
• Telephone

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Work Permit- Job Category ( Section C )

• Filled in by Lead Worker prior to work permit
  approval
• Identify the type of work ( category ) to be
  performed and check off the appropriate box(es)
• Non Hazardous Vessel/Line opening(
  Hydrcarbons /Chemical Use of open flames
  Toxic Gas )
• Hot Tap/Stopple Use of
  Electric, Pneumatic and /or buffing tools
• Use of IC Engine
  Equipments
• Radio Active sources Welding, Cutting ,
  Grinding, Drilling
• Vehicle Entry Use of Electronic
  Equipment not intrinsically
• Work on Energized Equipment safe
• Confined Space Entry
• Note If work requires confined space entry, a
  Confined Space Entry Permit must be used along
  with the work permit

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Work Permit- Permit Validation Report ( Section
D )

• Filled in by Operations
• Normal valid period maximum of 1 x 12 hour
  operations shift.
• Permits may be extended for extra shift
  additional 12 hours if determined safe following
  gas test
• Work permits in other locations other than
  operating areas 24 hours but no extension
• Renewal of permit Responsibility of Issuer
  receiver who have renewed the permit to ensure
  that all permits conditions are complied with in
  full at all times. Any non compliance to
  instruction results in immediate suspension of
  Work permit

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Work Permit- Other Instructions( Section E )

• Filled in by Operations Lead Worker
• Is a written approved procedure
  required, if yes,attach the procedure
• Other Instructions
• None Required

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Work Permit- Personal Protective equipment(
Section F )

• Operations Lead Worker will identify the PPE
  required to carry out the job
• Rubber gloves
• Life Line
• Rubber boots
• High Voltage gloves
• Safety Harness
• Face Shield
• SCBA
• Airline breathing apparatus
• Slicker suits

• Flash Suits
• Acid suits
• Goggles
• Dust Masks
• Respirators
• Others
• None

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Work Permit- Safe Work Checklist( Section G )

• At work site, Operations Lead Worker will
  complete the checklist. Each item to be confirmed
  Yes unless N/A
• Has the pertinent MSDS been reviewed
• Is the equipment isolated and visually checked
• Has the lock, Tag, and Try Procedure been
  followed
• Lock Box Number
• Has the blinding procedure been followed
• Is the equipment depressurized and/or drained and
  verified
• Is the equipment decontaminated
• Is the are taped or barricaded off
• Is there safe to/from the work location
• Scaffold

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Work Permit- Additional Requirements at Job Site
( Section H )

• At work site, Operations Lead Worker will
  complete the checklist.
• Pressurized Fire Hose
• Non Sparking Tools
• Fire Watch/Safety Operator
• Spark Proof sheeting/Fire Blanket
• Radio contact for workmen
• Cover drains ( Within 15 mts )
• Fire Extinguishers
• Steam Lance
• Fire Blankets
• Portable eyewash
• Spill Containment
• None

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Work Permit- Gas Testing ( Section I )

• At work site, Operations will do the gas test and
  make necessary entries
• Gas testing required ?
• Frequency
• Continuous
• Type of monitoring
• Gas Testing Mandatory for all hot works
  confine space entries
• Operations Decide the frequency of gas test
• Vessels, Pipes , Equipments opening LEL nominal
  10 and below
• H2S 10 PPM or less Benzene 0.5 PPM or less
• Hot Work LEL must be 0
• Work commence within on hour after gas test any
  delays require gas test again
• Retest before extension of Work Permit

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Work Permit- Approval Acceptance to begin work
( Section J)

• Operation Lead worker both ensure that all
  requirements which they have to comply with are
  completed and provided. Both sign with date
  time for approval acceptance and job starts
  now.
• The original permit shall be posted at the work
  site in a transparent plastic pouch
• Maintenance personnel arriving at the job site
  after a permit is issued are required to read,
  understand and sign the original. Or the lead
  worker should explain the job to be carried out
  and the hazards involved

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Distribution of Permit Copies

• Original ( Field Copy ) The original copy
  shall be posted at work site in a transparent
  pouch. The permit to be returned to the CCR
  following job completion or permit expiration and
  retained for a period of three months
• FIC ( Field Information Copy ) will be
  displayed in appropriate FIC. These copies
  should be disposed off properly when the
  original is returned
• Team Leader Copy will be taken by the Team
  Leader as soon as possible after permit is
  issued and used for posting in the appropriate
  units TL office in the CCR. These copies to be
  disposed off when the original is returned

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Work Permit- Job Completion ( Section K)

• When work is completed or permit has expired,
  Lead worker will notify operations and both will
  inspect work site and determine the following
  before work permit is signed off as complete
• Is work complete? If not, state condition
• Has maintenance locks been removed
• Is area clean and safe

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Explosive Range
100
Too Much Fuel

Upper Explosive Limit ( U.E.L )
Boom
of gas or vapor in air
Lower Explosive Limit ( L.E.L )
Too Little Fuel
0
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Authorized Representative

• Operations Team Leader, Assistant Team Leader
  or Operator currently certified in both work
  permit compliance and gas testing
• Maintenance( Lead Worker ) The person
  designated by maintenance or construction
  supervisor or supervisor of any other section to
  represent a group of people who will be
  performing a job.The Lead worker should be
  certified in work permit compliance.

Q-CHEM
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Duties of Issuer

• Clean and purge the area/equipment to remove
  hazardous chemicals and residues
• Isolate equipment and follow Lock , Tag Try
  Procedure
• Conduct gas test
• Perform a joint visit with the person doing the
  job
• Make sure area is physically safe for work
  to begin
• Identify the exact location of the equipment
  to be worked on and the scope of the work
• Point the emergency equipment like safety
  shower fire extinguisher
• Provide warnings of any local safety hazards
• Explain actions to be taken during emergency
• Communicate safety policies / rules
• Explain permit closure procedure

Q-CHEM
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Duties of Receiver

• Make sure you understand all aspects of the safe
  work permit
• Explain details of permit to other crew members
• Notify permit issuer if job scope changes
• Report of any hazards
• Clean up job site when work is completed
• Complete permit close-out section and return to
  the issuer

Q-CHEM
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Potential Problems with the Work permit System

• Permits are being prepared too far in advance,
  or the work has commenced
• The workers are not following, or do not
  understand the requirements of the permit system
  and the reason for it
• The person signing the permit has not
  inspected the job site to see if all the
  necessary procedures ( Lock, Tag Try,
  Isolation, testing etc )
• Supervisors are not enforcing or monitoring
  the work permit system
• The type or format of the permit does not
  conform with task to be completed

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The Role of Safety Watch

• The safety watch must be knowledgeable in
• The Emergency Response Plan
• The communication Procedure
• The Safe Operating Procedure
• The activities surrounding the work site

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The Role of Safety Watch

• The safety watch must
• Keep himself from imminent danger
• Be knowledgeable about all aspects of the
  permit
• Monitor atmosphere levels
• Stay alert at all times
• Remains at designated post at all times when
  personnel have entered in confined space
• Watch for potential hazards and alert the
  workers inside
• Maintain entry log

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Work Permit Flow Chart

• SECTION A - General ( Filled in by Lead Worker
  and Maintenance Supervisor )
• Type of permit, Date, Equipment Number,
  Unit/Area, Work order Number Description
  of Work

• SECTION D - Permit Validation ( Filled in by
  Operations )
• The Permit Validity, Expiry Extension,
  Extension Approval with Date Time

• SECTION H Additional Requirement at Job Site (
  Filled in by Lead worker Operations )
• Identify any other requirements needed for
  work to be performed and tick the appropriate
  box

• SECTION B Initiator of Permit ( Filled in by
  Maintenance Supervisor )
• Permit Initiated By, Signature
  Telephone

• SECTION E Other Instruction ( Filled in by Lead
  Worker Operations )
• Determine if any additional instruction
  required and take action

• SECTION I Gas Testing ( Filled in by authorized
  representative from Operations )
• Gas test results are filled and certifies that
  the area is safe to carry out the job

• SECTION F Personal Protective Clothing
  ( Filed in by Lead Worker Operations )
• Identify the required PPE for the job and
  tick the appropriate box

• SECTION J Approval Acceptance to begin work (
  Filled in by lead worker Operations )
• Both ensure that all requirements which they
  have to comply with are completed provided.
  Both signs for Approval Acceptance and job
  starts.
• Permit copies to be distributed

• SECTION C ( Job Category ( Filled in by Lead
  Worker )
• Identifies and ticks the appropriate Job
  category box.
• Note If work permit requires confined space
  entry, confined space permit to be filled in
  along with work permit

• SECTION G Safe Work Checklist ( Filled in by
  Lead Worker Operations )
• At work site, both will identify and complete
  the checklist

• SECTION K Job Completion ( Filled in by Lead
  Worker Operations )
• Both checks the status of the job and ticks
  the appropriate box and signs for permit
  closure.After three months, the work permits can
  be disposed off

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Work Permit Copy
WORK PERMIT