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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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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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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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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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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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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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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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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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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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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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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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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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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 < 19.5 % or > 23 %

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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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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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The operator will assign a vehicle pass number ( if needed )

Sign – out is required when departing due to work completion.

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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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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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Filled in by Maintenance Supervisor prior to work permit approval

* Permit initiated by* Signature* Telephone

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Filled in by Lead Worker prior to work permit approvalIdentify 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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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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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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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

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Flash Suits

Acid suits

Goggles

Dust Masks

Respirators

Others

None

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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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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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

belowH2S – 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 27

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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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 unit’s TL office in the CCR. These copies to be disposed off when the original is returned

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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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100 %

0 %

Too Much Fuel

Upper Explosive Limit ( U.E.L )

Lower Explosive Limit ( L.E.L )

Boom

Too Little Fuel

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.

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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

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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

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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 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 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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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 B – Initiator of Permit ( Filled in by Maintenance Supervisor )

• Permit Initiated By, Signature & Telephone

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 D - Permit Validation ( Filled in by Operations )

• The Permit Validity, Expiry & Extension, Extension Approval with Date & Time

SECTION E – Other Instruction ( Filled in by Lead Worker & Operations )

• Determine if any additional instruction required and take action

SECTION F – Personal Protective Clothing ( Filed in by Lead Worker & Operations )

• Identify the required PPE for the job and tick the appropriate box

SECTION G – Safe Work Checklist ( Filled in by Lead Worker & Operations )

• At work site, both will identify and complete the checklist

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 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 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 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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