Permit to Work

Safe Systems of Work.PTW – module 1

PTW - Module1

Objectives of this session

You shall be able to

•develop strong understanding of Fatima’s SSOW and qualify for Validation & Qualification test

•Understand the different permits used at site.

•Understand various requirements of the permits for safe execution of jobs.

It is line management’s responsibility to implement SSOW in the field. The cost of non-compliance to SSOW could be somebody’s life.

PTW - Module1

•Objectives of this session

•Purpose, scope and definitions – SSOW (PTW, HWP, Vessel Entry, Isolation & Dispensation)

•Permit Preparations

•Issuance and Authorization

•Permit closure

•Isolation standards

•Master control sheet

•Special cases

•Dispensation

•HWP

•Confined Space Entry

•Validation & Qualification test

Purpose & Scope of our Procedures

Purpose;

This Procedure defines the arrangements for the issue and acceptance of Permits to Work, (PTW), and the use of the Master Control Sheet system, (MCS) at the Fatima Fertilizer Company Limited.

Scope;

This procedure supports Health, Safety and Environmental standard requirements for safe systems of work to ensure that all jobs are carried out safely. This procedure applies to Fatima Fertilizer Site, Raw Water Pumping Station, Natural Gas line, water lines (raw water and plant effluent) and power transmission lines owned and operated by the company.

Definitions

1. PTW Issuing Authority;

The PTW Issuing Authority is the person nominated by the Production Manager concerned on Manager HSE recommendation for issuing Permit to Work (PTW) in his area of responsibility (see Appendix 3).

2. PTW Accepting Authority;

The PTW Accepting Authority is the person nominated by the concerned Maintenance Manager or concerned E&I Manager, on Manager HSE recommendation to accept Permit to Work (PTW) in his area of responsibility (see Appendix 4).

3. Inter Plant PTW;

This is another use of the PTW system whereby isolations required to carry out a task are outside of the control of the Issuing Authority for that PTW. (e.g. on another plant). The procedure for Inter Plant PTW is attached as Appendix 7 & 8.

4. PTW Exemption List;

A list of simple routine tasks of short duration that the Unit Manager, Maintenance Manager and HSE Manager have agreed, do not require a PTW.(see Appendix 5).

Definitions……

6. Hot Jobs;

A job where the heat generated is of sufficient magnitude and intensity to cause ignition of any flammable liquids, gases or any other material.

7. Confined Space;

A “confined space” is defined as any space:

– Large enough and so configured that an employee can bodily enter and perform assigned work.

– With limited or restricted means of ingress or egress.

– With limited or no natural ventilation.

– Not designed for continuous occupancy.

8. Own Isolations;

Term used for isolations carried out by the executor himself for certain E&I jobs. A permit shall be filled with comments in physical isolation section as “own Isolations”.

9. Dispensation;

A procedure that defines the steps in case of any deviation/absence of set procedures.

Lets Start

It is important to understand the cycle of any Permit,

Planned/unplanned Jobs

Executor to verify all preparations and take responsibility of safe execution after acceptance

Issuer to make necessary preparations and issue permit

Both issuer and acceptor to verify job closure, countersign as job closed and field copy to be retrained with Acceptor and book copy with Issuer.

PTW – Permit to Work

Lets take an insight into our PTW and discuss step by step its various sections,

their filling and responsibilities.

Permit preparations

The PTW Issuing Authority shall ensure before the job is started that:

• Accepting authority and Area operator have clear understanding of scope of work, hazards and precautions.

• The job is clearly defined on the PTW in Section-A and tagged. Write tag no. in section-A along with job description.

• There is positive identification of either the equipment to be worked on and/or the area in which the work will take place.

• All isolations shall be adequate, remain secure and are visibly tagged. The “Do Not Operate” tags used for this purpose can be signed by PTW issuer or his nominee.

• All residual hazards shall be identified in A1 and the necessary Precautions are clearly specified as PPE's and instructions in A2 and A3

• The PTW Accepting Authority has full understanding of the content of the PTW.

Permit preparations

PTW Document - Section A; (see Appendix-1)

This section shall be completed by the Issuing Authority. It records the clear definition of job to be done in clear and concise manner to avoid misunderstandings.

When a PTW has been issued and accepted, It will be valid for the only distinct, unambiguous and defined

jobs.

Section A

Time:________Hrs Date: ______________ Permit valid till:___________Hrs on ____________

This authorizes Mr. _____________________ to perform the following work in _____________ Plant Tag Nos:

Permit preparations (Cont…)

Section A1 - Risk Assessment;

Before completing this section the PTW issuer & acceptor shall visit the place of work to identify any hazards still present. The issuer shall circle those hazards, which exist or may exist after preparation work is complete.

A1 - Risk Assessment: Permit issuer to tick all that apply:

Access Moving machinary Fire/explosion

Corosive material Noise Gas/fumes

Created openings Height Equipment under pressure

Dust Steam Hot/cold surface

Electricity Stored energy Traffic

Falling object Toxic materilas Underground utilities

Others: ________________________

Section A2 - Precautions Already Taken;

The issuer shall record the precautions already taken such as de-pressurized, decontaminated, washed, purged, drained etc.


A2 - Equipment has been

Purged

Depressurised

Decontaminated

Washed

Drained

Tested

Others

Section A3 – Personal Protective Equipment (PPE);

The issuer shall tick mark all the necessary personal protective equipments to safely carry out this job.

Note; These personal protective equipments shall be in addition to mandatory PPEs i.e. safety shoes, safety helmet and safety glasses (light eye protection).


Full Face Mask Splash Goggles Working gloves Others:

Supplied Air Mask Chemical suit Rubber gloves Special Instructions:

Face Shield Dust Mask Ear plugs/muff

SCBA Safety Harness None

A3 - Personal Protective Equipments: (Followings PPEs are in addition to mandatory PPEs i.e. Safety shoes,safety helmet and safety glasses)

Section A4 – Physical Isolations

In this section Issuer shall identify the requirement for physical isolations.

a. In case the isolations have been done already on separate PTW, Issuer shall write down the reference PTW number.

b. All isolations points shall be identifiable through the application of “Do Not Operate” tags having specific serial numbers.

c. All isolations that have been achieved by means of inserting blinds shall be identified by “Do Not Remove” tags with specific serial numbers.


A4 - Physical Isolation:

Yes No

Physical isolation required (Y/N)

Equipment was isolated on PTW No

Tags applied & their Nos:(Use table below )

Blinds installed & tags applied: (Use table below)


Physical Isolations StandardsB: Blind;

DBB: Double block & bleed

TYPE OF WORK TYPE OF MATERIAL ISOLATION AUTHORITY FOR DEVIATION 1 Hot Work Flammable B As Below

Hot Work Other Hazardous 2

Other Work Flammable or Other Hazardous

B or

DBB

Short Duration Hot Work

Other Hazardous 3

Short Duration Other Work

Flammable or Other Hazardous

above 10 bars DBB

below 10 bars SV

4 Hot Work and Other Work

Non Hazardous (water and compressed air)

above 10 bars DBB

below 10 bars SV

As per HSE Procedure No. HSE/2/002

Mechanical Energy SourcesMechanical Energy Sources

WHEN there is the potential to be WHEN there is the potential to be exposed to Rotating equipment or exposed to Rotating equipment or

machinerymachineryMulti-Hole HaspMulti-Hole Hasp

Preferred methods for isolating a gas, Preferred methods for isolating a gas, liquid or vapor process stream are :liquid or vapor process stream are :

Isolation Tags

Section A5 – Other permit References

The issuer shall record in this section whether an Entry Permit, excavation permit or scaffolding fitness certificate is required or not. If other Permits are required the number of the Permits shall be entered.


A5 - Other permit references:

Yes No N/A

Entry Permit required Reference permit no: ____________

Scaffolding fitness certificate Reference permit no: ____________

Excavation permit Reference permit no: ____________

Date:_____________ Time:__________


Section A6 - Electrical Isolation;

a. The issuer shall identify in this section whether electrical isolation is required or not. In case Electrical isolation is required he shall coordinate with competent electrical technician.

b. Issuer shall also identify what kind of electrical isolation has been performed for the job and tick mark the relevant.

c. It is mandatory that concerned trade people put their own lock at breaker after isolation.

e. This section needs to be signed by Electrical technician only, who has been trained and authorized to perform these electrical isolations.

A6 - Electrical Isolation required? Yes No

Equipment No Racked out Lock appliedstart button

tried

Electrical Energy SourcesElectrical Energy Sources


Section A7 - Master Control Sheet;

Where a MCS is in operation the serial number of the MCS shall be entered here.

A7 - MCS number: ___________________

Master Control Sheet (MCS)

Master Control Sheet (MCS) Permits to Work;

• A MCS is a form that records the details of two or more tasks that depend on the same common electrical or physical isolation (IT IS NOT A PERMIT).

• The Issuing Authority shall write in the details of the common isolations in the space provided.

• Brief details of each PTW to be controlled by the MCS shall be entered in column 1. and the PTW number recorded in column 2.

• For a removal/replacement of activity to be carried out the Issuing Authority shall record in column 4 this requirement.

• As tasks are completed and PTW's are handed back by PTW Acceptors the Issuing Authority shall sign column 3 to record that the job is complete.

Master Control Sheet (MCS) Cont…

• PLANT ITEM/AREA……………………………………………………

• DETAILS OF THE COMMON ISOLATIONS

(valves locked off, electrical circuit references, slip-plating etc.)

Certify that all the Permits to Work listed on this Master Control Sheet have been closed and that Common isolation may now be opened. *Continued on Master Control Sheet No……………

Issuance & Authorization

Section B1 - Issue and Receive

When section A of the PTW has been completed the Issuing Authority shall sign in section B1 in order to authorize that it is safe to carry out the work specified. The accepting Authority shall also sign in section B1 to indicate that he understands the job, residual hazards and precautions necessary to carry out the job.

The Issuing Authority shall indicate which Area Operator will monitor the job and ask him to sign in this section. Area operator shall sign in B1 after carefully reading the following statement.

“I understand the job residual hazards and precautions necessary to carry out the job. It is my responsibility to audit the compliance in the field”.


Section B

B1 - Permit Authorization:

Permit Issuer: ____________________ Permit Acceptor:___________________ Area Operator: ________________

Name & Signature

Time____________

Time: ____________________

Name & SignatureName & Signature

Job handed over after complete preparations.

I have understood all the precautions and safety measures to be taken while undertaking the job and have verfied the Isolations and locks/tags.

I understand the job residual hazards and precautions necessary to carry out job. It is my responsibility to audit the compliance in the field.

Rotation Check Required

Section B2 - Rotation Check Required

a) If a Rotation Check is necessary to confirm satisfactory task completion then the Issuing and Accepting Authority shall both sign the PTW in section B2. The electricity supply may now be restored and the person restoring it shall first sign in section B2.

b) If further work is required (e.g. coupling up motor), the word “Yes” shall be crossed out and the Issuing and Accepting Authority shall sign together with the person who is re-isolating the electricity supply.

c) If no further work is required, the word “No” shall be crossed out, and the PTW can be signed off as complete and the electrician will sign in section B5 to indicate that the electrical supply has been restored.

Rotation Check Required

B2 - Rotation check authorisation:

Yes No Yes No

Rotation check required Reisolation Required:

Rotation check authorized

Issuer Issuer

Acceptor Acceptor

Electrical Technician Electrical technician

Date :___________ Time: __________ Date :___________ Time: _________

Isolation Standards

1) PTW Issuer shall issue PTW where blinds and/or line breaking and blanking are used to achieve isolation. Such work shall be considered in three distinct and separate phases.

a) Isolation

b) Main Task

c) De-Isolation

2) Where it is not possible to meet the relevant standard, PTW Issuers shall obtain dispensation from the relevant Production Manager.

3) PTW Issuers shall ensure that each isolation is secured and identified (by tagging) throughout the duration of the maintenance work.

4) The equipment identification tags detail needs to be put in section A along with description of job on PTW.

Isolation Standards (Cont…)

5) When there is a change of intent, PTW Issuers shall review the adequacy of the isolation arrangements and issue a new PTW.

6) When maintenance work is complete, PTW Issuers shall assess the hazards of de-isolation of equipment e.g. trapped materials and take appropriate precautions.

Completion of Job;

• When the job has been completed, the equipment is safe to be operated and the work area is left clean and tidy. The area operator shall sign in section B3 followed by PTW acceptor to close the PTW.

• If the PTW is returned as job incomplete, the Accepting Authority shall sign in section B3 and indicate what further work is required.

• When the work is complete PTW issuer shall then sign in section B3 accordingly.

Completion of Job;

B3 - Job completion: Yes No

The job is complete and area housekeeping has been done

If job is not completed,a new permit is required

Area operator: _____________________________ Date:_________ Time:_________

Issuer: __________________________

Acceptor: ________________________

Master Control Sheet (MCS) Cont…

• When all the PTW's listed on the MCS have been recorded as "Completed" the MCS

can be closed by PTW issuer accordingly.

• Master electrical isolations still in operation at this stage can only be reinstated once the Issuing Authority has signed section B4 on the last PTW.

• The electrical Technicians having checked that section B4 has been signed of last PTW on MCS, can then restore the electrical supply and sign in section B5 on the original PTW.

Master Control Sheet (MCS) Cont…B4 - Master Control Sheet

Isolation on MCS should remain active: ___________________________

Isolation on MCS can be removed: _______________________________

Issuer: ___________________________ Date ____________Time: _________

B5 - Electricity Supply Restoration Yes No

Equipment number

Lock removed

Electrical isolation to be transferred on PTW no:

Electrical Technician: ________________________________ Date: _________ Time: _________

Name & Signature

Electricity restored:

Isolation and Blind Tag No and Revalidation

Isolation/Blind Tag No.

Location of Tag

Inter plant permit

• PROCEDURE FOR INTER PLANT PERMITi) All issuers will be acceptors also, for inter plant PTW.

ii) Request for inter plant PTW will be raised before isolation required time, through Unit Manager or shift co-ordination Engineer in off hours

iii) Requester will be “acceptor”.

iv) Shift Engineer accepting request will be “issuer “for inter plant PTW.

v) Issuer will enter inter plant PTW in MCS.

vi) Acceptor will enter Inter plant PTW number, as one of isolation in PTW.

vii) Acceptor will enter this Inter plant PTW in MCS.

viii) Inter plant permit will be in the custody of “Acceptor “.

ix) When job is completed inter plant permit will be signed off by both issuer and acceptor, and close respective Master Control Sheets.

Exemption List

• PTW Exemption List;

A list of simple routine tasks of short duration that the Unit Manager, Maintenance Manager and HSE Manager have agreed, do not require a PTW. (see Appendix 5).

Appendix 5

Plant ………………… Section ………………………………………..

Issued By ………………………………………………… Date ………...……

• Unit Manager: _____________, Production Manager: ______________

• Maintenance Manager: __________

Training, Validation & Qualification test

• Training & Validation;

• The HSE Manager shall train all Line Managers in the use of this system.

• Line Managers with the assistance of the HSE and Training Managers shall train PTW Issuers and Acceptors and shall validate and authorize their ability to use the system.

• Contractors will receive basic training on the need for PTW's as part of their Induction Training Package.

Hot work Permit preparations


A1 - Risk Assessment: Permit issuer to tick all that apply:

Access Moving machinary

Corosive material Noise

Created openings Height

Dust Steam

Electricity Stored energy

Falling object Toxic materilas

Fire/explosion Traffic

Gas/fumes Underground utilities

Equipment under pressure Static charges

Hot/cold surface Others:


A2 - Preparation

Depressurised Purged Area Barrication

Decontaminated Drained warning signboards

Explosivity Reading (Nill) Fire blanket available

Fire Watch Fire Extinguisher availableClear of all combustable material Fire Hose/water available

MSDS Available Tool Box Conducted

Washed Others

Name & Signture of Analyser


Full Face Mask Splash Goggles Working gloves

Welding Hood Welding Covall Welding gloves

Supplied Air Mask Chemical suit None

Face Shield Dust Mask

SCBA Safety Harness Others:______________

Ear plugs/muff Rubber gloves

Special Instructions:________________________________________________

A3 - Personal Protective Equipments: (Followings PPEs are in addition to mandatory PPEs i.e. Safety shoes,safety helmet and safety glasses)


B1 - Permit Authorization:

Name Signature

Permit Issuer: Permit Acceptor:___________________

Shift Coordination Engineer: Name & Signature

Area Operator: ________________________________

Time

I understand the job residual hazards and precautions necessary to

carry out job. It is my responsibility to audit the compliance in the field.

Job handed over after complete preparations.

I have understood all the precautions and safety measures to be taken while undertaking the job and have verfied the Isolations and locks/tags.

Confined Space Entry Permit

Vessel Entry PermitVessel Entry Permit number:_____________ Work permit Ref number:_______

Sec 1 Plant:________________ Vessel / Confined Space ID:_______________________________

Reason for Entry:_________________________________________________________________

Permit Validity: Date:_________ From ____________ to _______________

Sec 2 Atmosphere Testing: Time: ________ Date:________

TimeO2 V/V 19.5 -

23.5

% LEL > 0%Toxic 1

Ammonia < 25 ppm

Toxic 2 H2S < 10 ppm

Toxic 3 Toxic 4Test instrument

model & Sr number

Last Calibration

dateAnalyst Signatures

Test 1Test 2Test 3Test 4

Sec 3

Pipe work Isolation Mechanical retrieval system availableElectrical Isolation Suitable for hot workVessel cleanliness Sufficient LightingVentilation Possibility of fumes from job

Temperature < 40 oC Possibility of fumes from outsideAccess (safe & Satisfactory) Possibility of Nitrogen accessVessel free from debris/sludge Is sludge/debris pyrophoric

Area Operator (Name & Siganture):_____________________ Issuing Authority (Name & Signature):_________________

Sec 4 Additional Safety requirements, i.e. PPEs, further testing, electrical equipments, lighting etc.

Harness 24 volt light Others:Goggles special toolsRubber gloves

Sec 5 In Case one or more of above conditions in section 3 are not met, Entry shall be carried out with SCBA assistance.

Sec 6 Revalidation: Till:___________________ Name & Signatures:___________________Till:___________________ Name & Signatures:___________________

Sec 7

Name & Signature:____________

Sec 8 Issuing Authority Accepting Authority:Name & Signature Name & Signature:

Sec 9

Date: Time: Signature Issuer Acceptor

Vessel Entry Permit

Test Results

I certify that plant is declassified and vessel is physically & electrically isolated. This permit holds good for the complete job with

atmosphere monitoring frequency after every____________.

Permit Closed: We certify that job has been completed, all entrants are out of confined space and equipment is boxed up and ready to be taken in process.

We Certify that I have personally examined the confined space and checked the follow ing (Tick Boxes)

Signed by Plant UM:________

Tally sheet of EntrantsVessel Name / Number

Maximum number of entrants allowed at any one time

Time

Name of Entrant In Out In Out In Out

Vessel registers with rescue plan

Plant_____________ Vessel Name__________________ Vessel Number_______________

Process Description ___________________________________________________________________

Nearest Extension number________________

Manhole Size _____________ Location_________________ Position ____________________

Harness or life line to be worn__________ Height from ground___________ Height from Floor_____________

Communication between stand by man and control room through____________________________________

Isolations Details

12345

6789

10

1112

Vessel Sketch showing inlet/outlet piping, location of manhole and working floor level

Electrical Isolations

Proces lines Isolations

Any Other Isolation required

Vessel Register & Rescue Plan

Documents

Permit to Work