WORK PERMIT

A.K.SINGH, CMFSINDIANOIL CORPORATION LTD.MATHURA REFINERY,

ROAD MAP

The session will include the following: Presentation on MR Work Permit

system followed by discussion Role of Issuing & Executing Authority Exercise how to fill the permit Questionnaire/QUIZ

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.

WHY WORK PERMITFollowing Oil Industry Safety Directorates Standards are in Indian Petroleum Rules :2002OISD -105 (Work permit system)

OISD-116 Fire Protection facilities for Petroleum Refineries and Oil/Gas Processing Plants OISD- 117(Fire Protection Facilities for Petroleum Depots and Terminals and pipeline installations OISD-118 (Layouts for Oil and Gas Installations) OISD-141 (Design and Construction requirements for cross country hydrocarbon pipelines)

OISD –156 (Fire Protection Facilities for Ports Handling Hydrocarbons )

“OISD Standard” means technical standards formulated by OISD and approved by Safety Council constituted under the Ministry of Petroleum and Natural Gas to ensure safety in Oil and Gas Industry (as amended from time to time).

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.

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.

WORKS - PERMIT NOT REQUIRED

Works carried out by Oprs. Dept. as a part of routine operation.

BLANKET PERMIT

ONE MONTH

WORK SHOP INSTRUMENT LAB/WORKSHOP LABORATORY INSPECTION

TYPES OF PERMITS6 types of work permit with specific colors. HOT WORK ,VESSEL ENTRY/VESSEL BOX UP/EXCAVATION/ VEHICLE ENTRY PERMIT (PINK& WHITE-

three copies) For use of or generates local source of ignition, vehicle & engine operated equip. entry to hazardous areas. (FS/F-1 Rev 3)

COLD WORK PERMIT (YELLOW & WHITE) FS/F-23, Rev-1(For all general Maint. works (no ignition source)

EXCAVATION CLEARANCE(PINK ,WHITE & YELLOW) FS/F-1/C

ROAD CUTTING & BLOCKAGE PERMIT

PERMIT FOR WORKING AT HEIGHT ( PINK & WHITE) (IOCL/MATHURA REFINERY/WAH Permit)

RADIATION WORK PERMIT( Light Blue & White) FS.F-24, Rev-1

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. …………………..

Special instructions printed on the permit

PROCEDURE FOR WORK PERMIT SYSTEM(WPS)

WPS OPERATE ON OWNER IN CHERGE CONCEPT(UNITS-CPNM,LAB-CQCM,TPS-CPUM, STORES-SMTM)

PERMIT IN PRINTED FORM SEPARATE PERMIT FOR COLD & HOT WORK PERMIT COLOUR CODED, SERIAL NUMBER DEPTL. OR CONTRACTOR JOB:PERMIT 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.

PROCEDURE FOR WORK PERMIT SYSTEM(WPS)

HOT WORKPERMIT EXECUTOR TO INITIATE THE FIRE PERMIT-

DUATION,LOCATION, 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 A. General Points ( 13 items) B.For Hot Work/ENTRY INTO CONFINE SPACE91o ITESM) ,C. FOR VEHICLE ENTRY (1 ITEM) 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.

PROCEDURE FOR WORK PERMIT SYSTEM(WPS)

HOT WORKPERMIT EXECUTOR TO INITIATE THE FIRE PERMIT-

DUATION,LOCATION, 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 as folows:

- A. General Points ( 13 items)

- B. For Hot Work/ entry into confined space(10 items)

-C. for vehicle entry (1 item)

-D. for excavation works (4 items)

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.

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 OFFSITE:DISTANCE EXCEEDING 15 METERS, SEPARATE FIRE PERMIT.

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(PN) AUTHORISES GSI & FPS AND LIST IS CIRCULATED.

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.

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.

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

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)

RESIDUAL HAZARDS

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

PROTECTION MEASURES

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

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

PROTECTIVE MEASURESCONTD.

To ensure positive isolation & maintain it all through

Ensure adequate ventilation all through Display copy of entry permit near entry

manhole

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

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.

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.

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.

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).

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

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 .

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.

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

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.

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.

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

TOXIC GAS - CO

TOXIC AS WELL AS FLAMMABLE

TLV - 50 PPM

STEL - 400 PPM

IDLH - 1500 PPM

LEL - 12.5%

UEL - 74%

GAS TEST - COHEALTH 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 .

OTHER TOXIC GASES

TOXIC GAS TLV STEL IDLH

NH3 25 35 -

SO2 2 5 -

CL2 0.5 1 30

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

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.

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.

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.

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.

‘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)

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

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.

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.

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.

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.

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).

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.

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 F&S shall be obtained after necessary preliminary investigations, to resume such work.

The Work Permit shall be revalidated to resume the work.

Any responsible member of the PN.dept. or F&S 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.

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.

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.

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

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.

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

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

AUDITOR’S 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

AUDITOR’S 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

AUDITOR’S 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

AUDITOR’S CHECK-LIST

Electrical isolation was reqd., carried out and documented.

Both issuing & executing authority signed mentioning name & signature, date & time.

AUDITOR’S 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

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.

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 F&S Approved by DGM(T) Permit registered at Fire Station. On completion , permit return to Fire Station.

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 F&S 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.

Vessel Entry

Request by executor(A grade and above) by filling all the entries clearance from EL maint./ Telecom.

Critical evaluation of 10 checklist items./ticking Approved by GSI Clearence from PN/Area in charge On completion , permit closure and return to Fire

Station/ Area in charge.