1. _______________________________
FIELD COPY
Date
Time
Initials
LEL %
Benzene
H2S
Other (Specify)
_____________
_______
_______________
____________
_______________________________
TRAINING PROGRAM ON
PERMIT TO WORK
PROCeDURE

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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 )

8. 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

9. 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

10. 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.

11. 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

12. 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

13. 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

14. 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 < 19.5 % or > 23 %

15. 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

16. 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.

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

18. 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

19. 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

20. Work Permit- Initiator of Permit ( Section B )
Filled in by Maintenance Supervisor prior to work permit approval
* Permit initiated by
* Signature
* Telephone

21. 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

22. 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

23. 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

24. 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

25. 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

26. 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

27. 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

28. 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

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

30. 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

31. 100 % Too Much Fuel Too Little Fuel 0 %
Explosive Range
100 %
Too Much Fuel
Upper Explosive Limit ( U.E.L )
% of gas or vapor in air
Boom
Lower Explosive Limit ( L.E.L )
Too Little Fuel
0 %

32. 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

33. 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

34. 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

35. 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

36. 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

37. 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

38. 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

39. WORK PERMIT
Work Permit Copy