20th February 2018 Duration :- 20 minutes Welcome PERMIT TO WORK
B.Com, IDipNEBOSH + EnvDipNEBOSH, Grad– IOSH + SIIRSM + MISQEM
IMS - LA ISO 9001 + 14001 + OHSAS – 18001 LEEA – Appointed person for Lifting operation
Total Experience = + 30 years (Gulf = + 22 Yrs Presently working at Qatar Steel +12 years -- Roque HSE Management System Supervisor Dcunha Agenda 1. Safety Moment – Video 2. Objectives and Outcomes 3. What is a work permit 4. Features of Permit to Work System 5. When are PTW systems applicable 6. Definitions 7. Types of Permit 8. Elements of a Permit to Work 9. Roles and Responsibilities 10. Validity of Work Permit 11. Preparation and Execution 1. Safety Moment Piper Alpha
Safety Moment Video: 3 : 47 min 2. Objectives and Outcomes Objectives and Outcomes
On successful completion of this presentation Attendees will Gain knowledge and understanding of:
. What is Permit to Work system and its requirements . Different types of work permits and applicability. . Roles and Responsibilities of the PTW signatories . How to complete the PTW form. . Full compliance of the system. … and to manage risk effectively! 3. What is a Work Permit Work Permit is a documented format that authorizes certain people to carry out specific work within a specified time frame / area. It sets out the precautions required to complete the work safely, based on a risk assessment.
4. Features of permit-to-work systems Features of permit-to-work systems
A Standard Operating Procedure, job or method statement and information
The equipment and tools to be used
A hazard and risk assessment
Required precautions, mitigating actions and control measures
All PPE requirements
The permit issue, extension and withdrawal details
The names and signatures of those who are responsible for the job
A Tool Box Talk signed by all workmen Features of permit-to-work systems
• Safe system of work - Proper planning - manage the risks for wide range of activities -- Prevent accidents and conduct work in a safe and responsible manner
• Written document of agreement signed & Understood
• Authorizes certain people Issuer / Executor / Field operator / AGT / Isolator -- to carry out specific work – Defined Scope --- link to supplemental or simultaneous activity
• Joint Risk assessment - to identify potential hazards – Associated Risks, at a certain time and place, and to take precautions / Prevention Controls – PPE / Emergencies for mitigation
• A work permit system consists Standard procedure essential – Details of the necessary preparatory work Method statement / JSA / RA Clear definition of responsibilities PTW is a formal recorded process --Completed -- Return to normal Permit Log sheet – Filing Monitoring / Inspection and Auditing, Reviewed to ensure that the system works as intended , Period must be determined Communicated-TBT - Display Authorized persons / Training includes contractors / Instruction in the issue, use and closure; Provision of adequate safety equipment Exception – Based on Risk Assessment – Planning for Gray areas 5. When are PTW systems applicable When are PTW systems applicable?
• Works which may adversely affect the safety of personnel, the environment or the plant
• High Risk / Non-routine activities which will require some form of JSA / RA prior to work commencing
• It is not intended that PTW procedures be applied to all activities as experience has shown that their overall effectiveness may be weakened When are PTW systems applicable?
• Non-production work e.g. maintenance, repair, inspection, testing, alteration, construction, dismantling, adaptation, modification of equipment or processes, cleaning etc • Temporary or permanent changes, • Jobs where two or more individuals or groups need to co-ordinate activities to complete the job safely; Hot work Hot work in explosive environment work of any type where 1. Work which may generate sparks or other sources of ignition; 2.Heat is used or generated (eg by welding, flame cutting, grinding etc); • Work on high voltage electrical equipment; Electrical troubleshooting or repair on live circuits
• Work involving the use of hazardous / dangerous substances, including radioactive materials and explosives (e.g. blasting); • Diving, including onshore operations near water; • Pressure testing; • Complex machinery • Evacuation near buried services / • Escape or rescue systems; • Temporary equipment, e.g. generators, welding equipment etc; • Critical Lifting, Use of mobile cranes • Bypassing or removing / altering Safety devices or equipment
• Work at height; Elevated works • Operational pipelines • Other applications Insulation or catalysts handling Product conversion of stationary or mobile or portable vessels and containers Exposure to moving / rotating machinery In proximity of vents, liquid of gas On process lines with gas release
Confined spaces Entry and work Potential oxygen deficiency or enrichment Potential flammable/explosive atmosphere Potential high temperature/pressure Potential hazardous chemicals, e.g.: toxic substances Confined space entry, e.g.: tanks, cold box, pit, normally closed vessels
CAUTION Opening in Ground Keep Out ! Confined Space Entry Permit
Location and description of confined space: Reason for entry: Permit issued to: Supervisor’s Name: Attendant’s name: Permit issuer’s name:
% oxygen: % lower explosive limit: ppm CO: H2S:
Requirements
Emergency Rescuer yes no Continuous Gas Monitor yes no Barrier for ground openings yes no Warning Signs yes o Safety Harness with life line yes no Tripod / Hoist / Pulley yes no
Excavations:
Poorly planned excavations can result in damage to underground services, such as electrical lines, natural gas lines, water lines, sewers and drains.
The consequence of damaged service lines is often complete shutdown of operations resulting in major business losses. Excavations:
Excavations may expose hazardous materials / toxic substances which have leaked and are contaminating the soil. MS /JSA Procedures Excavating
The safety representative must verify that all underground utilities have been located and staked out.
Provisions must be made to barricade the open trench, prevent collapse of trench walls, provide employees with a means of exit, Reroute ground water, all other requirements of excavating If soil is contaminated, safety and health plan. Exposure to Traffic / Vehicles / Combustion Engines Internal combustion engines or vehicles with internal combustion engines inside company buildings. produce poisonous gases such as carbon monoxide, and oxides of nitrogen.
Use of company owned equipment, such as personnel lifts, fork trucks, vehicles, etc., by employees of a contractor Prevent equipment emissions from contaminating air inside buildings and confined spaces. Unauthorized use of company equipment
can result in lost production and injury to untrained operators.
Require permission of area management, and Require verification of equipment operator training. Movement of large pieces of equipment,
Especially while other personnel are working nearby, can result in employee injury from falling material, or being struck by equipment.
Hazardous vapors and gases
Abandoned tanks, pipe lines, drums, and vessels may contain hazardous vapors and gases.
Permits may be issued to prevent toxic or corrosive exposures to workers
? Noise
Many construction processes create noise levels high enough to cause hearing loss. Boilers, High pressure vessels
Boilers, high pressure vessels, tanks, and reactors can undergo sudden failure resulting in disastrous consequences.
Permits may be issued requiring precautions and equipment to prevent system failures not covered by safe job procedures or project safety plans. Elevated Works where the consequence of noncompliance with fall protection requirements is severe, or where falling objects may endanger other workers below. Energized lines
Permits are required before work begins near energized lines which cannot be shut off if there is danger of fire, shock or electrocution. Non Routine / Routine work
Requiring special precautions must be clearly indicated and communicated to workers, and their supervision. PPE
Personal protective equipment and other safety equipment required is specified.
For each hazard present at the work site, the safety representative must specify a hazard control. Where to Get Help?
Your supervisor is responsible for providing equipment necessary to comply with Safe Work Permit requirements. When is a PTW not required?
• Routine activity as per approved list authorized by Manager based on Risk Assessment.
6. Definitions Definitions
• Responsible Person • Issuer • Executor • Field operator • Gas Testing AGT • Isolator Definitions Responsible Person - is a person authorized by Manager who will be responsible for keeping his area and staff safe . His responsibility includes Management of people, Processes, Materials, Equipment, Infrastructure, Contractors, Sub Contractors, Visitors & Environment.
Issuer must be a person who is trained, competent and authorized to issue a Permit to Work after ensuring that all the hazards, associated with the work being done in that area, have been identified and all necessary safety precautions are being implemented to ensure that the work can be completed safely.
Executor must be a person who is trained, competent and authorized who is responsible for the work being completed as described in the Permit to Work. The Executor must ensure that the work being done has been adequately described so that all associated hazards and risks can be identified.
Field operator is a competent person and supports the Isolator at site – checks the site compliance to permit conditions and signs the permit
Definitions continued
Gas Testing means the required Gas analysis like Oxygen content inside vessels for confined space entries, LEL % for hot works, H2S and Carbon Monoxide gas levels for confined space & hot works. It has to be done by a trained, certified and authorized person from the Issuing Authority before handing over the job to the Executing authority. Continuous gas monitoring (when required) will be done by trained and authorized executing members. Isolator Persons who are trained, competent and appointed in writing to carry out isolation and lockout on equipment. Certain competencies may require verification of competency by means of testing and/or assessment and may require the person to be certified as competent. This may include certification by an approved second or third party. Authorized person isolates Electrical (breaker / fuse isolation and/or racking out of switchgear) , Mechanical, Hydraulics, Pneumatic, (valves / physical blinding / flanges ) / Operations, Isolation(closing of process related air, gas or water piping manual valves.) Chemical, Gravity, Thermal, Radiation / All others sources of energy and Process
7. Types of Permit Types of Permit
Cold Work . Hot Work Confined Space Excavation Radiography Other Authorization – Photography & Videography Permit, Vehicle Entry Certificate, Electrical Isolation Tag shall also be required as applicable.
Contractor Safety Management
Cold Work
Cold Work includes, but is not restricted to: •Work on equipment or plant components that are under pressure or are energized in some form (e.g. mechanical energy); •Work on equipment or plant components that contain hazardous materials; •Work on vessels (e.g. tanks, pressure vessels); •Mechanical Isolations of pipe work, valves and associated vessels; •General construction; •Work on de-energised electrical circuits (shop bench work will not require a permit); •Work performed in the immediate vicinity of overhead power lines; •Routine and Non-routine maintenance work. •Visual inspection, laser temperature measuring and vibration monitoring do not require a permit.
Cold Work Permit A Cold Work Permit shall be obtained for all general work that does not involve activities related to hot work, i.e. the tools and equipment used or the work itself do not generate any spark. Examples: •Routine maintenance, inspection and condition monitoring activities using proper hand tools. •Excavation by hand tools, erection of scaffolds & barricades, chemical cleaning and use of air driven power tools which do not generate sparks during use. •Opening of process equipment such as, vessels, towers, pumps, compressors, heat exchangers, filters, tanks, etc. •Blinding (Spading), blanking, breaking of flanges and unions, tightening of flanges, hot bolting, cold cutting, hot work preparations, etc. •Industrial radiography using ionizing radiation source (excluding X-ray generators).
Hot work
Hot work is any work that could create a source of ignition that could result in a fire or explosion. Examples of hot work include, but are not restricted to: •Welding and torch cutting; •Spark producing tools such as grinders and chippers and power tools such as electric drills; •Use of explosives; •Use of non-intrinsically safe electrical or electronic equipment in high risk gas areas. •Hammering in high risk gas areas - unless spark free tools are used.
Hot Work Permit (1/2) by the Fire Marshal A Hot Work Permit shall be obtained for all work that involves activities with tools and equipment, or the work itself, that could generate spark or be a source of ignition. •The issuer of the Hot Work Permit is responsible for ensuring that the site and the equipment (vessel, piping, etc) are properly prepared to prevent the danger of fire & explosion involving flammable material. •Issuer shall ensure that, the equipment is emptied, cleaned of flammable materials and isolated from all sources by means of disconnection, blanking or insertion of blinds. Isolation by closed valve only is allowed. if, there is no other possible way of isolation and mechanical isolation has been done. This must be approved by QS Safety. •Issuer & executor shall ensure that, within 10 meters of a hot work site, any sample point, drain, surface manhole cover or relief valve outlet are covered to prevent the escape of flammable gas and vapors (sealed using flame- retardant tarpaulin, wet rags or metal plate). They shall also ensure that, these seals are maintained in good condition. •If there are any open drains or ditches into which flammable liquid can escape, the same shall be dammed and pumped dry. Outlets of all unit drains shall be plugged to isolate them from the rest of the sewer system.
Hot Work Permit (2/2) • Authorized Gas Tester (AGT) shall conduct the test for flammable gases (%LEL). LEL test is mandatory for all hot work at DR, Gas Metering Station, Gas Pipe line areas, as well as any area where the presence of flammable gas is possible. • Clear of heavy oil deposits, dried vegetation or other flammable/combustible • Working at Height - spread of sparks with fire-resisting/flame-retardant tarpaulin or metal sheets. Proper ventilation/ air circulation for the welder should be ensured. Barricade should also prevent direct eye contact of others with welding arc. • water for quenching / Firefighting equipment / extinguishers • inform Emergency Station about critical hot work • risk ranked based on a HIRA – Higher risk -- Competent
•
Confined Space, Excavation Confined Space OSHA defines a confined space as being made up of 3 main parts: 1)being large enough for an employee to enter and perform work; 2)has limited or restricted means for entry or exit; and 3)is not designed for continuous occupancy. Confined Space Entry Authorization
Excavation means a process of moving earth, rocks or other materials with tools, equipment or explosives. It includes earthworks, trenching, wall shafts, tunneling and underground work, using manual or mechanised methods. Excavation Authorization For excavations more than 1.2 meters deep a Confined Space Entry Authorization is also required. 8. Elements of a Permit to Work Elements of Permit To Work System :
1. Issue
2. Receipt
3. Clearance / return to service
4. Cancellation May also be an extension
1. Issue – Pre Job Checks
– Description of work to be carried out – Description of plant and location – Assessment of hazards – Identification of controls
– Additional permits e.g. hot work
– Isolation of services
– PPE
– Emergency procedures
2. Receipt – handover of permit
– Competent and authorised person issues permit to workers – Workers sign to say they accept controls • Work can now start • Plant is now under the control of the workers
• 3. Clearance – hand back of permit – Workers sign to say they have left the job site and equipment can restart.
• 4. Cancellation – Authorised person accepts plant back and can remove isolations etc. • Plant is now returned to the control of the “site”
9. ROLES AND RESPONSIBILITIES
Responsibilities
• The employer, site occupier or installation duty holder (ie the installation owner or operator) has overall responsibility for ensuring proper permit-to-work systems are developed and followed. • All workers / Contractors, subcontractors has responsibilities and duties under a permit-to-work system. It is important that each person is adequately trained and knows exactly what those responsibilities and duties are if they are to be carried out properly. 10. Validity of Work Permit Validity of Work Permit
1 Maximum Validity
Work not performed for over 2 2 hours
3 Change in Scope
4 Permit Renewal
5 Tracking
The work permit shall be tracked through the entire life cycle from initiation to completion / close-out. Suspension of Work Permit • In case of an emergency, injury or dangerous occurrence, work shall be suspended and validity of any work permit ceases. • Fire if there is a general alarm • if there are any changes in the agreed permit conditions Nature or scope of the work; where there is conflict with another scope of work.. • Suspended permit remains live until it is cancelled, it should be kept on the permit recording system. The work should not be restarted until the issuing authority has verified that it is safe to do so, and has revalidated the permit or issued a new permit • if the site conditions have changed for operational reasons, eg when the permit is for hot work and process fluid or gas sampling must be carried out at the same time, with the possibility of a release of a dangerous substance • a new hazardous situation appears. • Safety Regulations are violated, • Waiting for spares;
10. Preparation and Execution
• Permits must be reviewed and signed by:the safety representative / workers’ supervisor / issuer / Executer, work area manager. • Workers must be informed of required emergency procedures, location and operation of emergency equipment and area inherent hazards. • Material Safety Data Sheets must be supplied and special precautions reviewed with workers and their supervision. Display
• Copies of a permit-to-work should be clearly displayed: – at the work site, or in a recognized location near to the work site. – in the central or main control or permit co- ordination room, – In addition, a copy of the permit should be kept with the issuing authority, or with the area authority Handover • If work is carried over to another shift, eg the job takes longer then expected, then a shift handover procedure should be in place. • ensure that the incoming shift is aware of any outstanding permit-controlled jobs, the status of those jobs / plant. Hand-back
• The hand-back procedure should include obtaining answers to the following questions: – Has the work been completed? – Has the plant or equipment been returned to a safe condition, – In particular by removing isolations? Design of permit to work (1)
Permit Title Permit Number Date 1) Job Location/Plant Identification 2) Description of work 3) Time limits 4) Description of hazards 5) Tests and checks prior to work commencing 6) Further precautions: emergency procedures, PPE, etc. 69 Design of permit to work (2)
7) Authorisation: Signature by competent person confirming that isolations and precautions have been carried out 8) Acceptance: Signature of person in charge of work confirming understanding of work to be done, hazards involved and precautions required 9) Time Extensions/Shift Change procedures 10) Hand Back: Confirming work completed 11) Cancellation: Confirming work satisfactorily completed Note: All signatures to be legible 70 Elements of a Permit to Work Gas Testing Gas tests are required for hot work and confined space entry. It may also be required for some cold work and excavations. Gas Test of Work Permit shall be filled to record results of Flammable / Toxic Gases and Oxygen concentration as applicable to the location of work. Setting Requirement • Issuer shall determine the requirement of gasses to be measured and frequency of repeating the test or the need for continuous monitoring. Minimum requirement shall be once at the beginning of shift/work. • How it is Executed • Combustible gas is measured as a percentage of Lower Explosive Limit (%LEL). • For hot work, the reading at the point of work shall not exceed 1%, preferably 0% of the LEL. • For cold work breathing area shall be less than 10% of the LEL. • Who will Execute • An Authorised Gas Tester (AGT), who has a valid Third Party certification, shall carry out the gas test using an approved calibrated gas detector. He shall check the meter in fresh air and keep it on before actual test. In cases where the potential risk is very high, the AGT can test it with another detector for confirmation. • PPE • Gas tester wearing SCBA or carrying an escape mask shall test for Toxic gas, if the presence of toxic vapor or gases is known or suspected.
Your own safety is at stake when your neighbor's wall is ablaze.
Horace
205 min min
74