TRAINING PROGRAM ON PERMIT TO WORK PROCeDURE

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

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

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

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

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

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

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 )

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

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

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.

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

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

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

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 %

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

WORK PERMIT Work Permit Copy

TRAINING PROGRAM ON PERMIT TO WORK PROCeDURE