Training Package 0606 THE WORK PERMIT SYSTEM Reference

Training Package 06/06 THE WORK PERMIT SYSTEM (Reference document: AIGA 011/04 «Work Permit Systems» ) Asia Industrial Gases Association 3 Harbour. Front Place, #09 -04 Harbour. Front Tower 2, Singapore 099254 Internet: http//www. asiaiga. org

Acknowledgement This document is adopted from the European Industrial Gases Association document TP 10/04 – The Work Permit System, and acknowledgement and thanks are hereby given to EIGA for permission granted for the use of their document Asia Industrial Gases Association

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The Work Permit System: What is it? l A work permit system consists primarily of a standard procedure designed to ensure that potentially hazardous routine and non routine work on industrial installations can be carried out safely. The procedure should define the need for the following essential steps: Ø Details of the necessary preparatory work Ø Clear definition of responsibilities Ø Appropriate training of the work force Ø Provision of adequate safety equipment Ø A formal work permit with or without attached specific checklists. l This work permit: Ø specifies the work to be accomplished and authorizes it to be started under the strict observance of consigned work and safety procedures Ø After information and agreement of all other concerned parties (process, safety, customers, suppliers, …)

The Work Permit System : When? l For all non-routine works, l For hazardous routine works not covered by procedures, l When work is performed: Ø by your employees Ø and/or third parties

The Work Permit System (1/2): For what kind of work? l A work permit is required in case of: Ø Potential oxygen deficiency or enrichment Ø Potential flammable/explosive atmosphere Ø Potential high temperature/pressure Ø Potential hazardous chemicals, e. g. : toxic substances Ø Confined space entry, e. g. : tanks, cold box, pit, normally closed vessels Ø Bypassing or removing/altering safety devices or equipment Ø Elevated works Ø Introduction of ignited sources where not permanently allowed (fire permit), e. g. : open flame, welding, grinding, Ø Electrical troubleshooting or repair on live circuits Ø Maintenance or repairs in areas or to equipment or lines, containing or supposed to contain hazardous materials or conditions,

The Work Permit System (2/2): For what kind of work? l Or also in case of: Ø Manual or powered excavations Ø Use of mobile cranes Ø Insulation or catalysts handling Ø Use of adapters Ø Product conversion of stationary or mobile or portable vessels and containers Ø Temporary or permanent changes, alterations, modification of equipment or processes, Ø Exposure to traffic, Ø Exposure to moving/rotating machinery Ø In proximity of vents, liquid of gas Ø On process lines with gas release Ø Etc. .

The Work Permit System : Why? 1. Because: Ø In charge of the work, you don’t know everything Ø about the site and the process around Ø about the work Ø Safety measures have to be prepared Ø You cannot start the work without the OK of the production personnel or the customer or the supplier Ø The production needs your OK in order to re-start the plant after your work is achieved 2. To obtain a safe as well as a quick and cost effective work

The Work Permit System : With who? In order to define the scope of work for everyone concerned/involved by and during the work, the Work Permit must be prepared with: Ø Ø The person responsible for the work The person(s) in charge of the production, the customer or supplier, who will release the process before the work starts The other work bodies The person in charge of HSE measures

The Work Permit System : How? l Before issuing the Work Permit, you must: ØDescribe the work to be done ØList all the specifications and drawings which are required ØIssue detailed planning with all involved entities ØDetermine the logging and tagging procedures l Fill-in together the work permit and sign, The start of the work must be authorized by production and/or user, The re-start of the process must take place after the work is finished. l l

The Work Permit System : Review of flowsheets, drawings and specifications Purpose of the review is to ensure all key persons involved in job planning have a thorough understanding of the job. It should include: ØProcess fluids and materials involved, ØDegree of isolation, ØEffect of other processes, ØPower supply isolation, ØSpecialist advice, ØLocation of underground services and pipes, ØLocation of elevated power cables, ØLocation of elevated pipelines and walkways, ØPurging and lock-out requirements, ØPressure, Temperature, ØValve identification, ØEquipment specification, ØOperating and maintenance instructions, ØMaterials of construction and compatibilities

The Work Permit System : Work site inspection Anyone involved and signing the Safe Work Permit must visit the work place in order: • To inspect the work area Ø Neighbouring activities, site rules, overhead, underground, access, natural hazards (flood, rain, snow…), etc, . . • To identify potential hazards Ø Flammable, oxygen, toxic substances, confined spaces, electricity, pressure, temperature, moving objects, traffic, falls/trips/slips, etc, . .

The Work Permit System : Development of work procedures l Preparation of a detailed work procedure is essential to ensure the work will proceed safely in a planned and logical manner: Following requirements to be considered: Ø Reference drawings, Timing of various operations, Details of any special equipment, Needs to inform local authorities, safety precautions and equipment, Emergency procedures, etc, . . l The procedure should include: Ø Logging and tagging procedures: Electricity, process fluids Instrumentation, utilities (water, air, oil, …) Ø Depressurising, Draining, Venting, Purging, Flushing, Isolating, Atmosphere checking, Disassembly of equipment, Method of repair, Reassembly and installation, Quality control, Pressure and leak testing, Reinstatement of equipment, Hand-back procedure, etc. .

The Work Permit System: Example of form

The Work Permit System : Work Planning Ø Ø Ø Ø Ø WORK SCOPE REVIEW DRAWINGS / FLOWSHEETS INSPECT WORKSITE IDENTIFY SAFETY PRECAUTIONS COMPLIANCE WITH REGULATIONS DEVELOP WORK PROCEDURE ASSIGN RESPONSIBILITIES COMMUNICATION PROCEDURES WORK EXECUTION

The Work Permit System : Work Execution Ø Ø Ø Ø PREPARATORY WORK ISSUE WORK PERMITS SUPERVISION MONITORING WORK COMPLETED TESTING RE-INSTATE EQUIPMENT RETURN WORK PERMIT HANDBACK PLANT / EQUIPMENT

The Work Permit System : Permit issuer’s responsibilities Ø Ø Ø Ø INSPECTING WORK AREA IDENTIFYING HAZARDS DEFINING SAFETY PRECAUTIONS OBSERVING PRINCIPLES OF SAFE WORKING PRACTICES CREATING WORK PERMIT CONDITIONS REVIEWING WORK WITH PERMIT ACCEPTOR ISSUING WORK PERMIT IMPLEMENTING HANDBACK PROCEDURE

The Work Permit System : Permit acceptor’s responsibilities ØUNDERSTANDING OF WORK PROCEDURES ØUNDERSTANDING POTENTIAL HAZARDS AND SAFETY PRECAUTIONS ØACCEPTING THE SAFE WORK PERMIT ØOBSERVING PERMIT CONDITIONS ØCOMPLYING WITH HANDBACK PROCEDURE

The Work Permit System : In brief Many accidents have occurred due to lack of Work Permit or non observance of its consigned safety measures. l The Safe Work Permit is useful for: Ø The safety of persons in charge of the work Ø The safety of persons in charge of the process Ø The risk management of the process and equipment l It is not one more administrative paper! l Fill in and follow correctly the work permit, because…. It could save your life!