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Work Permit: A.K.Singh, Safety Manager Indianoil Corporation Ltd. Barauni Refinery, India
Work Permit: A.K.Singh, Safety Manager Indianoil Corporation Ltd. Barauni Refinery, India
ROAD MAP
The session will include the following: Presentation on BR Work Permit system followed by discussion Role of Issuing & Executing Authority Exercise how to fill the permit Questionnaire/QUIZ
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.
Major & Minor Maint. work. Inspection. Construction. Alteration. Process Equip. cleaning Entry into confined space. Excavation Vehicle entry into hazardous areas etc.
BLANKET PERMIT
SIX MONTHS BASIS / MAX I YEAR
TYPES OF PERMITS
7 types of work permit with specific colors.
HOT WORK & VEHICLE ENTRY PERMIT (Pink, light green & white) For use of or generates local source of ignition,vehicle & engine operated equip. entry to hazardous areas. BR:F&S:FR:1 CLEARENCE & COLD WORK PERMIT (YELLOW & WHITE) BR: F&S: FR:2 (For all general maint. works (no ignition source) DYKE CUTTING & EXCAVATION PERMIT(PINK ,light green & white) BR: F&S:FR:3 ROAD CUTTING & BLOCKAGE PERMIT (PINK & , yellow & light green) BR: F&S:FR:4 VESSEL ENTRY/VESSEL BOX UP/EXCAVATION (yellow & white) For personnel entry into confined space. BR: F&S:FR:14 WORK AT HEIGHT PERMIT (yellow & white) BR:F&S:FR:17 RADIATION WORK PERMIT( PINK & WHITE) BR:F&S:FR:18
WPS OPERATE ON OWNER IN CHERGE CONCEPT(UNITSCPNM,LAB-SQCM,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.
HOT WORKPERMIT EXECUTOR TO INITIATE THE FIRE PERMITDUATION,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 30 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.
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.
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.
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(T) AUTHORISES GSI & FPS AND LIST IS CIRCULATED.
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 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 MEASURES
CONTD.
To ensure positive isolation & maintain it all through Ensure adequate ventilation all through Display copy of entry permit near entry manhole
UEL(Upper Explosive Limit) : The maximum vapor to air conc.above which propagation of a flame will not occur(will not ignite).
Fatal emergency
over 700
TOXIC GAS - CO
TOXIC AS WELL AS FLAMMABLE TLV 50 PPM STEL - 400 PPM IDLH - 1500 PPM LEL - 12.5% UEL - 74 %
GAS TEST - CO
HEALTH 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.
TLV
25 2 0.5
STEL IDLH
35 5 1 30
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 rechecking. Trained Gas tester only shall carry out the test.
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)
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
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.
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.
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.
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.
AUDITORS 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
AUDITORS 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
AUDITORS CHECK-LIST
Electrical isolation was reqd., carried out and documented. Both issuing & executing authority signed mentioning name & signature, date & time.
AUDITORS 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
OPEN FIRE
PERMISSION-WEST SIDE OF RD.1 OR OUTSIDE GATE.2 NO OPEN CHULLA IN OMS,LPG & RUNNING PROCESS UNIT INCLUDING ROAD SIDES. IN SHUT DOWN UNITS UNDER REVAMP, JOINT INSPECTION BY AREA IN CHARGE /F&S+ RECOMMENDATION DGM(T) FOR ONE DAY
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.
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.
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 27 checklist items./ticking Approved by GSI Clearence from PN/Area in charge On completion , permit closure and return to Fire Station/ Area in charge.