You are on page 1of 28

released into a confined space or to

the atmosphere
.

Why isolate?
If you dont isolate equipment correctly, a terrible incident or fire could happen. Therefore,

Before you issue or receive any Work Permit, you must make sure that equipment is completely
isolated.

General Instruction 6.012 defines four approved types of isolation:
1.

single lock and tag,

2.

double block and bleed

3.

disconnection and

4.

Blinding.

For each isolation method, the GI 6.012 requires a four-step process:
1.

Lock,

2.

Tag,

3.

Clear and

4.

Try
.
For more details visit GI6.012
http://gi/html/data/0006_012.pdf

What should we isolate?
Here are some examples of the equipment that we should isolate:
1.

Electrical equipment
2.

Mechanical equipment
3.

Hydraulic equipment
4.

Air- or gas-operated systems
5.

Vessels, pipes and confined spaces.
How should we isolate?
Here are some methods of isolating equipment.
1.

Install blinds
2.

Remove piping
3.

Close and chain valves
4.

Open electrical breakers
5.

Remove fuses or disconnect wiring.
Blinds
Blinds
are metal plates that are installed in a pipeline or equipment.
They prevent liquids or gases from coming in contact with people.

They are used to isolate operating equipment such as tanks, vessels, pumps, compressors
and
Pipelines
.
Remove suction of pipe
Sometimes a section of piping can be removed to isolate equipment as
shown
in this picture
Chain valves
Use chains to prevent a valve from being opened by accident
.

Electric isolation
1.

Open breakers to isolate electrical equipment.
2.

Also, disconnect wiring or remove fuses if breakers cannot be locked in the open position. As
shown below

Preparation Review# 2
1.

Choose two methods of isolating equipment?
Removing piping and install blinds
2.

Why do we install blinds in process equipment?

To keep liquids or gases from contacting people
.
3.

Removing fuses from an electrical circuit or disconnecting electric wiring is an
example of
what?
Isolating electrical equipment
4.

Equipment is isolated to make sure it cannot be?
Started up. Leak or cause electric shock

Locks and tag
Lock and Tags.
Install locks to make sure electrical circuit breakers cannot be closed, a valve
cannot be
opened, or another method of isolation cannot be overcome.
Locks prevent accidental start-up of equipment while work is in
Tags
Tags explain why you installed your lock. :
You must fill out tags completely and sign them. , This is important.
Everyone must know why your locks and tags are installed.

Locks /tags sequence
Before issuing or receiving a Work Permit, you must :-
1.

Identify all locations where locks and tags must be installed
2.

Operations must install their locks and tags first.
3.

Then, one craftsman from each work crew, who will work on the equipment, must also install his
lock and tag..
Locks and key
There must only be one key for every lock used. , This way, the only person who
can open the lock is the person who
installed it
.







Test isolating device
As the Issuer,
You must test each isolating device, such as a disconnect switch or valve, to make sure it cannot
be operated.
,
You do this by moving it against the lock, lockout clip, or chain
to ensure that the equipment cannot start or
the valve cannot be opened.
You must try to start electrical equipment at the field switch like this operator is
doing.
Multiple lockout clips :
Allow several locks and tags to be installed at the same time.



Group lockout box
Sometimes it is necessary for large numbers of maintenance personnel to lock and tag process
equipment and/or
electrical breakers, such as during a Test & Inspection
or repair of a compressor. Each person must be afforded
individual protection. so In those cases, a "group lockout" procedure can be employed to ensure
individual protection
while avoiding large numbers of locks and tags on an isolation point. This is achieved
as follows:

1.

An operations representative will lock and tag each isolation point with a single keyed
lock as per the
standard written isolation procedures.
2.

The maintenance supervisor/foreman will also lock and tag each of the isolation points.


3.

The maintenance supervisor (or foreman's) key or keys to these locks are then placed in a
Group Lockout box.
(Lockout boxes can be acquired through SAP B2B. )
4.

Multiple lock clips (hasps) are incorporated or attached on the closed group lockout box
5.

The operations representative places his lock and tag on the box/hasp first and maintains
possession of his key
or keys until the job is complete.
6.

Each member of the maintenance crew then places his lock and tag on the multiple lock clip and
maintains
possession of his key or keys until the job is complete.

A clamp on breaker lockout device
1.

Such as you see here can be used to isolate 110 or 220 volt electrical breakers typically found
in indoor applications.

2.

Individual breakers in these applications are difficult to isolate securely, and

3.

Clamp-on breaker lockout devices permit the worker to assure that the electrical circuit
remains isolated while work is being performed
.


ower lines.
These are Restricted Areas because they may contain hazards that could cause an incide
nt and where all workers must take
special safety precautions.
Designated Restricted Areas
Restricted Areas can also be designated by Department Managers. This could be an area
that is not included in the previous
list.
Anyhow If there is a question about whether an area should be
restricted, the
department manager makes the final decision. [2] Do you think this is
a Restricted Area?
E.g. Designated Restricted Areas
Is this a Restricted Area?
Possibly! Anyhow There is nothing in the picture that would make this
a Restricted Area.
The use of heavy equipment alone does not automatically require
Work Permits. [3]
However, the work could be hazardous and the department manager
may decide that
Work Permits are required.


Low risk work
Most work done in Restricted Areas is hazardous because of the location or because of th
e work itself. Work Permits are
required for all hazardous work. , However, some work can be very safe to do, especially
in a nonhazardous area. So the
Issuer may decide that work is low risk and that the area where the work is to be done co
ntains no hazards. Then He can
then decide that a Work Permit is not needed.
Low risk work example
Some examples of low risk work include :
[1] visual inspection,
[2] sweeping,
[3] cleaning non-hazardous equipment,
[4] some non-flash photography or
[5] Brush painting.
Note: If you are the Issuer and you decide a Work Permit is not needed,
you must still control the
work and are responsible for the workers if there is an emergency.
Review #3
1.

Example of low risk work are; - ?
sweeping, visual inspection, and minor cleaning
2.

Select the choice where every item is a restricted area?
Pump station , sewage plants, wells
3.

Do need a work permit to work here ( this picture)
Yes
4.

What does restricted area required?
The work permit is issued
5.

A specific area is not normally categorized as restricted area. Who makes
the final decision Whether area is should be categorized as restricted
area?
Department manger
6.

Do need work permit to work here?
No
7.

When a work permit issuer decide that a work permit is not needed in a
Restricted area?
When he decides the work is low risk.
Work permit issuer
A Work Permit Issuer is a Saudi Aramco employee who is certified by his
division or department
head to issue Work Permits. And he is the person who is responsible for
equipment or for a work
area.
Issuer responsibility
Some of you will be Work Permit Issuers.
1.

An Issuer inspects the work site,
2.

Identifies what hazards and precautions must be taken to work safely,
3.

Fills out and signs Work Permits.

[*] An Issuer has a lot of responsibility for safety at the work site. And
he shares that responsibility
with the Receiver.

A Work Permit Receiver
Is a craft supervisor or craftsman who has been certified by his division or
department head to
receive Work Permits. , Receivers are the people who will do the work. They
have to comply with
all safety precautions written on the Work Permit, and they must sign the Work
Permit.
Receiver responsibility
Some of you will be Work Permit Receivers. Like Issuers, you have a lot of
responsibility for safety
at the work site. And You share this responsibility with the Issuer.


Designated representative
If the Issuer is busy, and Work Permits are needed, he can assign another
person to help him. This
person is called the designated representative, and must be competent,
understand the
requirements of the Work Permit system and be familiar with the equipment,
hazards and job

requirements.

The designated representative can inspect the work site, make sure the
equipment is ready to work
on and make sure that gas tests are taken. However, the designated
representative cannot sign the
Work Permit only the Issuer must do that.
Review #4
1.

Why is designated representative sometimes used?
The issuer may be busy and needs help
2.

An issuer has which responsibility?
Defines safety precautions and sign work permits
3.

A receiver must be what?
Senior crafts man
4.

What the receivers main responsibilities?
Complying with safety precautions and sign the permit
5.

What can the designated representative do?
Inspect the work site
6.

What is the work permit issuer responsible for?
Equipment or work area

Master quiz
1.

Which of the following is not restricted area?
Loading pier , gasoline station , tank farm , dump site
The answer is = dump site
2.

The safety of work site is a sole (only) responsibility of issuer?
False
3.

What do you call an area where a work permits are required?
A restricted area
4.

Restricted areas include which locations?
Pumps stations , tank farm , gas wells
5.

Who is work permit receiver?
A person certified to receive permits
6.

What is the purpose of work permit system?
To authorize specific construction or maintenance work
7.

Who can decide that work is a low risk and that a work permit is not needed?
The issuer
8.

What responsibility do issuer and receiver share when singing work permit?
Maintaining safety conditions at the site.
9.

Who decide whether an area should be restricted or not?
The department manger
10.

What type of work does the work permit system authorize?
Specific construction, maintenance , or repair work
Work permit issuer responsibilities






joint responsibilities
Issuer& Receiver are:
Both responsible for identifying hazards and reducing risks

Make sure that the work site is safe.
Both responsible for safety of people and
equipment at the site.
Issuer responsibilities
1.

As the issuer knows what the hazards are in his
area and how to work them safely , he has to make
sure the receiver full understand s all hazards and
the safety [precautions he must taken
Issuing a work permit
Before issuing the work permit , you must :
1.

Check the receivers certificate to be sure he is
certified.
2.

Lead the receiver on a Join Site inspection.
3.

Point out all hazards, and write on the work permit all safety precautions that
the receiver must
takes.
4.

Tell the receiver what you have written.
5.

Get any countersignatures that are required, and make sure that any design or
material
changes have been approved.
6.

Visit the site frequently after work starts to make sure the work continues safely

Receiver responsibilities #1
As receiver you must
1.

Ask the issuer for a work permit before the job starts.
2.

You must take part in the job site inspection and explain to the issuer exactly
what work you
will do and the equipment you will use.
3.

You must also look for hazards.
Receiver responsibilities #2
1.

You must read the work permit and agree to all conditions written on it by the
issuer.
2.

After sign the work permit you must make sure that all conditions are met and
all workers
understand the conditions.
3.

You must display the work permit at the site, or keep it with you.
4.

You need to stay at the work site to supervise all activities,
When receiver leaves site .
He has :
1.

To have the issuer permission.
2.

Must relinquish (
hand over
) supervisory control
(competent person
) to another certified
receiver until he comes back.\
3.

The alternate receivers name and badge number must be written on the permit
by the
issuer
Responsibility review#1 ( 7 questions )
1.

What join responsibility does issuer and receivers share?
Safety at the work site
2.

Why is it important that the issuer tell the receiver about safety hazards he may
find at job site?
The receiver may not have worked in the area before.
3.

What two things must the issuer do before issuing a work permit?
Check the receivers certificate and get countersignature
4.

Who goes on the join site inspection?
The issuer and the receiver
5.

What two things must the receiver do before receiving a work permit?
Read the work permit and agree to all conditions
6.

Where must the receiver keep the work permit after it is issued?
Displayed at the job site or in his possession.
7.

When can a receiver leave the job site?
When the issuer has given him permission

Joint inspection site
Things to check at JSI
1.

Take gas test.
2.

Check to see if equipment is prepared, isolated,
and cleaned.
3.

Do you need to install locks and hold tags, put up barricades or warning signs
or inspect
tools, excavations or scaffolds?.
4.

Can heavy equipment be safely used?
5.

Do you need to use special equipment or procedures? E.G handling asbestos.
Or a crtical
lift plan per( GI7.028-crane lifts- types and procedures) through this link
http://gi/html/data/0007_028.pdf

6.

Should workers wear personal protective equipment?.
7.

Do you need a fire watch or standby man?
No JSI if Low risk work at :
For some jobs, the issuer may decide not to do a joint site inspection

To do this, the work must be extremely low risk.
Remember , if you have any doubt that a hazard may exist, always make a joint
site
inspection
Example of low risk work
carpentry
Lubricating.
Cleaning
Brush painting
Checking instrument in control room
Taking vehicles into a non-hazardous area
Some types of non-flash photography.
Responsibility review#2 ( 4 questions )
1.

Who goes on a Joint Site inspection?
Issuer and receiver
2.

What is discussed during the joint site inspection?
Scope of work and equipment to be used.
3.

When would the issuer check to make sure equipment has been properly
prepared for
maintenance work?
During the joint site inspection
4.

Why do receivers go on the joint site inspection with the issuer?
To discuss hazards and risks
Fire watch
A fire watch must be assigned anytime work is done where a fire could occur
such As:
1.

Working on or near in-service hydrocarbon equipment
2.

Hot tap .
3.

Working near combustion material.
4.

Working near opens sewers , or pumps
5.

When a release of hazardous liquids or gases permit is issued .
Fire watch, who is he?
Usually an operator.
Could be from maintenance.
Could be a contractor if the operation and maintenance foreman agree
Must have had fire training.
Must know how to use equipment like fire extinguisher or hoses.
Must know how to report a fire

1.

Check the work site to make sure all safety precautions have been taken.
Covering sewers
Placing fire blankets.
Extinguishers are ready to use.
2.

Stay at the site after hot work is finished for 30 minutes.
To make sure all ignition sources are out

Note : The issuer must make sure the fire watch is trained and understands his
job before the work
permit is issued
Untrained fire watches have been responsible for small fire becoming majors
disasters

Standby man
The issuer may require a standby when :-
1.

When he sees the need for a person to be at the site to assist someone in doing
the job.
2.

And he may also be needed because of special skill he has.
Standby man who is he?:
A standby man could be a person assigned as a man-way watch during a
confined space entry so
he could be.
He may be a supervisor who standby during work on energized electrical
equipment,
or an operator who standby during on a critical instrument loop in case it must
be put
on bypass..
He could also be a specialized technician who standby during the start-up of a
new
piece of equipment.
The issuer must make sure the standby knows exactly what he is expected to do

Responsibility review#3 ( 5 questions )
1.

When should a fire watch be assigned?
3.

Whenever a fire could occur
2.

What would the issuer require when welding on in-service hydrocarbon
equipment?
4.

Fire watch.
3.

What must the fire watch be?
5.

Trained
4.

The fire watch has to know how to?
6.

Operate fire equipment given to him
5.

What do we call the person who is required to be at a job site because of a
special skill he
has?
7.

Standby man
Master quiz
1.

What training should a fire watch have?
Trained to operate fire equipment
2.

What is the purpose of the joints site inspection?
To discuss the scope of the work and identify any hazards or risk
3.

What must be checked during the joint site inspection? Select all items that
apply?
Safety devices
Equipment conditions
4.

Who should point out all hazards and write the hazards on the work permit?
Issuer
5.

Who should keep the work permit? ( this question should have more
explanation, such as
during the job .but anyhow the answer as below
Receiver
6.

Who should ask for the work permit before they start working?
The receiver
7.

Any worker can be assigned as standby man?

False
8.

Who should be assigned when working near a combustible materials ?
Fire watch
9.

Who is responsible for the safety of the work site?
Issuer & receiver
10.

The receiver can leave the job site anytime as long as he gets the permission of
his supervisor?
False
____________________________________
Work permit equipment preparation

The Learning Objectives are to
1.

Identify how and why equipment is prepared for
maintenance

2.

Identify what equipment is isolated and how it is isolated.

3.

Identify the purpose of Locks/Tags and how they are used
.
_______________________________________
Could the employee have prevented this? Could the Issuer? ,Could the Receiver
?

Yes! the employee could have avoided this by ensuring that the equipment was
de-energized and
isolated before beginning work.

___________________________________________________
Before you work on a piece of equipment, ;
1.

The Issuer must make sure the equipment is safe to work on.
2.

The Issuer must shut it down, isolate, de-energize, and purge or
clean it.
3.

The order in which the operator does these things depends upon the
type of equipment he is preparing.
4.

Usually, equipment is first Shut down and isolated, then
5.

Depressurized or de-energized,
6.

And finally Cleaned or purged.
PURGING
Sometimes, equipment is filled with a non-flammable, non-reactive material like nitrogen.
, This is done to
remove hazardous material and is called purging. [
Purging is a safe way to remove flammable or hazardous material from inside
equipment.

Warning: Nitrogen displaces oxygen. If there is not enough oxygen to breathe, people
could die.
Cleaning
Cleaning is done to remove all traces of flammable or toxic material that could injure
people.
This is usually done by steaming out the equipment, or using a water-wash.
Cleaning at this stage refers to the cleaning necessary to make the equipment safe to
enter or work
on.

Preparation Review# 1
1.

A nonflammable material commonly used to purge process equipment is ?
Nitrogen
2.

When preparing equipment for maintenance work, the issuer must make sure it
is?

Shutdown isolated and de-energized
.
3.

Tow common methods of cleaning process equipment include?
Water-wash and steaming
Isolation
Equipment must be isolated.

You isolate equipment to make sure it cannot start-up, turn, move,
leak or cause an electric shock.


Isolating equipment also prevents the unexpected release of energy or hazardous materials.


If the equipment starts up or moves, you or your co-workers could be injured or killed.


If a valve leaks or is accidentally opened, dangerous materials may be released into a confined
space or to
the atmosphere
.

Why isolate?
If you dont isolate equipment correctly, a terrible incident or fire could happen. Therefore,

Before you issue or receive any Work Permit, you must make sure that equipment is completely
isolated.

General Instruction 6.012 defines four approved types of isolation:
1.

single lock and tag,

2.

double block and bleed

3.

disconnection and

4.

Blinding.

For each isolation method, the GI 6.012 requires a four-step process:
1.

Lock,

2.

Tag,

3.

Clear and

4.

Try
.
For more details visit GI6.012
http://gi/html/data/0006_012.pdf

What should we isolate?
Here are some examples of the equipment that we should isolate:
1.

Electrical equipment
2.

Mechanical equipment
3.

Hydraulic equipment
4.

Air- or gas-operated systems
5.

Vessels, pipes and confined spaces.
How should we isolate?
Here are some methods of isolating equipment.
1.

Install blinds
2.

Remove piping
3.

Close and chain valves
4.

Open electrical breakers
5.

Remove fuses or disconnect wiring.
Blinds
Blinds
are metal plates that are installed in a pipeline or equipment.
They prevent liquids or gases from coming in contact with people.

They are used to isolate operating equipment such as tanks, vessels, pumps, compressors
and
Pipelines
.
Remove suction of pipe
Sometimes a section of piping can be removed to isolate equipment as
shown
in this picture
Chain valves
Use chains to prevent a valve from being opened by accident
.

Electric isolation
1.

Open breakers to isolate electrical equipment.
2.

Also, disconnect wiring or remove fuses if breakers cannot be locked in the open position. As
shown below

Preparation Review# 2
1.

Choose two methods of isolating equipment?
Removing piping and install blinds
2.

Why do we install blinds in process equipment?

To keep liquids or gases from contacting people
.
3.

Removing fuses from an electrical circuit or disconnecting electric wiring is an
example of
what?
Isolating electrical equipment
4.

Equipment is isolated to make sure it cannot be?
Started up. Leak or cause electric shock

Locks and tag
Lock and Tags.
Install locks to make sure electrical circuit breakers cannot be closed, a valve
cannot be
opened, or another method of isolation cannot be overcome.
Locks prevent accidental start-up of equipment while work is in
Tags
Tags explain why you installed your lock. :
You must fill out tags completely and sign them. , This is important.
Everyone must know why your locks and tags are installed.

Locks /tags sequence
Before issuing or receiving a Work Permit, you must :-
1.

Identify all locations where locks and tags must be installed
2.

Operations must install their locks and tags first.
3.

Then, one craftsman from each work crew, who will work on the equipment, must also install his
lock and tag..
Locks and key
There must only be one key for every lock used. , This way, the only person who
can open the lock is the person who
installed it
.







Test isolating device
As the Issuer,
You must test each isolating device, such as a disconnect switch or valve, to make sure it cannot
be operated.
,
You do this by moving it against the lock, lockout clip, or chain
to ensure that the equipment cannot start or
the valve cannot be opened.
You must try to start electrical equipment at the field switch like this operator is
doing.
Multiple lockout clips :
Allow several locks and tags to be installed at the same time.



Group lockout box
Sometimes it is necessary for large numbers of maintenance personnel to lock and tag process
equipment and/or
electrical breakers, such as during a Test & Inspection
or repair of a compressor. Each person must be afforded
individual protection. so In those cases, a "group lockout" procedure can be employed to ensure
individual protection
while avoiding large numbers of locks and tags on an isolation point. This is achieved
as follows:

1.

An operations representative will lock and tag each isolation point with a single keyed
lock as per the
standard written isolation procedures.
2.

The maintenance supervisor/foreman will also lock and tag each of the isolation points.


3.

The maintenance supervisor (or foreman's) key or keys to these locks are then placed in a
Group Lockout box.
(Lockout boxes can be acquired through SAP B2B. )
4.

Multiple lock clips (hasps) are incorporated or attached on the closed group lockout box
5.

The operations representative places his lock and tag on the box/hasp first and maintains
possession of his key
or keys until the job is complete.
6.

Each member of the maintenance crew then places his lock and tag on the multiple lock clip and
maintains
possession of his key or keys until the job is complete.

A clamp on breaker lockout device
1.

Such as you see here can be used to isolate 110 or 220 volt electrical breakers typically found
in indoor applications.

2.

Individual breakers in these applications are difficult to isolate securely, and

3.

Clamp-on breaker lockout devices permit the worker to assure that the electrical circuit
remains isolated while work is being performed