20WORK PERMIT TRAINING

INTRODUCTION

WORK PERMIT

FIRE WATCH/STANDBYMAN

GAS TESTING

OBJECTIVES

To eliminate work permit errors by:

 Improving workers’ awareness and understanding of the

work permit system .

 Reviewing the types of permits and the responsibilities of the

authorized Issuer and Authorized Acceptor.

 Reviewing the Fire watch / Standby man responsibilities

 Reviewing the Gas testing instruments

SAFETY IS THE RESPONSIBILITY OF EACH EMPLOYEE

WHAT IS A WORK PERMIT ?

A Work Permit is a written document authorizing a person or a group to perform specific

tasks as identified on the Work Permit and subject to specific conditions and precautions.

Before most work in any SAFCO facility can be started the workmen must obtain advance
approval in the form of a work permit.

Only one work permit shall be issued for each job.

Work performed on a single equipment involving more than one work group, each group
shall get separate work permit.

Each employee or contractor who is qualified will be issued a wallet size authorization card
signed by his Manager or Contract Administrator. This card will list the employee or contract
employee’s qualifications and shall be carried on by the person while at work.
The authorization card is valid for a two year period.

Personnel may re-qualify by attending refresher training.

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All work performed by non-operating personnel and work performed by operating personnel
outside the scope of their normal operating responsibilities shall require in advance a work
authorization by operating personnel in charge of the respective area.

There are two types of work permits:

1) Safe Work Permit

2) Hazardous work Permit

SAFE WORK:

Safe work is any work which is not hazardous in nature, will not generate heat that can cause
ignition of flammables, and will not involve personnel exposure to hazardous or toxic
substances or any other hazardous conditions.

Examples of Safe Work Permit:

• Adjusting instrument
• Using basic hand tools (screw driver) or hand impact tools (hammer).
• Inspection
• Scaffolding

HAZARDOUS WORK:

Hazardous work is any work which is hazardous in nature, can generate heat that can cause
ignition of flammables, and can involve personnel exposure to hazardous or toxic substances
or any other hazardous conditions (see 5.1.3 for examples).

Examples of Hazardous Work Permit:

• Hot work
• Confined space entry
• Excavation
• Work involving the use of, or possible exposure to radioactive sources.
• Operation of Internal combustion engines
• Camera with flash
• Vehicle entry
• Electrical above 24 volts

The Safe and Hazardous work permit will be issued by any authorized issuer from the area
where the work is to be done

WHAT IS A HOT WORK ?

Work activity capable of supplying ignition energy for flammable mixtures

Examples of Hot Work:

Cutting

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Grinding
Welding
Open Flame

Hot Work requires a Hazardous Work Permit.

The acceptable level of combustible for hot work is 0 % .

• The minimum fire protection for any hot work shall consist of one 30 lb. Dry
chemical fire extinguishers located at work site in addition to any unit fire protection
equipment available at the area.

EXCAVATION:

Any work that requires breaking the earth’s surface or pavement including the removal of
previously installed roadways, slabs or foundations at or below the surrounding ground level

• Excavation more than 1 meter deep shall be treated as a confined space entry.

There are two types of excavation:

1) Hand excavation: uses only hand tools like a shovel.

2) Machine excavation: uses machines for breaking hard surfaces like concrete or asphalt
areas e.g., jack hammer, concrete cutters, etc.

POTENTIAL HAZARDS IN EXCAVATION:

1) Property damage and / or injury resulting from contact with existing

utilities.
2) People becoming trapped or buried as a result of excavation wall failure.
3) People or equipment falling into excavations.
4) People being struck by tools or equipment used in the excavation.
5) Suffocation or other hazards associated with gases heavier than air.
6) Cars or trucks driving into the excavations.

The civil engineer is responsible for the activities when excavation is planned

AUTHORIZED ISSUER:
is an individual who has successfully completed the required training, authorized by his
manager to issue work permits, and hold a valid work permit authorization card.

AUTHORIZED ISSUER RESPONSIBILITIES:

• Confirm that the equipment and work area are properly prepared for the work
to
be done and ready for maintenance.
• Confirm the condition of the area and equipment.
• Lock and tag or confirm that equipment was locked out.
• Explain to acceptor all hazards associated with the job.
• Visit the job site with the acceptor and issue the permit at the job site.

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 • Notify appropriate personal within the affected area.
• Post the original copy of the work permit in the control room or the
designated
area.
• Conduct frequent visit to the job.
• Insure that gas tests are performed per the work permit instruction.
Gas test frequency must be noted on the safe and hazardous WP by the issuer.
The Issuer will decide if the gas test is required.
• Cancel the work permit if conditions change.
• Visit the job site with the acceptor to close the work permit, EVEN IF THE
WORK IS NOT COMPLETED.

AUTHORIZED ACCEPTOR:

Is an individual who has successfully completed the required training, authorized by his
manager to accept work permits, and hold a valid work permit authorization card.

AUTHORIZED ACCEPTOR RESPONSIBILITIES:

• Should understand the permit’s conditions covering the work to be
done
• Review with the issuer the hazards associated with the job.
• Comply with the work permit instructions.
• Remain in the area so that he is readily available if needed. If he
leaves
those areas, another acceptor must endorse the work permit.
• Notify the issuer of any work conditions changes.
• Clean up the work area and notify the issuer when work is completed.
• Visit the job site with the issuer to close the work permit, EVEN IF
THE WORK IS NOT COMPLETED.
• Should understand the permit’s conditions covering the work to be
done.
• Ensure that work permit is endorsed by operations.
• Post the rigid (hard) copy in visible location at the work site.
WHAT IS THE DURATION OF WORK PERMITS?

• Permits are valid for only one shift (8 or 12 hours shift) but may be extended
up
to a total time of 24 hours if endorsed by an authorized issuer and acceptor.
• Permits for construction type activities in non-operation areas can be issued
for
periods up to one week.
• Work Permits may be extended up to a total time period of 120 hours during
the
shutdown/turnaround for a specific job and specified equipment or group of
equipment such as welding machines, scaffolding, etc.
HOW TO ENDORSE WORK PERMIT AT SHIFT CHANGE?

At shift change: the employee coming on duty shall do the following:

• Review all active work permits in his area and endorse the control room copy
of the permit.

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 • Within one hours of shift change, visit the job site and endorse the hard copy.

To issue a work permit for a job in your unit and the job will involve equipment in another
area, you must check with the authorized representative in the other area and have him
endorse the permit.

Permits shall be canceled under any of the following conditions:

1) Failure to start the work within two hours from the issuance of the work
permit, or if there is an interruption of work for more than two hours.
2) If area or unit conditions change, e.g. gas release, liquid hydrocarbon spillage.
3) If there is incident took place while performing the permitted work.

Permits shall be suspended under the following conditions:

1) Whenever a fire or gas release emergency is announced by the sounding of the

plant emergency alarm or by other means
2) Any person is authorized to stop work, if he believes conditions under which
the permit was issued have changed or are about to change.
3) Any deviation without appropriate authorization shall result in immediate
suspension of the permit.
4) If operations do not endorse a permit at the work site within one hour.

INTERDEPARTMENTAL LINES:

For the interdepartmental work, the permit is issued by an authorized person from the area
where the work is done, and endorsed by authorized person from the owner department, and
other affected departments.

HOW PLANT EMERGENCY AFFECT WORK PERMITS?

All work permits plant wide shall be suspended. Worker shall proceed to safe assembly areas.

WHEN TO RESUME WORK?

When the “All Clear” is sounded. The issuer or last endorser will insure that it is safe to
resume the work.

METHODS OF EQUIPMENT ISOLATION.

• BLINDING

• DOUBLE BLOCK AND BLEED

The isolation of a piece of equipment by closing two positive shut off valves and
opening a bleed or drain valve in between.

• SYSTEM BLINDING:

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 To isolate several pieces of equipment as a single unit.

• PHYSICAL RESTRAINT:
The isolation of equipment by physically restraining its movement. Chains, bars, or
cables are used on mechanical equipment which might move and injure someone
working on it.

• SINGLE BLOCK VALVE ISOLATION

Is to isolate an equipment for cold work when there is only a single block valve

TYPE OF SINGLE BLOCK VALVE ISOLATIONS:

CLASS “C” (LOW RISK)

Steam traps ……. Controlled Flange Opening

CLASS “B” (MODERATE RISK)

• Line 8” or smaller
• Piping pressure 300 lb or less
• High pressure steam

CLASS “A” (HIGHER RISK)

• Class A includes anything not identified as class C or B.

CLASS A and B require a hazardous work permit and supervisor signature. Class A requires
superintendent signature

LOCKS FUNCTION:
To prevent the equipment from being accidentally energized while work is going on.

Low voltage (LV) 480 volts and below

High voltage (HV) above 480 volts

Electrical Authorization:
Electrical authorization is the responsibility of the Electrical Section.

PADLOCKS:
• Operation padlock (Green) and have the same key
• Maintenance padlock (Blue) and have different key
• Electrical padlock (Red) and have different key

Operation will install the tag at the substation and out in the field.

A board is available in all substations that have all locks and keys

High voltage above 480 volts will be isolated by an authorized electrical person

ELECTRICAL LOGOUT BOOK:

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 will be available in all substations and to be filled by operation/electrician after the
installation of the locks and tags

LOCK OUT STEPS:

• Shut off the electrical power to the equipment. Make sure all sources of power
are switched off.
• Place the disconnect handle in the (off ) or de-energized position.
• Place multi-lock hasp and an operations lock on the handle.
• Place DANGER, DO NOT OPERATE THIS SWITCH tag.
• Work permit acceptor shall place his lock and tag on the hasp.
• Work permit issuer and acceptor shall update the electrical lock out log book.
• Verify that the equipment will not operate by pushing the (on) switch at local
or
remote locations. (This shall be done by the issuer and acceptor).
• Place the tag on the local or remote start/stop switches.
• Work permit issuer and acceptor shall visit the job and verify that each step
has been completed.

Any work on live electrical equipment above 24 volts, requires a Hazardous Work Permit.

CONFINED SPACE
Any area that are not normally occupied by personnel, having limited means of entry, and
which could be subject to hazards of oxygen deficiency or the accumulation of toxic or
flammable gases.

EXAMPLES OF CONFINED SPACE:

Tanks Boilers Columns
Manholes Furnaces Pipes
Excavation (deeper than 1 meter)
Sewers Sumps

A confined space work area must always have:

a hazardous work permit, a sign in/sign out log and an authorized standby man.

Before entry into a Confined space, it must be:

• De contaminated
• Isolated
• Ventilated
• Ventilation - Ventilation must be provided entire time someone is in the
confined space. ( by natural draft or by air mover )
• Gas test - Gas test is always required for entry into a confined space. Oxygen
20.8% and LEL 0%.
• All entrants shall use a full body harness with a retrieval lifeline attached,
unless
the retrieval equipment would increase the overall risk of entry or would not
contribute to the rescue of the entrant.

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 If entry into a confined space is required for gas testing: The person shall enter only after
wearing the breathing equipment and a standby man shall be stationed outside the confined
space.

HAZARD:

Confined spaces have the potential for many hazards. For example:
• high temperature
• high noise
• fall from elevation
• electrical
• slipping
• O2 deficiency

All workers entering a confined space must be accounted for by the use of a sign in/sign out
log.

• At least one person in each confined space entry shall have a calibrated pocket
size oxygen meter with alarm.

EQUIPMENT:

Electrical equipment:

The following requirement must be met:

• Voltage must be limited to 120 volts maximum.
• Electrically grounded.
•
• Ground fault interrupter. (GFI)

Pneumatic tools:
• Air driven only. Other compressed gases are prohibited.

FIRE WATCH AND STANDBY MAN

FIRE WATCH:

When required:

• Hot work in an area where flammable materials is present, or there

is the possibility of flammable materials being released.

CAN A FIRE WATCH PERFORM HIS DUTIES FOR MORE THAN

ONE HOT WORK?

Yes, if they are close together.

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Fire watch Responsibilities:
• Make a joint job site inspection.
• Sign section 6 of the work permit.
• Assure that hazardous situations do not arise.
• Establish an effective communication with operations and
maintenance.
• The Fire Watch is responsible to see that all special protection, in
section 4 of the hazardous WP, is on the job site.
• Be alert and remain on the job scene.
• Wear orange vest and has a portable air horn. Work permit issuer will
make the decision whether to have a radio or not.
• Assure that all required fire fighting equipment are available and in
working condition prior to the start of the job.
• Assure that all permit conditions are maintained.
• Stop the job when the plant alarm sounds.
• Stop the job and notify operation if flammable material is released in
the immediate area.
• Upon job completion, he remains with the job until clean up is
complete

When a hot work is completed, the fire watch should inspect the job site to make sure:-
• there are no ignitable materials that may ignite later.
• that all used welding rods have been put in a metal container.
• all special equipment is cleaned and returned.

• In case a fire started by the hot work, the fire watch shall:
• Stop the work
• Sound the portable air horn
• Notify the control room, and attempt to put out the fire if it’s safe to do
so.

STANDBY MAN:

When required:

• Hole (Manway) watch for confined space entry.

• Cylinder watch for breathing air job.

It is necessary for the standby man to have a self contained breathing air unit at the job site all
the time.

CAN A STANDBY MAN BE A CYLINDER WATCH AND A MANWAY WATCH?

Yes, if condition permits.

Who provides standby man/fire watch?:

• Planning or the job contractor.
• For jobs of short duration, a person from operations may be assigned
the additional responsibility of standby man/fire watch.

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 • If standby man needs to leave the job site he shall do the following:
a) Ask for a replacement or
b) Stop the work removes all personnel from confined space
c) Shall place a sign and physical barrier over the entrance when the last
person working in a confined space has exited the confined space.

STANDBY MAN RESPONSIBILITY:

• Make a joint job site inspection.
• Be alert and remain on the job scene
• To assure situations involving hazards to personnel or operating
equipment do not arise.
• Wear orange vest and has a portable air horn. Work permit issuer will
make the decision whether to have a radio or not.
• Assure that all permit conditions are maintained.
• To keep track of each person who enters or exits a confined space by
a log that is signed by all persons when they go in and signed again
when they come out.
• After the permit has been issued, he shall remove the confined space
barrier.
• Sign section 6 of the work permit
• Communicate to permit issuer and acceptor that the job is complete or
suspended.
• Shall inform the permit issuer upon restart of any suspended entry job.
• Maintain visual/verbal contact with personnel in confined space at all
times.
• Has dedicated Scott air pack available.
• Monitor cylinder pressure, line and associated equipment.
• Place a sign and physical barrier over the entrance of a confined space
when the last person working in a confined space has exited the confined
space.

• When the plant fire/gas release alarm is heard, the standby man
should :
• Blow the horn to alert the men to stop the job
• Remove all personnel out of the confined space & secure the
job site
• Go to the nearest safe assembly area.

When a confined space job is finished, the standby man should:-

- Replace the confined space barrier
- Clean and return special equipment
- Notify permit issuer and acceptor that the job is complete

Rescue of personal:
• Call for help NEVER ATTEMPT TO ENTER.

GAS TESTING:

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Gas Testing is conducted to determine air quality, work atmosphere suitability and the
required personal protective equipment.

Before an employee is allowed to do gas test with any test equipment, he must be qualified
and authorized.

GAS TESTING INSTRUMENTS

The following instruments are being used for gas testing:

1- MSA (FiveStar Alarm)
2- BW Gas Alert Micro
3- Draeger (will be used by the Lab only)

MSA (FiveStar Alarm)

This is a portable instrument designed to monitor areas for flammable/combustible vapor,

oxygen percentage, H2S and CO at the same time.

The FiveStar Alarm contains sensors, which detect the above gases. Other sensors can be
installed by the Lab to detect other gases e.g. Ammonia (NH3)

The flammable ranges, LEL & UEL are not the same for all combustible gases.

Part:
a) On/Off power switch
b) Reset button
c) Page button
d) Alarm horn and light
Accessory:
Sampling lines, a 3 meter and 5 meter extension hose will be used if needed.

Allow 1 second for each meter length of the sampling line e.g. 3 seconds for 3 meter.
Operation:

• When you push the On/Off button, the backlight flashes, the screen flashes,
the alarm sounds and the alarm lights flash.
• When the word (FRESH AIR SETUP?) appears, the FiveStar Alarm is ready
for its Fresh Air Set up.
1- Press the Reset (YES) button
2- When the Fresh Air Setup (FAS) is completed; the instrument enters
the exposure display page, displays gas readings, and is ready for use.
3- If the MSA alarm cancels the Fresh air Setup request again, do not use
the instrument and send it to the Lab.

To bypass: press the Page (NO) button, or wait for five seconds.

MSA (FiveStar Alarm)

• The FiveStar Alarm has three standard and three optional display pages.
• You can move from one page to the next by pressing the Page button.

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 • You can return to the standard exposure display page by waiting for 15
seconds or by pressing the On/Off button.
• The optional display pages for the Lab use only.

• The standard display pages are:

Exposure display
Battery condition
Time and date

• If the battery is low, horn sounds (press Reset). After about 10 minute, the
instrument will shutdown.

• The battery can run for about 14 hours.

• The battery can be fully charged in 3 hours.

• An alarm will be sounded if the following levels are reached:

a) H2S 10PPM
b) CO 10PPM
c) LEL 1%
d) Oxygen 19.5% - 23%

• To turn the MSA off, press and hold the On/Off button for 3 seconds.

BW Gas Alert Micro:

• This is a portable instrument to be used for personal monitoring inside

confined spaces.

• At least one of the entrants shall use this instrument during entry into confined
space for continues monitoring at all times.

This instrument can be used to detect the following gases:

a) H2S
b) CO
c) LEL
d) O2

Operation:

• Press the top left (On/Off) button.

• The instrument will calibrate automatically each time it is started.
• To turn the instrument off, press and hold the top left (On/Off) button for 5
seconds.

• An alarm will be sounded if the following levels are reached:

a) H2S 10PPM
b) CO 10PPM
c) LEL 1%

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d) Oxygen 19.5% - 23%

• All entrants shall immediately leave the confined space if the alarm sounded.

• The battery can run for about 14 hours.

• The battery can be fully charged in 3 hours.

• Send the MSA and the Gas Alert Micro to the Lab for any problem or defect.

• Send the MSA and the Gas Alert Micro to the Lab for check and calibration
every 3 months

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