WORK PERMIT SYSTEM

BRAHMAPUTRA CRACKER AND POLYMER LIMITED

LEPETKATA, ASSAM.
 CONTENTS
1. INTRODUCTION……………………………………………………………………………………………………………………………….4

2. WORK PERMIT - OBJECTIVES .......................................................................................................4

3. WHY WORK PERMIT ? .................................................................................................................4

4. WORK PERMIT REQUIREMENT .................................................................................................5-6

5. LOCATIONS WHERE WORK - PERMIT NOT REQUIRED ...................................................................6

6. TYPES OF PERMITS ......................................................................................................................6

7. FEATURE OF WORK PERMIT FORM AND SAMPLE FORMAT……………………………………………………….6-8

8. PROCEDURE FOR WPS.................................................................................................................9

9. WORK PERMIT ....................................................................................................................... 9-10

I. Validity of work permit................................................................................................................. 10

II. Who can sign a work permit ........................................................................................................ 10

III. Issuing authority of work permit............................................................................................. 10-11

IV. Executing authority of work permit ............................................................................................. 11

V. Preparation of the equipment ..................................................................................................... 11

VI. Residual hazards ........................................................................................................................... 11

VII. Protective measures……………………………………………………………………………………………………………..…12

VIII. Why gas test is required? ............................................................................................................. 12

IX. Gas test for work permit .............................................................................................................. 12

10. GENERAL TERMINOLOGIES........................................................................................................ 12

I. Flash point .................................................................................................................................... 12

II. Auto ignition temperature ........................................................................................................... 13

III. Explosive limit............................................................................................................................... 13

IV. LEL (lower explosive limit) ............................................................................................................ 13

V. UEL (upper explosive limit) .......................................................................................................... 13

VI. Gas test for work permit .............................................................................................................. 13

2
 VII. Toxic substance ............................................................................................................................ 13

VIII. STEL (short term exposure limit) .................................................................................................. 13

IX. IDLH (Immediate Danger to Life & Health) .................................................................................. 13

X. Hydrogen Sulphide (H2S) ......................................................................................................... 14-15

11. TOXIC GAS – CO ........................................................................................................................ 15

12. OTHER TOXIC GASES ................................................................................................................. 15

13 WORKS THAT NEED GAS TEST………………………………………………………………………………………………....15-16

14. ELECTRICAL ISOLATION ............................................................................................................. 16

15. SPECIAL REQUIREMENT FOR WORKING WITH RADIOGRAPHY ............................................... 16-17

16. SPECIAL REQUIREMENT FOR HOT WORK ................................................................................... 16

17. VEHICLE ENTRY ......................................................................................................................... 17

18. REQUIREMENT FOR CONFINED SPACE ENTRY ....................................................................... 17-18

19. SPECIAL AUTHORISATION FOR WORK AT HEIGHT………………………………………………………………………..19

20. EXCAVATION AUTHORISATION ................................................................................................. 19

21. SUSPENSION OF WORK PERMIT ........................................................................................... 19-20

22. CLOSING AND FILING OF USED WORK PERMITS ........................................................................ .20

23. BASIC RESPONSIBILITIES OF ISSUING AUTHORITY ...................................................................... 20

24. BASIC RESPONSIBILITIES OF RECEIVING/EXECUTING AUTHORITY .......................................... 20-21

25. BASIC RESPONSIBILITIES OF FIRE & SAFETY REPRESENTATIVE .................................................... 21

26. GAS TEST .................................................................................................................................. 21

27. AUDITOR’S CHECKLIST .............................................................................................................. 21

28. ROAD CUTTING AND BLOCKAGE PERMIT .............................................................................. 21-22

29. EXCAVATION AND DYKE CUTTING ............................................................................................. 22

30. TRAINING AND COMPETENCE………………………………………………………………….……………………….22-23

31. MONITORING, AUDIT AND REVIEW OF WORK PERMIT SYSTEM …………….………………..……………..24

32. ANNEXURE-I…………………………………………………………………………………………………………………………..…….25

3
 WORK PERMIT SYSTEM
1. INTRODUCTION
A Work Permit system is one of the most important tools to ensure that all the Jobs in a
hydrocarbon processing / Petrochemical industry are being executed in safest possible
manner to prevent injuries to personnel, avoid occurrence of Fire, damage to property and
environment within the complex. Work permit is considered as one of the most important
safety systems in almost all chemical industries. With the umbrella of work permit, the
awareness of personnel about safety in general, safety rules, dos and don’ts for the specific
job, hazards / risks involved in the job etc. comes in the mind of person who thinks to execute
the job safely. All jobs are to be carried out as per the Safety work permit system as per OISD-
STD-105 & 137.These standards supersedes all requirements of work permit system and
hence shall be applicable from time to time and to be adopted by plant personnel.

2. WORK PERMIT - OBJECTIVES

a) To ensure proper authorization of non routine works such as hot work, vessel entry,
excavation, work at height etc.
b) To enhance awareness of the persons planning to carry out the work, about the risks
associated with it and precautions and control measures shall be taken before starting as
well as during the execution of the job.
c) To ensure that the person responsible for the area is aware of all the work being done
therein, under work permit system.
d) To provide record showing that the method of working and precautions required have
been explained and same has been understood by the team for safe execution of the job.
e) To comply the legal requirements of Factories Acts, 1948 and Assam Factories Rules, 1950.
f) A Safety work Permit is intended primarily to safeguard people, property and
environment, but it also may be needed as evidence in case of claims etc. by the company
for legal compliance.

3. WHY WORK PERMIT?

Work permit system systems should be considered whenever it is intended to carry out
work which may adversely affect the safety of personnel, plant or the environment.
However, work permit system systems should not be applied to all activities, as
experience has shown that their overall effectiveness may be weakened. Permits-to-work
are not normally required for controlling general visitors to site or routine maintenance
tasks in non-hazardous areas.
a) BCPL, Lepetkata handles mainly hydrocarbons and a few nos. of flammable, corrosive toxic
chemicals, which possess special risks.
4
b) Each working persons should be adequately familiar with safe working methods, hazards
and risks associated in his assigned jobs and precautions needs to be taken to execute the
job safely without any untoward.
c) An authorized team is essentially required to safely carry out jobs as per HSE Policy of BCPL.
a) Prevent personal injuries and significant loss to the organization.
b) Avoid fire and explosion followed by human sufferings and materials loss.
c) Ensure that all Jobs are carried out in a safe manner.
d) Permit specifies the conditions and procedures as well as it defines responsibilities for safe
execution of the job.
4. WORK PERMIT REQUIREMENT (As per OISD- STD -105)
All Type of job are to be carried out as per the provision of OISD- STD-105 & 137.
A work permit is to be used when there is danger from:-
 Fire
 Sparks from open flames, welding, cutting, furnaces, etc.
 Explosive, corrosive or toxic gases or atmospheres
 Pressure systems
 Steam or other hot materials (burns)
 Use / isolation of Electricity and other energy sources
 Accidental start-up of mechanical equipment
 Oxygen deficiency or oxygen enrichment
 Suffocation or drowning (for example, in bulk material bins or chemical/solvent/catalyst
storage tanks)
 Restricted access, exit and movement
 Toxic substances
 Radioactive materials
 Lasers
 Temperature extremes
 Any other recognized serious safety or health hazard
However there are a huge no. of Jobs carried out in normal O&M and during shut down of plant
and a few of them are mentioned below.
a) Major or minor break down maintenance as well as repair work.
b) Scheduled Inspection/preventive maintenance.
c) Construction and project execution( as per nature and location of job).
d) Alteration/modification jobs.
5
e) Process equipment cleaning.
f) Entry into & exit from confined space.
g) Excavation / Road block /Road Cutting
h) Vehicle entry in battery limit of hydrocarbon/flammable liquid or gas handling & storage
areas as well as to work at height and on fragile roof/AC sheets.
i) Running of Internal Combustion engine without spark arrestor
j) Using Non spark proof tools

5. LOCATIONS WHERE WORK - PERMIT NOT REQUIRED (WORK PERMIT FREE ZONE)
a) Process activities being carried out by process personals within their plant.
b) Fire Station for routine activities
c) Fire Training Ground for live demonstration.
d) Day-today routine activities in any office/building within the complex.
e) Chemical laboratory for routine activities.
f) Workshop for day today/routine activities within the walls of workshop.
g) Schedule sampling by Quality Control Personnel as per approved SOP.
6. TYPES OF PERMITS IN BCPL
a) Combine Permits under Hot Work Permit etc: - (Hot Work Permit, Excavation Permit,
Vessel Entry Permit, Vessel Box-up permit, Vehicle Entry Permit, Work at Height).
b) Cold Work Permit
c) Electrical Energisation / Deenergisation Permit

7. FEATURE OF WORK PERMIT FORM

Hot Work permit form consists of the following features as per the provisions of OISD –STD –
105.
a) The original and duplicate/ triplicate copies (02 no.).
b) Original copy belongs to “Receiver /Executing Authority” – Pink Copy.
i. Second copy belongs to F&S representative – Green copy
ii. Third copy belongs to issuing authority – White copy.
iii. Copies contain printed serial no.
Cold work permit form consists of Original (Green) with a single copy (white).

6
 Sample format:

COLD WORK PERMIT

PERMIT IS VALID FOR SHIFT ONLY
A. Work clearance from : Hrs. Date :
B. Work clearance upto : Hrs. Date :
C. Issued to :
D. Description of work :

THE FOLLOWING ITEMS SHALL BE CHECKED BFORE ISSUING THE PERMIT

[Tick in the appropriate box. Checklist marks marked with asterisk (*) shall be complied by receiver]
Sr. Not Sr. Not
Item Done Item Done
No. Required No. Required
1 Equipment / Work Area inspected 6 Equipment water flushed
Surrounding area checked, cleaned Equipment properly steamed
2 7
and covered / purged

Equipment blinded / disconnected / Proper ventilation and

3 8
closed / isolated / wedge opened lighting provided

Equipment properly drained and Area cordoned off & caution

4 9*
depressurised boards / tags provided.

Equipment electrically isolated and Gas test: HCs / Toxic etc.

HCs : % LEL
5 tagged vide 10
Toxic gas : ppm
Permit no. --------------------------- Oxygen : %

Remarks :

The activity has the following expected residual hazards (Tick the relevant items): Lack of Oxygen / H2S, Toxic Gases /
1 Combustible gases / Pyrophoric Iron / Corrosive Chemicals / Steam – Condensate / Others
_________________________________________________________________________________________

Following additional PPE to be used in addition to standards PPE (Helmet, Safety Shoes, Hand gloves, Boiler suit): Face
2
Shield / Apron / Goggles / Dust Respirator / Fresh Air Mask / Lifeline / Safety Belt / Airline / Earmuff etc.
3 Additional precaution if any: ________________________________________________________________
Signature of the Signature of the
Name of Issuer and Designation Name of Receiver and Designation
Issuer Receiver

7
 Sample format:

WORK PERMIT FOR HOT WORK / ENTRY TO CONFINED SPACE /

WORK AT HEIGHT / EXCAVATION
PERMIT IS VALID FOR SHIFT ONLY
A. Work clearance from : Hrs. Date :
B. Work clearance upto : Hrs. Date :
C. Issued to :
D. Description of work :
THE FOLLOWING ITEMS SHALL BE CHECKED BFORE ISSUING THE PERMIT
[Tick in the appropriate box. Checklist marks marked with asterisk (*) shall be complied by receiver]
Sr. Not Sr. Not
Item Done Item Done
No. Required No. Required
For Hot work / Entry to
A General points A
confined Sp
Proper ventilation and
1 Equipment / Work Area inspected 1
Lighting providing
Surrounding area checked, cleaned Proper means of exit /
2 2 escape provided
and covered
Standby personnel
Sewers, manholes, CBD etc and hot provided from Process /
3 3
surfaces nearby covered Maintenance / Contractor
/ Fire / Safety dept.
Considered hazard from other Checked for oil and Gas
4 operations and concerned persons 4 trapped behind the lining
alerted. in Equipment
Remarks :
The activity has the following expected residual hazards (Tick the relevant items): Lack of Oxygen / H2S, Toxic
1 Gases / Combustible gases / Pyrophoric Iron / Corrosive Chemicals / Steam – Condensate / Others
_________________________________________________________________________________________
Following additional PPE to be used in addition to standards PPE (Helmet, Safety Shoes, Hand gloves, Boiler
2 suit): Face Shield / Apron / Goggles / Dust Respirator / Fresh Air Mask / Lifeline / Safety Belt / Airline / Earmuff
etc.
3 Additional precaution if any: ________________________________________________________________
Name of Issuer and Designation Name of F&S and Designation Name of Receiver and Designation

Signature: Signature: Signature:

8
8. PROCEDURE FOR WPS
a) WPS operate on the concept of Shift to Shift basis..
b) Separate permit for each type of work.
c) Permit is color coded and provide with unique serial no.
(However, being system generated in case of SAP in future, only color stamped for
identification)
d) Permit receiving authority is any one officer/engineer of minimum E-1 level and above
or a person duly authorized by concern area in-charge/departmental head.
e) Permit issuing authority is a concern area shift in-charge of minimum E-4 level and above
or a person duly authorized by concerned area in-charge as per Safety Management
System (SMS).
f) Work order/JIS no. to be mentioned on permit.
g) Location, drawing/sketch and approval by competent authority must be ensured by
issuing authority prior to issue of work permit in case of modifications or alteration jobs.
h) Physical verification of equipment/system by issuer is necessary before ticking the
hazard/risk evaluation checklist of the work permit.

9. WORK PERMIT
a) Executor has to initiate request/Job Intimation Slip (JIS) for work permit.
b) Duration, location, equipment tag no., nature of work should be indicated by receiver or
executor.
c) Identify the hazards associated with the job; evaluate the risk potential, tick the point as
applicable, special instructions in consideration of risk shall be mentioned in space
provided in permit to prepare the area/equipment to carry out the work.
d) Shift in charge to ensure and instruct his co-worker to comply the preparations required
prior to handing over of the system/equipment to execute the job by receiver. If work
will continue in next shift also, message must be recorded in shift log book.
e) Shift in charge(Issuer) after going through log book (as mentioned in the previous shift in
charge) & discussion with the previous Shift In charge and executor must inspect the
area, satisfy himself with preparations and then sign to extend the permit.
f) Permit to be received by executor after signing the permit.
g) Intimation of exact nature of job to be executed to be specifically mentioned in the work
permit along with the no of persons who will be involved in the said job to assess the job
safety requirements by all signatories of the work permit.
h) Hazards and risk associated with the job and residual risk still associated/perceived must
be communicated to the permit receiver. Job Hazard Analysis to be carried out in respect
9
 of critical job to indicate the residual risks and additional safety measures to be taken for
execution of the permit.
i) Issuer to carry out gas test, inspect the area, ensure compliance of various safety
precautions mentioned in the permit, before allowing the receiver to execute the job.
This is in addition to the gas test by Safety representative to ensure accuracy /
correctness of both the instruments & to ensure safety of human involved in the job.

I. Validity of work permit (As per OISD-STD-105)

a) Normal shift of 08 hrs. , However in the state of Assam beyond 5:00 PM the permit is
renewable after authorization from GM of concerned area/Plant in-charge up to 8:00PM.
(Normally, all permits are issued till the end of that particular shift only and later on it
gets renewed by the next shift personnel)
b) Normally, hot jobs in night shift are not allowed unless job is most urgent, and under
such circumstances written permission of H.O.D of the concern
plant/section/area/department is essential and express approval of Concerned General
Manager is mandatory beyond General Shift hours.
c) For each location /equipment, separate hot work permit is required in same process
units.
d) In offsite, distance exceeding 15meters, separate permit is required. (In case the area is
isolated and barricaded from each other and for entrance separate exit route is
required.)
e) Work permit shall be initially issued for a period of one Shift and shall be further
renewed.
f) On need base, out of battery limit, permit can be given for maximum 7 days subject to
renewal on daily basis for project job(only with approval from concerned GM.
g) Clearance to be given after physical verification / inspection of site by all signatories.

II. Who can sign a work permit

a) 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.
b) HOD s of concern Department.
c) All the shift in charge / officers (E-1 & above) as well as the nominated persons in writing
by concern HOD are authorized.

III. Issuing authority of work permit

a) Issuing authority is responsible for preparation and handing over of the equipment in
safe condition to perform the work.

10
b) Authority to issue all types of work permits is generally granted to shift in charge/
officers/engineers (E-4 & above).

IV. Executing authority of work permit

a) Request for a work permit by executing authority. He shall indicate types of tools and
equipment necessary for performing the work.
b) He shall also ensure his tools, equipment and accessories are in good condition and have
applicable valid test certificates and license.
c) No trainee (officer) can receive a permit.
d) All the working team members are provided with proper PPE and were explained the
hazards and risk associated with the job and precautions to be taken.
V. Preparation of the equipment
a) Equipment is electrically isolated must be ensured by all, the issuing, Electrical and
receiving (executing) authority through Electrical Lock out Permit
no_______dtd____________.
b) Inspection/analysis for cold & hot job by issuing authority :-
c) Positively isolated from steam, air, gas and other parts of process & utility etc. and blind
details to be recorded in the permit/ annexure to be attached.
d) Depressurized
e) Drained
f) Positively isolated / blinded.
g) Steamed, water flushed and purged with air.
h) Ventilated & gas freed.
i) Continuous inert gas flow / continuous adequate ventilation arranged.
j) Vehicle/ equipment in good condition with spark arrestor, valid licenses & all statutory
documents e.g insurance, pollution check ,fitness, road tax, road permit as applicable to
the vehicle.
k) Radiation source removed (confined space entry)
l) Pyrophoric ignition source deactivated by Nitrogen purging or wetting by water.
VI. Residual hazards
a) Lack of oxygen
b) H2s and / or any other toxic gases
c) Combustible gases
d) Corrosive chemicals
e) Steam / condensate
f) Pyrophoric materials
g) Energized wire/cable
h) Uncovered pit and extended/pointed objects above ground.
i) High humidity and abnormal temperature
11
VII. Protective measures
a) Protective clothing
b) Hearing protection
c) Safety harness
d) Head protection
e) Eye protection
f) Face protection
g) Respiratory protection
h) Installed fire equipment / system and stand by.
i) Barricading the affected area.
j) Removal of flammable and combustible materials
k) Cover with fire retardant tarpaulins/blankets
l) Adequate oxygen concentration in confined space/vessel.
m) Arrangement of airline set
n) Keep man ways open during work
o) Allow minimum possible no. of persons inside confined space.
p) To ensure positive isolation & maintain till the work in progress.
q) Ensure adequate ventilation
r) Display copy of entry permit nearby workspace.
s) GAS TEST FOR WORK PERMIT

VIII. Why gas test is required?

Most of the gases are unwanted. Hazards involved are
a) Flammability (Fire & Explosion)
b) Toxicity (health hazard)
c) Oxygen deficiency
d) Common flammable gases (Nat. Gas, Hydrogen etc.) / liquids (Naphtha etc.)available at
BCPL site
IX. Gas test for work permit
a) Natural Gas
b) Common toxic gases,
c) CO, Cl2, H2S etc.
d) Ethane, Propane, Butane etc.
e) Flammable substance and other hydrocarbons
10. GENERAL TERMINOLOGIES
I. Flash point
Minimum temperature at which a liquid gives off sufficient vapour to form an ignitable
mixture, which will produce a flash, flame in presence of a source of ignition.
12
 II. Auto ignition temperature
The lowest temperature at which a substance will ignite without a spark or flame.
III. Explosive limit
The concentration range of vapor in air when explosion (ignition) occurs in presence of an
ignition source.

IV. Lower explosive limit (LEL)

The lowest concentration (percentage) of a gas or a vapor in air capable of producing a flash
of fire in presence of an ignition source (arc, flame, heat). The term is considered by many
safety professionals to be the same as the lower flammable limit (LFL).

V. Upper explosive limit (UEL)

Highest concentration (percentage) of a gas or a vapor in air capable of producing a flash of
fire in presence of an ignition source (arc, flame, heat). Concentrations higher than UFL or
UEL are "too rich" to burn. The maximum vapor to air conc. above which propagation of a
flame will not occur (will not ignite)

VI. Gas test for work permit

Material LEL UEL F Pt. (C)

Hydrogen 4 75 Flammable Gas
Methane 5 15 −188 °C (−306.4 °F;
85.1 K)
Propane 2 9.5 -104
Naphtha 1.1 5.9 -18
Diesel .7 5.0 32-96
Fuel Oil 1 5.0 66

VII. Toxic substance

TLV (threshold limit value)/ PEL (permissible exposure limit): The maximum permissible
conc. Of a toxic substance to which exposure of a person in general will have no adverse
effect on health for working 8 hours per day.

VIII. STEL (short term exposure limit)

Maximum conc. to which worker can be exposed for a period of 15 min. Without any
adverse effect to health. Maximum two times in shift subject an interval of minimum one
hour.

IX. IDLH (Immediate Danger to Life & Health)

A maximum concentration from which one can escape within 30 minutes without
irreversible health effect.
13
X. Hydrogen Sulphide (H2S)
Highly toxic, flammable, colorless and smell like rotten egg.
a) Effect on Human Body:

Physical Effect Concentration in ppm

Can smell as rotten egg 0.13
TLV 10.0
STEL 15.0
Smelling sense will dry within 2 min. burning 150-200
sensation in eye & throat.
Other Vital information about H2S:

Long-term, low-level exposure may result in fatigue, loss of appetite, headaches, irritability, poor
memory, and dizziness. Chronic exposure to low level H2S (around 2 ppm) has been implicated
in increased miscarriage and reproductive health issues among Russian and Finnish wood pulp
workers, but the reports have not been replicated.
Short-term, high-level exposure can induce immediate collapse, with loss of breathing and a
high probability of death. If death does not occur, high exposure to hydrogen sulphide can lead
to cortical pseudo laminar necrosis, degeneration of the basal ganglia and cerebral
edema, Although respiratory paralysis may be immediate, it can also be delayed up to 72 hours.

 0.00047 ppm or 0.47 ppm is the odour threshold, the point at which 50% of a human panel
can detect the presence of an odor without being able to identify it.
 0.0047 ppm is the recognition threshold, the concentration at which 50% of humans can
detect the characteristic odor of hydrogen sulphide, normally described as resembling "a
rotten egg".
 10 ppm is the OSHA permissible exposure limit (PEL) (8 hour time-weighted average).
 10–20 ppm is the borderline concentration for eye irritation.
 20 ppm is the acceptable ceiling concentration established by OSHA.
 50 ppm is the acceptable maximum peak above the ceiling concentration for an 8 hour shift,
with a maximum duration of 10 minutes.
 50–100 ppm leads to eye damage.
 At 100–150 ppm the olfactory nerve is paralyzed after a few inhalations, and the sense of
smell disappears, often together with awareness of danger.
 320–530 ppm leads to pulmonary edema with the possibility of death.
 530–1000 ppm causes strong stimulation of the central nervous system and rapid breathing,
leading to loss of breathing.
 800 ppm is the lethal concentration for 50% of humans for 5 minutes exposure (LC50).
 Concentrations over 1000 ppm cause immediate collapse with loss of breathing, even after
inhalation of a single breath.

14
b) Explosive limits: 4.6 to 46%, it gives blue flame when ignited.
c) First Aid: If Inhaled: Remove exposed person to fresh air and administer oxygen
immediately.
d) Protection: Use air supplied mask in case concentration exceeds 10 PPM.
11. TOXIC GAS – CO
a) Toxic as well as flammable

TLV 50 PPM
STEL 400 PPM
IDLH 1500 PPM
LEL 12.5%
UEL 74%

b) Health Hazards: CO combines with hemoglobin of blood and makes it unable to carry oxygen.

c) Symptoms: Headache, dizziness to unconscious and ultimately death.

d) First Aid: Move to fresh air and apply oxygen at the earliest.

12. OTHER TOXIC GASES

Toxic Gas TLV STEL IDLH

NH3 25 35 500
SO2 2 5 100
Cl2 1 3 25
I. For hot work the gas test results should be:
a) Combustible – Below 1% LEL (preferably NIL)
b) For confined space entry:
Oxygen : 19.5 % minimum V/V
Combustible : Preferably nil or maximum 1% of LEL maximum.
Toxic Gases : Preferably NIL.

II. WORKS THAT NEED GAS TEST

a) Gas test are required for all hot work/vehicle entry and confined space entry permits and
some cold work also.
b) Issuing authority shall arrange gas test and decide the frequency of rechecking.
c) Trained gas tester/analyst shall carry out the test.
d) Responsibilities of Gas Testing authority.
e) To check and confirm that the gas testing instrument is in perfect working condition
before proceeding for the area/equipment.

15
 f) To carry out gas test at all critical locations/positions.
g) To advise on safe method to work inside/at the location i.e. further gas freeing and then
again testing.
13. ELECTRICAL ISOLATION
I. Before issuing a work permit, it is essential to ensure that the equipment/facility to be
worked on is electrically de energized and electrical power is isolated and locked out to
the extent necessary for the safe execution of the work.
II. Issuing, Executing and Electrical representatives shall jointly decide the extent of
isolation required.
III. ‘DO NOT OPERATE’ tag shall be pasted/ displayed on the equipment, when isolation by
local switch is decided as adequate protection.
IV. Multi-lock systems to be used when different crafts are involved. (This is towards best
safety practices.)

14. SPECIAL REQUIREMENT FOR WORKING WITH RADIOGRAPHY

I. Radiography to be carried out as per OISD guidelines – 192, cl. 6.14.
II. As per OISD guideline 105, cl. No 5.0.t, radiography with X-ray machine shall be carried
out under hot work permit. Cold work permit may be done with if it is done with
radioactive isotopes.
III. Advance intimation must be given by the work executing authority to the issuer so as to
make various safety arrangements for this job.
IV. Risk assessment to be carried out through checklist.
V. Hazards and associated risk of the surrounding area must be surveyed with the help of
Dosimeter for barricading.
VI. Barricade the surveyed area and provide adequate warning signs (RADIOGRAPHY WORK
IN PROGRESS).
VII. Film badges shall be worn by the person handling radiography equipment.
VIII. Job preferably during night time or at the time when no person around.
IX. Continuous monitoring of cordoned off area by stand by person.
X. Job execution with consent of concerned area shift in-charge only.

15. SPECIAL REQUIREMENT FOR HOT WORK

I. The person who is issuing the hot work permit is responsible for ensuring that the site
and the equipment are properly prepared to prevent the danger of fire/explosion and
toxic release associated with flammable and toxic material.
II. The equipment/system shall be emptied out and cleaned off flammable and toxic
materials and shall be isolated from other sources of hazardous chemicals by means of
disconnection, blanketing or positive isolation.

16
 III. Equipment and surrounding areas shall be checked with LEL Meter to ensure that these
are free from any combustible/flammable materials and containers containing or used to
contain such materials shall be shifted at safe location.
IV. Any heavy oil deposit, dried vegetation of other flammable/combustible materials within
15 Mtrs. of a hot work site shall be cleared and cleaned.
V. No hot work shall be allowed within a radius of 30 Mtrs. of any hydrocarbon sampling
point, drain or relief valve open to air.
VI. The outlets of the unit drains seals within 30Mtrs of the hot work shall be plugged.
VII. If welding or grinding is to be done at height, adequate precautions shall be taken to
prevent the spread/fall of sparks and molten metal with fire resisting or flame retarding
tarpaulin placed out of booth.
VIII. Welding spark and molten metal to be prevented from entering any drain or process
sewage.
IX. At operational area to carry out any welding / cutting job, booth made up of Non
asbestos cloth to contain the hazards of welding spatters/molten metal due to cutting to
be constructed.
X. A hose capable of reaching up to the hot work point and connected to fire water main
along with fire extinguishers shall be arranged.
XI. Fire Control Room shall be informed.

16. VEHICLE ENTRY

I. A hot work/vehicle entry permit is required for entry of any vehicle in hazardous areas
(process plant, storage and their battery limit area). Other such areas shall be clearly
demarcated with signs indicating “No Entry without Vehicle Entry Permit” and/or with
removable chain.
II. The signatory authorities shall ensure that all vehicles/equipment’s exhaust shall be
equipped with spark arrestors of approved type.
III. LEL of 15 M surrounding of work place where the vehicle will be deployed must be
checked and ensured NIL.
IV. Road movement permit clearance must be obtained from F&S control room.
V. Entry shall be allowed only for loading and unloading of materials and not for passenger
transport.

17. REQUIREMENT FOR CONFINED SPACE ENTRY

i. OISD guideline 105, Clause no.4.3 & OISD guideline 192, Clause no.6.6 to be followed.
ii.Firm erection and stability of the confined space / vessel to be ensured.
iii. Temperature of Confined space/ vessel to be made near to/same as ambient
temperature.
iv. The process vessel/equipment is to be positively isolated by blinding / removal of
spool piece from other parts of the process. For critical system, block and bleed type
17
 system to be introduced. Utilities of the plant already taken in to line. Any Nitrogen line
connected to the confined space to be positively blinded.
v.Shall be made safe for entry by depressurizing, venting, draining, steaming, washing,
ventilating and purging. Radiation sources, if any, shall be removed.
vi. Radiation sources if any, shall be removed.
vii. Any moving equipment inside the confined space like stirrer for reactor vessel to be
electrically isolated and brought to zero energy state.
viii. The atmosphere within the confined space shall be checked initially and periodically
(gas test) for hazardous chemicals NIL and oxygen concentration is satisfactory.
ix. Concentration of Oxygen and possible toxic / poisonous gases to be checked through a
calibrated instrument. After checking through one instrument, counter check to be
carried through another instrument. Periodic check to be carried out throughout the
working duration.
x. Oxygen concentration shall not be less than 19.5% vol. in air & it is to be checked with
the help two different instruments. Breathable atmosphere to be made available inside
the confined space.
xi. Concentration of possible toxic and poisonous gases shall remain within the limit.
xii. Illumination inside the confined space shall be adequate.
xiii. Lighting connections and fittings are of maximum 24 volts only.
xiv. Rope ladder/ladder for safe entry/access is to be made available at site.
xv. Use of safety belt by the person entering inside and a person to hold the life line of the
person is to be arranged (till the person is inside).Stand by person to be made available
at site. Use of DSU by the persons working inside and other safe communication means
to be ensured
xvi. Proper Scaffolding along with platform with side rail and emergency escape ladder
around vertical vessel manhole has been arranged (in case of no provision of permanent
platform and handrails around manhole of vessel).
xvii. Running air hose for continuous air purging of the vessel and exhaust arrangement as
applicable to be made to carry out at least four air change per hour. Alternate source of
air supply also to be made available at site.
xviii. No entry to be made inside the vessel without authorization from the BCPL permit
issuer & Fire safety representative.
xix. For working on loose, granular or powdered material inside any confined space
material working to be done on strong platform.
xx. At the Entry point one person shall remain positioned as standby during the entire
working duration along with all safety measure to initiate rescue for the person inside.
xxi. For welding cutting job inside the confined space local exhaust ventilation to be used.
xxii.Entry & exit of all personnel inside the vessel to be recorded in the format attached as
Annexure - I.

18
18. SPECIAL REQUIREMENTS FOR WORK AT HEIGHT

i. Work at height to be carried out as per OISD Guideline 192, Cl.6.8.

ii. Work at height involves the following works at height at places where secured platform
does not exists.
 Working on a flat roof.
 Working on a ladder.
 Working near excavation area.
 Working near or adjacent to fragile roof.
 Performing job on the top of a scaffolding platform.
 Working on a steel structure.
iii. Working at height can be avoided by
 Long handled tools or other equipments can sometimes be used to safely carry out
a task from ground level, e.g. a long handle bruss or roller for painting and water
fed poles with brushes for window cleaning.
 Whether it is possible to design the need to work at height, for example could new
or replacement services such as pipes or cables, be put at ground level.
 If you can’t avoid the need to work at height, you must try to make sure the risk of a
fall is prevented.
iv. Fall from height can takle place from
 Opening at floor
 Wall opening
 Side or edges, to be prevented by standard equipments and methods of (a) guard
rail,(b) Safety net and personal Fall arrestor system.
v.

19. EXCAVATION AUTHORISATION

I. Authorisation for excavation is required for all excavations. Detail drawings of the
underground facilities shall remain attached with the authorization if available.
II. For excavations more than 1.5 M deep, arrangement of steel shutters is required.
III. Gas test shall be done as confined space in case the depth is more than 2 M and the
work is within toxic/hydrocarbon/flammable materials handling gas area.

20. SUSPENSION OF WORK PERMIT

I. All work being executed under work permit shall be immediately stopped when an
emergency alarm is sounded or accident of any kind occurs. Approval from the F&S shall
be obtained after necessary preliminary investigations, to resume such work.
II. The work permit shall be revalidated to resume the work.

19
 III. Any responsible Officer of the BCPL or F&S is authorized to hold work and with draw the
work permit in case, safety regulations are violated or has sufficient reason to justify that
the work is being done to endanger the health & life of any person or loss to the
organization.
IV. If work is not started or is stopped for over two hours, the permit shall be revalidated by
the issuing authority.
V. On holding of work, concerned shift In-charge shall be communicated about the reason
for holding and additional precaution needs to be complied before restarting the job.

21. CLOSING AND FILING OF USED WORK PERMITS (RETURN TO ISSUER)

I. Permit closure: Duly filled and signed by both receiving/executing and issuing authority
on completion of work.
II. Copies of the closed permits shall be properly filed and kept with the respective
disciplines for at least one year from the date of closure. Different types of permits shall
be filed separately in chronological order in box files.

22. BASIC RESPONSIBILITIES OF ISSUING AUTHORITY

I. To prepare the equipment and properly tick the checklist items.
II. To identify and indicate any residual hazard still exists and which cannot be eliminated
should be communicated to the executing authority.
III. To advise on protective measures and mention the same on the work permit.
IV. To carry out gas test etc. wherever required and enter the result with signature, date
and time on work permit.
V. To discuss with and explain the risk and precautions to executing authority for safe
execution of the job.
VI. Advise the concern to carry out electrical isolation wherever required.
VII. Close the permit when the job is completed at end of permit duration or stopped, which
one is earlier.
VIII. To preserve the permit for next three years.

23. BASIC RESPONSIBILITIES OF RECEIVING/EXECUTING AUTHORITY

I. To clearly understand the conditions of the equipment and residual hazards.
II. To discuss the above with issuing authority and decide upon the protective/preventive
measures.
III. To explain the job and associated hazards& risk and recommendations to be taken to the
working team/persons for safe execution of the job.
IV. To ensure that procedures/precautions required for safe execution of job are being
followed.
V. To check and ensure that all the hand tools/devices/equipments/arrangements made
are healthy and adequate.
20
 VI. To make the permit available at work site till the work is continuing.
VII. To close the permit when the job is over or at the end of permit duration, which one is
earlier.
VIII. Close the permit with issuing authority.
24. BASIC RESPONSIBILITIES OF FIRE & SAFETY REPRESENTATIVE
I. Whether the exact location of area/unit & equipment has been mentioned clearly.
II. Detail description of work is properly documented.
III. All points of work permit have been properly ticked.
IV. Fire station has been informed.
V. Permit issued to which department, section or project – all mentioned.
VI. Equipment preparation – Equipment has been properly prepared, all checklist items area
properly checked and ticked.
VII. Residual hazards – Identified and ticked/indicated.
VIII. Protective Measures – Requirements identified and properly marked.
IX. Other details – like provision of continuous ventilation, additional precautions etc.
X. Advice additional safety precautions required to execute the work safely.

25. GAS TEST

I. Test for all probable gases present with equipments/systems and actual readings to be
recorded with signature, date and time etc.
II. Frequency of rechecking identified and to be carried out.
III. Electrical isolation required to execute the job has been carried out, tagged and
documented.
IV. Both issuing and receiving/executing authority signed mentioning name, signature, date
& time.
26. AUDITOR’S CHECKLIST
I. Running water hose, fire extinguisher and other fire protection systems of work site are
operational.
II. LEL of the equipment and area checked and found nil. Oxygen concentration is above
19.5% v/v.
III. Permit has been closed by both issuing and executing authority with date and time.
IV. Closed permits has been properly filed and being preserved for next one year.

27. ROAD CUTTING AND BLOCKAGE PERMIT

I. Request approved by executing and issuing area in-charge along with attaching
sketch/indicating methods of cutting and blockage.
II. By pass road for emergency vehicle approach constructed in case of road cutting.

21
III. Clearance certificate signed by concerned area in-charge, Maintenance / Civil / Electrical
/ TC / instrumentation and Fire & Safety have been obtained.
28. EXCAVATION AND DYKE CUTTING
I. Request approved by executing and issuing area in-charge by filling all the entries and
attaching sketch/indicating on reverse of permit form.
II. Clearance certificate signed by concerned area in-charge, Maintenance / Civil / Electrical
/ TC / instrumentation and Fire & Safety have been obtained.
III. In-charge, maintenance/Civil/Electrical/TC/instrument and F&S have been obtained.
29. TRAINING AND COMPETENCE
Permit to-work systems do not have to be a complex process, but require continual use and
practice to reinforce workmen risk awareness and enhance safety performance.
Effective training is essential to achieve quality and consistency in the use of the work permit
system. There should be successive levels of training for those involved. Training provides
the foundation for effective implementation of a work permit system and supports user
competence. Training is the first step for work permit users — the continued participation of
all relevant employees in BCPL is necessary to improve understanding and system
ownership.
Engineers and Operators should take opportunities to share training where appropriate, to
encourage good practice and the harmonization of work permit system.
 Why: – to ensure that all relevant people are able to become competent and sufficiently
involved in the work permit system (OISD-STD-105); – to ensure understanding of the
hazards associated with the working environment and the necessary controls; – to drive
awareness and increase personal levels of risk perception which influence behavior; –
communicate work site hazards and risks through participation; – to allow cross-industry
sharing – especially of solutions.
 Who: – all workers who actively take part in and contribute towards the work permit
system; – new and transient personnel who may be required to participate in permit
activities during their time at site.
 What: – the principles of a work permit system; – when permits are required; – an
understanding of the types of permits, supporting various approvals and other
documentation (eg, Job Safety Analysis, risk assessments and method statements); –
responsibilities and competence requirements for signatories or authorised people
within the work permit system. An assessment of competency should cover practical
and thinking skills as well as knowledge. Training should focus on use of the work permit
system, but must also ensure that the individual understands the working environment,
the hazards associated with it, and more importantly, the controls required to
appropriately manage the risks presented by those hazards. These elements of
competency need to be demonstrated prior to work permit system training for issuers; –
responsibilities of permit users; – lessons from incidents associated with permits-to-
work and findings from audit and review.
22
 Where: – a quiet area, on site or at a suitable alternative location, for a detailed
explanation of the work permit system process and the completion of documentation; –
in a room, an office, in a variety of environments that will enable the training to be
practical in nature and to focus on work permit system requirements, types of
documentation, hazard identification and necessary site or equipment precautions .
 When: – as part of an induction and prior to undertaking any work authorised under a
work permit system, to ensure an understanding of the system and enable participation;
– prior to becoming an authorised person for work permit system signatures; –
refresher training is required after revalidation of individual competence and after
further assessment of competence based on individual needs as required by established
company performance standards, eg after a change in the system or following a system
audit.
 How: A combination of common training approaches should be employed, including: –
classroom presentations; – videos; – mentoring or coaching (e.g. on-the-job training); –
practical exercises; – computer-based training on SAP module; – coaching.
 Once training has been given, competence should be tested to ensure that satisfactory
standards have been achieved by the trainees. In addition, competence should be re-
tested at appropriate intervals.

 It is common practice for authorised issuers who are undergoing training to have their
work permit countersigned by experienced issuers for a period of time after training,
and for a trainee issuer to be asked to demonstrate an appropriate level of competence
to a line manager.

 Records of training and competence assessments should be kept, as they will be of

benefit for recording whether individuals are competent to perform particular roles
within work permit system.

30. MONITORING, AUDIT AND REVIEW OF WORK PERMIT SYSTEM

 The ultimate success of the work permit system depends on the awareness of the
employees carrying out the activity in BCPL. If the employees do not have a sound
understanding of permit or isolation requirements, what it means to them and what
their responsibilities are, the system will have a limited effect on preventing accidents.

 work permit system, approvals, JSA and risk assessments should be retained at site by
the issuing authority for at least 90 days after completion, and then archived for a
specified period(3 Years) to enable an effective monitoring and audit process.

 In addition to checks carried out by issuers, work permit system monitoring checks will
be undertaken by internal Safety audit team and supervisors to validate compliance
with detailed work instructions and control measures. Information gained from permit
monitoring will be used to reinforce safe working practices at site. Monitoring records

23
 should be archived at site, and reviewed during periodic work permit system audits
(once in a year by Internal Audit team).

 Work permit system will be reviewed regularly to assess their effectiveness. This review
will include both leading and lagging indicators as well as specific incidents that could
relate to inadequate control of work activity.

 The work permit system should be audited regularly (once in a year), by internal safety
audit team and who are familiar with local Safety management system (SMS)
arrangements. The audit process will examine monitoring records. Non-conformance
with the work permit system should be recorded as per OISD STD-105, and subsequent
remedial measures tracked to ensure all issues are effectively closed out.

 Management of BCPL will be notified immediately by issuer/Fire and Safety

representative/receiver/ any HOD, if any non-conformance is identified during routine
monitoring or auditing, which cannot be immediately resolved.

 System reviews, undertaken at least every three years with site and corporate
management, should consider audit reports and recent industry information (e.g.
learning from incidents, Mutual Aid partner/industry workgroups and other safety
alerts).

24
Annexure-I

25