Professional Documents
Culture Documents
P1085
NO.
CLIENT: CRUDE OIL TERMINAL AND
ASSOCIATED FACILITIES AT MUNDRA,
PROJECT
GUJRAT (EPCC-11) FOR HPCL
TITLE
RAJASTHAN REFINERY LIMITED
(HRRL)
PMC:
LOCATION MUNDRA, GUJRAT
DOC TITLE.
EPC PTW PROCEDURE
CONTRACTOR:
DOC No:1085-020-S01-601-009
NO. OF
SHEETS:12
Contents
1. Purpose............................................................................................................3
2. Scope................................................................................................................3
3. Definitions........................................................................................................3
4. Reference Documents.....................................................................................4
5. Responsibilities................................................................................................5
6. Instructions....................................................................................................10
7. Appendix........................................................................................................13
1. Purpose
The purpose of this procedure is to provide Permit to Work system requirements to be used
for construction and pre-commissioning activities where permits to work are necessary to
control work activities.
2. Scope
This procedure applies to all potentially hazardous work carried out on the Project
work sites whilst they remain under the operational control of CONTRACTOR.
All areas designated as “operational” and under the control of OWNER shall work
to the OWNER Permit to Work System.
3. Definitions
CONTRACTOR Chemie Tech DMCC
PMC/OWNER EIL/HRRL
AGREED Agreed between CONTRACTOR and
PMC/OWNER. SUBCONTRACTOR Appointed Contractors and lower-tier
contractors.
PI Authorised Issuer
(CONTRACTOR Authorized Permit to Work Issuer)
AGT Authorized Gas Tester
COM Commissioning Manager
PMC Project Management Consultant
MOC Management of Change
PTW Permit to Work
HSE Health, Safety and Environmental
PM Project Manager
PD Project Director
CM Construction Manager
SME Subject Matter Expert
PE Professional Engineer
RCM Resident Construction Manager
RA Receiving Authority
JSA Job Safety Analysis
HIRAC Hazard Identification & Risk Assessment & Control
AA Approving Authority
WL Work Leader
PA Permit Applicant
AAR Approving Authority Representative
RAR Receiving Authority Representative
4. Reference Documents
International Standards
ISO 14001 (Environmental Management System)
ISO 45001 (Occupational Health & Safety Management System)
National Standards
The Factories Act and concerned Factory Rules
The BOCW Act and rules
The Petroleum Act and Petroleum Rules
The Indian Explosives Act and Rules
The Motor Vehicle Act and Central Motor Vehicle Rules
The Workmen Compensation Act
The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
The Indian Electricity Act and Rules
The Indian Boiler Act and Regulations
The Water (Prevention & Control & Pollution Act)
The Air (Prevention & Control of Pollution) Act
The Atomic Energy Act
The Radiation Protection Rules
The Indian Forest Act
The Wildlife (Protection) Act
The Environment (Protection) Act and Rules
The Hazardous Wastes (Management & Handling) Rules
The Manufacturing, Storage & import of Hazardous Chemicals Rules
The Public Liability Act
Indian Standard Specification of Drinking Water
CONTRACTOR DOCUMENTS
HSE PLAN
TRAINING PROCEDURE
EMERGENCY REPONSE PLAN
PROJECT HIRAC
TRAFFIC MANAGEMENT PLAN
CHEMICAL MANAGEMENT PROCEDURE
PERMIT TO WORK PROCEUDURE
ENVIRONMENT MANAGEMENT PLAN
LIFTING PROCEDURE
WORK AT HEIGHT PROCEDURE
HOT WORK PROCEDURE
EXCAVATION PROCEDURE
5. Responsibilities
When an activity is defined for a certain position in this procedure, the
responsibility remains with that person although a designee may perform the
implementation of that activity. The appointment must be recorded, and the appointed
designee must report directly to the assigned individual.
Evaluate work activities and determine the schedule from when these Permit to
Work procedure/requirements shall come into force for commissioning activities
Those who shall be listed as Permit Issuer and shall Issue permit for the area
specified, should be;
Experienced and familiar with the work activities for which the permit is to
be issued
Capable of evaluation of work activities and scheduling the introduction of
the Permit to Work and various checklists.
Able to coordinate with the Area Construction Manager the development of
Work Instructions (WI) to cover the transition and interface
communications in advance of the transfer from construction led to
commissioning led activities in the field.
Clearly identifies the positions within CONTRACTOR and SUB-
CONTRACTOR organization and the roles and responsibilities in
implementing this procedure as indicated below:
Responsible for ensuring the effective implementation, dissemination and
education of the requirements throughout the CONTRACTOR and SUB-
CONTRACTOR organizations.
Able to ensure retention of all permits for a period of Project completion.
Trained and certified to issue Permit to Work,
Familiar with hazards associated with the work activities in their area.
Able to review all relevant Permits to Work and documentation.
Able to discuss scope of work with the Area Construction Manager.
Able to ensure a physical check of the area along with the HSE,
Permit Approver, assigned by them, prior to the issuing of a PTW to a
Task Supervisor,
Able to coach the Permit Applicant on the use PTW system
Sub-Contractors
Sub-contractors shall understand and comply with the Health, Safety and
Environmental requirements of this procedure applicable to the work
they perform.
Sub-contractors must report to their supervisor any equipment
malfunction or event that may affect the safe operation of the equipment.
They are empowered to stop work at any time.
Sub-contractors must advise their immediate Supervisor whenever
unsure of the instructions for a task or where concerned about the safety
status of any task.
Sub-contractors to ensure valid PTW available prior to work start.
6. Instructions
Examples of activities that require a Permit to Work are all activities except:
Site-wise Housekeeping.
Emergency Rescue Works.
Permit Applicants – Be able to read and speak basic English and carry out
JSA/risk assessment for tasks that will be performed by him.
Permit Approvers – Be able to read and speak basic English and carry out and
approve the risk assessment for tasks that will be performed by him.
Permit Coordinator - Be able to read and speak basic English and carry out,
approve and ensure adequacy of risk assessment for tasks that will be performed by him.
Permit to be used:
General Permit to Work: This permit will be used to perform works
exceeding one day at COT with a maximum validity period of 7 days. The
works envisaged are other than high risk and these permits are endorsed
by all the signatories, i.e., Authorised persons mentioned on the permit
form.
Confined space Permit to Work: All works in confined space shall be
performed by competent persons only, using the confined space permit.
This permit will be used to perform works exceeding one day at COT
with a maximum validity period of 7 days provided atmosphere test
conducted by AGT in a frequent interval.
6.3 Clearance Certificates
When there is a need to perform high risk work under the General permit to work,
clearance certificates as described below will come into force. The certificate shall have to
be obtained for the high-risk work that will be executed during the currency of the
General permit to work and will be valid for 7 days. It is mandatory to cross reference the
general permit to work number in the clearance certificate. The different types of
clearance certificates are listed below.
Hot work certificate: Required when Hot work is to be performed, e.g., welding,
grinding operations.
Lockout Tag out certificate: Required during energy isolation tasks.
Work at height certificate: When work is being performed in such a manner that
exposes workers to fall through a distance greater than 2 m, this clearance
certificate shall be used.
Excavation clearance certificate: Required for any excavation at the work site.
Lifting Certificate: Required whenever lifting activity has to be performed.
Radiation Certificate: Required when carrying out activity involving exposure of
workers to ionization / radiation, e.g., NDT of weld work. This permit will be
used to perform NDT works for one day at COT.
All additional Checklists must be attached to a General Permit to Work and shall
form part of the Permit to Work.
The completed General Permit to Work is the final but to acquire authorization to
proceed, all relevant checklists, drawings and documentation must be attached to the
Permit to Work prior to authorisation to proceed being given.
6.5 Termination
Requirements set forth in the Permit to Work are not effective (Permit to
Work withdrawn).
Working conditions change.
Scope of work is changed.
Unsafe or emergency conditions occur in the work area.
Upon termination of the work activity, the Permit to Work and all other certificates
shall be returned by the Task Supervisor to the Issuer. The Permits to Work shall be
retained and archived by the Permit Issuer for Project completion period and produced for
verification when required by OWNER / CONTRACTOR. It is a legal document and
must be produced during any investigation of incident, if any.
Any permit that lapses 02 consecutive days will be automatically revoked and a
new application will be required.
If work is stopped for any continuous period exceeding 1-day, new permit need to
be applied.
7. Appendix
General Permit to Work Form
Confined space entry Permit
Hotwork certificate.
Lockout Tagout certificate.
Work at height certificate
Excavation clearance certificate
Lifting Certificate
Radiation Certificate
Specialised / Rescue Equipments(if any): Permit validity (where work is going to last more than the duration of a day)
Permit Coordinator & Permit Applicant confirm by signing that the precautions required to work safely have been complied with prior to starting work each
day / work period and confirms that the work areas have been left in a safe condition and all staff has left the site.
Contractor List – Permit Applicant & Task supervisor to ensure their staff on site have made themselves familiar with the permit conditions, the work area
and the hazards of the work.
PERMIT APPLICANT Task Supervisor (Contractor)Permit Applicant Daily Close Out
Checklist Name : Company : Job Title : Date / Time Permit Applicant HSE Supervisor
Underground utilities Overhead power lines Rescue equipments Access and Egress Flammable materials
Task Supervisor:
Cutting
Nitrogen pressure test / DrillingFlow
Pressurised Housekeeping Adjacent
Lines Scaffold works
required Hydrostatic test
Noise Overhead works Grinding / Welding
Barricade/ Warning Signs
Hot Surface Hydro Jetting
Fire extinguishers
Grit blasting Banks man / Warden Lifting / Crane activities
OTHERS:
Lighting
Electrical activities
INSTRUCTIONS FOR APPLICANT
Extended working hours are works to be carried out between 1900hrs – 2200hrs only.
SIMULTANEOUS OPERATIONS Extended Working Hours Date / Time Task Supervisor (Contractor)
Adjacent Issuing Authority (Zone) Permit Applicant HSE Supervisor Permit Approver
Commissioning Working Along Boundaries
Permit No:
I/C Name: Signature:
Permit No: I/C Name: Signature: Permit No: I/C Name: Signature:
Date Date:
ID / Tag Number: ID / Tag Number: ID / Tag Number: I hereby declare that all works for which this permit was issued has been Completed / Cancelled / Renewed, all personnel under my control have been
withdrawn and the work area and any associated equipments has been left in a safe condition.
YESNO YESNO YESNO
Permit Applicant Permit Coordinator Permit Issuer
Pressure free Locked off Isolated Locked off Isolated Disconnected
Name: Signature:
anked off Locked off Flushed See Isolation certificate: Bypass
Date: Name: Name: Name:
Ventilated, specify: No. of Isolation Certificate/s:
Communications Requirements:
The Attendant must be able to communicate with the worker(s) inside the confined space at all times. Check (√) means of communication to be used:
RadioVoiceVisualOther (Specify):
Should the Attendant be unable to establish communications after several attempts, activate the Rescue Plan
Description of Work: Attachments - Clearance CertificateYesNo
Hot Work
Excavation
Radiation We have reviewed the work authorized by this permit and the information contained here, written instructions and safety procedures have
Safeguard Override been received and are understood.
Isolation LOTO
Work at Height
Permit Applicant (Site Engineer/Task Supervisor)
Permit Coordinator Permit ApproverPermit Issuer
Name: (HSE) (Superintendent/Designate)(Project Director / CM/Designate)
Lifting
Name: Name:Name:
LOCATION: (Attach drawing/sketch as necessary) ADDITIONAL PPE REQUIRED Signature: Signature: Signature: Signature:
Exact location of work: YESNO
Face Shield Chemical Suits N95 Respirator Date: Date: Date: Date:
Area
Cartridge Respirators Leather Gloves Neoprene Gloves Rubber Boots Eye Protection
Ear Protection Breathing protection (SCBA) Others (specify):
Time: Time: Time: Time:
Any additional PPE required shall be included in the MS & RA.
Permit validity
Equipments to be used: Permit Applicant confirm by signing that the precautions required to work safely in confined space have been complied with prior to
starting work each day / work period and confirms that the work areas have been left in a safe condition and all staff have left the site.
Contractor List – Task supervisor to ensure their staff on site are familiar with this permit to work conditions, the work area and the
hazards of the work.
Specialised / Rescue Equipments(if any): Gas Tests Performed by AGT: Name: Date/Time:
Electrical
Ionizing Radiation (X-Ray) Below Ground Level (Cave In)
Type:
(Additional other than those installed in the plant/work area),
The working area is defined with barriers or signs to prevent un-authorized entry/encroachment
Suitable spark containment, ARC shields/screens and Fire Blankets provided
Name:
Designated fire watch is assigned and understands their role.
Fire watcher remains on site for 15-30 minutes observation after work has been completed
Area within 15 meters of ignition sources are free of flammable materials or such materials are covered with fire retardant material Sewer m
HOT WORK IGNITION SOURCES (mark the applicable sources for the work being performed)
WeldingBlazingGas CuttingGrindingOther
LEL Testing Results during the Hot Work: Work to be halted if LEL readings are MORE than 1% LEL If non continuous testing is done sp
Time of reading:LEL readingTime of readingLEL readingTime of reading
LEL reading
Other Atmospheric Testing results if required: enter any potentially toxic gases to be monitored below in blank Reading
Time of reading:O2 ReadingTime of reading: ReadingTime of reading: Reading
VALIDITY OF THE HOT WORK PERMIT: I certify that I have reviewed the proposed work and I am satisfied that the workers understand th
Hot work as described in the Permit to Work is allowed between: From: To:
Name
Signature Date/time
Permit Applicant: Permit Approver
Task Supervisor
HSE Supervisor
Energy Type Isolated: Mark below (√) the type of energy to be isolated:
Electrical Steam Hydraulic Mechanical Pneumatic Other
Method of Isolation: Mark below (√) isolation being used
Other
Lock & Tag Tag Only Blinds Double Block & Bleed
_
1) Prepare for shutdown, 2) Equipment shut down, 3) Identify all equipment isolation points, 4) Apply L/O-T/O
Sequence of Lockout: device(s), 5) Release stored energy, 6) Verify equipment will not start, 7) Perform work, 8) Clear tools,
inspect equipment, 9) Clear personnel from area, 10) Remove lock out/tag out devices, 11) Restart
equipment
AUTHORIZED INDIVIDUALS (Individuals doing the Lock out/Tag out including verification of zero energy state– If more signatures are require
I certify that I have reviewed the proposed work and I am satisfied that the workers understand the hazards and that preventive measures are in place
with adequate supervision to proceed. The Isolation Work is allowed between:
Permit Approver
Adjacent Issuing Authority: :
RECONNECTION
I have verified that the equipment under Lockout/Tagout is no longer locked or tagged, has been re-connected and is in safe working condition.
Name Signature Date/time
Permit Applicant: Permit Approver: HSE Supervisor:
Task Supervisor:
Isolation points must be recorded. This is to assist in identifying and recording any lock out or tag out points used. This record is useful prior to beginning
work and at completion of maintenance work (prior to return to normal operation) by creating a useful check to assure all locks and tagged devices have
been returned to their safe operating state (inclusive of vents and drains) prior to restart. Check (x) “Blind Installed” column only for isolation points using a
blind.
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COMMENTS
Reference Serial No.
COT PROJECT
D WORK AT HEIGHT CERTIFICATE
Permit To Work No.
Location of work:
Description of work: Date / Time:
FIELD CHECKS (To be carried out before any Work at Height activities) (Tick where applicable)
YES NO COMMENTS
1 Can Engineering controls be applied, secure platform,
scaffolding, Mobile Elevated Work Platforms (MEWP)?
2 Are persons working exposed to unprotected edge?
3 Are hard barriers and warning signs required and displayed?
4 Are alternative walkways and emergency egress/exit routes identified?
5 Is there any barrier/ scaffold that require modifying or
removing? Is there a potential for objects to fall from height?
Tools fitted with lanyards / Contained?
6 Debris nets
Screened scaffolding?
Can objects be prevented from striking people below?
7 NO GO ZONES
Overhead protection
8 Standby person be required below work location?
9 Proper means of transferring tools and materials to working platform
at height been considered?
Have fall restraint and fall arrest differences been properly identified and
10 suitable equipment selected?
11 Equipment in good condition, inspected and tagged?
12 Are suitable anchor points identified? Inspected and serviceable?
13 Are rescue equipment’s readily available around work areas?
14 Are you using a ladder within the ladder length of a handrail or moving
equipment?
15 Is the ground level stable & ladder secure from falling over?
17 Are personnel trained in work at height and safe use of equipment?
18 Any of the person carrying out the work suffer from any condition that
may impede his/her ability to work at height E.g.( Vertigo, Epilepsy )
19 Communication link has been established with Site Control Room and
Emergency Response Team
20 Are rescue equipment’s readily available around work
areas? Additional Checks / Comments Required:
VALIDITY OF THE WORK AT HEIGHT CLEARANCE: I certify that I have reviewed the proposed work and I am satisfied that the workers u
Work at heights as described in the Permit to Work is
From: To:
allowed between:
Name Signature Date/time
Permit Applicant: Permit Approver: HSE Supervisor:
Task Supervisor:
a) Document below additional controls not otherwise included in this PTW to address job specific threats including: 1.
measures to minimize weather impacts on cave-ins, 2. provisions for safe access and exit for personnel who enter
the excavation, 3. additional rescue and emergency response provisions, 4 other threats specific to the job
Additional space to communicate via sketch information about hazards/threats and controls:
Validity of the Excavation Permit: I certify that I have reviewed the proposed work and I am satisfied that the workers understand th
Excavation Permit is allowed between:From:To:
NameSignatureDate/time
Permit Applicant: Permit Approver: HSE Supervisor:
Task Supervisor:
Description of Lift
Description of Load
(including hook, rigging, etc.) TONS
MAX. Working Radius
Boom Length SWL (load chart)
metres metres TONS
RemarksCrane Capacity
(if any)Used %
FIELD CHECKS (To be carried out on site before the actual lifting) (tick where applicable)
YES NO COMMENTS
Are lifting accessories (such as shackles, hooks slings) certified and free from visual signs of damage or deterioration?
Are the JSA/Risk Assessment and Lifting plan available and approved?
Are the involved equipment and accessories (i.e. slings, spacers, etc.) as indicated in the approved Lifting Plan?
Are the involved equipment (cranes, trailers with load, etc.) positioned according to approved Lifting Plan?
Is the daily crane checklist filled by the crane operator & the defects, if any, are reported & corrected?
Have the lifting crew been briefed on the safe lifting procedures?
Are the outriggers fully extended & approved pads provided?
Has the work area been barricaded with warning signs or other means of controlling pedestrian, vehicle or vessel traffic?
Has all environmental and SIMOPS hazards been identified? (including weather, visibility/lighting, traffic/human movement and other work act
Are all key personnel involved in the lifting identified and fit to work?
C
Emergency Contact Info:
Survey meter
Reading: mR, Calibration till:
Collimator
Audible warning devices
Emergency tool kit available
Tongs
Blinking warning lights available?
Area is defined with barriers and signs to prevent
un-authorized entry/encroachment
Are radiation workers wearing their film badge?
Prior to use all equipment is to be inspected and after each exposure both the camera and guide tube are to be surveyed
ensuring the source is in the shielded position. The radioactive source shall not be left unattended
Radiography will not commence until all safety requirements have been confirmed and all irregularities during work must
be reported immediately to Permit Issuer.
Date/Time: Reason:
Signature:
Date: Name:
Signature: Date/ Time: