HSE WORKING PERMIT PROCEDURE

A. Log Out / Tag Out ( LOTO )

1.0 INTRODUCTION

1.1 This standard instruction shall apply throughout the organization

and shall cover all types of facilities for locking out and tagging
out equipment and electricity during maintenance and repair.

2.0 PURPOSE

2.1 The isolation of all hazardous energy sources while services or

maintenance is performed.
2.2 To protect employees from the possible release of stored energy.

3.0 RESPONSIBILITY

3.1 The HSE Committee shall be responsible to the contents of this

standard instruction.
3.2 The HSE Committee / Project HSE Manager concerned are
responsible to ensure that this standard instruction is followed
within the worksite.
3.3 Project HSE Manager / HSE Officer shall advice on the
administrative of lock out and tag-out programmer and compliance
to the legal and other requirements.
3.4 All employees and contractors / subcontractors concerted are
responsible to comply with this standard instruction.
4.0 STANDARD INSTRUCTION

4.1 Instruction

4.1.1 Workers engaged in any of these activities are covered by

lockout / tag out when any of the following conditions
occur :
a ) The employee must remover or bypass guards or safety
devices ;
b) The employee is required to place a part of their body in
contact with the point of operation of a machine or piece
of equipment ; or
c) The employee is required to place a part of their body
into a danger zone associated with a machine operating
cycle.

4.1.2 Before working on any machinery or equipment authorized

employees must notify the project manager in the event of
any connection or disconnection of machine or appliances.
4.1.3 Connect or disconnect energy source(s) for any machine or
appliances.
4.1.4 The electrician shall with the Project Manager prior to any
connection /disconnection.
4.1.5 The electrician shall fill-up Lockout / Tag out Permit
before confirmation.
4.1.6 Then electrician shall connect / disconnect the relevant
sources or control and display the paper caution notice and
lock the system with padlock.
4.1.7 Periodic inspections should be performed to evaluate the
effectiveness of the lockout / tag out programe.

4.2 Verification
 4.2.1 Verification of the complete job will be done by Project
Manager / Contruction Manager / Project HSE Manager /
HSE Committee.

B. HOT WORK

1.0 INTRODUCTION

1.2 This procedure covers the requirements for hot work

performed by employees and contractors.

2.0 PURPOSE

2.1 To establish procedure for employess and contractors during

cutting, welding, brazing or other hot work operations.

3.0 RESPONSIBILITY

1.3 The Project Managers / Contruction Manager concerned shall be

responsible for the contents this permit-to-work.
1.4 The project Managers / Contruction Manager concerned shall be
responsible to ensure the implementation of this Permit-to-work.
1.5 The project HSE Manager concerned shall coordinate the
implementation and management of this Permit-to-work.
1.6 HSEO shall advice on compliance to legal and other requirements.
1.7 All employees and other relevant interested parties concerned are
responsible to comply with this procedure.

4.0 STANDARD INSTRUCTION

5.1 Hot Work Permit Instruction

5.1.1 Welding, cutting, brazing or other open flame work will not
be curried out without Hot Work Permit.
 5.1.2 The authorization and issuance of the permit will be done
by Project HSE / Site Safety Supervisor.
5.1.3 This permit is valid until work is completed. Permit to be
returned to HSEO / Site Safety Supervisor.
5.1.4 Verificaton of the completed job will be done by HSEO /
Site Safety Supervisor.

5.2 Gas Welding.

5.2.1 Protection from gas Welding Hazards

a) Eyes and Burns

i- Wear eye protection with a filter shade suitable for

gas welding.
ii- Wear welding gloves and overalls
iii- Chalk a warning into hot metal so others will not
touch it or stand on it.

b) Fires in the General Work Area

i- Before starting work ensure there are no

flammable liquids (solvents, petrol, kerosene etc.)
or combustible materials (rags, waste) near to your
work area.
ii- Do not leave a lighted welding torch unattended,
or hung over the gas bottles or regulators.
iii- Fires in the confined space
Never use pure oxygen, acetylene or propane to
freshen the air in a confined space. If oxygen
levels in the air exceed 21%, fires can start very
easily, and a welder’s clothes can easily ignite.
Where this can not be done, the oxygen and
acetylene connections shall be disconnected at the
 cylinders situated outside of the confined space.
Closing the velve is not a disconnection.

c) Heat Stress

i- Provided shade if welding or burning in the open.

d) Fumes and Welding Gasses

i- In poorly-ventilated areas, welding fumes can be

hazardous. Nitrogen dioxide and carbon monoxide
gases can build up in a confined or poorly-
ventilated space.
ii- You must follow the confined space permit-to-
work when working in a chamber, tank, manhole
or similar space and use mechanical fume
extraction in poorly ventilated areas.
iii- If welding lead, galvanized metal or coated metal,
fumes may be dangerous. Wear a rspirator
(suitable for welding fumes) or use a portable
welding fume extraction unit.

5.2.2 Explosions Due to Flashback

a) Uncontrolled burning of gas back through the blowpipe

mixer causes flashbacks.
b) A flashback can damage your welding equipment and in
the worst situation if the travels back into the fuel-gas
cylinder, it can cause the cylinder to explode.

c) To protect against flashbacks always use the following

instruction:

i- Ensure all connections are right.

 ii- Ensures all cylinder valves are open and all
blowpipe valves are closed.
iii- Set regulators to the required pressure.
iv- Purge each hose separately by opening the
blowpipe valve and allowing gas to flow out until
only pure gas remains in the hoses.
v- When complete close the valve for each gas.
vi- Only carry out this exercise in the open-air or well
ventilated area.
vii- Ensure there is a flashback arrester or non return
valve on the fuel gas line and the oxygen line as
well.
viii- Oxygen and acetylene hoses shall be turned off at
the cylinder valve anytime the equipment is not
being actively used. A check valve shall be
installed in both the oxygen and acetylene lines. A
flashback arrester shall be installed adjacent to the
acetylene regulator valve.

d) Should a flashback occur :

i- First turn off the blowpipe oxygen and then the

acetylene.
ii- Check for cylinder heating. If it is hot, cool with
water and evacuate others from the immediate
area.
iii- When flashback into hose occurs, the hose should
be replaced and all equipment checked before
reusing.

5.2.3 Explosions Due to the Incorrect Use or Storage of Gas

Cylinder

a) Grease ignites rapidly if it comes in contact with pure

oxygen.
 b) Acetylene can react with copper and silver to form
explosive compounds.

c) Acetylene itself can become unstable and is stored in

special cylinder with liquid acetone . If the cylinder is
left on its side, the acetone can leak out which may
make the acetylene unstable.

d) Heating of fuel gas cylinder can also cause explosions.

e) Oxygen and acetylene shall be stored separately in an

upright position, protective caps on and secured in place.
Preferably, the oxygen and acetylene shall be stored in
separate well ventilated areas. A minimum of 20 feet or
a non-combustible wall should separate the two types of
cylinders.

5.2.4 Release of Gases Under Pressure

a) Both fuel gases and oxygen are stored under very high
pressures.

b) If a cylinder is dropped and the valve breaks, the

cylinder can become a dangerous missile. They have
been known to smash through brick walls.

5.2.5 Cylinder Safety Rules

a) Do not oil or grease the valves or seal the thread with

tape.

b) Check the gas content in the workshop before carry to

site.
 c) Ensure there are any sign in the bottle gas mentioned the
content of the gas.

d) Do not drop or throw gas cylinders.

e) Secure cylinders against falling and store upright.

f) Keep cylinder away from flames and heat.

g) Use proper trolleys for moving cylinders.

h) Do not use chains to lift cylinders. Lift in proper frames

or carriages only.

i) The cylinders shall be in a vertical position in any place.

5.2.6 Explosions Due to Working on Drums and Tanks

a) Gas cutting of empty drums, pipes or containers that

contain residual flammable materials (solvents and
petrol) can cause explosions.

b) The flame heats up vapors inside the drums, which may

then explode. This can happen even when the drum or
thank looks empty. Find out what the vessel contained.
Never start cutting the vessel until you have found out.

c) If you need to weld or cut a container that has contained

flammable materials you must :

i- Arrange to have the container steam cleaned;

ii- Fill the container with water (leaving a vent to
allow vapors to escape); or
 iii- Fill with an inert gas such as carbon dioxide or
nitrogen prior cutting.

5.2.7 Explosions Caused by Leakage of Fuel Gases.

a) If gas leaks into pits or confined spaces, it can build up

and explode if ignited. For example a mixture of only
3% of acetylene in air can be explosive. LPG is heavier
than air and can collect in low or confined spaces such
as trenches, pits or basements.

b) A blowpipe should never be left burning.

c) Check hoses and gas fitting regularly for leaks. Use
soapy water to check hoses for leaks.

5.3 Electrical Welding

5.3.1 Protection from Electric Welding Hazards

a) Injuries From Burns During and After Welding

i- A full welding mask must be worn when electric

welding to prevent radiation damage to eyes.
ii- Overalls, gloves and neck protection should also
be worn. Exposed skin will be burn by the
radiation from the arc.
iii- Chalk a warning into hot metal so other workers
will not touch it or stand on it.
iv- If other workers are working nearby you should
erect a welding screen to protect them from
welding ‘flash’.

b) Electric Shock

i- Never arc weld in wet conditions.

 ii- Never connect work-return cables to structures
other than that to which you are welding. This
may cause damage or electrical shock.
iii- Check the insulation of all cables and the
conditions of the work-return clamp regularly.
iv- No work should be done on the wiring, switches
or other components of the welder unless it is
disconnected from the power source.

c) Fumes and Electrical Welding

i- Fumes are produced from the electrode and the

parent metal being welded. The fumes ca cause
health hazards ranging from a short-term illness to
more serious lung diseases.
ii- Always weld in a well-ventilated area.
iii- Check what you are welding. If welding lead,
galvanized metal or coated metals the fumes may
be dangerous. Wear a respirator (suitable for
welding fumes) or use a portable welding fume
extraction unit.

d) Fumes from Engine-Driven Welding Machines

i- When electric welding generators driven by

internal combustion engines are used inside a
building or confined space, the engine exhaust
must be ventilated to the outside air.
ii- Carbon monoxide in exhaust fumes can be deadly.

e) Suffocation and Electric Shock in Confined Spaces.

i- As with gas welding you must follow the confined

space procedure when working in a chamber, tank,
manhole or similar space.
 ii- Note that the risk of electric shock in a confined
space is higher because of the cramped conditions
and possible sweating of the welder. The welder
should stand on a dry wooden platform or other
insulating material if the confined space is a metal
structure.

f) Heat stress
i- Provide shade if welding work must be carried out
in the sun. Ensure that there is plenty of drinking
water for the welders.

5.3.2 Welding or Cutting in or on Containers.

a) As with gas welding, don’t weld or cut containers,

which have held combustible or flammable materials
without taking the required precautions.
b) For electric welding this should involve filling the tank
completely with water.
c) Never use a container to serve as a support for welding
if you do not know what it has held.
d) Reminders about the hazards of welding or cutting on
containers can be given at toolbox meetings or induction
sessions.
e) Empty oxygen tanks must be removed from the site.

5.3.3 Fires cause by Sparks

a) Before working ensure there are no flammable liquids

(solvents, petrol and kerosene) or combustible material
(rags and waste) near you or in the area where sparks
might travel.
b) Where there is a risk of fire you should ensure there is a
fire extinguisher or fire hose near by.
C. ID BADGE SYSTEM

1.0 INTRODUCTION

This standard instruction shall apply throughout the organization and shall
cover all types of activities, which involved subcontractor, visitor and
public in KAIZEN GRAHA MEKANIKA PT.

2.0 PURPOSE

 To ensure that all subcontractor, visitors and public conform to

HSE Policy and Procedures of KAIZEN.
 To ensure that the premises, access to the contractor and plant
and substances used by them are safe and free from risks to
safety, health and environment.
 Subcontractors who are self-employed carry the same
responsibilities as an employer to make proper provision for
health, safety and welfare during their activities on site.
 To make sure that the visitor and public is not put at risk by any
work carry out on the site.

3.0 RESPONSIBILITY

 The HSE Committee shall be responsible for the content of this

working instruction.
 The HSE Committee shall be responsible to ensure all sub-
contractors are registered.
 The HSE Committee / Project HSE Manager shall be
responsible to ensure all sub-contractors follows KAIZEN
HSE requirement.
 The HSE Committee / Project HSE Manager concerned are
responsible to ensure that the subcontractor, visitor and public
follow this procedure within the site.
 Project HSE Manager / Chief HSE shall advice on the legal
and other requirements.
  All subcontractor, visitor and public concerned are responsible
to comply with this working instruction.

4.0 STANDART INSTRUCTION

Working within AETRA premises and for the busines with AETRA shall
require the use of proper entry permit badge or ID badge.

Area Classification

 Green Zone

All employee and visitor entry to AETRA work area must be

use Employee ID Badge or Visitor ID badge.

 Red Zone

All person every entry the Red Zone area must be change all
type of ID Badge with Red Zone ID Badge.

Procedure

a. Change general ID Badge to Red Zone ID Badge.

b. Proper PPE must be used all time in mandatory areas.
c. Cellular phone must be switched off.
d. Unauthorized radio communication is not allowed unless by
authorization of Assigned Area Authority. (Safety dept)
e. No ignition and matches and cigarette lighter are allowed
unless by authorized by assigned area authority (Safety
Dept.) for welding lighters.
f. No picture taking and / or use flash light unless by
authorization of the assigned Area Authority (Safety Dept.)
g. No work without approval of Assigned Authorities.
h. Always be aware of warning sign boards regarding the above
issues.
i. If a person found working without appropriate failed to
comply with above rules. Company will apply disciplinary
actions to the violators and responsible Company Employees
who failed to observe such violation.