WORK

PERMIT
A.K.SINGH, SAFETY MANAGER
INDIANOIL CORPORATION LTD.
BARAUNI REFINERY,
INDIA
ROAD MAP
:The session will include the following
 Presentation on BR Work Permit
system followed by discussion
 Role of Issuing & Executing Authority
 Exercise how to fill the permit
 Questionnaire/QUIZ
 WHY WORK PERMIT?
 Petroleum Refinery handles Hydrocarbons
and toxic materials - poses special risks.
 Maint. Personnel are not adequately
familiar with process conditions.
 Operation will determine that it is safe to
perform the designated job.
 Basic purpose of permit system is to
prevent injuries to personnel.
 Protect property from damage
 Avoid fire
 Ensure that all work is carried out in
safest possible manner.
 permit specifies the conditions and
procedure for safe execution.
WORK PERMIT REQUIRMENT
Permit is required for the following jobs :
 Major & Minor Maint. work.
 Inspection.
 Construction.
 Alteration.
 Process Equip. cleaning
 Entry into confined space.
 Excavation
 Vehicle entry into hazardous areas etc.
 WORKS -
PERMIT NOT REQUIRED
 Works carried out by Oprs. Dept. as a part
of routine operation.
 FIRE STATION
 FIRE TRAINING GROUND
 BLANKET PERMIT
SIX MONTHS BASIS / MAX I YEAR
 WORK SHOP
 INSTRUMENT LAB/WORKSHOP
 LABORATORY
 INSPECTION
 TYPES OF PERMITS
7 types of work permit with specific colors.
HOT WORK & VEHICLE ENTRY PERMIT (Pink, light green & white) For use of
or generates local source of ignition,vehicle & engine operated equip. entry to hazardous areas.
BR:F&S:FR:1
CLEARENCE & COLD WORK PERMIT (YELLOW & WHITE)
BR: F&S: FR:2
(For all general maint. works (no ignition source)
DYKE CUTTING & EXCAVATION PERMIT(PINK ,light green & white)
BR: F&S:FR:3
ROAD CUTTING & BLOCKAGE PERMIT (PINK & , yellow & light green)
BR: F&S:FR:4
VESSEL ENTRY/VESSEL BOX UP/EXCAVATION (yellow & white)
For personnel entry into confined space. BR: F&S:FR:14
WORK AT HEIGHT PERMIT (yellow & white) BR:F&S:FR:17

RADIATION WORK PERMIT( PINK & WHITE) BR:F&S:FR:18

 FEATURES OF WORK
PERMIT FORM
Work Permit form generally consists of
the following features:
THE ORIGINIAL AND COPIES
 Original is unmarked and belongs to
“Executing Authority”-pink copy
 Printed serial number
 FORM NO. BR: F&S:FR:…...
 Special instructions printed on the
permit
 PROCEDURE FOR WORK PERMIT
SYSTEM(WPS)
 WPS OPERATE ON OWNER IN CHERGE CONCEPT(UNITS-
CPNM,LAB-SQCM,TPS-CPUM, STORES-SMTM)
 PERMIT IN PRINTED FORM
 SEPARATE PERMIT FOR COLD & HOT WORK
 PERMIT COLOUR CODED, SERIAL NUMBER
 DEPTL. OR CONTRACTOR JOB:PERMIT RECEIVING BY
MN/PJ/CONSTRN. SUPERVISOR OF IOCL.
 PERMIT INITIATION BY MN/PJ SUEPRVISOR.
 ALL PERMITS TO BE WRITTEN IN CAPITAL LETTERS
 WORK ORDER/LOA NO. TO BE MENTIONED ON PERMIT
 LOCATION DRAWING/SKETCH TO BE GIVEN ALONG WITH
PERMIT.
 RISK EVALUATION CHECKLIST TO BE TICKED BY ISSUER
(GSI(HOT WORK), SUPERVISOR. NOT BY EXECUTOR.
 PROCEDURE FOR WORK PERMIT
SYSTEM(WPS)
HOT WORKPERMIT
 EXECUTOR TO INITIATE THE FIRE PERMIT-
DUATION,LOCATION, EQUP.TAG NO., NATURE OF WORK,
NAME & SIGNATURE. ECECUTOR NOT LESS THAN “A”
GRADE OFFICER
 GSI( B GRADE AND ABOVE)-CHECK THE PERMIT, EVALUATE
THE RISK,TICK 30 ITEMS AS APPLICABLE, SPECIAL
INSTRUCTION IN SPACE PROVIDED IN PERMIT TO PREPARE
THE AREA /EQUIPMENT TO CARRY OUT THE HOT WORK.
 SHIFT IN CHRAGE IN E/N SHIFT TO FOLLOW UP & DIRECT
PREPARATIONS. N/SHIFT TO INSPECT THE AREA
/EQUIPMENT JUST BEFORE THE SHIFT CHANGE AND LEAVE
MESSAGE FOR FPS(C GRADE AND ABOVE)IN SHIFT LOG
BOOK.
 PROCEDURE FOR WORK PERMIT
SYSTEM(WPS)
HOT WORKPERMIT
 FPS AFTER GOING THROUGH LOG BOOK ,ACCOMPANIED
BY GSI & EXECUTOR INSPECT THE AREA, SATISFY
HIMSELF WITH PREPARTIONS AND THEN SIGN THE
PERMIT.
 PERMIT TO BE RECEIVED BY EXECUTOR BY SIGNING.
 REGISTRATION AT FIRE STATION.
 PINK COPY FOR EXECUTOR/ WHITE FOR ISSUER
 ISSUER REPRESENTATIVE-SHIFT PNE/SPNE/SPUE TO
CARRY OUT GAS TEST, INSPECT THE AREA, ENSURE
COMPLIANCE OF ALL SAFETY PRECAUTION GIVEN IN
PERMIT , THEN ISSUE CLEARENCE CERTIFICATE TO
START THE JOB.
 VALIDITY OF HOT WORK PERMIT
HOT WORK PERMIT
 NORMAL 8 HOURS( 8AM-5 PM). BEYOND 5 PM
RENEWABLE AFTER AUTHORISATION FROM HOD.RENEW
AT FIRE STATION ON EXTENSION.
 NORMAL HOT JOBS IN NIGHT SHIFT NOT ALLOWED
UNLESS JOB IS URGENT, PERMISSION FROM HOD REQD.
 FOR EACH LOCATION/EQUIPMENT SEPARATE HOT
WORK PERMIT REQUIRED IN PROCESS UNITS
 IN OFFSITE:DISTANCE EXCEEDING 15 METERS,
SEPARATE FIRE PERMIT.
 WHO CAN SIGN A WORK
PERMIT
 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.
 DGM(T) AUTHORISES GSI & FPS AND LIST IS
CIRCULATED.
 ISSUING AUTHORITY OF
WORK PERMIT
 Issuing authority is responsible for
preparation and handing over of the
equipment in safe condition to
perform the work.
 Authority to issue all types of work
permits is generally granted to shift
supervisor(PNE/SPNE, UTE,ELE)
level of OFFICERS and above.
 EXECUTING AUTHORITY
OF WORK PERMIT
 Request for a work permit by executing
authority. He shall indicate types of
tools and equipment necessary for
performing the work.
 He shall also ensure his tools,
equipment and accessories are in good
condition and all his workers are
provided with proper PPE.
 PREPARATION OF THE
EQUIPMENT
 Equipment electrically isolated
 Inspection tested(for cold & hot job)
 Isolated from steam,air & gas
 Depressurized
 Drained
 Positively isolated/blinded
 Steamed & water flushed
 PREPARATION OF EQUIP.
.CONTD

 Ventilated & gas freed

 Continuous inert gas flow / continuous
adequate ventilation arranged.
 Vehicle/equipment in good condition
with spark arrested
 Radiation source removed(Confined
space entry)
 RESIDUAL HAZARDS
 Lack of oxygen
 H2S and/or any other toxic gases
 Combustible gases
 Corrosive chemicals
 Steam / Condensate
 Pyrophoric iron
 High humidity
 PROTECTION MEASURES
 Protective clothing
 Hearing protection
 Safety Harness
 Eye protection
 Face protection
 Respiratory protection
 Keep fire equipment stand-by
 PROTECTIVE MEASURES
.CONTD
 Barricade the area
 Remove flammable and combustible
 Cover with fire retardant tarpaulin
 Crane with basket stand-by
 Attendance with Airline set
 keep man ways open
 Allow minimum possible no. of persons
inside confined space
 PROTECTIVE MEASURES
.CONTD
 To ensure positive isolation & maintain
it all through
 Ensure adequate ventilation all through
 Display copy of entry permit near entry
manhole
 GAS TEST FOR WORK
PERMIT
Why gas test is required ?
 Most of the gases are unwanted
Hazards involved -
 Flammability(Fire & Explosion)
 Toxicity(health hazard)
 Oxygen Deficiency
 GAS TEST CONTD
Common flammable gases/liquids in
refinery are -
 All petroleum products,Crude and
intermediates
 Hydrogen
 LPG
 Common toxic gases in refinery -
 H2S, CO,NH3,CL2, etc.
 .GAS TEST CONTD
COMMON TERMINOLOGIES :
For flammable substances:
 Flash Point :

Minimum temp. at which a liquid gives off

sufficient vapor to form an ignitable mix. It
.will give a flash, flame will not continue
:.Auto Ignition Temp
The lowest temp. to which a substance will
.ignite without a spark or flame
 GAS TEST CONTD
.

 Explosive limit :
The concentration range of vapor in air
when propagation of flame(ignition)
occurs in presence of an ignition
source.
 LEL (Lower Explosive Limit) :

The minimum concentration of vapor to

air required to propagate(ignite) flame.
 . GAS TEST CONTD
 UEL(Upper Explosive Limit) :
The maximum vapor to air conc.above
which propagation of a flame will not
occur(will not ignite).
 . GAS TEST CONTD
Material LEL UEL F Pt.(C) AIT(C)
Hydrogen 4 75 Gas 585
Methane 5 15 Gas 538
Propane 2 9.5 - 104 466
Naphtha 1.1 5.9 - 18 288
ATK/ATF 0.7 5.0 35-50 210
Diesel 0.7 5.0 32-96 256
Fuel Oil 1 5.0 66 262-407
 .GAS TEST CONTD
: Toxic substances
TLV (Threshold Limit Value / PEL(Permissible
: Exposure Limit)
The maximum permissible conc. of a toxic
substance to which exposure of a person will
have no adverse effect on health for working
.8 hrs per day
: STEL(Short Term Exposure Limit)
Maximum conc. to which worker can be
exposed for a period of 15 mins. without any
.adverse effect to health
 .GAS TEST CONTD
IDLH(Immediate Danger to Life & Health)
 A maximum conc. from which one can
escape within 30 mins. without irreversible
health effect.

 HYDROGEN SULPHIDE (H2S)

Highly toxic, combustible, colorless.
Smells like rotten egg.
 GAS TEST - H2S
EFFECTS ON HUMAN BODY
PHYSICAL EFFECT CONC.(PPM)
Can be smelled as rotten egg 0.13
TLV 10
STEL 15
Smelling sense will dry within 150 - 200
2 mins, burning sensation in
eye & throat
 .GAS TEST - H2S CONTD
PHYSICAL EFFECT CONC(PPM)
IDLH(Loss of smelling sense, 300
,heavy breathing, dizziness
headache,and total collapse
)within 1 to 4 Hrs
Dizziness,headache,lungs 450
problem and total collapse within 30 to
60 mins.
 .GAS TEST-H2S CONTD
PHYSICAL EFFECT CONC(PPM)
Slow down of heart beats, 700
,heavy breathing with coughing
then death, if not rescued

Fatal emergency over 700

Explosive limits : 4.6 to 46%, it gives blue

.flame when ignited
 .GAS TEST-H2S CONTD
: FIRST AID
- IF INHALED
Remove exposed person to fresh air and
.administer oxygen immediately
:PROTECTION
Use fresh air mask in case conc. exceeds
10 PPM
 TOXIC GAS - CO
TOXIC AS WELL AS FLAMMABLE
TLV - 50 PPM
STEL - 400 PPM
IDLH - 1500 PPM
LEL - 12.5%
% UEL - 74
 GAS TEST - CO
:HEALTH HAZARDS
CO combines with hemoglobin of blood
.and make it unable to carry oxygen
Symptoms : Headache, dizziness to
.unconscious and ultimately death
: First Aid
Remove to fresh air and apply oxygen at
.the earliest
 OTHER TOXIC GASES

TOXIC GAS TLV STEL IDLH

NH3 25 35 -
SO2 2 5 -
CL2 0.5 1 30
 GAS TEST CONTD.
For hot work the gas test results shall be :
 Combustible - Below 1 % LEL

( Preferably NIL)
For confined space entry :
 Oxygen - 19.5% minimum
 Combustible - 10 % LEL Max.
 Toxic gases - below TLV
 .GAS TEST CONTD
Confined space With BA protection :
 Combustible - 20% of LEL maximum
 H2S - Less than 100 PPM
 CO - Less than 500 PPM

However, no hot job can be carried out

inside the confined space at this
condition.
 WORKS NEED GAS TEST
 Gas tests are required for all hot
work/vehicle entry and confined space
entry permits & some cold permits also.
 Issuing authority shall determine the
requirement of gas test & frequency of re-
checking.
 Trained Gas tester only shall carry out the
test.
 RESPONSIBILIES OF GAS
TESTING AUTHORITY
 To check & confirm that the gas testing
instrument is working in perfect condition
before proceeding for the area/equipment
 To carry out gas test at all critical
locations/positions
 To advise on safe method to work inside/at
the location i.e., further gas freeing , use of
PPE etc.
 ELECTRICAL ISOLATION
 Before issuing a Work Permit, it is
essential to ensure that the equipment /
facility to be worked on is electrically safe
and electrical power is isolated to the
extent necessary for the safe conduct of
the authorized work.
 Issuing, Executing authorities and
Electrical Maintenance shall jointly decide
the extent of isolation required.
 ‘DO NOT OPERATE’ tag shall be used
when isolation by local switch is decided
as adequate protection.
 Multi-lock systems to be used when
different crafts are involved.(this is
towards best safety practices)
 SPECIAL REQUIREMENT FOR -
WORKING WITH RADIOGRAPHY

 Risk assessment through checklist

 Barricade the area and provide adequate
warning signs.
 Film badges and Dosimeters shall be
worn by personnel handling radiography
equip.
 job preferably during night time or with least or
no person around.
 Continuous monitoring of cordoned off area
 SPECIAL REQUIREMENTS
FOR HOT WORK
 The person who authorizes the Hot Work
Permit is responsible for ensuring that the
site and the equipment are properly prepared
to prevent the danger of fire & explosion
involving flammable material.
 The equipment shall be emptied and cleaned
of flammable materials and isolated from
sources of hydrocarbons by means of
disconnection, blanking or insertion of blinds.
 Equipment and surrounding areas shall be
checked to ensure that they are free from
any combustible gas.Carry out gas test.
 Any heavy oil deposit, dried vegetation or
other flammable / combustible materials
within 8 m of a hot work site shall be
cleared away.
 No hot work shall be allowed within a radius
of 15 m of any sample point, drain or relief
valve outlet unless precautions have been
taken to prevent the escape of flammable
liquids and vapors.
 The outlet of all units drain seals within 15 m
of the hot work shall be plugged.
 If welding or grinding is to be done at height,
then precautions shall be taken to prevent
the spread of sparks and molten metal to the
surrounding of the work area with fire-
resisting or flame-retarding tarpaulin.
 A hose capable of reaching up to the hot
work point and connected to fire water main.
 Fire Station (333/5989) shall be informed of
hot work.
 VEHICLE ENTRY
 A Hot Work / Vehicle Entry Permit is required
for entry of all vehicles in hazardous areas.
Such areas shall be clearly demarcated with
signs indicating “No Entry without Vehicle
Entry Permit” and/or with removable chain.
 The signatory authorities shall ensure that all
vehicles / equipment exhaust are equipped
with spark arrestors of approved type.
 Entry shall only be allowed for loading and
unloading of materials and not for passenger
transport.
 REQUIREMENTS FOR
CONFINED SPACE ENTRY
 The process vessel / equipment is to be
positively isolated by blinding.
 Shall be made safe for entry by
depressurizing, venting, draining,
steaming, washing and ventilating.
Radiation sources ,if any, shall be
removed.
 The atmosphere within the confined space
shall be checked initially and
periodically(gas test).
 EXCAVATION
AUTHORIZATION
 An excavation authorization is required for
all excavations. Detail drawings of the
underground facilities shall remain attached
with the authorization if available.
 In addition to an Excavation Authorization a
Cold / Hot work Permit is required to work.
 For excavations more than 1.2 meter deep
confined space entry permit is required. Gas
tests shall be done as per entry permit
requirements.
 SUSPENSION OF WORK
PERMIT
 All work shall immediately stop when
a fire or 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.
 The Work Permit shall be revalidated
to resume the work.
 Any responsible member of the
PN.dept. or F&S is authorized to
suspend work and withdraw the
Work Permit if, safety regulations are
violated.
 If work is not started or is stopped
for over two hours, the permit shall
be revalidated by the issuing
authority.
 VALIDITY OF PERMIT
 Work permit shall be initially issued for
a period of 8 hrs. and shall be renewed
for one more shift .
 On need basis , permit can be given for
max. 7 days period.
 Clearance to be obtained every shift.
 Clearance to be given after physically
checking the site.
 CLOSING AND FILING OF
USED WORK PERMITS
 Permit Closure: Duly filled and signed by
both executing & issuing authority at
completion of work
 Copies of the closed permits shall be
properly filed and kept with the respective
disciplines for at least one month from
the date of issue/closure. Different types
of permits shall be filed separately in
chronological order in box files.
 BASIC RESPONSIBILITIES
OF ISSUING AUTHORITY
 To prepare the equipment and properly
tick the checklist items
 To identify & indicate any residual
hazard
 To advise on protective measures &
mention
 To carry out gas test wherever reqd. and
enter the result with sign,date & time
RESPONSIBILITIES OF ISSUING
.AUTHORITY CONTD
 To discuss & explain with/to executing
authority
 Carry out electrical isolation whenever
reqd.
 Close the permit when the job is
complete or end of permit duration, which
one is earlier.
 To preserve the permit for next one
month.
 BASIC RESPONSIBILITIES
OF EXECUTING AUTHORITY
 To clearly understand the conditions of the
equipment and residual hazards
 To discuss the above with issuing authority
and decide upon the protective measures.
 To describe the job and associated
hazards to the workmen
 To ensure that safe procedure of
execution are being followed
 RESPONSIBILITIES OF
EXECUTING AUTHORITY
 To check all the hand tools / devices
/equipment and ensure that they are healthy
 To make the permit available at work site all
the time
 To close the permit when the job is over or at
the end of permit duration,which one is
earlier.
 To preserve the closed permit for next one
month
 AUDITOR’S CHECK-LIST
An Auditor shall check the following:
 Whether the exact location of area/unit &
equipment has been mentioned clearly
 Detail description of work is properly
written
 Fire station has been informed and
properly ticked
 AUDITOR’S CHECK- LIST
 Permit issued to which Dept.,
Div.,Section & Craft - all mentioned
 Equipment preparation - Equipment has
been properly prepared, all checklist
items area properly checked & ticked
 Residual Hazards - Identified and
ticked/indicated
 Protective Measures- Requirements
identified & properly marked
 AUDITOR’S CHECK-LIST
 Other details - like provision of
continuous ventilation, additional
precautions
 GAS TEST:
 Test for all probable gases carried out
and reading recorded with sign., date &
time etc.
 Frequency of rechecking identified and
carried out
 AUDITOR’S CHECK-LIST
 Electrical isolation was reqd., carried
out and documented.
 Both issuing & executing authority
signed mentioning name & signature,
date & time.
 AUDITOR’S CHECK-LIST

 Permit has been closed by both issuing &

executing authority with date & time
 Closed permits has been kept properly filed
and being preserved for next one month
 OPEN FIRE

 PERMISSION-WEST SIDE OF RD.1 OR OUTSIDE

GATE.2
 NO OPEN CHULLA IN OMS,LPG & RUNNING
PROCESS UNIT INCLUDING ROAD SIDES.
 IN SHUT DOWN UNITS UNDER REVAMP, JOINT
INSPECTION BY AREA IN CHARGE /F&S+
RECOMMENDATION DGM(T) FOR ONE
DAY
 Clearence permit/certificate

 for hot /cold work

 issued against permit no…….
 14 checklist items to be critically evaluated and ticked
 issued for one shift maximum/renewed shift wise.
 Closure on job completion/ clearing the area, signed ,
date, time, return to issuer.
.Not meant for billing 
 Road cutting& blockage
permit
 Request by executor(A grade and above) by filling all the
entries and attaching sketch/indicating on reverse of permit
form
 clearance from EL maint.
 Clearence from Civil
 Clearence from PN
 Clearence from IS dept.
 Clearence from F&S
 Approved by DGM(T)
 Permit registered at Fire Station.
 On completion , permit return to Fire Station.
 Excavation & Dyke cutting

 Request by executor(A grade and above) by filling all the

entries and attaching sketch/indicating on permit form
 clearance from EL maint./ Telecom.
 Clearence from F&S
 Clearence from CL
 Clearence from PN/Area in charge
 Registered at Fire Station.
 Approved by GSI
 On completion , permit closure and return to Fire Station/
Area in charge.
 Vessel Entry

 Request by executor(A grade and above) by filling all

the entries clearance from EL maint./ Telecom.
 Critical evaluation of 27 checklist items./ticking
 Approved by GSI
 Clearence from PN/Area in charge
 On completion , permit closure and return to Fire
Station/ Area in charge.