Generation Business Line

HSE Initiative
WCM Utilization & Improvement

Work Permit Procedure Course

 TABLE OF CONTENTS
 OBJECTIVE
 WORK PERMIT OUTLINES
 WORK CLEARANCE MANAGEMENT (WCM) SYSTEM
 TYPES OF WORK CLEARANCES
 LOCKOUT–TAG OUT, TRY OUT
 WORK PERMITS
 CANCELATION OF THE WP DUE TO UNSAFE CONDITIONS
 DURATIONAL VALIDITY OF WORK PERMITS
 CERTIFICATION OF WP ISSUER & RECEIVER
 DUTIES & RESPONSIBILITIES
 PPE. PERSONAL PROTECTION EQUIPMENT
 MSDS ( MATERIAL SAFETY DATA SHEET)
 TASK RISK ASSESSMENT
 OBJECTIVE

Orientation, Training for Generation business line

Managers, Supervisors , Employees and
issuers /receives of work permits.
like
power plant operation staff, maintenance staff,
technical support services Engineers and our
partners (contractors) who receive Work Permit in
power plants of Generation business line to
Implement safe work practices for safety
 GOALS
 Unifying work permit procedural methodology
across GBL.
 Awareness of 2nd revision of Generation work
permit procedure.
 Provide Work Permit trainers for each sector
/power plants.
 To find quick references of safety subjects from GI.
 Utilization of LOTO and PPE.
 Plant Emergency Phone Numbers

• Shift Supervisor
(59991)
In case • Fire Station
OF (59898)
• Security Shift Supervisor (59999)
Emergency • Clinic
(59778)
• Safety steam units
(59090, 59091, 59092)
• Safety CCPP (59553,
59644, 59621, 59547)
 WORK PERMIT OUTLINE

WORK PERMIT
 Work Permit is the basic document, which
authorizes a person to perform a maintenance
task,

WORK TASKS
 Any Inspection, Maintenance, Modification or
Construction work (hereafter collectively referred
to as tasks)
 Work permit used for authorizing such tasks .
 WORKPERMIT
WORK PERMIT OUTLINE
OUTLINE

Work Permit Issuers:

• Only certified plant operations personnel can issue these
documents and all such personnel are called Issuers.
Work Permit Receiver:
• Only certified personnel who supervise or perform a task
can receive such documents and all such personnel are
called Receiver.
Restricted Area:
• Area of Power plant proximity and related utilities like fuel
transport to power plants called restricted area and
require work permit to work.
 WORKPERMIT
WORK PERMIT OUTLINE
OUTLINE

TRA (Task Risk assessment):

 Task Risk assessment need to be carried out before issuing work
permit
TBT (Tool Box Talk):
 TBT need to be done before starting of the work at site.
Discussion about work hazards and risk involve at the work site.
 Discussion before work between work permit issuer & receiver
OR Work permit Receiver (supervisor) with co-workers at the
site.
Gas test
 Gas test is required before issuing Work permit in confined
space, fuel area or hot work permit.
What is
WCM

..
 WCM (Work clearance Management)

DEFINITION
WCM is system/Application, used to process work permits.

PURPOSE
To manage the lock out tag out and Work Permit procedure for
power plants equipment by following the highest safety
standards as per Generation work permit procedure

FOR DETAIL INFORMATION

Refer to Generation work permit procedure /section-3 / Work clearance Management / page-9
 WCM (Work clearance Management)

 Work order is required to start the WCM

process.
 Work order should be planned and status
should be scheduled before issuing work permit
(PM, CM, WOOM)
 In case of emergency (WOEM) order can be
issued to start the process with out schedule.
 WCM (Work clearance Management)

Work Approval (WA)

• Work Approval (WAP) is a control document for

integration between the Maintenance Order
and work permit / Work Clearance application
(WCA), which links with OWCD.
• WAP needs to be created in WCM work process
in order to prepare work permits, clearances
and Lockout / Tag out list.
 WCM (Work clearance Management)

Work Clearance Application (WCA)

• WCA required where work permit tasks need

isolation of hazardous energy, toxic &
combustible gases.
• Integrated with work permit & work clearance
documents.
 WCM (Work clearance Management)

Operation Work Clearance Documents (OWCD)

• O-WCD is a Tagging list document in which the specific

points of isolation are listed.
• It can be created by WCD templates
• OWCD consist of
• Points of Isolation in sequence with LOTO (with the
lock numbers)
• Drain & Vent points
• Points of grounding in case of electrical equipment.
 WCM (Work clearance Management)

WCM object hierarchy

 TYPES OF WORK CLEARANCE AND TAGS

1. HOLD ORDER CLEARANCE

2. TEST PERMIT CLEARANCE

3. CAUTION ORDER CLEARANCE

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-4/Process of Work Clearances /page-15
 TYPES OF WORK CLEARANCE AND TAGS

HOLD ORDER
1. Hazardous work having potential of
releasing energy.
2. Equipment or system need to be isolate
Electrically/ Grounding & mechanically.
3. System may required draining, purging.
 TYPES OF WORK CLEARANCE AND TAGS
• HOLD ORDER
 We have to prepare WCA along with Instructions &
Precautions which is linked with OWCD.
 OWCD which specify points of isolation boundaries
like;
1. Power supply breakers/switches
2. Isolation valves
3. LOTO points
4. Drain & Vent points
5. Grounding points in case of electrical equipment.
 TAGS USED IN HCL

Hanged at The Main Equipment

 TAGS USED IN HCL

Hanged at all the isolation boundaries points

 TAGS USED IN HCL

Hanged at all Electrical grounding point

 TYPES OF WORK CLEARANCE AND TAGS
TEST PERMIT
• Whenever any equipment or portions of the plant
is to be operated for purposes such as trouble
shooting, hydrostatic testing, preventive
maintenance, performance testing, Interlock
testing, commissioning of new equipment, a test
permit is issued (Hereafter called test ).
• During the test, the operation of the plant or
equipment under test is performed by either Plant
Operation or Maintenance personnel.
 TYPES OF WORK CLEARANCE AND TAGS
TEST PERMIT

– RECEIVER CAN OPERATE EQUIPMENT AS PER THE

AGREED TERMS AND CONDITON OF ISSUER.
– TEST PERMIT AND HOLD ORDER SHOULD NOT
ISSUED SIMULTANOUSLY ON SAME EQUIPMENT.
NOTE:
– WP ISSUER & RECEIVER SHOULD DISCUSSED THE
POSSIBLE RISK IN THEIR TOOL BOX TALK (TBT) and it
should be mention in instruction and precaution.
 TAGS USED IN TCL

Hanged at all the test points

 TYPES OF WORK CLEARANCE AND TAGS

• CAUTION ORDER
• When used for a caution order, the clearance sheet serves to
notify hazardous or abnormal conditions and lists the
boundaries isolated (if any) to contain the hazard or
abnormality.
• In case of a Caution order, no work permit is issued as no work
is authorized under a Caution order.
• Caution, Test permit clearance and Hold order Clearance should
not be issued simultaneously on same equipment at the time
 TAGS USED IN CCL

Hanged at all the Caution points

 LOCK OUT -TAG OUT & TRY OUT.

 Lockout – Tag out, Try out means isolating the sources of

energy then placing locks and tags on the specific control
equipment, then testing to ensure all sources of stored energy
are isolated correctly by Operation
 Maintenance personals should place their own locks on Group
locks box & Lock Out Hasps for Multiple Locks.

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-5/Lock Out–Tag Out & Try Out/page-25
 LOCK OUT -TAG OUT & TRY OUT.

• LOTO Station must be established in special room.

• It should be monitored, supervised and controlled
by competent and authorized person (by issuers)
and should be arranged well.
• It consist of locking devices like Group locks boxes,
Hasps etc.;

• see next slides for more devices

Lockout Tagout Devices
 LOCKS COLOR CODING
• Red Lock must use for Operation
work centers.

• Yellow Lock must use for Electrical

work center :

• Green Lock must use for

Instrumentation work center
 LOCKS COLOR CODING
• Blue Lock must use for
Mechanical work center

• Black Lock must use for

Technical Support &
FMD work center
 LOCK OUT -TAG OUT & TRY OUT.

Procedure
• Lock out /Tag out must be done after equipment have to
be de-energized/isolated/depressurized/drained/purged/
electrically grounded as per the potential hazard.
• Only approved lockout padlocks without master keys.
• Multiple lock out hasp/ Group Locks Box shall be used to
allow application of more than one padlock on disconnect
when more than one technician will work independently.
• Each technician shall install his own personal padlock.
• One key, one lock, and one authorized person is applied
whenever LOTO is required.
• Usage of Master keys is prohibited.
WORK PERMIT
What is the importance of
GAS TESTING
in work permits
 GAS TESTING
• GAS TESTING is required
to test oxygen, flammable
and toxic gases,
• Before issuing WP /during
work such as,
• Hot/Cold work,
• Confined space, (lack of
Oxygen)
• potential of flammable
and toxic gases that can
harm to worker or can
cause fire.
 What is LEL & UEL?

 Explosion, like fire, requires three elements:

 Fuel, Oxygen, and an ignition source.
 Each combustible gas or vapor will ignite only within a
specific range of fuel/Oxygen mixtures.
 Too little or too much gas will not ignite.
 These conditions are defined as the Lower Explosive
Limit (LEL) and the Upper Explosive Limit (UEL).
 Any amount of gas between the two limits is
explosive.
GAS TESTING Common Combustible Gas LEL's and UEL's
LEL UEL
Acetone (CH3)2CO 2.15% 13.0%
Acetylene C2H2 2.5% 100%

GA
Benzene C6H6 1.2% 8.0%
Butadiene C4H6 1.1% 12.5%
Ethane C2H6 3.0% 15.5%
Ethyl Alcohol CH2H5OH 3.3% 19.0%

S Ethyl Ether
Ethylene
Hexane
Hydrogen
(C2H5)2O
C2H4
C6H14
H2
1.7%
2.7%
1.1%
4.0%
36.0%
36.0%
7.5%
75.6

TE IsoButane C4H10
Isopropyl Alcohol (CH3)2CHOH
(IPA)
1.8%
2.0%
8.5%
12.7%

ST
Methane CH4 5.0% 15.0%
Methanol CH3OH 6.0% 36.0%
Pentane C5H12 1.5% 7.8%
Propylene C3H6 2.0% 11.1%
Toluene C7H8 1.2% 7.0%
 TYPES OF WORK PERMITS
COLD WORK
HOT WORK
CONFINED SPACE ENTRY
GAS RELEASE
ELECTRICAL WORK
EXCAVATION
DIVING
GAMMA RAYS TEST
WORK AT HEIGHT/ LIFTING WORK

COMPOSITE WORK PERMIT

 Work Permits

•No Heating, Welding, Cutting or use of

internal combustion engine driven
equipment is permitted while performing

Cold cold work.

•No spark producing work methods such
as grinding, cutting using a cutting wheel
Work etc. are permitted.
•Example: Tasks involving work with hand
tools.
•LEL limit 0.5 %

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-6/Process of Work Permit /page-39
 Work Permits

•A Hot Work Permit issued when any source of

ignition is used and the potential for flammable
or combustible materials is present.

Hot
•An Open Flame Hot Work such as Welding,
cutting, brazing or burning with a torch, electric
arc or soldering iron; Using a propane torch;
Using open flames; Grinding;

Work •Using Power tools which produce sparks such as

grinders, cutting wheels,
•Use of Internal combustion engine driven
equipment.
•LEL limit 0%

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-6/Process of Work Permit /page-40
 Work Permits

•A Non-Open Flame Hot Work that is capable of producing sparks

or heat that could be possible sources of ignition such as:
•Sandblasting (abrasive blasting; either wet or dry);
•Spray painting; • Chipping, ripping, Breaking concrete; or other

Hot
cutting by impact;
•Use of internal combustion equipment (vehicles, portable
generators, and air compressors, etc.)
•Using explosive-charge powered tools;

Work
•Hot Tapping; Using non-explosion-proof electric equipment,
such as heaters, motors, coils, extension cords, tools, and lights;
•Use of portable electronic devices (includes cellular phones,
pagers, radios, portable computers, and handheld computers,
etc.)
•The duration should be One Shift / 8 Hours .
•LEL limit 0%
 Confined Space Entry Work permit

•Any excavation work to a depth of 4 feet (1.2 meter) or more

is considered as confined space entry.
•Example: Tanks, Vessels, Boiler drums, Entry into any part of
the steam boilers through manholes, Ducting, Fan casing, Stack
(Chimney), condenser, Underground pits, circulating water
tunnels, water boxes. Sewer lines, Seawater intake, trenches
more than 4’ or 1.2 m deep Etc.
Confined space •A Confined space entry permit is issued in conjunction with
entry either a hot permit or cold work permit.
•CONFINED SPACE ENTRY/ EXIT form must be used in order to
maintain who is working in confine space along with duration.
Name and ID No. must be logged.
•Receiver must assigned a Watch man at the main entry point
having and maintaining confine space entry / exit form.
•The duration should be One Shift / 8 Hours .
•LEL limit 0.5 %

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-6/Process of Work Permit /page-40
Confined Space Entry Work permit

Confined space PPE

 Work Permits
Confined Space Entry
PPE
 Confined Space Entry, Gas
Detection & Height Safety
 Gas Detection Kits
 Confined Space Equipment
 Confined Space Entry Kits
 Height Safety Kits &
Harnesses
 Inertia reels & Rope lines
 Lanyards & Karabiners
 Temporary Anchors
 Permanent Anchors
 Confined Space Entry Work permit

Confined space PPE

 TYPES OFSpace
Confined WORK CLEARANCE AND TAGS
Entry Work permit
 TYPES OFSpace
Confined WORK CLEARANCE AND TAGS
Entry Work permit
 Work Permits
Gas Release Work permit
• GAS RELEASE

 To be issued for actual release or possible release of combustible gases,

chemical vapor/ liquids, low flash point liquids (< 65 OC), combustible
liquids or dust.

 Combustible gas release like swinging in/out of gas blinds piping.

 Liquid release like working on fuel or lubricating oil tanks, piping, valves
or pumps
 Chemical or Chemical vapor release, like acid cleaning activities in the
desalination & water treatment plants.
 Toxic dust or soot release Cleaning, cutting or grinding work inside
Boilers which has the potential to release soot and other toxic deposits
from the tubes or duct walls
Emptying
FORDETAIL sump pits of combustible liquids and chemicals.
INFORMATION
Refer to Generation work permit procedure/section-6/Process of Work Permit /page-41
 Work Permits
Gas Release Work permit
• Operational Gas release

 All work permits issued for maintenance tasks in the

area is unsafe, shall be stopped temporarily.
 Issuer must issue a separate work permit for the
release activity to himself.
 No work permit for any new maintenance task shall be
issued in the area.
 Permit valid till all combustible gas/chemical/vapor are
released area returns to safe conditions.
 For all such tasks Composite work permit required (Release+
Hot)
 Work Permits
Electrical Work permit
Electrical Work Permit

 Electrical WP required for such isolated, de-energized and

grounded electrical lines, transformers, cables, switchgear,
motors, control panels etc.
 Install proper ground on all HV equipment then only we
can issue WP
 All electrical work permits shall be accompanied by a
Clearance typically
 Meggering & Grounding of equipment are considered as
work on energized electrical equipment.
 Energized work permit can by issued only for 480V or less.
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-6/Process of Work Permit /page-42
 Work Permits
Excavation Work permit
• Excavation Permit

 All excavations work require an excavation permit.

 Before an excavation permit
1. Receiver to perform all required studies to verify that there are no underground
electrical cables, piping or any other structure in the excavation zone.
2. Receiver to produce all drawings needed to prove that the area to be excavated is
free from power cables and underground piping to the Issuer, for him to verify
before issuing the work permit.

 Addition to excavation, Composite work permit required with cold, hot or

confined space work permit like..
1. Chipping of concrete floors or asphalted cutting. (Excavation + Hot)
2. Excavation using hand tools (Excavation+ Cold)
3. Excavation using power tools, such as jack hammers or any other earthmoving
equipment, (Excavation + Hot)
FOR DETAIL INFORMATION
4. Excavation deeper than 4 feet or 1.2 meters, (Excavation + confined space)
Refer to Generation work permit procedure/section-6/Process of Work Permit /page-43
 WorkWork
Diving Permits
permit
• Diving Permit
 Required when underwater inspection, repairs at the
seawater intake or outfall requires.
 The divers must possess a valid diving license from an
approved agency.
 Issuer have to ensure, equipment have to stopped, LOTO
If the underwater work area is close to the running
equipment.
 Receiver have to ensure, the divers have appropriate
diving gear.
 A look out / guard must be assigned with the diver to
ensure that he is constant communication with him.
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-6/Process of Work Permit /page-44
 Gamma- Work Permits
Ray Test Work permit
 Gamma Ray test permit Required when need
radiography of welding joints.
 Gamma- Ray Test Work permit
 Receivers have to make sure that the radiation
source is adequately protected and handled in a
professional manner.
 Gamma rays can interact with cells in the body
and make them non functional
 Create safe zone by Issuer & the receiver.
1. surrounding the gamma ray test location by removing
all personnel from the zone
2. Cordoning off the area to prevent any entry of
personnel.
3. posting lookouts,
4. providing warning signs
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-6/Process of Work Permit /page-44
 Work at
Work Permits
Height
• All work at height (above 1.5 meter) .
Method of access ;
• Fixed Ladder, Portable extension Ladder, Man
cage via crane & climbing technique, safety belts
or full body harness and Name of standby
personal etc.
• Avoid work at height in unsuitable weather
conditions like wind, rain etc.

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-6/Process of Work Permit /page-44
 Work at Height safety harness (PPE)

Pre-use and post-use checks each time the

lanyard is used:

· Look for any small cuts and abrasion at

the edges. Examine the surface of the
webbing for cuts and signs of abrasion,
look for contamination with dirt or
chemicals.
· Look for any signs of damaged or missing
stitching.
· Look at fittings (e.g. carabiners) for any
signs of damage.

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-6/Process of Work Permit /page-44
 Work at Height safety harness (PPE)

:Procedure for the use of safety harness

A - Pre-use and post-use checks must be carried out
on the equipment each time it is Used.

B - The length of the work restraint lanyard must be

short enough to prevent a person reaching beyond
the edge of the roof or platform where it is used.

C - Ensure that harnesses are fitted snugly around the

legs and chest. Leg loops should be opened out when
fitting the harness as this prevents the harness being
stood on and being damaged/becoming dirty.

D - When cleaning harnesses and lanyards use only

water or a mild household detergent.
Work at Height (PPE)
 Work Permits
Lifting Work
• Issuer/Receiver should Consider;
• design, strength, stability and location of the lifting
equipment, Toxicity and/or flammability in case of chemicals.
• Types of lifting equipment;
• Gantry crane, tower cranes. Mobile cranes, lifting chains,
travelling cranes, hoists and lifting trucks.

• Routine lifts are normally carried out by trained crane

operators, whilst larger lifts are undertaken by specialists.

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-6/Process of Work Permit /page-45
 Composite Work permit
COMPOSIT WORK PERMIT

WORK PERMIT THAT HAS MULTIPLE SELECTION

.
ELECTRICAL WORK
WORK AT HEIGHT

CONFINED SPACE ENTRY

HOT WORK OR COLD WORK

EXCAVATION
CONFINED SPACE

Examples:
Enter in side boiler, to repair tube leak.
Internal cleaning water Tunnel?
Cleaning soot inside exhaust piping structure
Cleaning, inside the tank?
Erection of scaffolding in the boiler?
Run Electrical cable on the 10 feet high cable trays?
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-6/Process of Work Permit /page-46
WORK PERMITS
WORK PERMITS
WORK PERMITS
WORK PERMITS
WORK PERMITS
 Cancelation of the WP due to Unsafe conditions
• Work must be stopped and the Work permit withdrawn if Safety Engineer/ safety
representative or WP issuer notice any unsafe condition to cancel work permit such
conditions are as followed:

a. PPE not equivalent with task.

b. The TRA not enough for the job
c. Work Permit Type not matching with actual Work.
d. Not follow safety work procedure.
e. Unsafe condition
f. Unsafe act
g. Others

• A receiver notices an unsafe work condition.

• A operational gas release activity is to be performed and the maintenance work cannot
be allowed to continue once the release activity is started.
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-12/Cancelation of the WP due to Unsafe conditions /page-70
 Durational Validity of Work Permits

 In general, normal routine maintenance works, Valid up to

the end of Issuers shift. 8 hours.

 More than one shift but not more than (7) days
(Shift foreman (issuer) can issue work permit)

 For more than (7) days but not more than (30) days
Approval required. (Shift in-charge or supervisor & Supervisor of
maintenance / construction)

 For more than (30) days but not more than (120) days
Approval required. (Operation div manager or section head /
FOR DETAIL INFORMATION
maintenance div manager or construction)
Refer to Generation work permit procedure/section-8/Durational Validity of Work Permit /page-57
 Certification of WP issuer & Receiver

Work Permit Issuer Authorization requirement :

• Should have minimum 5 years of Experience.
• Should have attended following courses (All included in SAP) .
(a) Generation Work permit course .
(b) Power Plant Safety course.
(c) Fire Prevention / protection course.
(d) First Aid course.
(e) Risk assessment course.

• Nominated and authorized officially by his proponent division Manager /

Section head.
• Should be interviewed by two seniors, operation and area safety Engineer .
• The validity of a Work Permit Certificate is 2 years.
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-9/ Certification of WP issuer & Receiver /page-59
 Certification of WP issuer & Receiver

Work Permit Receiver Authorization requirement :

• Should have minimum 3 years of Experience.
• Should have attended following courses (All included in SAP) .
(a) Generation Work permit course .
(b) Power Plant Safety course.
(c) Fire Prevention / protection course.
(d) First Aid course.
(e) Risk assessment course.

• Nominated and authorized officially by his proponent division Manager /

Section head.
• Interviewed by one senior from his trade and other from operation and area
safety Engineer .
• The validity of a Work Permit Certificate is 2 years.
 Certification of WP issuer & Receiver

Work Permit Receiver (Contractor) Authorization

requirement :
• The contractor must have attend one day induction
course in plant given by area safety engineer and
Generation Work permit course .
• Nominated and authorized officially by TSD
Manager ,operation division Manager / Section
head .
• The validity of a Work Permit Certificate is 2 years.
Generation Issuer Receiver Certification Form (GWPF – 001) :
 Duties & Responsibilities

Authorized work permit issuer :

• Responsible for Issue and close of all work permits as per the GI.
• Processes clearances and work permits as per the GI and as instructed
by the Shift Foreman.
• Perform gas test according to the task requirement.

Receivers :
• Responsible for working in the safest manner and ensuring members
of his crew follow safe work practices.
• Responsible for notifying the Issuers if any unsafe condition develops
• Responsible to ensure that boundaries within which work is permitted
is not crossed .
FOR DETAIL INFORMATION
Refer to Generation work permit procedure/section-10/ Duties & Responsibilities /page-62
What is PPE

..
PERSONAL PROTECTIVE EQUIPMENTS
PERSONAL
PERSONAL PROTECTIVE EQUIPMENTS
PROTECTIVE EQUIPMENTS (PPE)
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

PERSONAL PROTECTIVE EQUIPMENTS

•
 PERSONAL PROTECTIVE
PERSONAL PROTECTIVE EQUIPMENTSEQUIPMENTS
(PPE)

Head Protection
All employees must wear he head
protection helmet in the following cases:

Feet Protection
All employees shall comply with the
using of safety shoes at entering an area
requiring the same.
 PERSONAL PROTECTIVE EQUIPMENTS
PERSONAL PROTECTIVE EQUIPMENTS (PPE)

•
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

• Noise

• Your ears can tolerate;

• At 85 decibels, up to 8 hours of exposure.

• At 91 decibels, up to 2 hours of exposure.
• At 100 decibels, damage can occur with 15 minutes of exposure.
• At 112 decibels, damage can occur with only one minute of exposure.
• At 140 decibels, immediate nerve damage can occur.
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

Protect your eyes and face at work,

Special protection consistent with the nature of work
hazards include:
 Parts of scattered objects where concrete cutting,
carving, chiseling or punching and coarse grinding works.
 Dust and small flying particles where sawing, cutting
using a thin saw, grinding, cleaning by sandblasting or,
metal works, peeling and cleaning by pneumatic
equipment.
 Metal scattering (such as welding spray or lead molding).
 Hazardous gases, vapors and liquids (such as acids,
caustics, ammonia and similar liquids and gases).
 Harmful radiant energy such as gas and electrical
welding.
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

• Hand Protection and Work Clothing

Employees working on electrical works must
avoid wearing jewels, key chains, or other
metallic pieces on fingers and arms, because it is
possible that such metal pieces contact an active
electric circuit.
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

• Rubber Gloves for Low-

Voltage Electrical Works
 Energized work permit can by issued
only for 480V or less.
 Low-voltage Rubber gloves should be
worn with the leather protectors.
 ARC FLASH SUIT
 Arc flash suit should be used for the
switching, isolation or grounding the
high voltage bus equipment like
breaker Local switching racking IN or
OUT, disconnects operations.
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

Electrical O&M General Rules

 The employees should follow the warning signs
 The maintenance staff should be aware
maintenance work procedures.

 Employees who work in energized parts and

insulated from the ground should not exchange
tools or other objects with other not insulated
employees form ground.

 Jumper connections shall be attached first to the

de-energized part then to the energized and the
removal shall be in the reverse order.
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

• Electrical Protection
 Avoid wearing rings, wrist straps, witches, chains and hats hat contain metal
parts and loose clothing.
 Approved Ground Fault Circuit Interrupter (GFCI) shall be used electrical
maintenance works especially when using portable power tools and
equipment’s.
 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

Working in chemical cleaning area.

Portable Eyewash and shower

•
Why PPE safety harness important?? Watch video.
 General Safety Requirements

MSDS
Material safety data sheets
 General Safety Requirements

MSDS
Material safety data sheets
TASK RISK ASSESSMENT
 TASK RISK ASSESSMENT

• Focus on the TRAP...not the cheese!

 TASK RISK ASSESSMENT
What is
 Electrical works
Hazardous Task  Mechanical works
 Cold works
 Hot works
 Work at Height
When  Gamma Ray Test
Examples
we have work at of such  Diving in sea water.
plant Hazardous  Lifting and Transporting
We have Task Tasks
 Chemical
related hazards  Work in Dark
 Work in windy weather

FOR DETAIL INFORMATION

Refer to Generation work permit procedure/section-7/Task Risk Assessment /page-47
 TASK RISK ASSESSMENT
Hazardous Tasks examples
 Entangled cloth, hair, jewellery with moving parts etc.
 Crushing due to Material falling off, tripping, rolling,
unexpected movement of the plant.
 Cutting, Stabbing or Puncturing with sharp objects
 Shearing, Friction, slipping, Striking, falling.
 Expose to high pressure fluid, steam, compressed air.
 Electrical live contact, overload elect circuit, poor
maintain elect leads cables, damaged switches, water
near electrical equipment, lack of isolation procedure.
 Poor housekeeping, Unprotected holes, oil spills
 Lack of proper platforms, ladders stairs, steep surface.
 TASK RISK ASSESSMENT PROCESS

Why TRA ?

 Task Risk assessment should be carried out to minimize the risk.

 Work permit issuer /receiver should assess the risk.
 Follow a systematic process by using Task Risk Assessment
 Consultation are required at every step of the risk with workers and
their safety representatives.
 TASK RISK ASSESSMENT PROCESS

TASK RISK ASSESSMENT STEPS

1. Identifying hazards
2. Assess the risks associated with these hazards,
evaluate WHAT and WHO is at the risk.
3. Evaluate the present risk control rating.
4. Reviewing risk control measures and make
additional control measures
5. Implement and maintain risk control
measures.
TASK RISK ASSESSMENT RISK

Risk Rating
=
Likelihood X Severity
 TASK RISK ASSESSMENT PROCESS

Remember

 A Hazard is something that has the potential to

cause harm or risk of injury (the severity),
 A Risk is the chance that harm will occur (the
likelihood)
 PROCESSING OF WORK PERMIT
TASK RISK ASSESSMENT STEPS
Likelihood Likelihood and Description: Rating

Extremely
Likely
It is inevitable that an injury, illness or damage will occur 5
Will happen more often than not. Additional hazardous
Likely conditions may be relevant but it is still likely to happen even 4
without these additional hazardous conditions being present

Injury, illness, or damage may occur if additional hazardous

Possible
conditions are relevant but it is unlikely to happen without them 3

Injury, illness, or damage might occur but the probability of this

Unlikely
happening is low 2
Only under unusual or unique conditions could there be any
Extremely possibility of any injury, illness, or damage occurring. All
Unlikely reasonable precautions have been taken. This should be the 1
normal state of the workplace
 PROCESSING OF WORK PERMIT
TASK RISK ASSESSMENT STEPS
Points Rating
Severity Severity and Description:
Fatality, and or Multiple Fatalities. Catastrophic damage to buildings, plant,
Very High equipment, leading to the complete, and total shutdown of the facility. 5
Major pollution with long-term implication and very high restitution costs
:
Major injury, or major occupational disease or illness that will require
professional medical and surgical treatment in addition to prolonged
High physiotherapy, or residential care. Damage to equipment resulting in 4
production shutdown and significant production loss. Severe pollution with
short-term localised implications incurring significant restitution costs

Event leading to a lost time injury or minor occupational disease or illness

that will require professional medical and or surgical treatment. Localised
Moderate
damage to equipment requiring extensive repair, significant loss of 3
production or moderate pollution incurring some restitution costs

Minor injury requiring first-aid treatment. Damage to equipment requiring

Slight minor remedial repair, some loss of production or impact to the 2
environment

Negligible injury or health implications, no absence from work. Negligible

Negligible
loss of production with no damage to equipment or the environment 1
PROCESSING OF WORK PERMIT
TASK RISK ASSESSMENT
TASK RISK ASSESSMENT
 Risk control
 Elimination – The most effective
control measure is to remove the
hazard or hazardous, If elimination is
not reasonably practicable, you must
minimize the risk by:
 Substitution – substitute the plant
equipment (or hazardous parts of it)
with plant equipment that is safer.
 Engineering control, Isolation – separate
the hazardous plant from people,
either by distance or physical barrier.
For
 Risk Control

 Administrative controls:
 Rely on human behavior and supervision.
 Follow safety procedure
 Implementing a lock-out, tag-out system to
ensure that plant is isolated from its power
source while maintenance work is being done,
 providing training and supervision,
 Using warning signs.
 Risk Control

 Use PPE :
 Protect worker by using PPE, such as
breathing protection, hard hats, gloves,
aprons and protective eyewear.
 Risk Control

CASES STUDY AND PRATICES

 UNSAFE CONDITIONS
 INCIDENTS/ ACCIDENTS
 NEAR MISS STUDY
Carry out TRA, Find out what are the hazard and risk involved for fuel oil
pump removal for overhauling,
Task: Overhaul the UNIT#12 FUEL OIL PUMP A
Likelihood; 1 – Extremely Unlikely, 2 – Unlikely, 3 – Possible, 4 – Likely, 5 – Extremely Likely
Severity; 1 – Negligible, 2 – Slight, 3 – Moderate, 4, High, 5 – Very High
It will be acceptable for work to proceed however continually review the work activity once it has begun to identify if the risk can be reduced
1 -6
further
Work may proceed but where possible the work activity should be redefined to take account of the hazards involved or the risk should be reduced
8 to 12
further prior to the work activity taking place
The work activity should not proceed. It should be redefined or further control
15 to 25 measures put in place to reduce the risk further. The risk control measures should be
re-assessed for adequacy prior to and throughout the work activity taking place
Risk Residu
Rating al Risk
Rating
Identified Who, or What is at Risk Existing Controls Residual Risk after
Hazards L S R Additional Control Measures L S R

Electrical
work
Mechanical
Electrician, / electrical shock

Mechanics / possibility of injury

GOD BLESS YOU ALL
Equipment Isolated, lock out tag out.

Equipment Isolated, lock out tag out.

Drain out
3 5 15 Ground the motor, do voltage test. Use
electrical PPE, training
2 3 6 Use proper tool and PPE
1 5 5

1 3 3
work
Welding job Welder / burn, fire ,injury
THANKS Gas testing 4 4 16 Drain and purge the pump, remove oil
from the area, use oil absorbent, fire
blanket
2 4 8

Pump lifting Mechanic / injury , damage equipment none 3 3 9 Proper training of crane operator, use 2 3 6
and proper sling wire, barricades the area.
transporting Secure the motor with pallet, drive with
extra care with warning light on. Follow
proper procedure.

Work at Oily Work crew / fire , slipping, falling, injury Equipment Isolated, lock out tag out. 3 4 12 Drain and purge/clean the pump, remove 2 4 8
area oil from the area, use oil absorbent, fire
blanket,
 WORK HAZARD
Focus on the TRAP...not the cheese
WORK PERMIT AND
SAFTY VIOLATION

LET’S IDENTIFY
HAZARD DO TRA
WITH GROUP
WORK PERMIT VIOLATION
WE SHOULD STOP THIS

What is
hazard ?
 RISK ASSESSMENT
What is
hidden
hazard ?

H idden dan ger.mp4

 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

What is
hazard ?
RISK ASSESSMENT

What is
hazard ?
What is
hazard ?
RISK ASSESSMENT

What is
hazard ?
RISK ASSESSMENT

What is
hazard ?
What is
hazard ?
What is
hazard ?
EXAMPLES OF UNSAFE PRACTICES
What is
hazard ?
What is
hazard ?
What is
hazard ?
What is
hazard ?
What is
hazard ?
What is
hazard ?
What is
hazard ?
What is hazard ?
WORK PERMIT VIOLATION
What is
hazard ?
Safety violation
What is
hazard ?
Do not cross
Yellow lines
 RESPONSIBILITY
 What is your responsibility after completing
this course?
 Our responsibilities are
 Prepare requirements such as venue location, training
material, knowledge and Exam to achieve GI awareness
program goals in your sector.
 Present training work shops in your sector according to the
schedule and you could get support from (Javaid / Hogan)
 Follow up with the trainees attendance and facilitate them
as per their need.
 THANKS
GOD BLESS YOU ALL