SAFETY WORK PERMIT

SYSTEM

CORPORATE S&ES

Safety Work Permit Issuer Training 1

 OBJECTIVES

BY THE END OF THIS TRAINING PROGRAMME THE PARTICIAPNTS

WILL BE ABLE TO UNDERSTAND :

--- WHAT IS A SAFETY WORK PERMIT

--- WHY IT IS REQUIRED

--- HOW IT SHOULD ISSUED

--- HOW IT MAKES THE SYSTEM EFFECTIVE

AND QUALIFY TO BE SAFETY PERMIT ISSUER, AFTER SUCCESSFUL

COMPLETION OF THE TEST

Safety Work Permit Issuer Training 2

 WHAT IS SAFETY WORK PERMIT

A DOCUMENT USED TO ENSURE THAT AN

HAZARDOUS WORK IS CAREFULLY PLANNED,

CONTROLLED AND EXECUTED SAFELY

Safety Work Permit Issuer Training 3

 REMEMBER !!!

• Issuing Safety Work Permit alone does not make

work safe

• How we perform the job depends on how we prepare

and how we proceed.

• Before we can prevent an accident we must think of

how it could happen.

Safety Work Permit Issuer Training 4

WHY WE MUST USE A SAFETY WORK PERMIT?

• Identify hazards.
• Communicate hazardous job requirements to
employees.
• Ensure proper safety equipment and procedures
are used/followed.
• Identify responsibility.
• Ensure all personnel understand what they must
do.
• Plan and control the job.

Safety Work Permit Issuer Training 5

WHO IS RESPONSIBLE FOR SAFETY WORK PERMIT?

• UNIT MANAGER IN CASE OF INOXAP FACILITIES

• INOXAP INCHARGE IN CASE OF INOXAP SUPERVISED

CUSTOMER ACTIVITIES

WHO CAN ISSUE A SAFETY WORK PERMIT?

• A PERSON WHO IS AUTHORISED BY THE PLANT MANAGEMENT
EITHER BY HIS EXPERIENCE AND BACK GROUND OR
QUALIFYING THE SWP ISSUERS TRAINING PROGRAMME.

• LIST POSTED OR AVAILABLE IN THE UNIT

• SELF PERMIT IS ALSO POSSIBLE AS IN THE CASE OF ECW

PERSONNEL
Safety Work Permit Issuer Training 6
 S W P EXEMPTED WORKS – GUIDELINES
1. Routine preventive maintenance tasks (lubrication, vibration monitoring, etc.) where
there is a documented procedure to indicate the hazards and the means for their control.

2. Work in an identified maintenance or construction shop.

3. Construction of new grassroots facilities (excavation work, confined space entry,

or certain uses of hazardous materials or techniques may require work
permits).
4. Grass cutting/lawn maintenance outside of process areas.

5. Fork lift or flat tire repair, etc., outside of process areas.

6. Use of vehicles (fork lift, man lift, etc.) outside of process areas.

7. Work in administrative buildings where the employee controls the hazard (i.e. changing
light bulbs, working on a PC or copy machine, etc.)

8. Work in R&D labs by the equipment owner/operator where the employee controls
the hazard.
9. Hot work in a maintenance shop or designated fabrication area.

It is important to note that the activities in the above listing are not all inclusive,
but should be used as a guide for determining whether permits are needed or not. Hence
there is a question as to whether a work permit should be
prepared, and then a permit is necessary.
Safety Work Permit Issuer Training 7
 WORKS WHICH TYPICALLY REQUIRE S W P
1. All maintenance or servicing activity in a process or operating area.
2. Working on or near or opening process equipment (this includes vessels,
pipelines,valves, utilities, controls, etc.), exclusive of normal operating activities.
3. Construction works in operating (process) areas.
4. Construction work adjacent to operating (process) areas.
5. Inspecting process equipment when it exposes employees to rotating parts, energized
electrical circuits, pressure hazards, or other energy related hazards, etc.
6. Removal of a guard from operating equipment or bypass of a safety control system.
7. Excavation/digging.
8. Use of vehicles in electrically classified areas.
9. Hot work (welding, torch cutting, etc.)
10. Confined space entry.
11. Construction or maintenance activities that use hazardous materials or techniques
(e.g. radiography, explosives, sandblasting, painting, high pressure water blasting,
etc.).
12. Any activity (normal or abnormal) which the facility manager determines is potentially
hazardous.
13. During the lockout/tagout of electrical, mechanical, or process equipment when
performed for maintenance or servicing activities.
14. When work is performed that would cause or require impairment to any fire protective
systems.
15. Involvement of outside contractor personnel in any activity listed above or cases the
contractor's work activity takes place in the process area of the plant.

Safety Work Permit Issuer Training 8

 DEFINITIONS

1. PERMIT CONTROL CENTRE :

A clearly defined and identified location(s) on a facility where Safety Work
Permits are administered, e.g. control room, site offices.

2. PERMIT ISSUER:

A person who has received training and / or authorized by the accountable

Facility Manager. They authorize the work to take place by use of the Safety
Work Permit Form

3. PERMITEE :

The person who receives the permit and carries out by himself or responsible
for carrying out hazardous work as indicated in the permit form.

Safety Work Permit Issuer Training 9

 DEFINITIONS (Cont’d)
4. AFFECTED:

The persons who would be directly affected if the safety precautions as per the
permit are not taken.

5. OTHERS:

The persons who are not connected with the work and should be warned of the
activities, so that they would not get them selves endangered by the hazardous
activities going around.

6. LOCK OUT / TAG OUT:

The placement of a lock and danger tag on an isolating device indicating that the
isolating device and its system shall not be operated until the lock and danger tag are
removed.

7. ISOLATION DEVICE:

A device which prevents the unwanted operation, pressurization, commissioning,

etc., of an energized system which could result in the death, injury, or ill health of
personnel working on or near that system. Eg: Blinds, block valves, electrical
breakers, etc Safety Work Permit Issuer Training 10
 TYPES OF SAFETY WORK PERMIT

• Master Safety Work Permit

A Master Permit is designed to allow all crafts to work under one
Safety Work Permit for the isolation of hazardous energy and a subsequent
permit (Secondary Permit) for job-specific hazards and precautions (US practice)

• Standardized Permit
These permits and tags are designed so they are reusable
for the same repetitive tasks. The use of standardized permits allows
facilities to reduce the workload of generating the same permit repeatedly for
jobs that require large amounts of tags (US practice)

• Safety Work Permit

These permits are issued for a specific job and is the preferred one. At
INOXAP, we use this type of permit only

Safety Work Permit Issuer Training 11

 PERMIT ISSUERS RESPONSIBILITIES

• Hazard Identification

• Energy Isolation

• Communication

• Monitoring

• Close out

Safety Work Permit Issuer Training 12

 HAZARD IDENTIFICATION

• Identify existing and foreseeable hazards

• Use B-SAFE technique to identify any existing and potential hazards

• Use Process knowledge, MSDS, knowledge of the activity planned, etc to identify
Possible hazards

• Eliminate or minimize hazards

• Provide protection against residual hazards which can not be removed

• Ensure equipments used for identifying hazards are working and used by
Trained personnel

Safety Work Permit Issuer Training 13

 ENERGY ISOLATION

EQUIPMENTS / PROCESSES REQUIRING ISOLATION:

• MACHINERY

• PRESSURISED SYSTEM

• CHEMICAL SYSTEM

• ELECTRICAL SYSTEM

• SAFETY AND EMERGENCY SYSTEM

Safety Work Permit Issuer Training 14

 MACHINERY ISOLATION

• ISOLATE THE ENERGY SOURCE FOR MOTION

SOURCE ISOLATION

Electrical Positively disconnect from source

Pneumatic Disconnect the impulse line

Hydraulic Disconnect or depressurize fluid line

Gravity Support to hold by physical means

Safety Work Permit Issuer Training 15

 PROCESS SYSTEM ISOLATION

CRITERIA FOR CONSIDERATION DURING ISOLATION OF A PROCESS

• The system fluid.

• Its pressure.
• Its temperature.
• The system volume behind it.
• The system design parameters,
e.g., it might be all welded with no flanges or removable spool,
or it may have a single isolation valve only.
• The effect on personnel and the surrounding area in the event of an
isolation failure.

USE CIRCLE OF SAFETY OVER P&ID AND VERIFY BY PHYSICAL

INSPECTION AT SITE

Safety Work Permit Issuer Training 16

 PIPE LINE ISOLATION

IN THE DECREASING ORDER OF SAFETY:

1. Remove piping spool (physical disconnection) and fixing blind flanges.

2. Fixing Blinds
3. Double Block Valve and Bleed Valve
4. Closing of isolation valves and locking to physically restrain from operation.
5. Closing and providing warning tags

DO NOT RELY ON…….

CHECK VALVES to isolate.

CONTROL VALVES to isolate (unless additional precautions have been taken).
PRESSURE GAUGES being accurate.
PURGES unless constantly monitored.
SPRING FLANGES to give bleed.
GLOBE VALVES with pressure under the seat unless CLAMPED.
BLEED VALVES staying clear.

Safety Work Permit Issuer Training 17

 ELECTRICAL ISOLATION

• To be isolated by competent persons only.

• Isolators, breakers and switches should be locked in the de energized

position.

• If not lockable use other methods physically restraining them from

inadvertent operation.

• Attempt to start the equipment to ensure positive isolation.

• If the work is on the electrical equipment itself, remove fuse, pull out
breaker and ensure physical isolation of the circuit.

• Endorse the isolation details in the Safety Work Permit or Isolation record
sheet

Safety Work Permit Issuer Training 18

 LOCKOUT / TAG OUT

• Use Locks to physically restrain an isolation device in case the energy cannot
be isolated by physical disconnection.

• Locks used for this purpose should have id nos. which should be mentioned in
the energy isolation record or in the SWP.

• Keys of the locks should be under the control of the permit issuer.

• More locks are put for a single safe work permit, all the keys can be kept in one
box and locked, whose key shall be under the control of permit issuer.

• If the system is not lockable then tags can be used to warn people from
inadvertent tampering of the isolation.

• Such tags should be unique and possess serial no which should be indicated
in the energy isolation record. The stubs are to be attached with the
permit copy in possession of the permit issuer.

• After locks or tags are removed, close the energy isolation record.

Safety Work Permit Issuer Training 19

 ENERGY ISOLATION RECORD
Description of the Job:

Safety Work Permit No:

Date / time Isolation Type of Id. Number Signature Remarks Date /time Signature
of isolation Location / Isolation of Lock / of the of removal of the
System (Lock/ Tag/ tag authorized of isolation authorized
Description blind/ person person after
others) removal

Safety Work Permit Issuer Training 20

 SAFETY WORK PERMIT TAGS
BLACK
S No:99999

RED
DANGER
DANGER
THIS

DO NOT REMOVE VALVE OPEN

THIS SAFETY SWITCH CLOSE
(Strike off the ones not applicable)
WORK PERMIT TAG Reason: …………………………….
……………………………………….
DO NOT OPERATE UNTIL
THIS TAG IS REMOVED
SEE THE OTHER SIDE Signature ………………………………..
PERFORATION
FOR DETAILS Date: …………………………………… FOR REMOVING
VALVE OPEN S No:99999 THE STUB
SWITCH CLOSE
Location: …………………………….
Signature ………………………………..
………………………………………. Date: ……………………………………

FRONT SIDE
BACK SIDE

TO BE USED EXCLUSIVELY FOR ISOLATION IN CONNECTION WITH ISSUE

OF SAFETY WORK Safety
PERMIT Work Permit Issuer Training 21
 COMMUNICATION

Permit Issuer to conduct pre job discussion to the permitee at the job site,
which include:

• The details of the job to be performed

• The hazards identified and eliminated by way energy isolation, locking and tagging
• The residual hazards present before and during the course of performing the job and
the precautions to be taken up as listed in the reverse side of the permit form
• The emergency situations that could arise and how to react to them

As far as possible, communicate to all the persons involved in the job.

Get their acknowledgement in the SWP form to the effect that they understand
all the risks involved, precautions taken and emergency response are
understood.

Communicate to others by display of permit, warning signs, barricade, etc.

Safety Work Permit Issuer Training 22

 MONITORING

Permit Issuer should monitor periodically the work progress and

compliance of all safety work permit conditions.

Any responsible person walking around the work area, can cross
check if all the conditions stipulated in the work permit displayed or in
possession of the permitee are complied. If not, the permit issuer can
be informed and the work suspended till the conditions stipulated in
the permit are restored.

Monitoring by instruments or other equipments if warranted by the

permit should be recorded in the permit or in appropriate form.

Safety Work Permit Issuer Training 23

 CLOSE OUT

THE WORK SHOULD BE STOPPED IF :

• There is a site emergency.

• The Receiver is instructed to do so.
• There is a change of conditions or any operational reasons which invalidate
the Safety Work Permit.
• They intend to leave the work site or facility.

IN CASE OF EMERGENCY, THE WORK PERMIT CAN BE :

SUSPENDED, if the reasons for stoppage can be removed and restarted

CANCELLED, If the permit is unlikely to remain valid, even after the reason for stoppage is removed

The reasons for suspension or cancellation should be clearly indicated

In the permit.

Transferring Permit Issuer responsibility: if the permit issuer is to leave the work spot for
any reason and cannot supervise the activities can transfer to another authorized person.

Permit is closed, if the crew changes and fresh permit is issued.

Permit is signed off, both by the permitee and permit issuer at the work spot after satisfying that
the work is completed and the area is made safe and clean.
Safety Work Permit Issuer Training 24
 PRECAUTIONS AGAINST RESIDUAL HAZARDS
Potential exposure to Hazardous Atmospheres:

POSITIVE ISOLATION: Spool piece removal, fixing blind, double block and bleed, closed and locked

PURGING: Remove hazardous atmospheres (No flammable, toxic or oxygen enriched or deficient )

MONITORING: Flammable Gas – should be less than 10 % of LEL of the expected Gas
Toxic Gas – Less than the TLV of the expected gas
Oxygen content – should be between 19 to 22.5 %
Done using calibrated instrument, at higher frequency initially and at a reasonable
frequency later.
PROTECTION AGAINST HAZARDOUS ATMOSPHERES: PPE’s such as respirators, clothing, etc

IN CASE OF ENTRY IN TO VESSELS ADDITIONALLY :

COMMUNICATION: between the entrant and the attendant, effective, quick and understandable

EMERGENCY HANDLING: Rescuer, rescue equipment, alarm signals etc

Safety Work Permit Issuer Training 25

 PRECAUTIONS AGAINST RESIDUAL HAZARDS (Cont’d)

Elevated Work: (Work more than 2 metres from ground or platform without any permanent handrail)

LADDER INSPECTION: (Sturdy uniform rungs, suitable for load, no metal ladder near electrical installation.

LADDER SUPPORTED: From top or bottom tied, held by a person, projecting three rungs above the top
landing

LADDER ON LEVEL AND STABLE: Have safety foot, ground is stable, hard and flat

SCAFFOLDS: Stable and suitable for load, no loose planks, strong enough to withstand at least 4 times
the expected maximum load, side rails available, if made of casuarinas, fresh and strong.

BARRICADING: Area below the work area with yellow / black or red/while tapes with caution sign board

TOOLS HANDLING: Use of tool box or bag to carry tools, kept securely, not to drop and fall

PPE’s: Safety belt with suitable body harness. Suitable location for fixing the rope, Safety net

Safety Work Permit Issuer Training 26

PRECAUTIONS AGAINST RESIDUAL HAZARDS (Cont’d)

EXCAVATION : (normally more than one metre deep by manual, and for any depth, when
machine is used)

UNDERGROUND UTILITIES: Identified, and isolated, special precautions discussed .

EARTHING: If mechanical tools are used, earthing, caution on any electrical over head or
near by sources.

CAVE IN PROTECTION: Shoring or slopping if the depth is more than 1.2 metres, depending
upon the soil quality and space available.

BARRICADING: Yellow / black or red/ white tape to caution.

REMOVAL OF WASTE : Remove at least one metre away from the pit to avoid slide back.

LIGHTING: In case of deep and long ditches, provide adequate lighting

ESCAPE /ACCESS STAIRS: Steps at every 8 metres length for access and emergency
escape.

ATMOSHPERIC MONTIRING: if there is possibility of gas leakage from underground pipelines

or sewerage system

Safety Work Permit Issuer Training 27

 PRECAUTIONS AGAINST RESIDUAL HAZARDS (Cont’d)

ELECTRICAL SHOCK POTENTIAL:

ISOLATION: Power supply isolated, locked and tagged, Circuit checked of zero voltage

INSPECTION: Electrical cables and tools inspected loose wires, bad insulation, bad joints, etc

SAFETY WATCH: Second person, in case of remote location, trained what to do in case of emergency

ELECTRICAL LINE CLEARANCE: 4 metres clearance maintained from the electrical power line /
conductors, when working near or using cranes, long tools or equipment

PPE’s: Approved electrical and leather gloves appropriate for the line voltage is provided

FUSE PULLER: Fuse puller provided to isolate and line up

RUBBER MATS: Especially while working on the electrical panels

CURRENT LEAK PROTECTION: Ground Fault Circuit breaker provided, when working with tools, or
with equipments which can cause over loading due to any reason.

Safety Work Permit Issuer Training 28

PRECAUTIONS AGAINST RESIDUAL HAZARDS (Cont’d)

FIRE AND EXPLOSION POTENTIAL JOBS:

• The equipment and the surroundings are tested for flammable and explosive gas (< 10 % of
LEL )

• All combustible material removed

• Fire fighting system provided, checked for its functioning

• Area wetted

• Fire blanket / fire extinguishers provided

• Spark resistant tools used

Safety Work Permit Issuer Training 29

PRECAUTIONS AGAINST RESIDUAL HAZARDS (Cont’d)
MOBILE CRANE ACTIVITIES:

• Crane inspected before use

• Valid test certificates and permits available

• Out riggers supported

• 4 metre electrical power line clearance checked

• Crane is kept on level

• Slings inspected and found suitable

• Load / lift rigging discussion held

• Safety observer assigned

Safety Work Permit Issuer Training 30

PRECAUTIONS AGAINST RESIDUAL HAZARDS (Cont’d)

SAFETY & FIRE FIGHTING SYSTEM IN DISABLED CONDITION:

• Proper documentation and communication of safety system bypass.

• Alternate Safety system available and communicated.

• Alternate arrangement for Fire fighting available

• Or, activities with fire risks are suspended.

• Increased vigilance of activities ensured

Safety Work Permit Issuer Training 31

 PROCEDURE TO ISSUE SWP ( a summary)

• Fill up the preliminary details in the form and go to the work spot

• Ensure hazards are identified and removed where possible.

• Ensure that all precautions from the residual hazards as listed in the SWP form are
taken care.

• Conduct pre job discussion with all the affected personnel at the work spot.

• Fill up the form and the permitee’s acknowledgement.

• Give the first copy to the permitee and the second one for display at the permit
control centre.
• Supervise at regular intervals the progress of the job safely.

• Once the permitee informs that the job is over, go the work spot and ensure that the
job is completed as per the requirement, and the area is clean and free from any
hazards.

• Permit is signed off by the permitee and the permit issuer in both the copies and one
of them is kept in the files for records and audit verification.
Safety Work Permit Issuer Training 32
 IMPLMENTATION PROCESS STEPS

• List the exempted jobs

• Ensure that exempted jobs do have procedures and persons are
trained well.
• Identify persons who need to be certified as SWP issuer
• Conduct training programme on SWP and qualify to be a SWP issuer
• Implement the system
• Keep the SWP and other related documents for audit and review
• Review the effectiveness of the system after one year
• Correct the system if required to make it more effective

Safety Work Permit Issuer Training 33

Safety Work Permit Issuer Training 34