WORK PERMIT

1. WORK PERMIT A.K.SINGH, SAFETY MANAGER INDIANOIL CORPORATION LTD. BARAUNI REFINERY, INDIA

2. 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

3. 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.

4. 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.

5. 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.

6. WORKS - PERMIT NOT REQUIRED • Works carried out by Oprs. Dept. as a part of routine operation. • FIRE STATION • FIRE TRAINING GROUND

7. BLANKET PERMIT SIX MONTHS BASIS / MAX I YEAR • WORK SHOP • INSTRUMENT LAB/WORKSHOP • LABORATORY • INSPECTION

8. 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

9. 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:…...

10. Special instructions printed on the permit

11. 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.

12. 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.

13. 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.

14. 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.

15. 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.

16. 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.

17. 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.

18. 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

19. 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)

20. RESIDUAL HAZARDS • Lack of oxygen • H2S and/or any other toxic gases • Combustible gases • Corrosive chemicals • Steam / Condensate • Pyrophoric iron • High humidity

21. PROTECTION MEASURES • Protective clothing • Hearing protection • Safety Harness • Eye protection • Face protection • Respiratory protection • Keep fire equipment stand-by

22. 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

23. PROTECTIVE MEASURESCONTD. • To ensure positive isolation & maintain it all through • Ensure adequate ventilation all through • Display copy of entry permit near entry manhole

24. 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

25. 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.

26. GAS TESTCONTD. 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.

27. 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.

28. 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).

29. 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

30. 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.

31. 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.

32. GAS TEST - H2S EFFECTS ON HUMAN BODY PHYSICAL EFFECTCONC.(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

33. GAS TEST - H2SCONTD. PHYSICAL EFFECTCONC(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.

34. GAS TEST-H2SCONTD. 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.

35. GAS TEST-H2SCONTD. 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

36. TOXIC GAS - CO TOXIC AS WELL AS FLAMMABLE TLV - 50 PPM STEL - 400 PPM IDLH - 1500 PPM LEL - 12.5% UEL - 74 %

37. 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.

38. OTHER TOXIC GASES TOXIC GAS TLV STEL IDLH NH3 25 35 - SO2 2 5 - CL2 0.5 1 30

39. 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

40. 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.

41. 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.

42. 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.

43. 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.

44. ‘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)

45. 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

46. 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.

47. 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.

48. 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.

49. 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.

50. 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).