safe maker

Responsibilities of Area Owner

• Ensure work cannot be done by alternative means of lower risk
• Ensure proper hazard identification and hazard mitigation are implemented
• Ensure requirements of WORK PERMIT are implemented, maintained, and followed in area of responsibility
• Ensure proper hazard identification and hazard mitigation are implemented
• Ensure Permit Issuers, Receivers, Safe Makers, Gas Testers, and Standby’s persons are trained and authorized
• Ensure qualified person selected to attend work permit training and meet the requirements to receive authorization card

Principles

• Issuers, receivers, safe makers, standby/fire watch, and gas testers shall be Authorized by EHSS
• All equipment shall be positively identified – equipment (physically shown and tagged)
• Issuer + receiver must conduct a joint site inspection
• Issuer ultimately accountable (equipment + area) is safe
• Issuer must be of Supervisory level or above for hot work permit, radiation work permit, and confined space
• Competency of issuers below supervisor’s level shall be identified and approved by area owner

Zero Tolerance

• Anyone has the authority to stop unsafe acts and rectify unsafe conditions immediately if it is posing a possible danger to him or to others
• No one shall ignore unsafe acts and/or conditions: it should be corrected immediately, or if it is not possible to correct it, the situation shall be safely stopped, reported, and recorded

Risk Assessment & JSA Application

• Energy Types: Thermal Energy, Mechanical Energy, Pressure Energy, Chemical Energy, Electrical Energy, Radiant Energy

Confined Space & Hot Work

• Knowing the definition of confined space according to OSHA Standard 29 CFR 1910.146
• Knowing the types of confined spaces and types of Hazards
• Knowing the hazardous for every confined space type and prevention control measures
• Knowing the definition of hot work according to OSHA Standard 29 CFR 1917.152
• Knowing the hazardous for hot work and prevention control measures
• Knowing gas Testing Requirements
• Knowing gas test Frequency Matrix
• Knowing threshold limits value (TLV) for commonly tested substances

Principles of Safe Work

• One permit per task
• Equipment shall not be taken for maintenance unless declared safe
• Making repairs or modifications on a tank, Pipeline, or other installation without shutting down operations

Definitions

• Radioactive Source Work: any work that involves radiography or X-ray of welded metal joints, performing corrective or preventive maintenance on radioactive sources, handling, storing, and transporting of radioactive source materials
• Radiation Safety Officer (RSO): a person assigned by TPC in accordance with applicable local regulations/standards for managing radiation sources within TPC
• Routine Works: work performed by any personnel in their normal duties as part of a Standard Procedure or Work Instruction
• Vehicle / Equipment Entry: the entry of an internal combustion engine vehicle or equipment in a classified hazardous area
• Risk Assessment: the application of one or more risk assessment methods to describe ongoing hazard identification, risk assessment, and determination of necessary controls for mitigation of risks

Safe Work Permit

• Why Do We Need A Work Permit?
  • Work permits ensure people safe, equipment safe, environment protected, and area safe
  • Allows work to start after safety measures and procedures obtained
  • Safe maker declared equipment and area is safe
  • Record that all probable hazards have been considered
  • Specifies what must be done to maintain a safe working environment
• Work Permit Types

Confined Space Entrant Responsibilties

• Ensure to "sign in" or "sign out" on the Confined Space Entry Log Sheet
• Follow all hazard mitigations in the permit and be alerted to changing conditions
• Be competent in using safety equipment as specified on the permit
• Exit and alert the Standby man in case of evacuation order, warning signs or symptoms of exposure, change in hazardous condition, or emergency siren activation
• Always follow Standby man's instructions and report any defects in equipment to the Standby man

Standby/ Fire Watch Core Responsibilities

• Present authorization card to the permit issuer before signing on the work permit
• Familiarize themselves with location, use of emergency equipment, and alarm buttons
• Communicate immediately in case of an emergency by activating the nearest Manual Call Point, paging, radio, etc.
• Ensure emergency equipment is available and familiarize craftsmen with escape routes, Emergency Assembly Point, and Safe Assembly Area
• Follow the Emergency Control Plan and monitor work permit requirements and gas test frequencies
• Stop work if working conditions are unsafe, an emergency occurs, or sirens are activated

Maintenance Manager Responsibilities

• Ensure the WORK PERMIT process is applied as per the method
• Communicate reported WORK PERMIT deviations during the IMRS Forum meeting and take action
• Audit frequently all issued work permits to ensure compliance
• Ensure rescue equipment is provided by contractors

EHSS Fire Chief Responsibilities

• Carry out rescue operations within Confined Spaces as requested by the area owner
• Inspect life-supporting equipment and other emergency equipment for temporary use
• Ensure certification and qualifications of third-party rescuers when outsourced
• Conduct rescue drills before task execution

Permit Issuer / Receiver Common Responsibilities

• Conduct a face-to-face discussion to ensure understanding of Scope of Work, JSA, and conditions
• Conduct a site joint visit to identify hazards and agree on proper hazard mitigation
• Ensure all process and asset work hazards are identified and mitigated
• Ensure proper hazard mitigation is taken for all identified hazards and asset work-related hazards

Standby/ Fire Watch Core Responsibilities

• Communicate permit conditions to the replacement Standby/Fire Watch before handing over the shift
• Not leave the post until relieved by another qualified person or the task is completed or called off
• Not perform additional activities/tasks while performing Standby/Fire Watch duties
• Immediately report problems in the specific unit to the communication control center or control room
• Wear a reflective vest to be identifiable while on Standby/Fire Watch duty
• Be certified and trained in fire extinguisher training by a third party

Fire Watch Responsibilities During Hot Work

• Take precautions to keep people from entering the area underneath hot work at above ground level
• Keep sewer openings, drains, and floor openings covered
• Watch for fires created by hot work
• Be familiar with the Emergency Control Plan in the event of a fire
• Handover work permit status to the counterpart at shift change
• Ensure all work permits are immediately suspended in the event of an emergency
• Ensure re-validation of work permits after suspension

Permit Issuer Responsibilities

• Ensure compliance to work permit Method
• Ensure original copies of work permits and associated documents are displayed at the designated area
• Verify authorization of required work permit signatories during the issuing step
• Issue work permits after receiver signature and handover the copy to the Permit Receiver
• Conduct a work area field check with the incoming Safe Maker and have a face-to-face discussion
• Ensure work permits are closed out when the task is completed, changed, or when the validity period expires
• Have full control over the number of permits issued for all permits in the area

When Work Permit is Not Required

• For TPC Operations' forklift driven by operation within the Hazardous Area Classification
• For any operation work performed by qualified contractors working under operation within their normal operating responsibilities
• For work in designated exempted areas with a Job Safety Analysis conducted and approved by the Area Owner

Process Isolation

• Process Isolation includes the following categories:
  • Proved Isolation
  • Isolation
  • Positive Isolation
• Proved Isolation by Double Block & Bleed method is considered safe for Cold Work only.
• Double Block & Bleed method involves closing two positive shut-off valves and opening a bleed (vent/drain) valve in between.

Proved Isolation

• Valves used for Double Block & Bleed may be remotely or automatically operated.
• In some cases, the energy supply (air, electricity, etc.) shall be disconnected and the position of the valve shall be assured by a spring, pin, or other locking device.
• Isolation valves shall be verified to be properly holding, and Bleeders must show no leakage.
• All valves shall be locked and tagged with a “Danger - Do Not Operate” tag.
• The Safe Maker shall visit the area frequently to check and ensure the isolation integrity.

Isolation

• Isolation by Single Valve & Bleed is considered for Cold Work in very limited cases where provision of Double Block & Bleed is not available at the asset and with satisfying protection and mitigation conditions.
• Rotating equipment, where available, shall be positively stopped (pinned, locked, or equivalent).
• Methods used for disconnecting belts, chain drives, and mechanical links on shaft-driven equipment.
• Disconnecting mechanical drivers, shafts, securing mechanical parts, and disconnecting steam heat tracing.
• Pressurized actuators, fail-open/fail-closed valves in accumulators, and rundown tanks are considered mechanical isolation.

Positive Isolation

• Positive Isolation by installing a Rated Blind or Disconnecting Pipe is considered for Hot Work and/or Confined Space Entry.
• To verify that the isolation valves are holding, the Bleeder must show no leakage.
• All valves shall be locked and tagged with a “Danger - Do Not Operate” tag.

Equipment/System Isolation Requirements

• Any isolated equipment/system shall contain all and/or the following:
  • Master Tag list that is prepared and verified by the shift supervisor for listing and identifying all locked valves and/or locked electrical sources.
  • Master blind list that is prepared by the area staff of operations, approved by the Area Owner, for listing and identifying all blinds and pipe disconnections.
  • Marked-up P&ID.

JSA Form

• Before issuing a work permit, all process and non-process equipment to be worked on shall be made safe.
• The issuer shall ensure that the following are completed before the permit is issued:
  • The equipment to be worked on shall be positively identified.
  • Identify potential hazards and take precautionary action to control/mitigate/eliminate the hazard.
  • Isolate the energy sources.
  • Isolate the process from the equipment.
  • Prepare the equipment itself for safe working on it.

Safe Making

• All process and non-process equipment to be worked on shall be made safe before the work permit is issued.
• The equipment to be worked on shall be positively identified by tagging prior to the start of the work.
• All required information must be written on the tag, including equipment number, name, date, and signature of the safe maker.
• Tags can be attached to equipment by any appropriate means suitable for the application.
• Tags must be placed in a clearly visible position.
• After completion of all tasks, it is the responsibility of the Safe Maker (area operator) to remove the tags after work completion.

Confined Space Entry

• Confined Space Entry Package and preparation:
  • Confined Space hazard identification
  • Confined Space Entry preparation
  • Ventilation requirements and gas testing for Confined Space
  • Rescue plan preparation and requirements for Confined Space Entry
  • Safe access and exit for Confined Space
  • Condition changes during Confined Space Entry Permit
• Work inside Confined Space.

Factors Contributing to Confined Space Injuries

• Failure to recognize confined spaces
• Underestimating the danger
• Unspecialized people attempting to rescue their colleagues

Confined Space Categories

• “A” Category Confined Space Authorization: Confined space where it is possible for hazardous substances to be present and permanent breathing apparatus shall be worn during the execution of the task.
• “B” Category Confined Space Entry Authorization: Confined space where there are no hazardous substances or where the environment can and has been made safe and can be kept safe during the execution of the task.

Confined Space Entry Package and Preparation

• JSA
• Ventilation plan
• Master blind list & marked up P&IDs
• Master tag list & marked up P&IDs
• Energy isolation form
• Lifting plan
• Excavation request certificate

Energy Isolation

• Energy Isolation including:
  • Electrical Isolation
  • Process Isolation
  • Mechanical Isolation
• Before deenergizing, the equipment shall be in the off condition.
• Equipment tag information shall be matching with the Master Tag List.
• “Bump Test” shall be done to ensure equipment cannot be restarted.
• Low Voltage to be isolated by a qualified and trained Operations representative.
• Medium and High Voltage to be isolated by a qualified and trained Electrical Technician.
• Energy isolation form to be completed for each discipline.

Confined Space Requirements

• All electrical equipment must be properly insulated and grounded with a GFCI (ground fault circuit interrupter) connected.
• Electrical equipment used in confined spaces must be less than 24 volts.
• Pneumatically driven power tools with conductive air supply hoses should be used where possible.
• All hand-held electrical equipment must meet applicable local/regional/international standards.
• Cord and plug connected electrical equipment must be equipped with ground fault circuit interrupters.

Hot Work Requirements

• A Hot Work Permit is required in addition to the Confined Space Entry Permit.
• Equipment must be prepared for hot work.
• A detailed analysis (JSA) must be developed and followed.
• Adequate ventilation is required at all times when performing hot work in a confined space.
• Vessel internals must be carefully checked to ensure complete removal of materials that might be a source of flammable, toxic, or other gases, liquids, vapors, or dusts.

Gas Detectors

• Gas detectors can be used by contractors or third parties after being checked and approved by the related maintenance department.
• Competent third parties must calibrate gas detectors.
• Only trained and competent personnel can carry out calibration, repairs, and maintenance of gas detectors.
• Periodic checks must be carried out on or before the inspection expiration date to ensure the portable gas testing device is reliable.

Working at Heights

• Personnel working at heights higher than 2 meters must be protected.
• A required safety harness with two lanyards must be worn.

Excavation Work Preparation

• The type of excavation (manual and/or machine excavation) must be clearly defined.
• De-energization of underground utilities is not possible or location is not identified, then the method of excavation shall be established to minimize hazards.
• Cable detectors shall be used to identify underground cables or utilities.
• Trail pits by hand excavation along the area to be excavated.
• Hand-tools must be used in areas of underground services.
• Workers and equipment must be insulated from possible electrical contact.

Gas Testing Outlines

• Gas testing is conducted to determine air quality, work atmosphere suitability, and required personal protective equipment.
• Atmospheres that have not been tested shall be considered hazardous until tests prove otherwise.
• Gas detectors shall only be used in atmospheres containing oxygen between 10-20.8%.
• Gas testing is mandatory for hot work, confined space entry, vehicle/equipment entry, and working in live electrical circuits in classified areas.

Hot Work Outlines

• Hot work includes any work capable of supplying an ignition source or presenting a hazard or high risk to employees and/or plant facilities.
• Hot work permit shall be obtained for running/operating equipment and machines at site when exceeding the duration of the vehicle/equipment entry permit.
• Working on live electrical circuits, using non-intrinsically safe electrical tools, explosive power cartridges, cameras, or other activities that produce internal sparks, hot surfaces, or other ignition sources.
• Hot work shall not be allowed in any confined space where other activities are in progress that could increase flammable gas levels in the space or create hazards for others in the space.