One day, SWP- safe maker.pptx

Classification: Tasnee - General Information Chapter One Safe Work Permit 1 Classification: Tasnee - General Information Why Do we need A Work Permit? Introduction  Work permits ensure:     People safe Equipment safe Environment protected Area safe  Allows work to start:  After safety measure...

Classification: Tasnee - General Information Chapter One Safe Work Permit 1 Classification: Tasnee - General Information Why Do we need A Work Permit? Introduction  Work permits ensure:     People safe Equipment safe Environment protected 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: Describes the type of work. Indicates the persons responsible for the activity. Specific activity is recorded on the permit. Describes the precautions and actions to be taken to ensure that conditions will remain safe for the duration of the activity.  Provides tools for monitoring of conditions to ensure early detection of deviations that might lead to unsafe conditions.     2 Classification: Tasnee - General Information Introduction Work Permit types? 3 Classification: Tasnee - General Information Introduction Risk Assessment & JSA Application The intention of risk assessment is to describe on-going risk and determination of necessary controls for mitigation of risk and how to perform job safety analysis 4 4 Classification: Tasnee - General Information Introduction Energy Types  Thermal Energy  Mechanical Energy  Pressure Energy  Chemical Energy  Electrical Energy  Radiant Energy 5 Classification: Tasnee - General Information Introduction Confined Space & Hot Work  Knowing the definition of confined space according to OSHA Standard 29 CFR 1910. 146  Knowing the types 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 6 6 Classification: Tasnee - General Information Principles of Safe work Principles One permit per task. Equipment shall not be taken for maintenance unless declared safe. The work to be performed must NOT have:  Any negative effects on the Occupational Health and Safety of the personnel;  Any negative impacts on the Environment or to the operating unit 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. Issuer below supervisor’s level shall have 5 years in Petrochemical operation experience and minimum 3 months in TASNEE to sign only in his area of qualification for cold work permit and vehicle /equipment entry work permit. A Permit Issuer is not allowed to issue or approve a permit to himself. Permit to work system shall be auditable and Any deviation from this procedure will be subjected to disciplinary action. The maximum time allowed in the SWP is 12 hours. 7 Classification: Tasnee - General Information Introduction 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.  If it is not possible to correct it, the situation shall be safely stopped, reported and recorded.  Explain and let the person understand the potential consequence of his act or the condition. This should allow him to realize what was wrong and help implement corrections.  Disciplinary measures shall be in place for any people who intentionally ignore unsafe acts and/or conditions.  No corrections or alterations on a permit shall be allowed. 8 Classification: Tasnee - General Information Adjacent Area: Definitions Unit, section or area which borders the permit issuers unit and is not the permit issuers area of responsibility. Activity: “Activity” in terms of this procedure means a single step that may with other steps make up the total Task. Task: A task is a number of activities to be performed on a specific, uniquely identified, item or equipment that will achieve a desired result. Authorizing Manager: A General manager countersigning special permits (e.g. Category “A” vessel entry permits). Area Owner: The Facility/ Department/ Plant Manager or Superintendent or delegate who is responsible for all activities within his area or for area that has SAL agreement signed for other area. Work Permit issuer: A trained and certified person who is in charge of the process and is authorized to 9 issue work permits for a specific area under his area of responsibility. Classification: Tasnee - General Information Work Permit Receiver: Definitions A trained and certified person to receive work permits for performing or supervising works on equipment, facilities or work environment in a specific area. Craftsman: Competent person in executing a specific task, leading and working with the team that performs the task for activities where many personnel are required to do the work. Safe Maker: A trained and certified person with valid authorization card who is designated on the permit by the Permit Issuer for safe making. Hot Work: Any work capable of supplying source of ignition energy for igniting flammable mixtures or combustible materials or working on live electrical circuits Cold Work: Any work that does not create enough heat or sparks to ignite flammable gas-air mixtures or flammable materials including working on de-energized electrical equipment. First line break: initial opening of piping or process equipment which may have contained hazardous material or been under pressure. 10 Classification: Tasnee - General Information Excavation Work: Definitions A hole, pit, trench or any opening in the ground that is within the TPC that can be done by:  Use of manual tools.  Use of mechanical excavator. Hot Tapping: The technique of attaching connections to equipment or piping by the method of welding or drilling while the equipment or piping is in service. Making repairs or modifications on a tank, Pipeline, or other installation without shutting down operations 11 Classification: Tasnee - General Information Radioactive Source Work: Definitions Any work that involves any of the following:  Radiography or X-ray of welded metal joints  Performing corrective or preventive maintenance on radioactive sources (e.g., level measurement on reactors)  Handling, storing and transporting of a 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 (e.g., for KSA, RSO shall be certified by Nuclear and Radiological Regulatory Commission (NRRC). Routine Works: Work performed by any personnel in their normal duties as part of a Standard Procedure or Work Instruction. 12 Classification: Tasnee - General Information Vehicle / Equipment Entry: Definitions Is the entry of an internal combustion engine vehicle or equipment in a classified hazardous area. 13 Classification: Tasnee - General Information Definitions 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. Job Safety Analysis (JSA) Is a systematic approach to identify, analyze and record the steps involved in performing a Job task. It is a method of prevention for identifying and controlling or eliminating the hazards associated with the job task, It focuses on the relationship between the worker, task, tools, and work environment, JSA is a technique that focuses on a job tasks to identify hazards before they occur. It focuses on the relationship between the worker, task, tools, and work environment Control Measure A control measure is any measure taken to eliminate or reduce the risk by way of engineering, substitution, elimination, behavioral, administrative or reduction of risk through personal protective equipment. ALARP The residual risk shall be As Low As Reasonably Practicable. Consequence 14 15 Classification: Tasnee - General Information Risk A Combination of the probability of occurrence of an adverse effect on people, environment, assets, profits, quality or reputation of the Company and the consequences of that effect. Definitions Reduced Risk Risk remaining after the proposed mitigation. Residual Risk Risk remaining after additional control measures required. Task Supervisor It is the person that is responsible for supervising/overseeing the actual Task execution (i.e. Operation Shift Supervisor, Maintenance Supervisor, Site Project Engineer / Assigned responsible person etc.). Risk Acceptance Decision to accept a risk as per the limits of authority as described in the method section below. Company Risk Matrix (EHSS & Business) Is a document that utilizes consequence and probability to determine the risk score. 15 16 Classification: Tasnee - General Information Definitions Energy source. Any equipment or process may produce or transfer energy like Electrical, Process, Mechanical energy. Energy Isolation: Physically preventing transmission or release of energy, by disconnecting or mechanically blocking the equipment from the energy source. This is accomplished by locking out (for example a manually operated electrical circuit breaker); disconnect switch, valve, or installing a mechanical device such as a slip plate, blind etc. Lock Out Device: A device that utilizes a positive means such as a lock, either key or combination type, to hold a mechanical or electrical energy isolating device in a safe position and prevent the energizing of a machine or equipment/ A padlock that is uniquely identified by number and controlled in a register and used to isolate or lock-out equipment or electrical circuits. Positive isolation: The installation of blind or disconnecting piping in process lines or process equipment to prevent the passage of toxic and/ or flammable substances. When screwed piping is used, caps or plugs may be used to blind the open lines. Process Isolation: A means of preventing a liquid or gas process stream, from being conveyed past a pre- 16 Definitions Classification: Tasnee - General Information Confined space: Any enclosure having a limited opening for entry and exit, unfavorable natural ventilation, which could contain or produce dangerous air contaminants presents serious hazards to occupants; or which is not intended for continuous employee occupancy. These include, but are not limited to drum, column, tank, heat exchanger, ducts, stack, pipe, manholes, pits, excavation more than 1.2 meters in depth and can be categorized into:  Confined space category A  Confined space category B 17 Classification: Tasnee - General Information Confined space Entry: Definitions The action by which a person passes through an opening into a confined space. Entry is considered to have occurred as soon as any part of the person’s body breaks the plane of an opening into the space. A confined space entry means when the head or feet of a person passes the outside limits of the confined space and enters into it. Chemical Hazards: The chemical properties of process substances pertaining to their toxicity, flammability, explosiveness, corrosiveness, reactivity, and other characteristics that, when released, create hazards to people, facilities, and the environment. 18 18 Classification: Tasnee - General Information Definitions Chemical substances: Any toxic, harmful, corrosive, irritating or smothering substance or mixture of such substances. Toxic materials: A liquid, gas or vapor and solid material capable of causing serious injury or death to person. Wet-bulb globe temperature (WBGT): Wet-bulb globe temperature a type of apparent temperature used to estimate the effect of temperature, humidity, wind speed(windchill),and visible and infrared radiation (usually sunlight) on humans. It is used by industrial hygienists, athletes, and the military to determine appropriate exposure levels to high temperatures. Extreme Temperature: A temperature which is above or below the Occupational Health limits. 19 19 Classification: Tasnee - General Information Definitions Rescue plan: A Plan that is used to rescue the persons from the Confined Space regardless of confined Space category Lifeline/Retrieval line: A line (such as a rope or similar) used for preserving or saving life. A lifeline is used to maintain contact with a person in a dangerous or potentially dangerous situation (such as Confined Space). If retrieval line is used, the line can be used for rescue in case of an emergency. Venting: Allowing gases or vapors to be released to the atmosphere or flare or a recovery system during the activities of depressurization or purging. Ventilation: Ventilating a vessel or area by using an air moving device (e.g. fan) to draw fresh air through the vessel or Ventilating by natural flow of fresh air through the equipment by natural means. Breathing Apparatus: Line-air supplied via manually operated pump or cylinders of compressed air, self-contained apparatus carried by the wearer or a recycled air system. Canisters, 20 20 cartridge and other forms of filter mask do not constitute Breathing Classification: Tasnee - General Information Definitions Lower Explosion Limit (LEL): The minimum concentration of vapor in air below which propagation of flame will not occur in the presence of an ignition source. The LEL is expressed as a volume percentage of vapor in air. Threshold Limit Value (TLV): Toxic gas concentration above which it is not safe to work extended periods. Upper Explosive Limit (UEL): The maximum concentration of a flammable/combustible gas, vapor, mist, or dust in air that will support combustion when an ignition source is present. Gas Tester: A person who has undergone training on the use of gas detecting equipment and is authorized to conduct gas test. Oxygen Deficient Atmosphere: An atmosphere containing less than 19.5% by volume, oxygen at sea level. The oxygen we normally breathe at lower elevations is about21 21 20.8%. Definitions Classification: Tasnee - General Information Oxygen Enriched Atmosphere: An atmosphere containing more than 22.5% oxygen by volume. Oxygen-rich atmospheres expand the range of flammability, lower the ignition energy, and will cause combustible materials to burn violently when ignited. 22 22 Classification: Tasnee - General Information General Manager Responsibilities Shall be certified in work permit and responsible to countersign permits with regards to:  Hot taps.  Work on flare headers,  Category A confined space entry. Shall ensure that  The work cannot be done by an alternative means of lower risk.  Shall ensure proper hazard identifications and hazard mitigation are implemented. 23 Classification: Tasnee - General Information Responsibilities Area Owner Shall be certified in work permit and responsible to countersign all permit of:  Hot work.  Radioactive source work.  Confined space entry. Shall ensure that:  The requirements of WORK PERMIT are implemented, maintained and followed in his area of responsibility.  Proper hazard identification and hazard mitigations are implemented.  Permit Issuers, Receivers, Safe Makers, Gas Testers, and Standby’s persons are trained and authorized.  Qualified person selected to attend work permit training and meet the requirements to receive authorization card.  Qualified and certified person to sign on his behalf, on call staff consider as delegate area owner. 24 Classification: Tasnee - General Information Area Owner Responsibilities Shall ensure that:  Company forklift operated by Area Operators within the Hazardous Classified Locations is inspected and certified.  Temporary fabrication areas outside the Hazardous Classified Location are authorized as a designated exempted area from the work permit requirements as per the conditions stated in the method.  The reported work permit deviations been communicated during the IMRS Forum meeting.  All possible confined spaces in his area of responsibility been identified.  Only trained Operations personnel perform requested electrical energizing, de-energizing and or electrical trip first reset on low voltage (400 Volt) equipment only.  All issued work permit been audit frequently to ensure the compliance.  Area owner superintendent Shall review, accept and approve final JSA. 25 Classification: Tasnee - General Information Maintenance Manager Responsibilities Shall ensure that:  Shall ensure the WORK PERMIT Process applied as per the method.  Shall communicate the reported WORK PERMIT deviations during the IMRS Forum meeting and take action based on reported cases.  Shall audit frequently all issued work permit to ensure the compliance.  Shall ensure rescue equipment’s are provided by contactors. 26 Classification: Tasnee - General Information Responsibilities EHSS Fire Chief  Shall carrying out rescue operations within Confined Spaces, as requested by area owner.  Shall ensure an inspection of life supporting equipment and other emergency equipment for temporary use by personnel provided by third parties to be used in Confined Spaces.  Shall ensure certification and qualifications of the 3rd party rescuers when outsourced.  Shall ensure to conduct rescue drill before task executed. 27 27 Classification: Tasnee - General Information Responsibilities Permit Issuer / Receiver Common Responsibilities  Shall conduct a face-to-face discussion with each other ( issuer & Receiver ) to ensure understanding of the Scope of Work, JSA and any other conditions.  Shall conduct site joint visit ( issuer & Receiver ) to identify the hazard of the work and agree on the proper hazard mitigation.  Shall ensure all process and asset work hazard associated to work has been identified.  Shall ensure proper hazard mitigation has been taken for all identified hazard and asset work related.  Shall handover work permit status to his counterpart at shift change.  Shall ensure all work permit are immediately suspended in the event of an emergency.  Shall ensure a work permit Revalidation take place following any Suspension when the Task needs to start again.  Shall ensure the Fire watch not leave the work location after completion of hot work were welding activity or grinding took place for 1 Hour to check any potential delay ignition.  Shall sign the work permit continuation accepting Handover of Responsibility as per the method. 28 Classification: Tasnee - General Information Responsibilities Permit Issuer Shall ensure compliance to work permit Method. Shall ensure original copies of work permit and associated documents as identified in the work permit are displayed at designated area of work permit. Shall verify authorization of required work permit signatories (e.g. Permit Receiver, Safe Maker, Standby Man etc.) during work permit issuing step. Shall issue work permit after receiver signature and handover the copy of work permit to the Permit Receiver. Shall conduct a work area field check with the incoming Safe Maker and have a faceto-face discussion with other incoming work permit signatories prior to signing the work permit original and copy at the work area. Shall ensure work permit is closed out when Task execution is completed; Task Scope of Work is changed or when the validity period expires. The permit issuer shall ensure that he has full control over the number of permits issued for all permits in his area. Shall stop issuing additional permits and ask for support If the numbers of permits are too high and out of control Shall cancel the work permit if any changes occur which directly jeopardize the safety of personnel or plant and affecting the environment Shall sign-off both copies of the work permit on completion of the work, and keep the original copy filed accordingly. 29 Classification: Tasnee - General Information Responsibilities Permit Receiver  The Permit receiver must personally apply for the permit.  Shall continuously supervise the Task execution, while in progress.  Shall assign a Craftsman with proper hand over when Task execution cannot be continuously supervised to take over Task supervision.  Shall cancel the permit when re-validation has not been completed within one hour.  Shall return the field copy to the permit issuing office when the validity of the permit expires or after completing the task for permit close out  Shall check and ensure that personnel under his control can safely perform the task specified on the work permit.  Shall ensure that all relevant tools and equipment has been identified, inspected and safeguarded as per the requirements of the work permit.  Shall ensure that personnel under his control understand, sign the applicable Job Safety Analysis and/or work procedure for the specific task prior to start of the task.  Shall ensure that asset to be work on is positively identified on site to the persons executing the task.  Shall withdraw personnel from the work site and ensure that the work permit is returned to the permit issuer if any change of conditions occur which could jeopardize the safety and/or health of personnel on the plant or have any negative impact to the 30 environment Classification: Tasnee - General Information Responsibilities Permit Receiver  Shall report any incidents to the permit issuer.  Shall ensure that prior to start of work, emergency equipment, as required by the work permit is available at the job site.  Shall ensure additional lighting is provided whenever required.  Shall ensure that lock-out, tag out have been carried out.  Shall ensure that workers entering confined spaces, understand the requirements of the Confined Space Entry.  Shall ensure housekeeping is in place during and after activities is conducted.  Shall sign off the work permit Forms after task execution completed.  Permit receiver can be regarded as safe maker in his custody. 31 Classification: Tasnee - General Information Responsibilities Permit Receiver  Shall ensure that the required control measures from the JSA are implemented and mitigation measures are signed off.  Shall ensure that personnel carrying out the Task are oriented in the associated hazards.  Shall ensure the attendance sheet on the JSA form is signed by all craftsmen and contractor carrying out the task.  Shall ensure JSA is reviewed and approved. 32 Classification: Tasnee - General Information Confined Space Entrant Responsibilities  Shall ensure that he “signs in” or “signs out” as appropriate on (the Confined Space Entry Log Sheet).  Shall follow all hazard mitigations in the permit and be alerted to changing conditions.  Shall be competent to use the safety equipment as specified on the permit as applicable.  Exit and Alert the Standby man whenever:  An evacuation order is given by the Standby man.  The entrant recognizes any warning sign or symptom of exposure to a dangerous situation.  The entrant detects change on hazardous condition.  An emergency siren is activated.  Shall always follow the Standby man instruction.  Shall report any defect in the equipment to the standby. 33 33 Classification: Tasnee - General Information Standby/ Fire Watch Core Responsibilities Responsibilities  Shall present himself to the permit issuer with his authorization card, before signing on the work permit.  Shall be familiar with location, use of emergency equipment, alarm buttons.  Shall Immediately communicate (Activate nearest Manual Call Point, paging, radio, etc.) when an emergency occurs.  Emergency equipment required is available.  Familiarize himself and the craftsmen with escape route, Emergency assembly point , Safe Assembly Area  Follow Emergency Control Plan.  Monitor work permit requirements in terms of hazard mitigations are available as specified.  Ensure gas tests frequency been monitored.  Stop the work, if working conditions are unsafe, emergency condition occur or when sirens are activated. 34 Classification: Tasnee - General Information Responsibilities Standby/ Fire Watch Core Responsibilities Communicate permit conditions to replacement standby / fire watch before handing over shift. A Standby man / fire watch may not leave his post until he is relieved by another qualified person, or the task has been completed or called off. Shall not perform any additional Activities / Tasks while performing standby /fire watch duties during Hot Work and confined space entry. Shall immediately report any problems in the specific unit to the communication control center or control room when: Detrimental change in conditions within or outside the confined space. Any abnormal behavior by personnel. If work permit conditions are not met. Persons who are on standby or fire watch duty must be clearly identifiable by wearing a reflective vest. Fire watch shall be certified and trained in fire extinguisher training by third party. 35 Classification: Tasnee - General Information Fire Watch Responsibilities During Hot Work  If hot work is being performed above ground level, Responsibilities precautions must be taken to keep people from entering the area underneath the hot work.  Sewer openings, drains and floor openings kept covered.  Watch for fires that may be created by the hot work.  Familiar with the ECP in the event of a fire.  Shall ensure that all the vehicles / equipment used are switched off and secured (to prevent any possibility of fire/emergency while unattended)  Fire watch shall not leave the work location for 1 Hour after completion of hot work were welding activity or grinding took place, to check for any potential delay ignition. Fire watch can be standby but standby can’t be fire watch unless he trained and certified by third party 36 Classification: Tasnee - General Information Standby Responsibilities During Confined space Work Responsibilities  Standby Man shall be continuously present for the confined space entry at each entrance not barricaded.  Ensure the Confined Space Entry Log Sheet is completed prior to entry and directly after exit for each person who enters any confined space.  Never enter a confined space, even in the event of an emergency.  Ensure that the entrance to a confined space is positively barricaded and / or locked during periods when no work is performed.  Regularly observe conditions within and outside the specific confined space (without entering the confined space personally). 37 Classification: Tasnee - General Information Craftsma n Responsibilities  The craftsman may also be the Receiver. Under these circumstances the responsibilities of the Receiver also apply to the craftsman.  Shall sign the work permit when accepting Handover of activity as per the method on applicable work permit form.  Shall assure the work can be performed safely under the conditions as required on the permit.  Shall be aware with the location of the tagged equipment.  Shall follow all hazards mitigation which specify in work permit.  Shall ensue the execution team are familiar with hazard identification and mitigation.  Shall brief his team about emergency equipment’s.  Shall report incidents to the permit issuer and receiver.  Shall ensure that housekeeping is completed before the permit is closed out. 38 Classification: Tasnee - General Information Responsibilities Superintendent/Section Head (Area Owner)  Area owner superintendent Shall accept and approve final JSA. Task Supervisor  Shall initiate the JSA through the electronic system eRM.  Shall ensure the completion of the JSA.  Shall ensure JSA is completed by cross functional teams as per the method.  Shall ensure that JSA briefing is carried out before and after taking the signature specially for the employees (example labor / Forman / craftsman/ welder) who did not attend JSA meeting.  Shall ensure to upload records of JSA into electronic system. Task Specialist /Engineer  Shall review Task Steps, Description of Hazard, Control Measures Required Responsible Person, Signature after Implementation in JSA form. Area Owner Specialist /Engineer  Shall review JSA. 39 40 Classification: Tasnee - General Information Safe Maker Responsibilities The safe maker shall be designated by the permit issuer, and he is responsible to sign in the appropriate space on the permit form and shall:  Be a qualified in his work permit area and authorized as safe maker.  Ensure that equipment/work area has been prepared prior to signing the Work Permit.  Ensure that equipment to be worked on has been positively identified and tagged.  Perform electrical energizing, de-energizing and electrical trip first reset on low voltage (400 Volt) electrical equipment only.  Ensure that Energy isolation has been carried out as per method  Ensure that the equipment and surrounding area has been tested by taking the appropriate gas tests.  Ensure that the work area and equipment to be worked on has been inspected and all safety precautions specified on the work permit have been met. 40 Classification: Tasnee - General Information Safe Maker Responsibilities  Ensure that the emergency equipment required by the permit is available at the work site.  Shall continuously visit the execution area, while the job in progress to ensure hazard mitigation doesn’t change.  Ensure that housekeeping is observed at all times and before the permit is closed out.  Conduct a joint Work Area Field Check with the Permit Receiver to verify Task execution complete and housekeeping in order.  Update the closed work permit status in shift handover log.  Sign the work permit continuation accepting Handover of Responsibility.  Safe maker in operation activities can be regarded as permit receiver in his area of qualification. 41 Classification: Tasnee - General Information When Work Permit is Required When / When Not ? A work permit is required for following works :  All work performed by non-operating personnel.  Any work performed by operating personnel outside their normal operating responsibilities.  Any Maintenance works to be done on the buildings and facilities shall require a work permit.  Required for all types of modifications and construction related work.  Vehicle Entry and Internal Combustion Engine Equipment inside operation area. 42 Classification: Tasnee - General Information When / When Not ? When Work Permit is Not Required work permit is not required for following works : Any work performed by operating personnel within their normal operating responsibilities. Any energize or de-energize equipment or to do first reset of equipment that has been tripped. Any persons carrying out visual inspections. The visitor’s logbook for entering these areas must be completed. Work performed by maintenance personnel as part of their trade inside the Maintenance Workshops. Routine/day to day Maintenance activities performed by experienced employees inside the permanent Warehouses, Permanent maintenance workshops in their area of custody except modification in the Warehouses, workshops and building (e.g. drilling of wall). 43 Classification: Tasnee - General Information When Work Permit is Not Required When / When Not ? work permit is not required for following works :  TPC Operation’s Forklift driven by operation within the Hazardous Area Classification under the conditions that Forklifts designed and constructed to be used safely within the Classified Hazardous Location.  Any operation work performed by qualified contractors working under operation within their normal operating responsibilities. 44 Classification: Tasnee - General Information When Work Permit is Not Required When / When Not ? Designated Exempted Areas: The Area Owner may designate work locations where work can be carried out without a work permit under the following conditions:  Area must be classified as non-hazardous area.  A Job Safety Analysis conducted for Task to be done with EHSS and approved by the Area Owner.  A form “Designated Area Work Permit Exemption” must be used for this purpose and must be displayed at the designated site. Special Conditions:  During extreme cases crisis or emergency, worker may be required to perform work without a permit, only where safety and health of persons is threatened. Area Owner shall be informed. 45 Classification: Tasnee - General Information JSA Requirements JSA is Mandatory for all critical activities including:  All Confined space activities  All Hot work (open flame/welding/grinding) activities inside the process/production areas  All Radioactive source activities  All activities on Rotating equipment  All repair on lifeline  All activities executed by none ARC contractors  All hydro jetting/Sand blasting activities  All activities using Man-lift with cage  All activities require Diving 46 48 Classification: Tasnee - General Information JSA Requirements JSA is optional based on the permit issuer decision as per the below criteria:  Jobs with a potential for severe accidents/incidents, including, as appropriate, routine jobs.  Catastrophic potential: fire, explosion, chemical release, toxic atmospheres, oxygen deficient atmospheres  Tasks with a history of injuries, or near misses.  New jobs and jobs where changes to the work method/process have been made, or when using new/modified equipment (Tasks done in new environments).  Task result on incident/potential incident (task specifically identified during root cause analyses from incident investigations).  Rarely performed jobs.  Jobs complex enough to require written instruction.  Job conducting 1st time in TPC.  Big Maintenance Crew involved in the work (More than 10 employees). 47 49 JSA Requirements Classification: Tasnee - General Information JSA is optional based on the permit issuer decision as per the below criteria:  Preparation for work on pumps.  Preparation for work on Machinery and prime movers.  Preparation for rotating equipment alignment.  Removal of material for equipment preparation.  Welding, cutting activities outside the production/process area.  Hot work activities outside the production/process area.  Excavation.  Lifting operations with cranes.  Electrical activities, Electrical/Cable installation through cable tray or High Voltage Cable Vault and Manhole Entry. 48 50 Classification: Tasnee - General Information JSA Methodology  JSA shall be completed by cross functional teams consisting out of the following:     Task Supervisor. Craftsperson. PTW Issuer. Other interested parties as applicable.  Break down the task into Sequence steps:  Breakdown of the task should contain enough steps to describe accurately the work is being done based upon experience and common sense.  These steps shall represent the actions required to do the jobs.  Steps should be as brief as possible and not too fine or too general.  List down the steps in sequence as required for performing the job.  Identify the hazards from activity, surroundings, tools and equipment:  Identify the hazards related to fire, safety of working people 49 51 JSA Methodology Classification: Tasnee - General Information  Recommend Risk Control Measures to overcome identified hazards.  Review each job steps and main contributors to hazards for determining the ways to eliminate/control the hazards identified.  Recommendation shall be job or procedure specific, general statements may add no value.  Eliminate/Mitigate the source or cause of the hazard and potential consequences by using the following technique, Hierarchy of Control, (Highest effectiveness Elimination and Lowest effectiveness - PPE).  List down the recommendations identified in third column of JSA form.  List down the responsible person for each recommendation in the fourth column of JSA.  Ensure JSA recommendations are implemented during site preparation and performing the work, as applicable. 50 52 JSA FORM Classification: Tasnee - General Information 51 JSA FORM Classification: Tasnee - General Information 52 Classification: Tasnee - General Information What to do before issuing work permit?  All process and non process equipment to be worked on shall be made Safe Making safe before the work permit is issued.  Issuer shall ensure that the following are completed before the permit issued:  The equipment to be worked on shall be positively identify  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. 53 Classification: Tasnee - General Information What To Do In Order To Achieve Safe Making? Safe Making  All process and non process equipment to be worked on shall be made safe before the work permit is issued.  All process equipment to be worked on must be positively identified by tagging prior to the start the work as follows: All required information must be written on the tag, equipment number, name, date and signature of safe maker. It is not allowed to display a general tag on equipment for work to be performed. 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 task, it is the responsibility of the Safe maker (area operator) to remove the tags after work completion.  No Tagging required: If it is not connected to process equipment Zero checks on transmitters MPI and wall thickness tests X-rays 54 Classification: Tasnee - General Information Energy Isolation Safe Making  Energy Isolation including:  Electrical Isolation.  Process Isolation.  Mechanical Isolation.  Electrical Isolation.  Before deenergizing, the equipment shall be 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 qualified and trained Operations representative.  Medium and High Voltage to be isolated by qualified and trained Electrical Technician.  Energy isolation form to be completed for each discipline.  Process Isolation including the following categories:  Positive Isolation by means of Installing Rated Blind or Disconnecting Pipe ( for Hot Work and/or Confide Space Entry )  Proved Isolation by Double Block & Bleed isolation method ( for Cold Work only) 55  Isolation process Isolated by Single Valve & Bleed for Cold Work in very Classification: Tasnee - General Information Safe Making Energy Isolation  Mechanical Isolation including physical restraining movement due to its weight, stored energy or affect of wind circulation even after power is isolated.  Rotating equipment, where available, shall be positively stopped (pinned, locked or equivalent)  Some methods are used disconnecting belts, chain drives and mechanical links on shaft driven equipment’s,  Disconnect mechanical drivers, shafts, secure mechanical parts, disconnect steam heat tracing,  Pressurized actuators, fail open/ fail closed valves in accumulators and rundown tanks are considered mechanical isolation.  Equipment / system isolation requirements any isolated equipment / system shall contain all and/or the following:  Master Tag list that prepared and verified by shift supervisor for listing and identifying all locked valves and/or locked electrical source.  Master blind list that prepared by area staff of operations, Approved by Area Owner for listing and identifying all blinds and pipe disconnection. 56 Classification: Tasnee - General Information Safe Making Process Isolation Process Isolation including the following categories:  Positive Isolation  Process Isolated by Installing Rated Blind or Disconnecting Pipe.  Considered as process isolation for Hot Work and/or Confide Space Entry.  To verify that the isolation valves are holding, Bleeder must show no leakage.  All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. 57 Classification: Tasnee - General Information Process Isolation Safe Making Process Isolation including the following categories:  Proved Isolation  Process Isolated by Double Block & Bleed method is Considered as process isolation for Cold Work only.  Double Block & Bleed method is closing of two positives shut off valves and opening a bleed (vent/drain) valve in between.  The theory behind this method is that if the first isolation valve fails, the material in the line would discharge through the bleed valve and not into the work area.  In some cases, valves used for a double block and 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 verify are properly holding and Bleeders must show no leakage.  All valves shall be locked and tagged with a “Danger - Do Not Operate” tag.  Safe maker shall visit the area frequently to check and ensure the isolation integrity. 58 Classification: Tasnee - General Information Process Isolation Safe Making Process Isolation including the following categories:  Isolation  Process Isolated by Single Valve & Bleed is Considered for Cold Work in very limited cases where provision of Double Block & Bleed not available at asset and with satisfying protection and mitigation condition.  Single valve with bleed method limited to be used for non-hazardous materiel (such as LP water, LP air, LP N2, etc.).  In-case hazardous materiel involved and required to use this method then area owner approval is required.  Single valve with Bleed limited as isolation for Cold Work activities  Isolation valves shall properly hold, and Bleeder(s) must show no leakage.  All valves shall be locked and tagged with a “Danger - Do Not Operate” tag.  Safe maker shall visit the area frequently to check and ensure the isolation integrity and no hazards in the area.  Repair jobs on equipment shall continue without interruption and without the technician leaving the 59 Classification: Tasnee - General Information Safe Making Blinding Guidelines  The blind handle shall extend out several (3 inches) beyond the outside diameter of the flanges and serves as an indicator that a blind is in place to install the blind tag number.  Blind shall be seen from ground level if it is on pipe rack or high elevation.  For single activity yellow strip shall be tie to blind location to be visible from any distance and red strip for more than one activity.  Orifice flanges may be used for blinding, but the following actions shall be taken to ensure orifice plates are not mistaken for blinds:  Highlight on the blind list the fact that a blind has been installed in an orifice flange.  The orifice plate should be hung on the flange from which it is removed, or nearby to verify its removal.  Blind tag number shall be reflected in Master blind list  Maintenance review shall be obtained for correct size, gasket type, pressure class and bolts before installation. 60  Maintenance and Operation shall verify the blind(s) are installed as per the Classification: Tasnee - General Information Safe Making LOTO 61 Classification: Tasnee - General Information Safe Making Energy Isolation Form 62 Classification: Tasnee - General Information Master Blind List MASTER BLIND LIST Plant Area Equipment Number Equipment Description 2) Confirmation of installation & removal shall be filled & signed by the person who physically implemented it in the field. Isolation Box Number: Maintenance Method SN P&I D Number 3) Shortcuts: RB: Rated Blind. DL: Disconnect line. P/C: Plugged/Capped I ssuer Lock Number Line Number Size Blind Tag Number Description RB DL Operation Confirmation for correct size, gasket type, pressure class, bolts & installation P/C Name Date Time I nstallation Confirmation Signature Name Date Time Removal Confirmation Signature Name Date Time Signature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Area Owner Remarks (if any): Prepared by (Area Staff) Final I nstallation acceptance (Operation Supervisor) Signature Name Area Owner Approval Date Final Removal acceptance (Operation Supervisor) Signature Name Date Signature Signature Initial /Signature 2nd quarter Date Initial /Signature 3rd quarter Date Initial /Signature 4th quarter Date Initial /Signature 1st quarter Date Initial /Signature 2nd quarter Date Initial /Signature 3rd quarter Date Initial /Signature 4th quarter Area Owner Date Area Owner 1st quarter Area Owner LongTermisolation exceeding30 days frominitial date of implementation I declare that the equipment that has been blinded well maintained under my control and audited regularly in quarterly basis confirming the equipment conditions are not changed Area Owner Approval Name Date Signature Area Owner Date Area Owner Name Area Owner Date Area Owner Name Area Owner Safe Making 1) No scratch or change on this form is allowed & no changes to the form design & content is allowed. Purpose Of I solation Date Initial /Signature 63 Classification: Tasnee - General Information Safe Making Blind list marked up P&IDs 64 Classification: Tasnee - General Information Safe Making Master Tag List 65 Classification: Tasnee - General Information Safe Making Tag list marked up P&IDs 66 Confined Space Outlines Classification: Tasnee - General Information Confined Spaces outlines:  Confined space categories.  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 Exists 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 attempt to rescue their colleagues. 67 67 Classification: Tasnee - General Information  Confined space categories. Confined Space Requirements  “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 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.  Fire interruption / isolation form  Rescue plan 68 68 Classification: Tasnee - General Information  Confined space hazard identification: Confined Space Requirements shall be recognized by posting sign boards stating the confined space condition as follows:  “Oxygen Deficient atmosphere”.  “DANGER CONFINED SPACE – ENTER BY PERMIT ONLY”.  DANGER Nitrogen / Inert Gas Purge in Progress”. 69 69 Classification: Tasnee - General Information  Confined Space Entry preparation Confined Space Requirements  Free of dangerous chemical substances / liquid As far as practically possible for “A” category and mandatory for “B” category  Energy isolation in terms of:  Electrical Isolation for energy sources of all driven equipment as well as Lockout/Tagout process.  Positive Isolation by installing rated blind / disconnecting line.  Process or utility lines entering or leaving the equipment / unit must be positively isolated at the nearest location to working asset  Radiation sources removed / isolated.  No process material remains.  Sewer openings in immediate area shall be covered.  Air shall be tested, and Ventilation shall be provided.  Communication systems shall be available. 70 70 Confined Space Requirements Classification: Tasnee - General Information  Ventilation Requirements and gas testing for Confined Space.  Oxygen content between 19.5% to 22.0%.  Flammable gases and vapors (LEL) below 5%.  Potential toxic air contaminants in terms of CO and NH3 maximum allowable concentration is 25 PPM.  Wet bulb globe temperature ≤ 35°C or Ambient Temp ≤ 46 °C as maximum.  Atmospheric temperature according to the Weather Condition Health & Safety Advisory reported by TASNEE clinic.  Depending on the situation, type of ventilation shall be selected ( natural draft, use of fans, or air movers or air conditioning systems )  Pure Oxygen shall not be used to ventilate confined spaces.  Plant air shall not be used to ventilate unless it is used for pull out ventilation.  Air movers shall be listed for the area electrical classification and grounded to prevent the accumulation and discharge of static electricity. Please note that : All confined spaces must be considered “A” category until tested and 71 71 verified as a “B” category. Classification: Tasnee - General Information Confined Space Requirements  Ventilation Requirements for Confined Space.  For horizontal exchanger which are opened from both ends during the confined space entry, ventilation plan is not required.  Do Not use Nitrogen to ventilate confined spaces, as this could lead to oxygen enrichment/deficiency of the space.  Only pneumatic driven blower, fans and air movers are allowed to ventilate the confined spaces.  Fans and air movers shall be ensured that it is electrically bonded and grounded to the vessel.  Air conditioners can be installed as an alternate of ventilation wherever it is convenient. Air Conditioners capacity will be used to identify the ventilation rate required. However, in case of use of Air Conditioners for ventilation, Air Movers shall be kept ready to use in case of Air Conditioners shutdown or any emergency.  A positive means of ventilating confined space shall be established and kept operated the entire time while work is in progress.  Following tips shall be considered for ventilation:  Positioning of mechanical aspirators, drawing of fresh air, routing of exhaust air.  Ventilation plan shall be prepared and approved as per IMRS 13-02-01-23 Ventilation plan.  Ventilation of a space will also vary depending on the type of material that is being ventilated from the space. 72 72 Classification: Tasnee - General Information Rescue plan Preparation and requirements for confined Space Entry. If hazard cannot be mitigated, then Rescue shall be prepared prior to entry. Confined Space Requirements When required ?  Rescue Plan is mandatory for all Confined Space entry types.  Rescue Plan shall consider the following:  The hazards outcome of the JSA.  The location of the work.  Number of workers, even if there will be only single worker.  The duration and period the of work.  The resources needed for the rescue and the number of people required.  Internal Configuration  Elevation  Manway Size  Confined Space Access 73 Classification: Tasnee - General Information  It is important to consider the following conditions when planning for a confined space entry work.  Internal Configuration: Confined Space Requirements  Confined space contains some type of obstruction that a rescuer would need to maneuver. For example, a baffle or mixing blade, large equipment, such as a ladder or scaffold, brought into the confined space for work purposes would be considered an obstruction if the positioning or size of the equipment would make the rescue difficult.  Elevation:  Elevated a confined space entry where the entrance or opening is above ground by 4 feet or more. This type of confined space usually requires knowledge of high angle rescue procedures because of the difficulty in packaging and transporting a victim to the ground from the confined space.  Non-elevated a confined space entry with the entrance located less than 4 feet above ground. This type of space will allow the rescue team to transport an injured worker normally.  Manway Size:  Restricted a Manway of 24 inches or less in the smallest dimension. Manways of this size are too small to allow a rescuer to simply enter the space while using SCBA. The Manway size is also too small to allow normal spinal immobilization of an injured worker.  Unrestricted A Manway of greater than 24 inches in the smallest dimension. These Manway allow relatively free movement into and out of the confined space.  Confined Space Access:  Horizontal the Manway is located on the side of the confined space Use of retrieval lines could be difficult.  Vertical the Manway is located on the top or bottom of the confined space. Rescuers must climb down or up the permit space respectively to enter it. Vertical portals may require knowledge of rope techniques, or special patient packaging to safely retrieve a downed entrant. 74 Classification: Tasnee - General Information Rescue plan Preparation and requirements for confined Space Entry. Confined Space Requirements All confined Space Entry shall have a developed Rescue plan as per the method (using Rescue plan form) how to enter, exit, escape, and rescue personnel working in confined spaces it shall be done during the job planning phase and before confined entry Permit issuing. Confined spaces on a site visit shall be assessed to determine what special equipment or procedures may be involved when conducting a rescue operation Rescue Plan shall be prepared by task execution Supervisor or above from Tasnee team and contractor. Familiarize all execution team with the approved rescue plan before starting the activity. Provision of Rescue Equipment: Rescue Equipment shall be suitable and sufficient to respond to an emergency in a timely and safe manner. for example, rescue equipment may include: Full body harness with retrieval line attached. Hand-cranked mechanical winch and tripod (required when entrant is five feet or more below the entrance). Lifeline. Explosion-proof lighting. Breathing apparatus. Stretcher. Based on the type of the confined spaces entry and the condition of the work and location rescue plan need to be devolved. 75 Classification: Tasnee - General Information  Rescue plan Preparation and requirements for confined Space Entry. Confined Space Requirements If confined Space Entry Category B, the Rescue shall be prepared prior to entry with obtained approval as below:  Whom will prepare and How to ?  Rescue plan shall be countersigned by permit issuer.  Rescue plan shall be reviewed and approved by Incident Commander.  Rescue plan shall be attached with confined space entry permit at site.  Minimum rescue equipment shall be readily and available.  Rescue plan Preparation and requirements for confined Space Entry. If confined Space Entry Category A, the Rescue shall be prepared prior to entry with obtained approval as below:  Whom will prepare and How to ? Rescue plan shall be countersigned by permit issuer. Rescue plan shall be reviewed by Incident Commander. Rescue plan shall be approved by Incident Commander. Rescue plan shall be attached with confined space entry permit at site.  Minimum rescue equipment shall be readily and available.     76 76 Classification: Tasnee - General Information Confined Space Requirements  Safe Access and Exists for confined Space.  The manway and or cover shall not be opened until made safe to enter.  All open manway and or cover not in use must be positively barricaded.  barricading tape is not allowed to be used for manway and or cover.  In all cases, adequate and safe access and exit out shall be provided for the confined space.  Personnel should not be lowered into confined spaces, without facilities to climb back out themselves.  Use of cage for lifting material / person in the confined space shall be included in the JSA.  personnel shall not be underneath when material is lowered or removed from confined space through winch / rope, cage, basket, etc. Condition Changes during confined Space Entry Permit. If a confined space condition been interrupted due to potential toxic or respiratory hazardous atmosphere arise or any emergency that requires immediate departure from the confined space:  the Standby Person shall notify the concerned issuer as soon as possible.  The Permit shall be withdrawn.  All the entrants shall leave the confined space immediately.  Permit issuer shall immediately cancel the confined entry permit.  The confined space shall be evaluated to determine how the hazardous atmosphere developed.  Control measures shall be implemented to eliminate the hazardous atmosphere prior to any subsequent entry. 77 Classification: Tasnee - General Information  Work inside confined Space. Confined Space Requirements Work at elevation inside confined space.  The area below elevated work shall be barricaded  Splash pans (used to collect oil spillage) shall be provided as needed.  warning signs of overhead work shall be posted  workers underneath elevation shall be protected from objects falling by means of suitable temporary barrier. Equipment and Tools for Confined Space.  All electrical equipment shall be properly insulated and grounded with GFCI (ground fault circuit interrupter) connected.  All electrical equipment shall be less than 24 volts.  Pneumatically driven power tools equipped with conductive air supply hoses shall be used where possible.  All hand-held electrical equipment shall meet the applicable local/regional/international standards.  All cord and plug connected electrical equipment shall be equipped with ground fault circuit interrupters.  Scaffolding, whenever required, shall does not obstacle the entrance or exit into or out of the confined space. 78 Classification: Tasnee - General Information Hot Work inside confined spaces. Confined Space Requirements When Hot Work is necessary inside confined space, special precautions must be taken according to the obtained hot work requirements:  A Hot Work Permit shall be issued in addition to the Confined Space Entry Permit.  The Equipment shall be prepared for hot work.  A detailed analysis (JSA) shall be developed and followed.  Adequate ventilation shall be required at all times when performing hot work in a confined space.  Vessel internals such as vortex breakers, columns, , trays, etc. shall be carefully checked to ensure complete removal of material which might be a source of flammable, toxic or other gases, liquids, vapors or dusts at working location.  Hot work shall not be allowed in any confined space where there are other activities in progress which could increase flammable gas levels in the space or create hazards for others in the space.  An approved dry chemical fire extinguisher (A, B, C) shall be positioned as near the entrance as possible.  Fire Extinguishers must be provided by the contractor.  TASNEE Fire extinguishers shall not be used for hot work by contractor.  When persons are working in close proximity or overhead of each other, suitable barriers shall be provided. 79 Classification: Tasnee - General Information  Hot Work inside confined spaces. ( continued ) Confined Space Requirements When welding taken place in confined spaces the following precautions shall be followed. Atmosphere Testing shall be carried out. Welding machine shall be grounded. Compressed Gas cylinders and welding machines shall be kept outside the confined space. Gas-burning or welding torches shall not be left inside the confined space while unattended. If removal of the torches is impractical, the hose at the regulator shall be disconnected. The gas cylinders shall be removed from the operating area at the end of any work period. When arc welding is to be stopped for any reason, the electrode shall be removed from the electrode holder and the holder carefully located so that accidental contact cannot occur. The welding machine shall be shut down or disconnected from the power source while unattended All arc welding leads and oxy-acetylene hoses shall be inspected for cuts, leaks, breaks, and insulation damage prior to use and repaired or replaced before use. Hoses and torches should be lowered through the manhole. 80 Hot Work Outlines Classification: Tasnee - General Information  Hot Work Outlines:  Nature of hot work  Asset preparation for hot work  Tools and location preparation for hot work  Prohibited of hot work 81 Hot Work Requirements Classification: Tasnee - General Information  Nature of hot work Any work capable for supplying of ignition source or any work that presents a hazard or high risk to employees and/or plant facilities. such as but not limited to:  Use of open flame/spark producing equipment, welding, torch cutting, brazing, chipping, grinding, etc.  Hot work permit shall be obtained for running/operate equipment’s and machines at site when exceeding the duration of vehicle / equipment entry permit.  Working on live electrical circuits.  Use of non-intrinsically safe electrical tools, explosive power cartridges, cameras or other activities which produce internal sparks, hot surfaces or other ignition sources. 82 Hot Work Requirements Classification: Tasnee - General Information Asset preparation for hot work: Asset has been De- pressurized, vented, purged, ensuring no flammable or combustible or other related materials remaining. Blocked valves including double block and bleed arrangements are not acceptable methods of positive isolation for hot work. positive isolation by installing rated blind or disconnecting line whenever applicable. JSA. Master blind list & marked up P&IDs. Master tag list & marked up P&IDs. Energy isolation form. Instrument impulse tubes shall be purged, disconnected and tagged. The lines and sources of flow or pressure shall be positively isolated. 83 Hot Work Requirements Classification: Tasnee - General Information Tools and area preparation for hot work: An initial combustible (LEL) gas test shall be done prior to commencing the hot work. Gas tests shall be continuous or periodically repeated according to the plant condition criteria. flammable and combustible materials shall be controlled and removed ensuring no materials present within (11 m) radiance from the hot work area sewers, drains and floor opening shall be covered and wetted. Gas cylinders and welding machine shall be kept in a safe distance from the welding / cutting operation. Sparks generated shall be totally contained All equipment and tools shall be free of any defects Oxygen cylinder hoses and fittings shall not be in contact with oil or grease. Valves on cylinders and torches must be closed not in use. Gas cylinders must be chained and secured upright in cylinder trolley. Welding machine shall be inspected and grounded. 84 Hot Work Requirements Classification: Tasnee - General Information 85 Classification: Tasnee - General Information Gas Testing  Gas Testing Outlines:  Gas testing is conducted by using a gas testing device (gas detector) to determine air quality, work atmosphere suitability and the required personal protective equipment.  It ensures that worker will not be exposed to harmful concentrations of hazards substances or an oxygen deficient atmosphere,  Atmospheres that have not been tested shall be considered hazardous until tests prove otherwise.  Even during conducting gas testing, don’t enter or insert your body into a hazardous atmosphere.  Gas detectors shall only be used in atmospheres containing oxygen between (10 - 20.8 %) as the device will not accurately function beyond this range.  Gas testing subtitles:     Gas Testing Requirements. Gas test Frequency. Concentrations & Safe Ranges of Gases. Gas Detectors Maintenance & Calibration. 86 Classification: Tasnee - General Information Gas Testing  Gas Testing Requirements:  Gas testing is mandatory for hot work, confined space entry, vehicle/equipment entry, and working in live electrical circuits in classified areas.  All users of portable gas detectors shall be trained and certified.  Works outside the designated hazardous location may no longer require a gas test.  For measurement on enclosed locations the following precautions shall be taken:  Avoid condensation or sucking up liquid into the sample tube.  Hot work (e.g., flame, arc, or spark) shall not be permitted until atmospheres has been tested and concentration of gas or vapor is less than 5% of the LEL.  Portable or continuous monitoring devise shall be equipped with An audible alarm and visible light for warning purpose.  The alarms of the gas testing device should stay until the device is reset or the concentrations have returned to safe level.  Whenever gas detector alarm sounded all workers shall stop the work, evacuate to safe assembly area and report to permit issuer.  For open flame / spark, continuous gas monitoring is mandatory.  The test result shall be recorded in the Work Permit by the authorized gas tester. 87 Classification: Tasnee - General Information Gas Testing Always test the air at various levels to be sure that the entire space is safe. Good air near the opening does NOT mean there is good air at the bottom! 88 Classification: Tasnee - General Information  Gas test Frequency:  Maximum allowable frequency between gas test is 2 hours. Gas Testing  Gas test frequency shall be clearly identified in the work permit  In the case of continuous gas test,  Functional test shall be carried out for the Gas detector device at least during start of the operation each new shift.  Gas test result shall be recorded in the Work Permit every 2 hours.  A fresh gas test shall be carried out before:  Restarting hot work in the event that the job is stopped/ interrupted for more than one hour.  If an operational upset occurs or conditions change during the course of the work which could affect the concentration of hazardous or toxic gas at the work site.  If there’s a doubt or requested, gas testing shall be conducted/repeated. 89 Classification: Tasnee - General Information Gas Testing Gas Test Frequency 90 Classification: Tasnee - General Information Gas Testing  Concentrations & Safe Ranges of Gases:  No person is allowed to work in an atmosphere containing toxic gas or vapor in a concentration beyond threshold limits value (TLV) without using appropriate protection.  Threshold limits value (TLV) for each substance can be found in SDS. 91 Classification: Tasnee - General Information Gas Testing  Gas Detectors Maintenance & Calibration:  Operations shall ensure that maintenance and calibration of portable gas detector instruments shall confirm with the manufacturer’s specifications and recommendations.  Maintenance and calibration of these gas detectors shall be undertaken by the Maintenance or authorized third party.  Any fault indications, noted by the operator using the equipment, shall be reported immediately to the Operation Shift Supervisor.  The Operations Shift Supervisor shall ensure that operational checkup of these gas detectors is done to ensure their reliability and its condition.  All Operations personnel authorized to conduct gas test must first check the condition of the equipment prior to its use.  Gas detectors by contractors or third parties are allowed after it's been checked and approved by related maintenance department.  Competent third party shall calibrate gas detectors.  Only trained and competent personnel shall carry out calibration, repairs and maintenance of gas detectors.  Periodic checks shall be carried out on or before the inspection expiration date to ensure the portable gas testing device is reliable.  In case of detector calibration validity date expired, the detector shall not be utilized.  (Refer to below Photo Gas Detector device & inspection expiration). 92 Classification: Tasnee - General Information Working at Heights  Personnel working at heights higher than two (2) meters shall be Safe Making protected  Wear the required safety harness with two (2) lanyards.  Scaffold requirements must be adhered to at all times.  Scaffolding validity is every two weeks from erection date.  Valid Scaffold Tag (Scaff tag). 93 Classification: Tasnee - General Information Excavation Work Excavation Work Preparation Safe Making  Clearly define the type of excavation, manual and/or machine excavation.  If de-energization of underground utilities is not possible or location is not identified, then the method of excavation shall be established to minimize hazards by such means as:  The cable detector shall be used to identify the underground cable or utilities.  Trail pit by hand excavation along the area to be excavated.  Use of hand-tools in area of underground services.  Insulate workers and equipment from possible electrical contact.  Use tools or equipment that will reduce the possibility of damage to underground services and hazard to workers. 94 Classification: Tasnee - General Information Excavation Work Excavation Work Preparation  Excavations will require a plan provided by the requester and approved by Technical (R&I) Safe Making Department:   Excavation depth is more than 1.2 meters.  Excavation location is adjacent to structures or equipment.  Excavation location is subject to vibration or ground water. If the excavation will obstruct any roadway or access partially or totally, the Security and Fire Sections shall be notified. Obtain necessary permission fire interruption/ isolation form. 95 Safe Making Classification: Tasnee - General Information on i t a v st a c ue x E eq R 96 Classification: Tasnee - General Information Lifting Precautions  Forklifts shall never be used to lift a person. Safe Making  Barricades shall be put up around the work area.  Nobody shall be allowed to walk or reach under a raised load.  Only one operator shall be inside the cradled platform and manning the controls.  No passenger shall be allowed to ride with the Scissor platform.  The load to be lifted shall not exceed the maximum allowable loading capacity.  When lifting a load, the center of gravity must not 97 Classification: Tasnee - General Information Lifting Plan Requirements Safe Making  Lifting in congested areas where structures, pipelines, power lines, or other obstacles are located.  Lifting that involving “turning” or “flipping” the load over where “shock loading” and/or “side loading” is likely to occur.  Lifting where the load weight is not known.  Lifting in areas of poor soil, gravel or unknown ground conditions. i.e., Lifts involving potentially unstable pieces.  Lifting involving multiple cranes. 98 Classification: Tasnee - General Information Permit Golden Rules  No corrections or alterations on a permit shall be allowed. Permit Rules  Work permits shall be completed ( issuing and closing ) in original and duplicate copy.  The duplicate (field copy) shall be handed to the permit receiver and shall always be available for inspection and/or review at the work site.  The original copy of the permit shall be retained at the permit office and be available for inspection at all times.  All relevant documents for the issued permit should be attached to the duplicate (field copy) of the permit.  Sequence of permit signatures shall follow workflow chart and work permit form as specified in the method.  Blank permits shall, under no circumstances, be signed in advance. 99 Classification: Tasnee - General Information Permit Golden Rules Permit Rules  Where a task extends over more than one equipment, a separate work permit for each equipment is required Where attachment list for the equipment shall be attached with permit as required.  Task that have the same hazardous and can be identify within same area, level and location can be executed in one permit for example and not limited to (scaffolding works, greasing of pumps, taking vibration measurement)  The minimum TPC PPE requirements are safety helmet, safety glasses, Safety Shoes and long sleeve clothe which apply for all employees & contractors or visitors entering plant area.  The additional PPE shall be selected from company approved PPE Matrix 100 Classification: Tasnee - General Information Permit Rules Permit Golden Rules  During radiographic work, all other active tasks within the affected area shall be temporarily stopped and revalidated afterwards.  Prior to resuming the work hazards Identification & mitigation need to be confirmed If conditions have not changed then the work may be revalidated and continue.  If conditions changed then a new permit shall be issued.  If the work is not completed within the agreed duration, it can be Extended MAX 12 hours total working time during normal operation and MAX 24 hours total working time during TAM.  When the Receiver changed then the continuation of the work permit shall be signed on both copies. 101 Thank You Classification: Tasnee - General Information Any Questions? 102