Saudi Aramco Work Permit System PDF

4. Work Permit System 4.1 Purpose This chapter describes minimum requirements of the Saudi Aramco (SA) Work Permit System at maintenance and/or construction work sites that apply to SA employees and contractors. 4.2 References SA General Instructions...

4. Work Permit System 4.1 Purpose This chapter describes minimum requirements of the Saudi Aramco (SA) Work Permit System at maintenance and/or construction work sites that apply to SA employees and contractors. 4.2 References SA General Instructions (GIs): GI 2.100, Work Permit System GI 2.709, Gas Testing With Portable Gas Monitors SA Safety Handbook, Minimum Safety Rules 4.3 General Requirements 4.3.1 Work permits shall be used to control hazardous work activities at all SA facilities and locations. For SA operated facilities and for projects after the facility, or portion thereof, has been certified as mechanically complete, the SA work permit system shall be implemented per GI 2.100. 4.3.2 During the construction phase of grassroots projects and before a facility, or portion thereof, is certified as mechanically complete, the contractor shall implement an approved work permit system in line with GI 2.100 for all hazardous work requiring the appropriate planning, control, and authority, which does not meet the criteria defined in Section 4.3.1, to ensure safe execution of construction activities. The contractor’s work permit system shall be subject to approval by the SA proponent organization (SAPO). 4.4 Certification 4.4.1 Work permit issuers and receivers shall have a valid SA issuer or receiver certificate, respectively. They shall attend and pass the work permit issuer or receiver course conducted by SA Training & Development, as well as any required prerequisite training per GI 2.100. 4.4.2 The issuer/receiver’s division head or, in the case of a contractor, the SAPO division head who has contractual authority over the contractor, shall sign the issuer/receiver certificate. 4.4.3 Issuers/receivers with signed certificates from one organization shall not issue/receive permits at a different organization/facility, unless the responsible SAPO division head signs a reissued certificate that reflects the current organization, or some other method of agreement between the two organizations is agreed. CSM I-4 Work Permit System December 2016 Page 1 of 7 4.5 Permit Types 4.5.1 There are four types of SA work permits. As per GI 2.100, they are: Equipment Opening/Line Break, Form 9873-1 (yellow) The purpose of the Equipment Opening/Line Break Permit is to ensure that proper planning and precautions are taken during work activities associated with the initial opening of equipment, vessels, or piping that is part of a closed system that contains (or has the potential to contain) flammable, combustible, toxic, or injurious materials (e.g., high-pressure steam). This permit does not authorize releases; rather it is to ensure that the appropriate precautions are in place to prevent a release. Hot Work, Form 9873-2 (red) The purpose of the Hot Work Permit is to control work activities that may produce sufficient energy to ignite flammable atmospheres or combustible materials. Activities in restricted areas requiring a hot work permit include, but are not limited to:  Open flames, welding, or torch cutting.  Use of spark-producing tools or equipment.  Abrasive blasting.  Use of internal combustion engines.  Work on or in close proximity to live electrical apparatus.  Use of a device not rated for the electrical classification of the area. Cold Work, Form 9873-3 (blue) The purpose of the Cold Work Permit is to control work activities that will not produce sufficient energy to ignite flammable atmospheres or combustible material but could contribute to injury. This permit may be used for, but not be limited to, the following work in restricted areas:  Structural demolition or collapse of nonoperational buildings.  Removal or disturbance of asbestos-containing material.  Work activities involving cryogenic materials.  Scaffold erection or dismantling.  Painting.  Excavating by hand. CSM I-4 Work Permit System December 2016 Page 2 of 7   Concrete pouring and formwork.  Use of hand tools that have no electrical power. Confined Space Entry, Form 9873-4 (green) The purpose of the Confined Space Entry Permit is to ensure:  Proper preparation of confined spaces prior to entry.  Safe entry by personnel, including provisions for rescue.  Restoration of confined spaces. Work activities inside a confined space may require a Hot or Cold Work Permit to be issued in combination with the Confined Space Entry Permit. Refer to Chapter I-6, Confined Spaces, for further requirements. 4.6 Issuance and Approval of Permits 4.6.1 Issuers and receivers shall have in their possession a valid SA work permit certificate. 4.6.2 Certified permit receivers shall request the proper permit(s) from a SAPO- certified permit issuer (e.g., supervising operator, operations supervisor) prior to executing any job. Permits shall identify the specific work to be performed by the work crew at a specific location. 4.6.3 The issuer shall approve and issue a permit only after he (or his designated representative) has performed the following: A. Verified that “Section 1 - Work Description” of the work permit form has been completed. Work permits shall clearly specify date and duration of the work, work location, work to be performed, and equipment to be used at the job site. B. Completed “Section 2 - Hazard Identification and Control” of the work permit form. Work permits shall clearly identify the types of energy, isolation method(s), potential exposures, required protective equipment, fire protection methods, additional safety precautions, and actions to be taken in the event of an emergency. General statements, such as “work safely” or “wear PPE,” are inadequate and shall not be written on the permit. C. Reviewed precautions and restrictions to control the hazards associated with the job site and/or work activity (see applicable work permit sections in this instruction) with the receiver and listed them on the work permit. D. Attached applicable checklists/forms to the work permit that provide supplemental information and/or approvals for the particular work activity, including but not limited to excavation checklist, confined space entry log and gas test form, blind list/isolation plan, critical lift plan, or hydrotest form. All checklists/forms shall be completed. CSM I-4 Work Permit System December 2016 Page 3 of 7  E. Conducted a joint site inspection with the receiver using the Hazard Analysis Checklist on the back of the work permit form. The individuals who participate in the joint site inspection shall sign the Hazard Analysis Checklist on the work permit to verify the checklist was completed. See GI 2.100, Supplement 2.100-3 for information regarding conducting the joint site inspection and completion of the checklist. 4.6.4 The issuer’s and receiver’s signatures, plus any other required approvals/signatures shall be on the completed permit. Issuers shall obtain countersignatures from applicable units/departments as needed. 4.6.5 Additional approvals/signatures shall be required for renewed/extended work permits (see GI 2.100 and Section 4.7 of this chapter), as well as when certain atmospheric limits are present at the job site (see GI 2.709). 4.7 Issued Permits 4.7.1 Permits are normally issued for a single operating shift. 4.7.2 Permits may be renewed for one consecutive operating shift, regardless of the shift duration, but the total permit duration cannot exceed 24 hours. This renewal requires the signatures of both the issuer and receiver coming on shift, and the notification of all countersigning organizations. 4.7.3 Permits (except for equipment opening/line break permits) may be issued for a period greater than two consecutive operating shifts, but not in excess of 30 days. This extended duration applies to prolonged construction or maintenance work where the job site hazards and precautions remain unchanged. The permit shall be approved by the division head or above of the issuing and receiving organizations, and the following conditions must be satisfied: A. It is highly unlikely that conditions at the job site will change or develop that would create a hazard to personnel, damage to equipment or facilities, disruption in operations, or harm the environment. B. Precautions are taken, prior to performing the work, to ensure safe conditions throughout the work activities. C. Both the issuing operation’s division head and the receiver organization’s division head (and countersignature organizations’ division head, if applicable) agree to the job conditions and control measures to be used and shall sign the permit (see GI 2.100 for additional details). 4.7.4 The custody of open work permits shall be transferred to an alternate issuer in the event that the issuer is required to leave work. This transfer of custody of the work permit shall follow the same process as a renewed work permit, however the notification of all countersigning organizations is not required. CSM I-4 Work Permit System December 2016 Page 4 of 7  4.7.5 Receivers are to remain on the job site at all times. However, if a receiver must leave the immediate work area, he shall give the permit to another SA-certified permit receiver. This alternate receiver shall be agreed to in advance by the issuer and his name, certificate number, and badge number shall be recorded on the work permit by the issuer. 4.7.6 Receivers shall keep permit copies, either in their possession or posted in plain view at the job location, at all times, so that it is available for inspection or cancellation if necessary. 4.8 Canceling Permits 4.8.1 Work permit(s) shall be immediately canceled, the work stopped, and new permit(s) issued if a change occurs in the work activities or site conditions that could potentially create an additional hazard to personnel, damage to equipment or facilities, disruption in operations, or harm to the environment. 4.8.1.1 When work is stopped the issuer must obtain the work permit, write on the permit the reason for the work cancelation, the time, and other relevant information. 4.8.1.2 The issuer and receiver shall take action to correct deficiencies to allow the job to resume. 4.8.1.3 When all deficiencies have been corrected, the issuer shall issue a new work permit(s). 4.8.2 The issuer and/or receiver has the responsibility to stop work any time the job site does not meet the work permit conditions or any applicable SA safety and health requirements. The issuer and/or receiver shall take action to correct the deficiencies before work can resume. 4.8.3 In the event of an emergency, all work permits are canceled within the area affected by the emergency condition and as specified by the Incident Commander. 4.8.4 Emergency work can be authorized without applicable work permits under the direction of the Incident Commander. However, the work activity shall follow all SA safety rules and standards normally applicable for the specific emergency situation. Once the “All Clear” has been declared, the work permit system shall be used for all subsequent work activities. 4.9 Closing Out and Filing the Permit 4.9.1 After completion of the job or when the permit’s duration has expired, the issuer (or his designated representative) shall ensure a joint site inspection has been conducted with the receiver to verify that the work area has been left in a safe and secure condition before the work permit can be closed. Note: During activities involving cutting, welding, or open flame, the 30 minute fire watch period must be completed prior to closing the permit. CSM I-4 Work Permit System December 2016 Page 5 of 7  4.9.2 Work permits shall be closed by both the issuer and receiver signing the permit form. When distance and remoteness makes signing impractical, alternative closing method is determined and stated on the work permit when it is issued. 4.9.3 The original permit shall be maintained on file by the issuing department for a minimum of 3 months. 4.10 Permit Rules 4.10.1 The issuer and receiver are jointly responsible for the safety of personnel and equipment at the job site. A joint site inspection shall be conducted for all work permits. Work shall not begin before the permit has been properly signed. 4.10.2 The correct permit(s) shall be issued for the job: Hot, Cold, Confined Space Entry and/or Equipment Opening/Line Break. More than one permit may be required for some jobs (e.g., most confined space entries). 4.10.3 Atmospheric gas testing shall be conducted with SA-approved portable gas monitoring equipment for all types of work permits for work that is performed in “restricted areas” as well as for Confined Space Entry Permits, Equipment Opening/Line Break Permits, and/or Hot Work Permits outside of “restricted areas” where the presence of flammable vapors or gases is suspected. Tests for hydrogen sulfide (H2S), oxygen concentration, flammable gases, and/or any applicable toxic substances shall be performed before issuing these permits. Gas tests shall be performed for Cold Work Permits where applicable. See GI 2.100 and GI 2.709. 4.10.4 Hot work is not permitted if the atmosphere is above 0% of the lower explosive limit (LEL). 4.10.5 A breathing apparatus (e.g., self -contained breathing apparatus) shall be used if any of the following atmospheric conditions exist:  Oxygen (O2) concentrations are less than 20.0%.  Flammable mixtures are at or above 5% and less than 10% of the LEL.  Hydrogen sulfide (H2S) concentration is between 10 and 100 parts per million (ppm). 4.10.6 Job descriptions and equipment to be used shall be clearly stated on the permit(s). Permits shall be issued for specific tasks at specific locations. One permit shall not cover more than one location. 4.10.7 Proper locks and hold tags shall be used where applicable (e.g., multiple clips with locks or chains with locks). See Chapter I-5, Isolation, Lockout, and Use of Hold Tags, for further requirements. CSM I-4 Work Permit System December 2016 Page 6 of 7  4.10.8 Permits shall be issued for the specific period of time required to complete the job. 4.10.9 Prior to the start of work, the work permit receiver shall communicate the hazards and precautions for the job, as well as other requirements on the permit, to all workers working under the permit. 4.10.10 Periodic reviews of the job site, including gas testing, shall be conducted as required. 4.10.11 Oncoming shift issuers and receivers shall inspect the job site, write the renewal time and sign the permits when renewing permits for another shift (per Section 4.7). 4.10.12 Special requirements and precautions, such as: fire watches, self-contained breathing apparatus (SCBA), lifelines, and/or barricades shall be written on the permit. 4.10.13 During activities that involve cutting, welding, or open flame, a fire watch shall remain in the area for no less than 30 minutes after the hot work is finished. 4.10.14 In the event of an emergency, all active permits in the affected area shall be immediately cancelled and work activities stopped. 4.10.15 Work areas shall be cleared of nonessential personnel to avoid exposing them to unnecessary hazards. 4.10.16 The issuer or receiver shall stop work and cancel the permit if there are changes in the work activities or site conditions that could potentially create an additional hazard to personnel, damage to equipment or facilities, disruption in operations or harm to the environment. If a permit is cancelled, a new permit shall be issued after the work site has been made safe (see Section 4.8). 4.10.17 Permits shall be closed out (per Section 4.9) after the work is completed or the permit expires. The issuer and receiver shall inspect the job site and sign the permit to close it. When distance and remoteness make signing impractical, an alternative closing method is determined and stated on the work permit when it is issued. CSM I-4 Work Permit System December 2016 Page 7 of 7