Permit to Work Manual PDF

## Permit to Work Manual **Status:** Approved **Reference Number:** HPSL/TEL/HSE/S/PS3/007/01 **Version:** 1.00 **Valid Until:** Sep. 09, 2025 ### Introduction * In case of emergency where equipment is required to be operated immediately and housekeeping is pending, Issuer may cancel permit with...

## Permit to Work Manual **Status:** Approved **Reference Number:** HPSL/TEL/HSE/S/PS3/007/01 **Version:** 1.00 **Valid Until:** Sep. 09, 2025 ### Introduction * In case of emergency where equipment is required to be operated immediately and housekeeping is pending, Issuer may cancel permit with written reasons for cancelling permit without necessary housekeeping. Working party will carry out housekeeping as per agreement with Issuer through a new permit. ### Manual Completion of Permits * If the Maximo System is unavailable (software fault, interruption of electrical supplies to the terminal, etc.) the following action should be taken: * Permits will be issued manually where all protocols and workflows will remain same as described in above. Difference being printed and approved blanks of Permits will be filled manually and all exchanges between Issuer and Receiver will be manual (controlled by signatures rather than Maximo). * Issuer preparing a Permit will ensure legibility of all copies and Block Capitals will preferably be used for all details entered on handwritten Permits. * Overwriting in manual permit not allowed in any case. * Issuer SHALL ensure that identification of equipment appearing on Permit is consistent with the identification appears on the equipment itself and relevant Work Order. * Care will be taken to fill in the correct detail in the appropriate section of each permit and any sections not filled in will be marked “NONE” to show that consideration has been given to that section. * Each Permit Will be identified by a unique number. * As soon as Maximo System is re-established and outstanding Permits which are handwritten should be recalled, cleared and cancelled and a replacement Permit issued from Maximo. Those handwritten Permits which are prepared, issued, cleared and cancelled entirely within the time that Maximo System is unavailable need not be recreated within Maximo System upon re-establishment. * The cancelled manual Permit Will be archived in the appropriate file in the Control room. ### Abnormal Clearance of Permit * This action will be applied at HPSL Site whenever any of the following situations arise: * **Loss of Permit, Receiver Key or Field Lock Key** * If a Permit, Receiver Key or Field Lock Key (only in case of ROSH and TEST) is lost, Receiver must immediately stop the work being carried out under that Permit or Permit whose Receiver Key is lost, withdraw working party and report matter to Issuer. * Receiver will clear permit and Issuer will cancel it using Abnormal Procedures Form mentioning the loss and status of work as exceptions. * **Loss of Drain Earth** * If Receiver of Permit has lost a Drain Earth he SHALL report matter to Issuer when clearing Permit and acknowledge the loss by completing the appropriate section of the Abnormal Procedures Form. * Prior to cancelling Permit Issuer SHALL ensure that the circuit is clear of Drain Earths and record this check on the Abnormal Procedures Form. * **Unavoidable absence of Receiver with Permit enforced** * It is a requirement that Permits are surrendered/cleared by Receiver before leaving the site. * If due to any reason, Receiver is not available at site while Permit is enforced, the Section Head of Receiver's Section or his/her nominee must immediately instruct to stop the work being carried out under that Permit, withdraw the working party and report matter to Issuer using Abnormal Procedures Form. * The Section Head or his/her nominee then assess the condition of work and SHALL surrender permit on behalf of Receiver if permit is available at site or follow the lost Permit protocol to clear it. * Permit then can be reissued to new Receiver for further progressing the work. * **Emergency Protocol** * All Permit(s) (Issued Status) in electronic PTW System SHALL be considered as "surrendered" in case of plant evacuation due to any emergency. All Permits will be formally surrendered to and then reissued from an Issuer after evacuation is over. #### Radiography Protocol * For Radiography activity, Radiography Safety Checklist SHALL be filled by Site Radiography Adviser (SRA), based on which Issuer SHALL issue Permit. * All other Issued Permit(s) of a specified area SHALL be surrendered to an Issuer if "Radiography" is to be carried out within that area. SRA will co-ordinate with Issuer in confirming that identified Permits are surrendered. The above condition will be met before announcing for the start of the 'Radiography". * Subsequently all required permits will be reissued after the confirmation received by SRA for the completion of ''Radiography". ### General Requirements * There SHALL be a Permit for every job unless exempted through SOC. * PTW Will be issued to preferably HPSL permanent employees, who have been duly authorized by management, while contractor staff hall work under Supervision of HPSL Receiver(s). * In special cases permit can be issued to contractors who have been duly authorized by management staff. However, all pre-requisites of permit package will be completed by relevant HPSL department. * In case he holds a permit that requires continuous supervision he can only hold one such Permit at a time. However, in case of a Permit ROSH/TEST/LIVE/SC no other permit can be held by Receiver simultaneously. * Upon Operations shift changeover the incoming Issuer SHALL review all enforced permits. He may verify his understanding by visiting area and checking prevailing conditions (isolations/precautions taken etc.) All enforced permits will be his responsibility. * All Permits SHALL be surrendered/cleared by Receiver before leaving the Plant site. ### Permit Validity * The below table shows Permit Re-validation and time limit; | Type | Re - Validation | Max. Time Limit | |---|---|---| | General Work Permit (without Isolations) | Every Shift or Issuer/Receiver Change over | 30 Days | | General Work Permit (other than without isolations) | Every Shift or Issuer/Receiver Change over | 7 Days | | Confined Space Entry Permit | Every Shift or Issuer/Receiver Change over | 7 Days | | Hot Work Permit | No Revalidation | 1 Day | * All Permits validity starts from the date on which Issuer prepare Permit except for Hot work Permit which has a validity of 01 day only. * This validity can be altered by Issuer but cannot exceed the maximum limits provided. * For outage/shutdown periods, Permit validity will be extended as per outage days. However Hot Work Permit validity will remain same. * Permit become void at the expiry time written on Permit when issued. * If a work cannot be completed within the validity period defined by Issuer, the validity can be extended such that it cannot in any case exceed the maximum validity defined above. ### Permit Records * All permit record will be maintained in the Maximo, which can be referred at any time to check all details regarding a Permit. * For manual record following protocol to be followed: * A hard copy of every permit issued should be maintained in Permit office for the duration that permit is enforced. * After clearance of permit, copy inside issued file to be discarded. * Record of Permits along with Defeat Form/Back in Service Form, Isolation/De-Isolation forms to be kept for six months in control room and will be available in record of Operations for 5 years. ### Permit Security * Permits and associated documents and keys when prepared but not to be issued immediately, are kept secured in Control room and passed on from shift to shift. * The same procedure will be used for the secure retention of documents and keys when being suspended. * Permits, associated documents and keys when cleared but not cancelled will be kept secure within the control room * It is the responsibility of Issuer receiving surrendered permits to check that all associated documents and keys are verified and that the appropriate sections of the Transfer Record are satisfactorily completed before storing all permits and keys securely. ### Authorization Process * HSE Manager will ensure that: * All relevant documents relevant to PTW System are available to and where appropriate, issued to each candidate for authorization. * Candidates receive required formal training (which may be comprise of self-study), local familiarization (equipment and application of PTW System), and practical testing to reach a suitable level of preparation to enable them for properly discharging authority under PTW System. * Candidates are made aware of scope of appointment and the limits of Equipment on which the person is to be authorized, and these are specified in writing on appointment. * Appropriate Authorization panels are convened. * Full records of all present and previous authorization at the Plant is maintained. * Refresher training is provided. #### Level of Authorization for PTW | Level | Type | Voltage Level | |---|---|---| | Level I | General Permit, Hot Work Permit, Confined Space Permit | Without isolations & Up to 400 V - single ended circuit | | Level II - a | General Permit (HV) | Up to 6 kV single ended circuit | | Level II - b | General Permit (HV) | Above 6 kV including all interconnected circuit | | Level III | General Permit (ROSH) | All | | Level IV | General Permit (Test) | All | | Level V | General Permit (Live) | All | #### Authorization Process * As a pre-requisite, all candidates will have sufficient job specific technical knowledge. * All candidates will be given a comprehensive understanding of PTW System related procedures and systematic practical training to enable them to perform duties competently within proposed limits of their jurisdiction. * Understanding will include: * Complete understanding of formal PTW System. This can be done through self-study of procedures and discussing ambiguities with line manager/HSE Manager. * On the Job training by attachment to a senior person who has already gone through the process and qualified. * Additional understanding will be obtained by Issuers/Receivers who are to deal with ROSH, TEST, LIVE Permits and associated procedures. This will be done through reading relevant procedures and clarifying and ambiguities with line Manager/Operation Manager. * For Level I authorization, candidate will appear in a written test arrange by HSE Section and passing criteria of 95%. * On successful completion of written test candidate will be presented for assessment to an authorization panel. * For other levels of authorization only panel assessment will be required. #### Authorization Panel | Level | Type | |---|---| | Level I | Operations Manager, HSE Manager, Shift Manager | | Level II - a | Plant Manager, Operations Manager, HSE Manager | | Level II - b | Plant Manager, Operations Manager, HSE Manager | | Level III | Plant Manager, Operations Manager, HSE Manager | | Level IV | Plant Manager, Operations Manager, HSE Manager | | Level V | Plant Manager, Operations Manager, HSE Manager, E&I Manager | * Note: Plant Manager may opt to nominate his designee (in writing) to be part of authorization panel. * The authorization assessment may be combined with the practical test at the discretion of the authorization panel. * Upon satisfactory completion of the assessment, HSE Manager will issue Certificate of Authorization specifying level of authorization. In case of ROSH, TEST, LIVE, a list of those procedures for which Issuer/Receiver is trained and nominated SHALL be included on the Certificate of Authorization. * HSE Manager Will maintain and publish an up-to-date list of Issuers, Receivers and Skill Certified Person along with their Authorization levels and get it updated in Maximo. #### Withdrawal/Suspension of Authorization * The Authorization of a person will be withdrawn if: * He resigns, retires or is terminated from duty. * Permanent change in his responsibilities that no longer require PTW Authorization. * Found responsible for breach of PTW procedures. * In case of withdrawal of Authorization: * HSE manager to ensure that all related parties are informed of the withdrawal. * If the Person's authorization is to be subsequently re-instated, then the person SHALL have to qualify again through the whole Authorization procedure. #### Level of Authorization for Skill Certified Person (SCP) * Following are different level of authorization for SCP | SKIL CERTIFIED PERSON | TYPE | VOLTAGE LEVEL | Authorization Authority | |---|---|---|---| | Isolations | Up to 400 V - single ended circuit | Operations Manager | | Gas Testing | All Plant & Electrical Equipment | Operations Manager | | Excavation Clearance | All Plant | HSE Manager | | Switching | LEVEL I | Safety Switching of Single Ended Electrical Equipment up to 400V | E&I Manager | | | LEVEL II | Operational Routine Switching of High Voltage Single Ended Electrical Equipment up to 6.0kV | Operations Manager | | | LEVEL III | Operational and Safety Switching of High Voltage Single Ended Electrical Equipment up to 6.0kV | Operations Manager | | | LEVEL IV | Operational, Local, Safety and Emergency Switching of all Electrical Interconnected Circuits above 6kV | Operations Manager | ### Objections on Safety Grounds * If any person receiving instructions in the application of the PTW System has any objections on safety grounds to carrying them out, then he should refer the case for consultation as per the hierarchy of position defined below: * Operation Manager * Issuer (Shift Engineer/Manager/Coal Engineer) * HSE Manager * Plant Manager * If such cases the decision made by Plant Manager will be delivered to the originator in writing and will be considered final. ### Breach of PTW System * Breach of PTW system SHALL fall under breach of Cardinal Rule and disciplinary action will be taken post formal investigation. ### Lock Out Tag Out (LOTO) Protocol * This section describes the key elements of an energy control program that must be met to comply with OSHA lockout requirements contained in 29 CFR 1910.147, Control of Hazardous Energy. #### Standard Isolation List * Approved Standard Isolations Lists will be available in Maximo that can be used as reference for defining LOTO Plans. It remains, however, the responsibility of Issuer, to decide on the suitability of the precautions/isolations in line with the work to be done. * For outage/shutdown activity, Standard Isolation Lists will be made part of Blanket Permits. Other Permits on same equipment/System can be issued with reference to the Blanket Permits. * Detailed method of isolations are given below; #### Methodology * Before an individual commences work on or inside equipment where hazardous energy (Electrical/Mechanical/Stored) could be encountered, all relevant sources of hazardous energy SHALL be isolated, locked and tagged. * Following method is adopted when applying LOTO Protocol; * During permit preparation step, Issuer SHALL prepare a LOTO Plan on Standard Isolation list and hand it over to the Skilled Certified Person (SCP) for Isolation and/or Switching, as appropriate, for implementation. * SCP SHALL implement LOTO plan ensuring that, Field Lock Keys(s) securing the points of isolation are all individually labelled. * All isolations SHALL be recorded along with lock number on Isolation Form by Skill Certified Person. He SHALL also operate the ON/OFF switch (try) to ensure the supply source is cut off. * For all mechanical equipment isolations, SCP SHALL ensure that equipment is depressurized, drained and purged (where applicable). * SCP SHALL submit the signed copy of Isolation Form to Issuer along with Field Lock Key(s). * Issuer SHALL place these keys and in a designated Lock Out Box (LOB) (except those to be handed over to Receiver with Permit ROSH and TEST) and take the Key of LOB to be issued with Permit, mentioning the same in Maximo. The LOB SHALL also be locked by a Master Key which is to be placed securely to maintain joint control of Issuer and Receiver. * In case of work request from 2nd working party on the same equipment, which is already under permit, and if the isolations previously made are sufficient for the job, Receiver from 2nd working party may verify isolation as mentioned above and sign off same Isolation Form. Afterwards, Issuer will hand over him another key of the same LOB. * In case if existing isolations are not enough and some additional isolation are required then “cascading" will be applied. In this case, additional isolations will be made by the SCP on instruction of Issuer on new Isolation Form. These isolations SHALL be verified by 2nd Receiver and he SHALL sign off new Isolation Form. All keys of additional field locks will be placed in new LOB along with the one locking key from the previously used LOB. The new LOB will also be locked by a Master Key which is to be placed securely to maintain joint control of Issuer and Receiver. A Key from new LOB will be handed over to Receiver along with new Permit and mentioned in Maximo. * In case of a ROSH and TEST Activities, Issuer WILL mention in permit under "Precautions which may be varied by receiver" those isolations which may be changed/varied by Receiver during the course of work and also select appropriate procedure. #### Mechanical Equipment * For work on mechanical equipment where isolation is required following precautions to be taken: * The mechanical equipment SHALL be Isolated. When Isolating Devices are used, they SHALL where practicable, be immobilized and locked. All points of Isolation SHALL be tagged. * If mechanical equipment is connected to a prime mover that SHALL also be isolated. * If any electrical devices connected with mechanical equipment which could give rise to hazard (such as space heater) they SHALL also be locked and tagged. * The contents of the mechanical equipment SHALL be adjusted to a level which avoids Hazard and where drains could give rise to Hazard they SHALL be tagged and, where practicable locked in the appropriate position. * Where Hazard could arise from pressurization mechanical equipment SHALL be vented to atmospheric pressure; where vents could give rise to Hazard they SHALL be tagged and, where practicable, locked in the appropriate position. * Where internal access is required, the mechanical equipment SHALL be purged if the residue of contents could cause Hazard. * Where Hazard could arise from the release of stored energy, action SHALL be taken to contain or dissipate this energy safely. * If other equipment in the vicinity of work can give rise to Hazard that can be eliminated by restricting the work area, this can be achieved by mentioning such instructions in special instructions section otherwise the adjacent source SHALL also be isolated, locked and tagged. #### HV Electrical Equipment/Circuit * For work on HV electrical equipment/circuit where isolation is required following precautions to be taken in addition to detailed already: * HV electrical equipment SHALL be Isolated through field locks. All points of Isolation SHALL be tagged. * Primary Earths SHALL be applied within the Isolated Zone and, where reasonably practicable, immobilized and locked. All Primary Earths SHALL be Tagged. * Where Hazard from induced voltage could arise during the course of work, Drain Earths SHALL be applied. Any portable Drain Earths SHALL be issued with permit, together with an Earthing Schedule. #### LV/MV Electrical Equipment/Circuit * For work on LV/MV Electrical Equipment where isolation is required following precautions to be taken in addition to detailed already: * The LV/MV Electrical equipment SHALL be Isolated. All points of Isolation SHALL be locked and tagged. * When it is unreasonable to isolate or isolation is not possible, work on LV/MV electrical equipment can be carried out by following the LIVE work Permit protocol. #### For work on Live LV/MV Electrical Equipment * In case of LV/MV Electrical equipment where it is essential for Live work to be carried out the following requirements Will be fulfilled: * A General Permit for LIVE Activity SHALL be issued clearly mentioning the details of the work to be carried out. * An approved procedure hall be issued along with permit, detailing method of work and precautions required to cater all risks associated with the system being worked upon. * If other equipment in the vicinity of work can give rise to additional risk that can be eliminated by restricting the work area, this can be achieved by mentioning such instructions in special instructions section otherwise the adjacent source SHALL also be isolated. #### For work with Restoration of System Hazard (ROSH) * When work is to be carried out Equipment and it is essential to restore a source of energy to facilitate that work then working safely will be achieved and maintained as follows: * A General Work Permit (ROSH) SHALL be prepared, considering the requirements outlined above. * An approved Restoration of System Hazard (ROSH) procedure SHALL be issued with Permit, detailing the work to be carried out and clearly specifying the requirements to cater all risks associated with the system being worked upon while system is energized during activity. * An Isolation Point which can be varied/changed by Receiver under the ROSH Permit SHALL be tagged with special ROSH tags. #### For Testing of Mechanical and/or HV Electrical Equipment * When testing is to be carried out on mechanical and/or electrical equipment and it is essential to introduce testing supplies and/or remove isolations and/or the removal of Primary Earths to facilitate that testing, risk associated with system will be controlled as follows: * A General Work Permit for TEST activity SHALL be prepared, considering the requirements outlined in this procedure. * An approved Test procedure SHALL be issued with Permit, detailing the work to be carried out and clearly specifying the requirements to cater all risks associated with the system being worked upon. * Only testing, and associated work of a minor nature, that is essential to the completion of testing, SHALL be carried out under a General Permit for TEST activity. #### Procedures that require approval within the PTW and LOTO protocol: 1. **ROSH (Restoration of System Hazard)** – Where supplies are essential for the work to progress. 2. **TEST** - Where it is essential to introduce testing supplies and/or remove isolation and/or remove Primary Earths. 3. **LIVE** - Where it is essential and justified to work Live and without the Low/Medium Voltage Apparatus being Isolated. 4. **Exceptional Circumstances**- Those circumstances when it is impossible to apply the PTW & LOTO protocol or there are strong reasons, commercial or technical, for not applying the protocol in full e.g., High Voltage igniters on Boilers, earths required but cannot physically be applied. ### Confined Space Entry Permit (CSEP) **Scope** * A Confined Space Entry permit is to be obtained before any person enters a location defined as Confined Space. This permit allows only the 'entry' into a process vessel or tank not any work to be done therein. If any work is to be performed in the process vessel or tank, then the respective permit, Hot, General permit must also be obtained. This permit must comply with all the requirements of the Confined Space Entry Standard. * This standard contains the basic rules to protect personnel from the hazards of entry into confined spaces. Common hazards include oxygen deficiency, flammable vapors, toxic substances, difficulty in escaping, rotating parts and electrical shock. * Examples of confined spaces include tanks, vessels, certain pits, ditches, sewers/septic tanks, excavations and vessel support skirts. Entry will be allowed only after compliance with the specific guidelines of this standard. * A Confined Space requiring a permit has one or more of the following characteristics: * Contains or has a potential to contain, a hazardous atmosphere. * Contains a material that has the potential for engulfing the entrant. * Has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls or by a floor that slopes downward and tapers to a smaller cross section. * Contains any other recognized serious safety or health hazard. **Authorizations** * A Confined Space Entry Permit (CSEP) will be issued by the authorized Issuer before personnel can enter a permit space. **Responsibilities** **Issuer** * Properly emptying, cleaning, steaming, neutralizing and purging (as necessary) all confined spaces before entry is permitted. * When it is necessary to enter a vessel to clean it out and there is any possibility of toxic fumes being released from pockets of crusty or sludgy material, the necessary personal protective and respiratory equipment must be worn. * Locking and tagging of all power-driven equipment * Ensuring that rotary equipment is mechanically secured/Isolated * Ensuring that the internal moving parts are secured to prevent them from turning * Ensuring that blinding (where applicable as per identified blind locations), disconnecting or capping of all pipelines attached to a vessel is complete as required. * When there is double block and bleed option available then blinding the line may not be required. * Ensuring that all isolating valves in the involved pipelines are set in the required positions as specified in the approved confined space entry procedure for the equipment and are properly tagged * A list or sketch of the blinding plan and disconnections must be available in the control room. * Ensuring that gas testing for oxygen deficiency, explosively and toxic materials is complete * Ensuring that all permits have been properly filled, signed and issued * Obtaining agreement with maintenance interfaces on the minimum precautions needed to perform the work safely * Note: The Confined Space Entry permit automatically expires when an emergency alarm sounds in the area. It needs to be re-issued as per protocol **Receiver** * Ensuring that their employees are qualified on work permit. * Ensuring that all personal protective equipment (PPE) is worn as specified on the permit * Displaying the permit at the job location * Obtaining agreement with Operations interfaces on the minimum precautions needed to perform the work safely * Understanding the duties of the standby employee * Copy of blinding plan is attached with permit * Ensuring rescue plan is available with permit and well known to working party. * Deputing qualified standby personnel * Providing necessary safety equipment **Standby Person** * Know potential hazards and beware of the effect of hazards on entrants * Be familiar with the location of safety shower, exits, emergency siren, and the rescue plan. * Be physically capable of performing the duties assigned. The standby person is responsible for stopping the job and ensuring personnel's exit from the confined space if emergency siren is sounded * Remain at the entry point if anyone is inside the confined space and remain alert for anything that could affect the employee's safety (e.g., fumes and noise). Keep un-authorized person from entering the space. * Perform rescue that does not require entry into confined space. In case he must go somewhere like call of nature then some other member from the working party will be nominated as Standby by supervisor and to be mentioned on back side of the permit in respective column. * Have a safety harness, plus a lifeline, a megaphone (in case of work at heights or unavailability of walkie-talkie / intercom) and either a SCBA or fresh-air mask. * Maintain a list of all those who are always inside the confined space. * Frequently confirm that the personnel inside the confined space are all right. Alert and inform them about any hazard. Ensure air hoses / exhaust pipes and lifelines are intact and remain in good shape. During an emergency, require them to exit the confined space. Assist in safe handling of materials and tools and in conveying messages. * Use the walkie-talkie / intercom / megaphone to summon help in case of emergency. Communicate with Control Room to sound the siren in case emergency warrants so. The standby person must not enter the confined space, even in an emergency, until another qualified standby person arrives and unless he has been trained as a rescuer. * The standby person must not allow anyone to enter the confined space to start a rescue unless he is part of the emergency squad / designated member of rescue team and is wearing the necessary personal protective equipment * A standby person cannot leave the job location while someone has made an entry to the confined space or in case, he needs to leave to attend the call of the nature etc. At no point in time a standby person can leave a confined space with someone inside it except for calling for help. **Persons Entering the Confined Space** * All personnel who enter confined spaces must understand the hazards, to which they may be exposed, properly use necessary personal protective equipment and communicate with the standby Person: * Each individual working on equipment is responsible to ensure that it is safe for him to proceed with the work. * Individuals leaving the permit space and job must cross out their names on the CSEP / entry list available with the standby person and remove their locks and tags. * Lifelines used in vessels greater than 12 feet in depth will be kept snubbed with minimum slack so that the standby person can provide enough support to prevent individuals from falling from the ladder when entering or leaving the vessel. * Lifelines that have been disconnected in the tank should be reconnected to the individual prior to exiting the vessel or confined space. * Job space must be considered when determining how many persons are permitted to enter. * Contractor personnel assigned work in the confined space must be authorized by the relevant Maintenance Engineer/Supervisor and must follow necessary safety instructions passed on to them by Shift Manager/Maintenance Supervisor/designates. **Preparation for Entry** **Isolating Confined Spaces** * Isolate all process material lines, including nitrogen purging lines. This includes steam, water or other coolants in coils of confined spaces to be entered. Put blind as close to the vessel as possible at the identified locations. * When the stack or duct is in dedicated service to the space being entered and is open to the atmosphere, blinding or disconnecting the stack or duct is not necessary. If the stack or duct is left open, any other line to the stack or duct should be disconnected or blinded. **Lockout** * All power-driven equipment associated with the permit must be locked out in accordance with the Lock, Tag and Try Procedure. * Moreover, agitated / rotating equipment must be physically disconnected from the power source and tagged, even though the work may not involve that piece of equipment. **Obstructions** * The areas surrounding the access to confined spaces should be maintained in a safe housekeeping condition: * Access must not be blocked with equipment or materials that would interfere with safe exit from the confined space. * Lines, cords, hoses, etc. must be properly arranged and secured to prevent tripping hazards. **Test the Atmosphere inside the Confined Space** * The atmosphere of the confined space under Permit must be checked for proper oxygen content and to ensure that no flammable vapors or toxic gases are present. The tests must be conducted in the following order: * Oxygen * Lower explosive limit (LEL) * Toxic gases * Others * Consideration must also be given to the work to be performed and any conditions nearby that could cause an oxygen deficiency, create a flammable atmosphere or form toxic gases. **Oxygen** * The oxygen test must be carried out by a properly trained and qualified person no more than 30 minutes before initial entry. Permit Issuer may ask for frequent testing during the work depending upon the condition. Receiver of the work permit is responsible to get the oxygen tested after the agreed interval from operations. It is required to get gas test rechecked on start of every shift at least. * Test readings should be taken at several locations and levels within the confined space under permit. * A minimum reading of 21% percent is required (same as fresh air). If the oxygen concentration is normal and provided all other conditions are acceptable * When the oxygen content is between 19.5 to 21%, a high-pressure breathing device must be used provided all other contaminants are within the limits outlined in the table under "Allowable concentration for entry into vessels". When the oxygen content is outside the acceptable limits (below 19.5% or above 21.5%) or when air contamination is suspected, check the air for toxic materials. Correct the situation causing their presence and use positive (forced air) ventilation to improve the quality of air in the vessel. Results of this test must be recorded on the confined space entry permit and signed by the employee performing the test. * Continuous Oxygen monitoring may be required on some jobs, such as interior welding on small tanks. * In case of any materials that could affect the safety of the employees, forced air blowers should be used and continuous oxygen tests should be made. **Explosive Atmosphere** * An explosively meter must be used by qualified personnel to test the air in a permit space at several elevations or locations no more than 30 minutes before initial entry, at the beginning of each shift, after break and as required while the work proceeds. Results of the explosion test must be entered on or attached to the confined space entry permit. Testing procedures are as follows: * If the meter indicates more than ZERO percent (0%), the source of flammable vapor must be identified and removed, if possible. If a minor vapor source cannot be removed, Shift Engineer must evaluate the degree of hazard and need for additional precautions and then allow entry only after determining that work can proceed safely. * In no case SHALL entry be permitted if the meter indicates as much as 0.5% of the LEL and that also will be allowed with high pressure breathing air equipment. * A lack of oxygen will nullify the function of the explosivity meter; therefore, this test must not be made unless acceptable oxygen readings are obtained. **Toxic Materials** * When presence of toxic materials or fumes is known or suspected in a confined space, entry must not be permitted until the concentration of the material is determined. Results of the toxic materials test must be entered on or attached to the confined space entry permit: * Each area will develop procedures and utilize appropriate testing equipment for determining the concentrations of toxic materials used in that area. * Tests must be made at several elevations or locations no more than 30 minutes before initial entry. * If the concentration exceeds the "allowable concentrations" outlined in the table below, no permit will be issued unless reviewed by SOC and supplemented by approved procedures. **Note: List of Confined Space with locations and KKS no. is available in Maximo.** **Allowable Concentrations for Entry into Vessels** * Before issuing an entry permit, test should be carried out to ascertain the presence of poisonous gases if any. Lowest allowable concentrations are as follows: | Agent | Without Breathing Air Equipment (for 8 Hours) | With High Pressure Breathing Air Equipment | No Entry Permit | |---|---|---|---| | Hydrocarbon (500 PPM) | 0.05% LEL Max. (500 PPM) 21% Min. | 0.5% LEL Max. | Above 0.5% LEL Max. | | Oxygen | 10 PPM Max. (same as Fresh Air) | 19.5% Min. | Less than 19.5% | | Hydrogen Sulphide | 10 PPM Max. | 100 PPM Max. | Above 100 PPM | | Carbon monoxide | 50 PPM Max. | 100 PPM Max | Above 100 PPM | | Hydrogen | 500 PPM Max. | 1000 PPM Max. | Above 1000 PPM | | CO2 (Carbon dioxide) | 2500 PPM Max. | 5000 PPM Max. | Above 5000 PPM | **PPEs & Safety Equipment** * Safety equipment required for a job must be indicated on the permit. Before entry can proceed, safety equipment must be available at the entry point for each person who is to enter and for each standby employee. Safety equipment will be checked before each use to be sure that equipment has not exceeded its usable date or limit and is in good working condition: **Safety Harness and Lifeline** * Each person in the confined space will wear safety harness and lifeline at all times where practical. If the work cannot be performed with the lifeline attached, the issued to be discussed with Issuer. Two extra sets of harnesses and lifelines for emergency use must be available at the location. The lifeline must be kept available at the confined space entry point with one end secured outside the tank / vessel. **Canister Masks** * Canister masks are NOT approved for confined space entry. **Megaphone** * A megaphone will be kept available for immediate use by the standby person. **Lighting** * Lighting equipment (and wiring) inside the confined space must carry no more than 24 volts. Equipment requiring more than 24 volts to operate should be used only with an ELCB. The transformer should be located outside the confined space. Cables of lighting equipment should not create hindrance in the exit path. **Power Tools** * Normally, only pneumatic or low voltage (12/24 volts or less) electric power tools are allowed in confined space. Electric tools with higher voltage can be used after necessary reviews and if waiver has been obtained (in writing) SOC Chairman. Power for such tools must be supplied thru an ELCB. **Two Way Radios (Walkie-Talkies)** * Two-way radios will be used when the standby person cannot maintain visual or audible contact with a person in the permit space. **Welding** * When welding or cutting inside a vessel is to be done, it is critical that adequate breathing air must be provided to avoid gas pockets and fumes. When breathing air is deficient, a special air supply welder's hood must be used. The maintenance engineer/supervisor of the employee doing the welding or cutting must initiate and approve the necessary procedures for this work. Continuous monitoring for oxygen deficiency and other toxic gases / explosively should be carried to further ensure a safe atmosphere. Air Blower can also be installed to maintain a constant flow of air. **Cylinders and Welding Machines** * When welding or cutting is to be done inside a confined space, all cylinders and welding machines should be left outside the permit space. * A hot work permit must be obtained and displayed at the work site while carrying out a hot job as per Hot Work Permit protocol. **Rescue Plan** * A detailed rescue plan prepared by Receiver and approved by Issuer to be attached with Permit. Rescue plan will include but not limited to * A Sketch detailing lifeline and anchor points * Method of communication among entrants and stand by person * Location of emergency phone set * Name of person from working party to be contacted in case of emergency **Box Up Certificate** * At the time of task completion, and Confined Space Entry Permit Cancellation Box up Certificate to be filled and completed by Receiver to ensure that all requisite precautions have