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									                  WORK
                  PERMIT
A.K.SINGH, SAFETY MANAGER
INDIANOIL CORPORATION LTD.
BARAUNI REFINERY,
INDIA
ROAD MAP
The session will include the following:
 Presentation on BR Work Permit
  system followed by discussion
 Role of Issuing & Executing Authority
 Exercise how to fill the permit
 Questionnaire/QUIZ
    WHY WORK PERMIT?
 Petroleum Refinery handles
  Hydrocarbons and toxic materials -
  poses special risks.
 Maint. Personnel are not adequately
  familiar with process conditions.
 Operation will determine that it is
  safe to perform the designated job.
 Basic purpose of permit system is to
  prevent injuries to personnel.
 Protect property from damage
 Avoid fire
 Ensure that all work is carried out in
  safest possible manner.
 permit specifies the conditions and
  procedure for safe execution.
WORK PERMIT REQUIRMENT
    Permit is required for the following
    jobs :
   Major & Minor Maint. work.
   Inspection.
   Construction.
   Alteration.
   Process Equip. cleaning
   Entry into confined space.
   Excavation
   Vehicle entry into hazardous areas etc.
           WORKS -
     PERMIT NOT REQUIRED
   Works carried out by Oprs. Dept. as a part
    of routine operation.
   FIRE STATION
   FIRE TRAINING GROUND
         BLANKET PERMIT
    SIX MONTHS BASIS / MAX I YEAR
 WORK SHOP
 INSTRUMENT LAB/WORKSHOP
 LABORATORY
 INSPECTION
          TYPES OF PERMITS
7 types of work permit with specific colors.
  HOT WORK & VEHICLE ENTRY PERMIT (Pink, light green & white)
  For use of or generates local source of ignition,vehicle & engine operated
  equip. entry to hazardous areas.
                                                          BR:F&S:FR:1
  CLEARENCE & COLD WORK PERMIT (YELLOW & WHITE)
                                                          BR: F&S: FR:2
  (For all general maint. works (no ignition source)
  DYKE CUTTING & EXCAVATION PERMIT(PINK ,light green & white)
                                                       BR: F&S:FR:3
  ROAD CUTTING & BLOCKAGE PERMIT (PINK & , yellow & light green)
                                                BR: F&S:FR:4
  VESSEL ENTRY/VESSEL BOX UP/EXCAVATION (yellow & white)
  For personnel entry into confined space.     BR: F&S:FR:14
  WORK AT HEIGHT PERMIT (yellow & white)       BR:F&S:FR:17

 RADIATION WORK PERMIT( PINK & WHITE)                BR:F&S:FR:18
      FEATURES OF WORK
         PERMIT FORM
Work Permit form generally consists of
 the following features:
THE ORIGINIAL AND COPIES
 Original is unmarked and belongs to
  “Executing Authority”-pink copy
   Printed serial number
   FORM NO. BR: F&S:FR:…...
   Special instructions printed on the
                  permit
       PROCEDURE FOR WORK PERMIT
             SYSTEM(WPS)
   WPS OPERATE ON OWNER IN CHERGE CONCEPT(UNITS-
    CPNM,LAB-SQCM,TPS-CPUM, STORES-SMTM)
   PERMIT IN PRINTED FORM
   SEPARATE PERMIT FOR COLD & HOT WORK
   PERMIT COLOUR CODED, SERIAL NUMBER
   DEPT L. OR CONTRACTOR JOB:PERMIT RECEIVING BY
    MN/PJ/CONSTRN. SUPERVISOR OF IOCL.
   PERMIT INITIATION BY MN/PJ SUEPRVISOR.
   ALL PERMITS TO BE WRITTEN IN CAPITAL LETTERS
   WORK ORDER/LOA NO. TO BE MENTIONED ON PERMIT
   LOCATION DRAWING/SKETCH TO BE GIVEN ALONG WITH
    PERMIT.
   RISK EVALUATION CHECKLIST TO BE TICKED BY ISSUER
    (GSI(HOT WORK), SUPERVISOR. NOT BY EXECUTOR.
       PROCEDURE FOR WORK PERMIT
             SYSTEM(WPS)
    HOT WORKPERMIT
   EXECUTOR TO INITIATE THE FIRE PERMIT-
    DUATION,LOCATION, EQUP.TAG NO., NATURE OF WORK,
    NAME & SIGNATURE. ECECUTOR NOT LESS THAN “A”
    GRADE OFFICER
   GSI( B GRADE AND ABOVE)-CHECK THE PERMIT,
    EVALUATE THE RISK,TICK 30 ITEMS AS APPLICABLE,
    SPECIAL INSTRUCTION IN SPACE PROVIDED IN PERMIT
    TO PREPARE THE AREA /EQUIPMENT TO CARRY OUT
    THE HOT WORK.
   SHIFT IN CHRAGE IN E/N SHIFT TO FOLLOW UP & DIRECT
    PREPARATIONS. N/SHIFT TO INSPECT THE AREA
    /EQUIPMENT JUST BEFORE THE SHIFT CHANGE AND
    LEAVE MESSAGE FOR FPS(C GRADE AND ABOVE)IN
    SHIFT LOG BOOK.
       PROCEDURE FOR WORK PERMIT
             SYSTEM(WPS)
    HOT WORKPERMIT
   FPS AFTER GOING THROUGH LOG BOOK ,ACCOMPANIED
    BY GSI & EXECUTOR INSPECT THE AREA, SATISFY
    HIMSELF WITH PREPARTIONS AND THEN SIGN THE
    PERMIT.
   PERMIT TO BE RECEIVED BY EXECUTOR BY SIGNING.
   REGISTRATION AT FIRE STATION.
   PINK COPY FOR EXECUTOR/ WHITE FOR ISSUER
   ISSUER REPRESENTATIVE-SHIFT PNE/SPNE/SPUE TO
    CARRY OUT GAS TEST, INSPECT THE AREA, ENSURE
    COMPLIANCE OF ALL SAFETY PRECAUTION GIVEN IN
    PERMIT , THEN ISSUE CLEARENCE CERTIFICATE TO
    START THE JOB.
       VALIDITY OF HOT WORK PERMIT
    HOT WORK PERMIT
   NORMAL 8 HOURS( 8AM-5 PM). BEYOND 5 PM
    RENEWABLE AFTER AUTHORISATION FROM HOD.RENEW
    AT FIRE STATION ON EXTENSION.
   NORMAL HOT JOBS IN NIGHT SHIFT NOT ALLOWED
    UNLESS JOB IS URGENT, PERMISSION FROM HOD REQD.
   FOR EACH LOCATION/EQUIPMENT SEPARATE HOT
    WORK PERMIT REQUIRED IN PROCESS UNITS
   IN OFFSITE:DISTANCE EXCEEDING 15 METERS,
    SEPARATE FIRE PERMIT.
    WHO CAN SIGN A WORK
          PERMIT
   Personnel who are authorized to sign on
    the Work Permit shall have thorough
    knowledge of the work to be performed
    and the conditions under which the work
    will be performed.
   DGM(T) AUTHORISES GSI & FPS AND LIST IS
    CIRCULATED.
    ISSUING AUTHORITY OF
        WORK PERMIT
 Issuing authority is responsible for
  preparation and handing over of the
  equipment in safe condition to
  perform the work.
 Authority to issue all types of work
  permits is generally granted to shift
  supervisor(PNE/SPNE, UTE,ELE)
  level of OFFICERS and above.
    EXECUTING AUTHORITY
      OF WORK PERMIT
   Request for a work permit by executing
    authority. He shall indicate types of
    tools and equipment necessary for
    performing the work.
   He shall also ensure his tools,
    equipment and accessories are in good
    condition and all his workers are
    provided with proper PPE.
    PREPARATION OF THE
        EQUIPMENT
 Equipment electrically isolated
 Inspection tested(for cold & hot job)
 Isolated from steam,air & gas
 Depressurized
 Drained
 Positively isolated/blinded
 Steamed & water flushed
    PREPARATION OF EQUIP.
                 CONTD.


 Ventilated & gas freed
 Continuous inert gas flow / continuous
  adequate ventilation arranged.
 Vehicle/equipment in good condition
  with spark arrested
 Radiation source removed(Confined
  space entry)
     RESIDUAL HAZARDS
 Lack of oxygen
 H2S and/or any other toxic gases
 Combustible gases
 Corrosive chemicals
 Steam / Condensate
 Pyrophoric iron
 High humidity
    PROTECTION MEASURES
 Protective clothing
 Hearing protection
 Safety Harness
 Eye protection
 Face protection
 Respiratory protection
 Keep fire equipment stand-by
    PROTECTIVE MEASURES
                CONTD.
 Barricade the area
 Remove flammable and combustible
 Cover with fire retardant tarpaulin
 Crane with basket stand-by
 Attendance with Airline set
 keep man ways open
 Allow minimum possible no. of persons
  inside confined space
    PROTECTIVE MEASURES
                 CONTD.

 To ensure positive isolation & maintain
  it all through
 Ensure adequate ventilation all through
 Display copy of entry permit near entry
  manhole
     GAS TEST FOR WORK
           PERMIT
Why gas test is required ?
 Most of the gases are unwanted
    Hazards involved -
   Flammability(Fire & Explosion)
   Toxicity(health hazard)
   Oxygen Deficiency
         GAS TEST CONTD
  Common flammable gases/liquids in
  refinery are -
 All petroleum products,Crude and
  intermediates
 Hydrogen
 LPG
 Common toxic gases in refinery -
 H2S, CO,NH3,CL2, etc.
           GAS TEST CONTD.
COMMON TERMINOLOGIES :
For flammable substances:
 Flash Point :
  Minimum temp. at which a liquid gives off
sufficient vapor to form an ignitable mix. It
will give a flash, flame will not continue.
Auto Ignition Temp.:
  The lowest temp. to which a substance will
ignite without a spark or flame.
           GAS TEST CONTD.
 Explosive limit :
 The concentration range of vapor in air
  when propagation of flame(ignition)
  occurs in presence of an ignition
  source.
 LEL (Lower Explosive Limit) :
 The minimum concentration of vapor to
  air required to propagate(ignite) flame.
         GAS TEST CONTD.

UEL(Upper Explosive Limit) :
The maximum vapor to air conc.above
 which propagation of a flame will not
 occur(will not ignite).
           GAS TEST CONTD.
Material    LEL   UEL    F Pt.(C) AIT(C)
Hydrogen    4     75      Gas      585

Methane     5     15      Gas     538
Propane      2    9.5    - 104    466
Naphtha     1.1    5.9     - 18    288
ATK/ATF    0.7    5.0    35-50   210
Diesel      0.7    5.0    32-96    256
Fuel Oil    1     5.0       66  262-407
           GAS TEST CONTD.
Toxic substances :
  TLV (Threshold Limit Value /
PEL(Permissible Exposure Limit) :
  The maximum permissible conc. of a toxic
substance to which exposure of a person
will have no adverse effect on health for
working 8 hrs per day.
  STEL(Short Term Exposure Limit) :
  Maximum conc. to which worker can be
exposed for a period of 15 mins. without
any adverse effect to health.
          GAS TEST CONTD.
IDLH(Immediate Danger to Life & Health)
 A maximum conc. from which one can
  escape within 30 mins. without
  irreversible health effect.

HYDROGEN SULPHIDE (H2S)
Highly toxic, combustible, colorless.
Smells like rotten egg.
        GAS TEST - H2S
EFFECTS ON HUMAN BODY
PHYSICAL EFFECT               CONC.(PPM)
Can be smelled as rotten egg    0.13
TLV                              10
STEL                             15
Smelling sense will dry within 150 - 200
2 mins, burning sensation in
eye & throat
   GAS TEST - H2S CONTD.
PHYSICAL EFFECT             CONC(PPM)
IDLH(Loss of smelling sense,        300
heavy breathing, dizziness,
headache,and total collapse
within 1 to 4 Hrs)
Dizziness,headache,lungs             450
problem and total collapse within 30 to
60 mins.
         GAS TEST-H2S CONTD.
PHYSICAL EFFECT                CONC(PPM)
Slow down of heart beats,          700
heavy breathing with coughing,
then death, if not rescued

Fatal emergency                    over 700

Explosive limits : 4.6 to 46%, it gives blue
flame when ignited.
      GAS TEST-H2S CONTD.
 FIRST AID :
IF INHALED -
 Remove exposed person to fresh air and
administer oxygen immediately.
PROTECTION:
 Use fresh air mask in case conc.
exceeds 10 PPM
      TOXIC GAS - CO
TOXIC AS WELL AS FLAMMABLE
TLV       -   50 PPM
STEL      - 400 PPM
IDLH       - 1500 PPM
LEL        - 12.5%
UEL       - 74 %
          GAS TEST - CO
HEALTH HAZARDS:
 CO combines with hemoglobin of blood
and make it unable to carry oxygen.
 Symptoms : Headache, dizziness to
unconscious and ultimately death.
First Aid :
  Remove to fresh air and apply oxygen at
the earliest.
    OTHER TOXIC GASES

TOXIC GAS   TLV   STEL IDLH

   NH3      25     35    -
   SO2        2     5    -
   CL2      0.5    1    30
         GAS TEST CONTD.
For hot work the gas test results shall be :
 Combustible - Below 1 % LEL
               ( Preferably NIL)
For confined space entry :
 Oxygen - 19.5% minimum
 Combustible - 10 % LEL Max.
 Toxic gases - below TLV
       GAS TEST CONTD.
Confined space With BA protection :
 Combustible - 20% of LEL maximum
 H2S - Less than 100 PPM
 CO - Less than 500 PPM
However, no hot job can be carried out
  inside the confined space at this
  condition.
    WORKS NEED GAS TEST
   Gas tests are required for all hot
    work/vehicle entry and confined space
    entry permits & some cold permits also.
   Issuing authority shall determine the
    requirement of gas test & frequency of re-
    checking.
   Trained Gas tester only shall carry out the
    test.
RESPONSIBILIES OF GAS
 TESTING AUTHORITY
   To check & confirm that the gas testing
    instrument is working in perfect condition
    before proceeding for the area/equipment
   To carry out gas test at all critical
    locations/positions
   To advise on safe method to work inside/at
    the location i.e., further gas freeing , use of
    PPE etc.
     ELECTRICAL ISOLATION
   Before issuing a Work Permit, it is
    essential to ensure that the equipment /
    facility to be worked on is electrically safe
    and electrical power is isolated to the
    extent necessary for the safe conduct of
    the authorized work.
    Issuing, Executing authorities and
    Electrical Maintenance shall jointly decide
    the extent of isolation required.
   „DO NOT OPERATE‟ tag shall be used
    when isolation by local switch is decided
    as adequate protection.
   Multi-lock systems to be used when
    different crafts are involved.(this is
    towards best safety practices)
    SPECIAL REQUIREMENT FOR -
    WORKING WITH RADIOGRAPHY

 Risk assessment through checklist
   Barricade the area and provide adequate
    warning signs.
    Film badges and Dosimeters          shall be
    worn by personnel        handling radiography
    equip.
   job preferably during night time or with least or
    no person around.
   Continuous monitoring of cordoned off area
SPECIAL REQUIREMENTS
   FOR HOT WORK
   The person who authorizes the Hot Work
    Permit is responsible for ensuring that the
    site and the equipment are properly
    prepared to prevent the danger of fire &
    explosion involving flammable material.
   The equipment shall be emptied and
    cleaned of flammable materials and
    isolated from sources of hydrocarbons by
    means of disconnection, blanking or
    insertion of blinds.
   Equipment and surrounding areas shall be
    checked to ensure that they are free from
    any combustible gas.Carry out gas test.
   Any heavy oil deposit, dried vegetation or
    other flammable / combustible materials
    within 8 m of a hot work site shall be
    cleared away.
   No hot work shall be allowed within a
    radius of 15 m of any sample point, drain
    or relief valve outlet unless precautions
    have been taken to prevent the escape of
    flammable liquids and vapors.
   The outlet of all units drain seals within 15
    m of the hot work shall be plugged.
   If welding or grinding is to be done at
    height, then precautions shall be taken to
    prevent the spread of sparks and molten
    metal to the surrounding of the work area
    with fire-resisting or flame-retarding
    tarpaulin.
   A hose capable of reaching up to the hot
    work point and connected to fire water
    main.
   Fire Station (333/5989) shall be informed
    of hot work.
             VEHICLE ENTRY
   A Hot Work / Vehicle Entry Permit is required
    for entry of all vehicles in hazardous areas.
    Such areas shall be clearly demarcated with
    signs indicating “No Entry without Vehicle
    Entry Permit” and/or with removable chain.
   The signatory authorities shall ensure that all
    vehicles / equipment exhaust are equipped
    with spark arrestors of approved type.
   Entry shall only be allowed for loading and
    unloading of materials and not for passenger
    transport.
     REQUIREMENTS FOR
    CONFINED SPACE ENTRY
   The process vessel / equipment is to be
    positively isolated by blinding.
   Shall be made safe for entry by
    depressurizing, venting, draining,
    steaming, washing and ventilating.
    Radiation sources ,if any, shall be
    removed.
   The atmosphere within the confined
    space shall be checked initially and
    periodically(gas test).
            EXCAVATION
           AUTHORIZATION
   An excavation authorization is required for
    all excavations. Detail drawings of the
    underground facilities shall remain
    attached with the authorization if available.
   In addition to an Excavation Authorization
    a Cold / Hot work Permit is required to
    work.
   For excavations more than 1.2 meter deep
    confined space entry permit is required.
    Gas tests shall be done as per entry permit
    requirements.
    SUSPENSION OF WORK
          PERMIT
 All work shall immediately stop when
  a fire or emergency alarm is sounded
  or accident of any kind occurs.
  Approval from the F&S shall be
  obtained after necessary preliminary
  investigations, to resume such work.
 The Work Permit shall be revalidated
  to resume the work.
 Any responsible member of the
  PN.dept. or F&S is authorized to
  suspend work and withdraw the
  Work Permit if, safety regulations are
  violated.
 If work is not started or is stopped
  for over two hours, the permit shall
  be revalidated by the issuing
  authority.
    VALIDITY OF PERMIT
 Work permit shall be initially issued
  for a period of 8 hrs. and shall be
  renewed for one more shift .
 On need basis , permit can be given
  for max. 7 days period.
 Clearance to be obtained every shift.
 Clearance to be given after
  physically checking the site.
    CLOSING AND FILING OF
     USED WORK PERMITS
   Permit Closure: Duly filled and signed by
    both executing & issuing authority at
    completion of work
   Copies of the closed permits shall be
    properly filed and kept with the respective
    disciplines for at least one month from
    the date of issue/closure. Different types
    of permits shall be filed separately in
    chronological order in box files.
    BASIC RESPONSIBILITIES
    OF ISSUING AUTHORITY
 To prepare the equipment and properly
  tick the checklist items
 To identify & indicate any residual
  hazard
 To advise on protective measures &
  mention
 To carry out gas test wherever reqd. and
  enter the result with sign,date & time
RESPONSIBILITIES OF ISSUING
     AUTHORITY CONTD.
 To discuss & explain with/to executing
  authority
 Carry out electrical isolation whenever
  reqd.
 Close the permit when the job is
  complete or end of permit duration,
  which one is earlier.
 To preserve the permit for next one
  month.
 BASIC RESPONSIBILITIES
OF EXECUTING AUTHORITY
 To clearly understand the conditions of
  the equipment and residual hazards
 To discuss the above with issuing
  authority and decide upon the protective
  measures.
 To describe the job and associated
  hazards to the workmen
 To ensure that safe procedure of
  execution are being followed
     RESPONSIBILITIES OF
    EXECUTING AUTHORITY
 To check all the hand tools / devices
  /equipment and ensure that they are
  healthy
 To make the permit available at work
  site all the time
 To close the permit when the job is over
  or at the end of permit duration,which
  one is earlier.
 To preserve the closed permit for next
  one month
   AUDITOR’S CHECK-LIST
An Auditor shall check the following:
 Whether the exact location of area/unit
  & equipment has been mentioned
  clearly
 Detail description of work is properly
  written
 Fire station has been informed and
  properly ticked
    AUDITOR’S CHECK- LIST
 Permit issued to which Dept.,
  Div.,Section & Craft - all mentioned
 Equipment preparation - Equipment has
  been properly prepared, all checklist
  items area properly checked & ticked
 Residual Hazards - Identified and
  ticked/indicated
 Protective Measures- Requirements
  identified & properly marked
    AUDITOR’S CHECK-LIST
 Other details - like provision of
  continuous ventilation, additional
  precautions
 GAS TEST:
 Test for all probable gases carried out
  and reading recorded with sign., date &
  time etc.
 Frequency of rechecking identified and
  carried out
     AUDITOR’S CHECK-LIST
 Electrical isolation was reqd., carried
  out and documented.
 Both issuing & executing authority
  signed mentioning name & signature,
  date & time.
    AUDITOR’S CHECK-LIST

 Permit has been closed by both issuing
  & executing authority with date & time
 Closed permits has been kept properly
  filed and being preserved for next one
  month
               OPEN FIRE

   PERMISSION-WEST SIDE OF RD.1 OR OUTSIDE
    GATE.2
   NO OPEN CHULLA IN OMS,LPG & RUNNING
    PROCESS UNIT INCLUDING ROAD SIDES.
   IN SHUT DOWN UNITS UNDER REVAMP, JOINT
    INSPECTION BY AREA IN CHARGE /F&S+
    RECOMMENDATION         DGM(T) FOR ONE
    DAY
    Clearence permit/certificate

   for hot /cold work
   issued against permit no…….
   14 checklist items to be critically evaluated and
    ticked
   issued for one shift maximum/renewed shift
    wise.
   Closure on job completion/ clearing the area,
    signed , date, time, return to issuer.
Not meant for billing. 
       Road cutting& blockage
               permit
   Request by executor(A grade and above) by
    filling all the entries and attaching
    sketch/indicating on reverse of permit form
   clearance from EL maint.
   Clearence from Civil
   Clearence from PN
   Clearence from IS dept.
   Clearence from F&S
   Approved by DGM(T)
   Permit registered at Fire Station.
   On completion , permit return to Fire Station.
     Excavation & Dyke cutting

   Request by executor(A grade and above) by
    filling all the entries and attaching
    sketch/indicating on permit form
   clearance from EL maint./ Telecom.
   Clearence from F&S
   Clearence from CL
   Clearence from PN/Area in charge
   Registered at Fire Station.
   Approved by GSI
   On completion , permit closure and return to Fire
    Station/ Area in charge.
                 Vessel Entry

   Request by executor(A grade and above) by
    filling all the entries clearance from EL maint./
    Telecom.
   Critical evaluation of 27 checklist items./ticking
   Approved by GSI
   Clearence from PN/Area in charge
   On completion , permit closure and return to Fire
    Station/ Area in charge.

								
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