KOC.sa.004 Permit to Work Procedure

KOC.SA.004 - Permit to Work Procedure Page 1 of 55

Permit to Work Procedure Document Number: KOC.SA.004 Document Coordinator

Document Author:

TL Safety

Approved by:

KOC HSEMS Procedure Sub-Committee

Authorized by :

KOC HSSE Implementation Committee

Original Issue Date:

27th July 2004

Revision / Review Date:

17 June 2015

Document Control

Tier: Next Review Date:

TL Standard

Tier 3 16 June 2018

1.0 Purpose/Scope The purpose of this document is to provide a coordinated, communicated and controlled safe system of work, which shall be carried out in hazardous / non – – hazardous areas under KOC jurisdiction. It is intended to achieve a safe working environment by providing the control needed to identify and mitigate any hazard (either actual or potential) that would have an adverse effect on either on the personnel performing the work, people adjacent to the work, public or on the facilities or environment. Without exception all non-routine works to be carried out within KOC premises shall have appropriate permit to work authorized by respective Permit Issuer.

2.0 Definition e-WP (Electronic Work Permit): Electronic Work Permit (e-WP) is a web-based solution through KOC intranet to manage electronically the authorization process of non-routine activities which are carried out in KOC business as per Permit to Work Procedure (KOC.SA.004).

Permit Applicant: Applicant:

A person representing representi ng the controlling department ( such such as Maintenance, Projects Managements, Major Projects etc) who has been nominated in writing by the respective Team Leader to raise a Work Permit. He must have the technical knowledge, skill & competence to consider and guard against the potential hazards associated with the work activity.

Permit Issuer : A person representing the asset operating team (in whose area of control the work is to be carried out) who has been nominated in writing by the respective Team Leader to issue a work permit. He will have a complete overview of all operational activities and also have detailed knowledge of the ‘Permit to W ork System’. Worksite Supervisor : A person representing the controlling team (such as Maintenance, Project Management, Major Projects etc) who has been authorized by the respective Team Leader to supervise the work at the worksite. The worksite supervisor can be a person belonging to the Company (KOC) or Contractor, as deemed suitable in the opinion of the controlling team taking into consideration the criticality of work and its associated hazard. He must have detailed knowledge of the ‘Permit to Work System’. Authorized / Competent Electrical Person: Person: An electrical person, who has been authorized in writing by the respective area Snr. Electrical Engineer, to work / isolate / deisolate (energize / de – energize) – energize) a high & / or low voltage electrical equipment He must have sufficient technical knowledge and experience gaining the skill required to identify potential hazards and control measure associated with the high & low voltage electrical work. The authorization must specify the competency of the person for low voltage or high voltage electrical works depending upon the qualification, experience & skill of the candidate. Control Tier 3

Revision Date: 17 Jun 2015 Uncontrolled Copy if Printed


Authorized Gas Tester: A person who has successfully completed training on Gas Tester Certification and accordingly been nominated by the HSE Group or asset / directorate HSE Team. An authorized Gas Tester can be a person belonging to the HSE Group, asset/ directorate HSE Teams or asset operating teams who has the detailed knowledge of Permit to Work System. An authorized gas tester can carry out gas test for any work permit related activities except for ‘Confined Space Entry’ initial gas t est which will be conducted by ‘Competent Person for Entry Permit Gas Test’ as defined in “Entry into Confined Space Procedure’ (KOC.SA.07). However, for Green Field areas, Project Management Consultants (PMC) can be authorized as gas tester including for confined space entry gas test also. The authorized Gas Tester shall successfully complete the PTW test and hold a valid PTW card issued by Controlling Controlling Team. Certified Radiographer: A certified person who has the necessary qualifications, experience and skill recognized by the Radiation Protection Department under Kuwait Ministry of Public Health for compliance with government regulations and Company approved codes of practice for f or work involving ionizing radiations. Controlling Team: A Team: A Team, which schedules, plans and coordinates the work. It must ensure all personnel under its jurisdiction are adequately trained and competent to perform their duties as required by the Permit to Work System. H2S SIMOPs (Simultaneous Operations): For the purpose of H2S SIMOPs in North Kuwait operations, H2S SIMOPs shall include any two or more sets of activities occurring at the same time and at t he same location by different entities, organizations, or under different management systems. In this context, production operations (e.g. a live sour flow line, or sour wells) and drilling / workover operations are included as one of the activities. Other activities, such as construction, inspections, etc on, or in the vicinity of the above could interact adversely with each other, causing loss of containment, resulting in increased risk to workers. Work in H2S SIMOPs Zones will be carried out in accordance with 'Work Instruction for H2S SIMOPs Management (PPGG-PRO-001) and 'Respiratory Protective Equipment Selection & Use' (PPGG-PRO-002). H2S SIMOPs Zones: Work areas where there is a risk of H 2S presence or release. Applicable Applicable KOC H 2S-related QRAs provide technical justification for these zones. T hese areas are clearly marked with H 2S Hazard Warning signs. As a general rule-of-thumb, any work within 200 m of sour North Kuwait infrastructure requires coordination with the H2S SIMOPs Coordinator. Specific North Kuwait H 2S SIMOPs Zones are designated as:      

Within 50 m of NK sour flow lines Within 200 m of EPF 50 fence line Within 100 m of NK sour well sites Within 200 m of Um-Niga well sites Within 250 250 m of well well center for NKJG drilling & workover workover operations; operations; or Anywhere work work will will encroach upon or enter an NK H 2S signed area.

H2S SIMOPs Coordinator: A Coordinator: A position, designated in writing by Manager P&PG / Team Leader EPF O&M, and/or Managers /Team Leaders of Drilling Groups, to coordinate and endorse concurrent work as defined under H 2S SIMOPs in this document. H 2S SIMOPs coordination pertains to all work associated with EPF O&M production facilities or sour drilling / workover operations within an H 2S SIMOPs Zone in NK. Hot Work Permit: A Permit: A document document that specifies precautions, precautions, identifies hazards and controls controls all work involving actual naked flames, sparks or has potential for creating sparks or heat. Cold Work Permit: Permit: A document that specifies precautions identifies hazards and controls all work that is not hot and radiographic in nature. Radiography Work Permit: Permit: A document that specifies precautions identifies hazards and controls all work involving radioactive sources. Control Tier 3



Authorized Gas Tester: A person who has successfully completed training on Gas Tester Certification and accordingly been nominated by the HSE Group or asset / directorate HSE Team. An authorized Gas Tester can be a person belonging to the HSE Group, asset/ directorate HSE Teams or asset operating teams who has the detailed knowledge of Permit to Work System. An authorized gas tester can carry out gas test for any work permit related activities except for ‘Confined Space Entry’ initial gas t est which will be conducted by ‘Competent Person for Entry Permit Gas Test’ as defined in “Entry into Confined Space Procedure’ (KOC.SA.07). However, for Green Field areas, Project Management Consultants (PMC) can be authorized as gas tester including for confined space entry gas test also. The authorized Gas Tester shall successfully complete the PTW test and hold a valid PTW card issued by Controlling Controlling Team. Certified Radiographer: A certified person who has the necessary qualifications, experience and skill recognized by the Radiation Protection Department under Kuwait Ministry of Public Health for compliance with government regulations and Company approved codes of practice for f or work involving ionizing radiations. Controlling Team: A Team: A Team, which schedules, plans and coordinates the work. It must ensure all personnel under its jurisdiction are adequately trained and competent to perform their duties as required by the Permit to Work System. H2S SIMOPs (Simultaneous Operations): For the purpose of H2S SIMOPs in North Kuwait operations, H2S SIMOPs shall include any two or more sets of activities occurring at the same time and at t he same location by different entities, organizations, or under different management systems. In this context, production operations (e.g. a live sour flow line, or sour wells) and drilling / workover operations are included as one of the activities. Other activities, such as construction, inspections, etc on, or in the vicinity of the above could interact adversely with each other, causing loss of containment, resulting in increased risk to workers. Work in H2S SIMOPs Zones will be carried out in accordance with 'Work Instruction for H2S SIMOPs Management (PPGG-PRO-001) and 'Respiratory Protective Equipment Selection & Use' (PPGG-PRO-002). H2S SIMOPs Zones: Work areas where there is a risk of H 2S presence or release. Applicable Applicable KOC H 2S-related QRAs provide technical justification for these zones. T hese areas are clearly marked with H 2S Hazard Warning signs. As a general rule-of-thumb, any work within 200 m of sour North Kuwait infrastructure requires coordination with the H2S SIMOPs Coordinator. Specific North Kuwait H 2S SIMOPs Zones are designated as:      

Within 50 m of NK sour flow lines Within 200 m of EPF 50 fence line Within 100 m of NK sour well sites Within 200 m of Um-Niga well sites Within 250 250 m of well well center for NKJG drilling & workover workover operations; operations; or Anywhere work work will will encroach upon or enter an NK H 2S signed area.

H2S SIMOPs Coordinator: A Coordinator: A position, designated in writing by Manager P&PG / Team Leader EPF O&M, and/or Managers /Team Leaders of Drilling Groups, to coordinate and endorse concurrent work as defined under H 2S SIMOPs in this document. H 2S SIMOPs coordination pertains to all work associated with EPF O&M production facilities or sour drilling / workover operations within an H 2S SIMOPs Zone in NK. Hot Work Permit: A Permit: A document document that specifies precautions, precautions, identifies hazards and controls controls all work involving actual naked flames, sparks or has potential for creating sparks or heat. Cold Work Permit: Permit: A document that specifies precautions identifies hazards and controls all work that is not hot and radiographic in nature. Radiography Work Permit: Permit: A document that specifies precautions identifies hazards and controls all work involving radioactive sources. Control Tier 3



Confined Space Entry Permit: Permit: A document that specifies precautions, identifies hazards and controls all work involving entry to an enclosure, which has limited means of entry & exit, not designed for continuous occupancy and where there is a risk of encountering hazardous substances such as exposure to flammable, toxic, oxygen deficient, hot or humid atmosphere or any combination of it. Vehicle / Mobile Plant Entry Permit: Permit: A document that specifies precautions identifies hazards and controls all work involving entry of a vehicle or Mobile Plant into a hazardous area. Suspended Work Permit: Permit: A permit for which isolations, precautions precautions etc. are still in place, but the work is not in progress. Routine Activity: Activity: It is an activity carried out by Asset Owner as a part of day to day operational requirement without effecting safety & integrity of facility or area under their jurisdiction. A few examples examples of Routine Routine Activities Activities are – are – well well checking, shifting of well from one header to another, switching over of equipment from operational mode to standby mode & vice versa, depressurizing a vessel or pipeline, filling chemicals in the tank etc. A few activities (such as taking reading of equipment, diesel transfer, topping up lube oil etc) being carried out by Asset Maintenance Team may also be treated as routine activities with agreement from Asset Owner. A routine activity may not require work permit; however must be carried out by Asset Owner or Asset Operating Team as per operating procedure with all precautionary measures for its safe execution. The Asset Owner / Permit Issuer being the highest authority on Work Permit System can decide about the routine activities and its precautionary measures. However, Asset Maintenance Team as Permit Applicant must seek the approval of Asset Owner to decide on routine activity. Non – routine Activity: Activity: It is an activity, which is carried out by KOC or Contractor as a part of and / or combination of works such as - construction, well site preparation, installation, dismantling, inspection, testing, repairing, maintenance, servicing etc at a facility or area under KOC jurisdiction. The non – – routine activity must be controlled through an appropriate & authorized permit to work.

3.0 General Requirements 



KOC HSE Management System Guidelines – Guidelines – Element Element 05 – 05 –2 2 H2S Controls: All Controls: All non-routine work to be carried out on sour infrastructure in North Kuwait shall apply H 2S controls specified in 'Work Instruction for H 2S SIMOPs Management (PPGG-PRO-001) and 'Respiratory Protective Equipment Selection & Use' (PPGG-PRO-002), whether the work is carried out under the same or different management systems.

4.0 Key Responsibilities 4.1

Permits Applicant An appropri appropriate ate Work Work Permit Permit shall be be raised raised by the Permit Permit Applic Applicant ant for any any work within within a RESTRICTED or HAZARDOUS AREA and shall be submitted for authorization to the respective Permit Issuer in whose area of control the work is to be carried out. A Permit Applicant: Applicant: a) Is a member of the controlling department (such as Maintenance, Projects Management or Major Projects etc.) who will initiate the work. b) Is nominated in writing writing by the respective Team Leader on on the recommendatio recommendation n of the Permit Applicant’s line supervisor . c) Must have the technical competence to consider and guard against the potential potential hazards associated with work activity . Control Tier 3



d) Must have have detailed detailed knowledge knowledge of the Permit to Work System. The appropriate permit shall be raised by the following listed authorities / personnel belonging to Company (KOC) or the Contractors depending upon the criticality of the work and its associated hazard: S. No

1

2

3 4

5

Work Category

Nominated Permit Applicants

Company or Contractor

Cold Work Permit & Hot Work Permit

Snr. Engineer, Engineer, Maintenance Supervisor, Snr. Foreman, Foreman, In-charge Mechanic. Snr. Mechanical Technician, Snr. Instrument Technician, Service Engineer, Foreman, Lead Instrument Technician, Lead Mechanical Technician, Lead Electrical Technician, Supervisor

KOC or Service Contractor

Cold Work Permit

In-charge Electrician, Snr. Mechanic, Snr. Electrician, Electrician, Mechanic, Foreman, Charge-hand, Mechanical Technician, Instrument Technician, Electrician

KOC or Service Contractor

Radiography Work Permit Vehicle / Mobile Plant Entry Permit

Snr. Engineer, Engineer, Maintenance Supervisor, Service Engineer, Snr. Foreman, Foreman

Confined Space Entry Permit

Snr. Engineer, Engineer, Maintenance Supervisor, Snr. Foreman, Foreman, In-charge Mechanic.

Certified Radiographer

KOC or Contractor KOC or Contractor KOC or Service Contractor

However, it is highly recommended for respective KOC Permit Applicant to apply the permit particularly for critical works to be carried out during normal working hours. The authority to raise the appropriate permit for service contract personnel shall be approved by the Controlling Team and the approved list shall be copied to the Fire Team, respective area HSE Team & Asset Operating Team for reference and cross check. KOC supervision will will be mandatory in case the service contract personnel are not approved for raising the appropriate permit. It is to note that a Permit Applicant can apply multiple permits at a time in his area of responsibility but cannot supervise more than one work (at a time). The permit applicant shall comply with the following preparatory actions while raising a permit: a) All the required information information as stipulated in the Permit must be entered before the permit is submitted for f or approval and authorization. b) Any required preparatory work work must be stipulated stipulated on the permit application. application. c) Method statement (if any) for the work work has been reviewed reviewed and approved approved . d) The Job Safety Analysis (JSA) for the scheduled work has been carried out by the Permit Applicant. e) All personnel under under his responsibility responsibility must be advised advised of their responsibilities under Work Permit System. f)

No job can begin until he is satisfied that the Worksite Supervisor Supervisor fully understands understands his his responsibilities under Work Permit System.

g) The safety gears and and appliances appliances required for the work must be be available. available. h) He will carry out regular inspection of the worksite to ensure safe work practices and permit requirements are being adhered. 4.2

Permits Issuer The responsibility for authorizing work permits rests with the Asset Operating Team responsible for the operation of the facilities. The respective asset operating Team Leader permit (in whose area of control the work is to be carried out) can delegate the responsibility of permit Control Tier 3



authorization to their subordinates, provided that they have a complete overview of all operational activities and also have a detailed knowledge of the ‘Permit to Work W ork System’. Additiona Additionally lly as a part of furthe f urtherr control and management management of work, the Asset Owner can deliver standing instructions aiming to mitigate potential hazards associated with the work. Moreover as part of work planning Permit Issuer shall ask for method statement (functional work procedure) from Permit Applicant, whenever a critical activity is to be carried out. Examples of a few critical activities are - excavation deeper than 1.2 Meter, working at height more than 2 meters, heavy lifting, lifting above process pipes, confined conf ined space entry, working inside confined space, wellsite preparation for workover etc. However, the list is not exhaustive & it can include any activity, which Permit Issuer considers as critical. The following table, which for the guidance only, lists authorities or sub-ordinates who who might be nominated in writing as Permit Issuers by their Team Leader in compliance to job competency and the nature of work: S. No

Teams / Groups

Nominated Permit Issuers

Remarks

1

Export Operations

Shift Supervisor, Senior Engineer, Terminal Supervisor, Engineer, Controller, Operator Meter Test, Operator

Operator Meter Test is authorized to issue Hot Work Permit also, whereas other Operators can issue cold work permit only.

2

Marine Operations

Port Captain, Harbour Master, Pilot, Supervisor, Foreman

Foreman is authorized to issue Cold Work Permit only

3

Marine Services

Snr. Marine Engineer, Marine Maintenance Engineer, Engineer Port Services, Supervisor, Foreman, Assistant Assistant Foreman, Foreman, Snr. Technician Technician

Asstt. Foreman Foreman & Snr. Snr. Technician are authorized to issue Cold Work Permit only

4

Production Operations

Production Supervisor, Production Controller, Operator – Operator – I, I, Operator - II

Operator- II is authorized to issue Cold Work Permit only

5

Drilling Operations

As mentioned mentioned in Appendi Appendix xB

6

Electrical Maintenance

Electrical Supervisor

For electrical substation such as B1 & B2 and Ahmadi distribution

The PERMIT ISSUER is responsible to ensure that: a) All hazards hazards associated with the proposed work work have been been identified. b) Before any work begi begins, ns, the worksite is safely prepared, examined examined and all specified specified precautions have been taken. c) Work permits that may interact interact or affect one another are cross-referenced clearly. clearly. d) The worksite is is examined to ensure that itit is in safe safe & acceptable condition i.

When work is suspended.

ii.

Before restarting the work

iii.

When returning to normal operation

e) The shift change handover handover procedure is properly followed and permit renewal renewal / endorsement and transfer of responsibilities have been completed. Work of an urgent nature may continue during the shift change period provided agreement has been obtained from the asset owner in advance. f) Prior to closing or cancelling a work permit, any precautions and isolations have been withdrawn and the system returned to normal operation.

g) When work is completed and the work permit is signed off the Permit Issuer closes the work permit and returns the equipment to operation . Control Tier 3



4.3

Worksite Supervisor The Worksite Supervisor shall be a person authorized in writing by the Controlling Team to supervise the work. The Worksite Supervisor is responsible to the Permit Applicant for all aspects of safety related to work and the work party. He must have a detailed knowledge of the Permit to Work System. The Worksite Supervisor can be a person belonging to Company (K.O.C) or Contractor as deemed suitable in the opinion of Controlling Team considering the criticality of work & its associated hazards . It is to note that each worksite shall have a dedicated supervisor and he / she can not supervise multiple works / worksites at a time. The Worksite Supervisor shall ensure: a) He has detailed working knowledge of procedures related to his work activity. b) He does not start any job requiring a work permit until it is authorized & issued. c) He understands the limitations and restriction of the work permit in order that work may proceed safely. d) All members of the work party adhere to safe working practices and are fully conversant with the limitations, restrictions and hazards involved. e) He conducts toolbox talk and pre-job briefing to ensure all precautions specified in work permit are taken. f) He does not leave the work site during Hot Work, Vessel Entry, Radiography and Excavation Work. g) Permission is obtained from the Permit Applicant and Permit Issuer to leave the worksite during performance of Cold Work.

h) He initiates permit renewal ensuring the work permit is renewed / endorsed as necessary and responsibilities are passed to the oncoming worksite supervisor at the shift change handover . i)

The job described on the work permit is completed and the worksite as well as equipment is left in a safe condition if not completed.

j) On completion of the job, the work permit is signed off and passed to the Permit Applicant & Permit Issuer for the equipment / worksite to be returned to the asset owner . k) The original work permit along with all referred documents and relevant certificates is prominently displayed at the worksite at all times during the work. 4.4

Nomination / Authorization of Personnel for Permit to Work System All the personnel associated with Permit to Work System shall fulfil the following competency requirements before being authorized for their stipulated role: a) In addition to his pre-requisite educational qualification and experience for the job, he must have detailed knowledge of the ‘Permit to Work System’. b) He must have successfully completed training on the ‘Permit to Work System’ and have passed the qualifying test (written as well as oral) relevant to his role. The passing score for such test shall be minimum 70% and can be further increased by Controlling Team taking into account work criticality, competency and skill required for the job. It is to note that competency and skill is not limited to knowledge about ‘Permit to Work’ only but essentially of jobs / activities relevant to the role. c) The concerned controlling team, which has ultimate responsibility for safe execution of work in their area of jurisdiction, shall arrange such training on PTW and qualifying tests for respective workers as per their stipulated role. d) Once the concerned employee or contractual worker successfully qualifies in the PTW Test; he will be issued a laminated authorization card (as sampled below) by the concerned controlling Team:

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e) The test questionnaires for each category of authorization shall be provided by the concerned controlling Team. A sample of questionnaires on Permit to Work has been provided by HSE Group and also made available on safety Team webpage. f)

The cardholder may get the Work Permit Authorization Card revalidated on its expiry (every 2 years or contract period whichever is earlier) after completing again the required training and testing.

Affix Photo

Ref.No. ………………………

Authorized as: Tick mark relevant () & O and cancel the rest-

Date: ……………………………

() Permit Applicant (Hot - O / Cold - O / Radiography-O / Confined Space - O / Vehicle Entry - O)

Kuwait Oil Company (K.S.C.) Work Permit Authorization Card

Name

:

Designation

:

ID No.

:

Company/Contractor

:

() Worksite Supervisor (Hot - O / Cold - O / Confined Space - O / Vehicle Entry - O) () Authorized Gas Tester (KOC Employee) – O () Competent Person for Confined Space Entry Gas Test - O () Competent Electrical Person (HV - O / LV - O) Valid till: …………………………..   Authorized By (Controlling Team): …………………………...

Contract No. (if Applicable) : Controlling Team

() Permit Issuer (Hot - O / Cold - O / Radiography - O / Confined Space - O / Vehicle Entry - O)

a) Designation:

b) Signature:

:

Front View

Rear view

5.0 Procedure The ‘Permit to Work’ (PTW) Procedure is a formal written system that utilizes a document (Work Permit) to control work by means of potential hazard identification and risk assessment. The work permit is also a means of communication among various Supervisors or their representatives belonging to Operation, Maintenance, Controlling Teams and Contract personnel, who are involved in work preparation and / or its execution. The issuance of Work Permit does not, by i tself, make a job safe. Safety can only be achieved by those preparing the work & those carrying out the work. To ensure the “Permit to Work System” is effective DO NOT ATTEMPT TO BYPASS IT. The system is intended to ensure personnel and environmental safety as well as plant and equipment integrity. The work permit is not simply a permission to carry out the job; rather it is a cornerstone for a safe system of work, which determines how that job can be carried out safely. A work permit is not just an exercise in form filling. Your signature on Work Permit confirms your responsibility towards the safe preparation and execution of the work. If you are unsure of any instruction on a Work Permit or in any doubt regarding a procedure, STOP & ask your immediate Supervisor for guidance. 5.1

Work Covered By Work Permit Work shall not be carried out unless: a) It has been approved by a Service Request, Maintenance Work Order, Routine Maintenance Work, Planned Corrective W ork, Preventive Maintenance Schedule, and Plant Modification Approval. All other works not defined above must be approved and agreed by the Permit Issuer. However, work of a routine operational nature does not require permit authorization . b) The work is permitted under the e-BEAMS Service Request or Work Order. c) The work has been planned and agreed twenty – four (24) hours in advance, or is of a breakdown nature or priority unplanned work which requires immediate action. Control Tier 3



d) All works have been properly authorized. All works that are not of a routine nature, in any area require a Work Permit, with the exception of emergency safety work that is either ‘loss of life actual’ or ‘loss of life potential. In the event of such situations, the Permit Issuer or the senior most KOC personnel available at site is authorized to verbally allow the work to commence immediately, and informing the asset owner subsequently. Work permits shall be prepared as soon as practical to cover the work being carried out. In case of such ‘Emergency Work’, it must be recorded in Operation Log Book & signed by the Permit Issuer. It is to note that even though work permit is not needed for routine works; however such routine activities must be carried out by skilled and competent persons considering all precautionary measures and applicable procedural requirement for the job. 5.2

Work Planning An essential requirement for safe and efficient administration of the Work Permit System is comprehensive forward planning. A work permit meeting shall be held on each location to define: a) The precise work to be performed & sub-sequential execution of work. b) The tools & equipment required and any necessary safety procedures. c) The area, system and equipment to be worked on and any hazards or potential hazards that may arise. d) Whether the work shall affect any other area, system or equipment either adjacent or remote. The timing of this meeting (usually 24 hours in advance of the planned work) shall be decided locally, and as minimum shall involve the Permit Applicant, Permit Issuer, Worksite Supervisor and Contractor Safety Officer. The respective asset Safety Engineer / Safety Officer may also be invited for such meeting depending upon work criticality. Breakdown and priority unplanned work may necessitate immediate action.

5.3

Types of Work Permits The Permit to Work System incorporates the use of 5 types of Work Permits: 

Cold Work Permit



Hot Work Permit  Radiography Permit  Vehicle / Mobile Plant Entry Permit 

Confined Space Entry Permit

Note: Confined Space Entry Permit and Vehicle / Mobile Plant Entry Permit are valid for entry purpose only. Any work to be carried out inside the Confined Space or in the facility will require additional appropriate permit. 5.4

Work Permit Validity 

Hot / Cold / Radiography: Valid for a maximum duration of seven consecutive days from the date of issue subject to renewal by the Permit Issuer. The permit has to be renewed / re-endorsed in case of shift change, transfer of responsibility, work suspension or as recorded in the permit. The validity period for Cold or Hot Work permit pertaining to non – routine activities (such as minor construction / maintenance / renovation ) in a non-hazardous area can be extended for a maximum period of one month with due approval from concerned Team Leader, taking all precautionary measures for safe execution of work.

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KOC.SA.004 - Permit to Work Procedure Page 9 of 55 

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5.5

Confined Space Entry Permit: Valid for one continuous work shift or part thereof; however the permit is to be renewed / re-endorsed in case of crew change, transfer of responsibility, work suspension or as recorded in the permit. Vehicle / Mobile Plant Entry Permit: Valid for one continuous works shift for Vehicle entry, whereas for Mobile Plant Entry it is valid for maximum 7 consecutive working days from the date of issue subject to renewal by Permit Issuer. The permit needs to be renewed / re-endorsed in case of shift change, work suspension or as recorded in the permit.

Work Permit Application All identified work must be authorized and planned prior to work permit application. It is to note that separate work permit has to be applied for each activity or equipment or location.The Permit Applicant shall raise the appropriate work permit with a full description such as: 

The Worksite



The Equipment to be worked on



The exact nature & scope of work (supported with sketches or drawings if available)



Special tools or equipment that may impact on safety at the worksite.

The Permit applicant shall to the best of his knowledge complete the relevant sections on the work permit, attaching completed JSA Sheet and present it to the Permit Issuer for review and authorization. 5.6

Work Permit Authorization The Permit Issuer shall review the work permit and any supporting documentation and complete the appropriate sections. He shall arrange for equipment preparation e.g. depressurising, draining, flushing, purging and any process, mechanical, safety and electrical isolations. When he is satisfied that the worksite has been safely prepared and safety precaution put in place, he shall authorize the work to proceed. It is to be ensured prior to authorizing the permit that only work identified on the work permit shall be carried out on and no account can any deviations to the agreed work scope take place without a new permit being written.

5.7

Work Permit Issuance The Worksite Supervisor assigned by the Permit Applicant shall sign to acknowledge he understands and accepts the work permit & associated worksite responsibilities. 







The Worksite Supervisor shall then obtain the first endorsement for the work to proceed from Permit Issuer. No amendment to the work permit is permitted without the approval of the Permit Issuer. Mistakes must be crossed out with a single line and initialled by the Permit Applicant and Permit Issuer. Any overwriting or correction fluid on the Work Permit invalidates it and it shall be cancelled immediately. If a work permit has all the endorsements complete but the isolation and work are to continue, a new permit shall be raised. The new permit number shall be deleted and the previous number annotated on it thus preserving the original isolation tags. The new work permit must be applied for and authorized following the normal procedure. Similarly, if the number of isolations required are more than the number of endorsement boxes provided in the work permit (referred to as original), a new permit shall be raised with the new permit number struck out with a single line and replaced

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with the original work permit number so that all the isolation tags as per original work permit are preserved. Each work permit endorsement / renewal is only valid for a maximum period of one shift (12 hours) or as recorded in the permit by Permit Issuer. Work extension to the next shift must be endorsed / renewed by the oncoming Permit Issuer. If the work permit endorsement / renewal boxes have all been completed then a new work permit must be raised.



5.8

Transfer / Share of Responsibilities: 

Permit Issuer : The work permits issued in the same shift shall be presented for transfer of authority to the oncoming Permit Issuer in case the original Issuer has to leave the permit control centre. However, it is to note that permit renewal in case of shift change shall not require any transfer of responsibility but only shift endorsement. In case of two Asset Owners (for example Production Operations & Gas Operations) in the same work location, the endorsement from the 2 nd Asset Owner may be taken in the ‘Transfer of Responsibilities Box’. Additionally in all transfer of responsibilities whether for Permit Applicant and Worksite Supervisor, the endorsement of Permit Issuer will be essential.





Permit Applicant: Similarly, the responsibility has to be transferred to the oncoming Permit Applicant in case the original Applicant is leaving the area of his responsibility for any reason whatsoever. Worksite Supervisor : Work must stop if he leaves the site unless a substitute authorized by the Permit Applicant & Permit Issuer is present.

If the need of responsibility transfer (for Permit Applicant / Worksite Supervisor) arises more than once during the permit validity period; then in such situation the existing permit has to be cancelled and a new permit is to be applied. 5.9

Cross – referencing All work permits associated with the same work or equipment must be cross-referenced by mentioning the work permit number in the box provided on each permit.

5.10

Work Permit Suspension In the case of a dangerous situation at the worksite or adjacent facilities all work must stop immediately and shall not recommence until worksite is declared safe and subsequently the permit is endorsed / renewed by the Permit Issuer. In such situations (such as fire or gas leak) the workers on hearing the dangerous situation alarm, shall vacate the area after making the worksite safe and will proceed to the designated assembly point for mustering and further instruction. The Permit Issuer, Permit Applicant and personnel from Fire Team / HSE Team / HSE Group are authorized to stop the work in the event of a work permit violation, unsafe acts or unsafe conditions. Any person can advise to stop the work if they observe any hazard or potentially hazardous condition. Any unsafe or hazardous condition must be immediately reported to the Permit Issuer, Permit Applicant and the respective area HSE Team as well as Fire Station. If on investigation it is determined that the work permit is to be suspended the Permit Issuer must be informed immediately. Any suspended work permit shall be endorsed ‘S in Box 10 (Shift Change Endorsement Box) of that permit and be kept in the custody of the Permit Issuer under the suspended work permit file. A work permit can be suspended for a maximum of 5 days or until the expiry of its validity period (whichever is sooner) in which case the work permit must be Control Tier 3



cancelled and signed off. Either a new work permit shall be raised or the system and equipment placed in long-term isolation as appropriate. 5.11

Closing a Work Permit On completion of the work the Worksite Supervisor shall check the worksite and ensure all tools & equipment have been removed as well as housekeeping completed. He will inform the Permit Applicant and both shall sign the work permit signifying hand-over of the equipment. The Permit Applicant is responsible for satisfactory hand-back of the worksite. The Permit Issuer shall ensure the area is acceptable prior to signing to accept t he handover of the area and equipment. The Permit Issuer can allow de-isolation of the equipment. The Permit Issuer shall ensure that all isolations are removed, the system and equipment purged and aligned as necessary. He shall then sign to close the work permits and allow the equipment to be re-instated.

5.12 Work Permit Distribution: Work Permits will be made out in four copies: 

The original will be kept by the Worksite Supervisor for worksite



1st copy shall be kept with the Permit Applicant



2nd copy of all permits (except Cold Work Permit) will be forwarded to Fire Team by the Permit Issuer prior to Job commencement or respective area Fire Station is notified and subsequently 2 nd copy is forwarded to Fire Team within 48 hours from the permit authorization.



3rd copy shall be retained by the issuing authority.

After successful completion of the work and permit closure as per procedure, the original shall be kept on record with the Permit Issuer whereas the 1 st copy shall be retained by the Permit Applicant, for a minimum period of 6 months before it is sent to Dead Record Room for archiving. The 3 rd copy can be given to Worksite Supervisor for their record and reference. If an accident or incident occurs associated with a work permit, the original copy of the work permit shall be attached to the incident report and a copy retained on the file

5.13

Worksite Preparation It is the responsibility of the Permit Issuer to ensure the safe preparation of the worksite. When deemed necessary by the Permit Issuer, a formal Plant and Equipment Preparation Procedure shall be prepared prior to work commencing making reference where necessary to any simultaneous Operation procedures. The equipment to be worked on shall be isolated from all sources of energy (such as electrical, mechanical, hydraulic & pneumatic etc) and prepared as per the job requirement (such as depressurisation, de-contamination, flushing & purging etc.) to confirm safety & integrity of worksite. The Permit Issuer in liaison with the Permit Applicant shall mark-up P&IDs in conjunction with detailed valve isolation, vent or drain valves open details (Mandatory for all vessel entry & process isolation).

The possible impact of the work on the surrounding area must be assessed and care taken NOT to issue a work permit which could impact on the safety conditions for other work permits in the area.

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Based upon the detailed work description, the hazards shall be assessed and the required precautions to be taken to enable the work to proceed safely shall be indicated on the work permit. 5.13.1 Cold Work Any work that does not involve a source of ignition or naked flame or does not have sparkgenerating potential is classified as Cold Work. The performance of cold work shall require, but is not limited to the following precautions: a) If a gas test is required, it shall be carried out immediately prior to the commencement of work, and, if the work party has left the worksite, immediately prior to recommencement of the work. b) If continuous gas monitoring is required, the Worksite Supervisor and the person performing the work shall ensure that the portable gas detectors remain charged and in working order. c) The Worksite Supervisor shall ensure that all personnel under his control strictly adhere to the constraints of the work permit i.e. Work Description, Equipment / Area / Terms & Conditions / Restriction of the work permit. d) The Worksite Supervisor must remain at the worksite during performance of the work. Should the Worksite Supervisor require leaving the worksite, he must make prior contact with the Permit Applicant & Permit Issuer advising the reason & duration, he will be absent from the worksite. The Worksite Supervisor can leave the worksite only if the Permit Applicant & Permit Issuer agrees it. This privilege applies only to Cold Work permits. 5.13.2 Hot Work Any work, which involves the use of naked flame or a source of ignition or spark generating potential, capable of igniting a combustible or explosive material, is classified as Hot Work. Prior to any hot work being authorized, the Permit Issuer must consider the following points: a) Can the work be removed to a safe location? b) Is it essential for Production or Safety reasons to perform the work during operation of the plant? Can the work be deferred until a shutdown or partial shutdown? c) Have the work scope and potential hazards been discussed among the Permit Applicant, safety personnel, Permit Issuer and worksite supervisor? d) Paint spraying and hand painting are not permitted during performance of the hot work. e) Cold work permits likely to cause a gas release must be suspended. f)

The Permit Issuer & Permit Applicant shall make regular site visits during the work.

g) Total isolation from flammable or toxic gas / liquids must be achieved by either: 

Physical disconnection. .

Blanking / Spading (using correctly rated blind / spade)  Double isolation valve with bleed valve in between.  Any combination of the above as deemed necessary by Permit Issuer & Permit Applicant. 

h) It may be necessary to raise a Cold Work permit for this preparatory work. The Permit Issuer shall assess this after discussion with Permit Applicant. i)

Before any hot work can begin, the Permit Issuer must ensure the equipment is free of liquid / gas by: 

Depressurising

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j)



Draining



Venting



Purging & flushing



Any combination of the above

During hydrocarbon venting to atmosphere, any hot work permit at the location must be suspended.

k) The hot work site must be free of hydrocarbons and combustible materials e.g. sludge, scale, deposits etc. l)

The worksite shall be gas tested and certified as being gas free by an authorized gas tester. The maximum LEL (Lower Explosive Limit) permissible for authorized hot work is 0% LEL.

m) If the work generates spark or chippings, the work must be suitably confined. n) If the work is above access ways, precautions must be taken to ensure that no sparks or hot metal can fall below. Additionally the area beneath the worksite must be barriered off and warning notice posted in English & Arabic. o) Mobile plant and equipment shall not be sited in hazardous or non-hazardous locations unless it meets the safety requirements specified for its area of operation. 5.13.3 Radiography Work Any work that involves the use of a radioactive source shall be covered by a Radiography Permit. The transportation, control and handling of radioactive isotopes must be in compliance with Radiation Protection Manual and Kuwait Ministry of Health Regulations in this regard. Precautions that must be adhered to include but are not limited to: a) The Permit Applicant shall raise a Radiography Work Permit. Where possible this work shall be scheduled during mealtimes or night shift. b) The radiography work permit shall be issued / endorsed for a maximum of seven days subject to renewal by Permit Issuer. c) A three-dimensional control area shall be designated and marked by barriers. d) Prior to commencement of radiography, all other work permits within the controlled area or as specified by the Permit Issuer, shall be suspended. e) Identified UV detectors shall be over-ridden and recoded in the work permit. f)

A Public Address (PA) announcement (as available) shall be made 30 minutes prior to radiography commencement advising all non-affected personnel to make safe their work place and vacate the area. A further P.A. announcement (as available) shall be made 5 minutes prior to radiography commencement advising non-affected personnel to vacate the area immediately.

g) The Radiographer & Assistant Radiographer shall check the area to ensure all nonclassified personnel have vacated the area. Then final P.A. announcement (as available) shall be made advising the radiography is commencing. 5.13.4 Confined Space Entry Permit Any enclosure having a limited means of entry & exit and not designed for continuous occupancy is defined as a Confined Space. Examples include (but are not limited to) the following: i. Process vessels, tanks, bins, stacks, large pipe, ducts, pits, and vaults. ii. Any enclosure where the presence of air contaminants may be harmful to a worker and prevent his ability to escape unaided.

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The following are the minimum precautions that must be taken. They apply even when a person’s head is inserted into the confined space for the purpose of a quick visual inspection. These requirements are applicable to all process and utilities systems irrespective of service: a) Entry to confined space can only be authorized by the Permit Issuer (Asset Owner). At

the start of each shift, a new confined space entry permit must be issued in due consideration of precautionary measures required as per HSEMS Procedure - Entry into Confined Space (KOC.SA.007) b) The Permit Issuer and Permit Applicant must make regular site visits during the work. The worksite supervisor shall be fully aware of the confined space entry procedure and the Permit to Work System. c) The confined space must be positively isolated from all processes and utility systems by blanking, spading or disconnection. Where disconnection is employed as a means of isolation, the lines shall be blanked. d) Isolations must be achieved as close to the confine space as possible, preferably on the nozzles. If this is not achievable then the next nearest point of isolation will be selected. e) If the confined space is equipped with a source of electrical power, an electrical isolation must be carried out and ensured that the confined space and equipment to be used are earthed prior to the issue of entry permit. f)

The confined space must be tested for oxygen levels, flammable vapor and toxic gases prior to entry and at an interval as specified in the permit subsequently. If the confined space is vacated a new gas t est shall be performed prior to re-entry. A portable gas monitor must also be sited for continuous monitoring.

g) When determining the criteria for confined space entry without breathing apparatus, the associated hazards due to sludge, scale and deposits must be considered. These residues can contain and emit dangerous levels of vapor. Pyrophoric Iron Sulphide may also be present and the danger of ignition if allowed to dry out and be exposed to oxygen must be considered. h) A standby man shall be stationed at each confined space entry point. He shall be equipped with a portable radio and must keep visual contact with personnel working inside the confined space. i)

The standby man will inform Control Room each time the confined space is entered or vacated & all entries as well as exits will be recorded in Control Room log book. Additionally the standby shall also keep a record of personnel’s entry / exit at the worksite.

j)

In case of emergency inside the plant, the confined space entry must stop immediately. The standby man shall advise the Control Room by radio, when the personnel inside the confined space have vacated, the site shall be made safe and the personnel shall proceed to muster at t he designated assembly point.

k) If an emergency occurs within the confined space, the standby person must not enter it until rescue team arrives. It is the responsibility of standby man to summon aid immediately by contacting the Control Room through radio or other available means of communication. l)

Personnel working inside the vessel will be given a rest period at each 30 minutes intervals, or more frequent depending upon prevailing conditions such as heat stress, humid atmosphere etc.

m) The area around the confined space must be barriered off and warning sign posted in English & Arabic.

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n) As and when needed the opinion and assistance from HSE personnel may be sought to ensure the safety aspects of a confined space entry. (For further detail refer - “Entry into Confined Space Procedure” Doc. No. KOC.SA.007 ) 5.13.5 Vehicle / Mobile Plant Entry Permit Any Vehicle or Mobile Plant will not be allowed to enter into a hazardous area except under duly authorized Entry Permit subjected to inspection & authorization by the Permit Issuer. However the vehicle entry to a Tank Farm will require a permit only if it enters the plant area (such as bund wall) to carry out specific work / activity duly authorized by asset owner. a) The vehicle or mobile plant required to enter inside a hazardous area under duly

authorized entry permit must be checked by the permit Applicant prior to applying the permit to confirm its suitability, safety & integrity. (Refer to HSEMS Procedure on Temporary Mobile Equipment KOC.SA.013).

b) The mobile plant (such as air compressors, welding machines, primus stoves, tar boilers & Diesel Engine Generator etc.) must have at least two fire extinguishers duly approved by Fire Team. c) The validity of entry permit for the Vehicle will be one continuous work shift whereas for Mobile Plant, it will be valid for 7 consecutive days from the date of issuance subject to renewal by Permit Issuer. It is to be noted that the permit is valid for entry only; however for carrying out any work, a separate appropriate permit is to be authorized as per procedure. d) The entry permit needs to be endorsed / renewed by on-coming shift after carrying out necessary gas test. 5.13.6 Excavation Notification Excavation Notification is not a permit to work but a document to notify the concerned authorities, which have responsibility and jurisdiction for safety & integrity of aboveground and underground services existing at the proposed site of excavation. An Excavation Notification is required for all excavations regardless of the depth. The Excavation Notification shall be raised by the respective supervisor or engineer and must be endorsed by all concerned parties. a) An Excavation Notification must be supported by a primary work permit duly authorized by the permit issuer. A Cold Work permit shall be additionally required where only hand excavation tools are to be used. Whereas for excavations work using powered tools (such as mechanical excavator, back hoe, shovel, loader etc) will need a duly authorized Hot Work Permit if work is to be carried out in a hazardous area. Mechanical excavation is not allowed inside the plant or facility or within 5m radius from any underground facilities. b) For excavations deeper than 1200mm, a Confined Space Entry Permit is required and in some circumstances gas free certification also. (Refer Excavation Procedure KOC .SA.026 for further detail on Excavation)

c) A drawing or sketch of the proposed excavation site (showing above & underground services) must accompany the Excavation Notifications to enable the affected disciplines to check and specify precautions & hazards prior to signing the approval. d) If a buried cable or pipeline is encountered during excavation, the work must stop immediately and the Permit Issuer informed. The Permit Issuer shall liaise with the Permit Applicant to decide best course of action. e) The Excavation Notification is valid for a period of 90 days from the date of issuance (i.e. date asset owner has signed) or as stated in the permit. f)

The endorsement from Fire Team on Excavation Notification is required prior to digging /trenching/cutting within the bunded area of crude oil/effluent or oily water storage tank.

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g) The Excavation Notification should be linked and cross-referenced with KOC Recommended Practice (KOC-L-002) or its updated version for clearance requirements on buried pipelines, cables and other underground services. h) The respective supervisor or engineer initiating the Excavation Notification must ensure that the proposed excavations / trenches will not obstruct the movement of emergency vehicles (such as fire tender, ambulance etc.) to the worksite.

5.14

Isolation, Multi-lock & Tag out Isolation, Multi-lock and tag are an integral part of the “Work Permit System”. If plant or equipment is specified requiring isolation as a condition of work permit, then the required isolation (such as Electrical, Mechanical, Instrument & Telecommunications) must be identified by Permit Authorities (Applicant & Issuer) and mentioned in the appropriate section of the work permit. The isolation shall be carried out by nominated & authorized personnel only ( from KOC & service contractor) and the isolation detail must be entered on relevant sections of the work permit. If isolations require ‘Locking Off’ then the official Company padlocks clearly stamped with an individual ID number must be used. If the padlocks cannot be installed, other immobilizing device (as specified by the Permit Issuer) can be used. Each isolation point (such as padlock, immobilizing devices, valves or spades / blinds / blanks) and any vent or drain which has been opened or closed must have ‘Do Not Operate’ tag referencing the permit and / or isolation certificate. Moreover, such tags shall be strong enough to withstand the weather condition and possible impact f rom adjacent activities.

5.14.1 Mechanical Isolation Any mechanical isolation of equipment, pipeline or unit in the facility shall be carried out by the operation personnel with due approval from the shift controller. Prior to approving such isolation, the Control Room Operator shall review the overall impact on the safety and integrity of the plant, process as well as to the workforce, which may arise due to it. The isolation point in the plant area must be tagged to prevent any interference. Any spading or blanking of the pipeline shall be taken up through a duly authorized Cold Work Permit. The task shall be carried out under overall responsibility of the mechanical maintenance crew with approval from asset owner. The type of isolation used shall depend on the level of risk associated with the work to be performed. a) Positive Isolation; physical disconnection and blanking of open ends; the turning of spectacle blind; the insertion of spades between flanges or the replacement of a spacer with a line blind. Blanks, Spades (blinds), Bolting and Gaskets shall conform to the piping specification and rating for the equipment. b) Double block & bleed, valve isolation is the industry standard for isolating a valve. c) The isolation point, spade location and any deviation from normal operation (such as opening or closing of vent / drain valve) must be marked on the P&ID and attached with Control Tier 3



the work permit for ready reference. Moreover, such isolation / deviation must also have “Do Not Operate’ Tag at the location to prevent unintentional interference. d) The mechanical isolation and spading information shall be maintained at the facility Control Room in the form of record register sampled as Appendix – C of this procedure. The effectiveness of isolations must be tested and proved. If an isolation valve is passing, it may be necessary to shut additional valves or take further plant and equipment out of service.

5.14.2 Electrical Isolation Prior to authorizing a ‘Work Permit’ it is essential to ensure that the equipment to be worked on is safe and electrical power isolated for the safe conduct of authorized work. The requirement for electrical isolation shall be specified by the Permit Issuer in liaison with the Permit Applicant. The authorized Electrical person as appropriate completes the electrical isolation and enters the detail on Work Permit subsequent to discussion with the Permit Issuer. The authorized electrical person shall keep the padlock key in safe custody to prevent inadvertent tampering. Once electrical power is isolated for any equipment and the Work Permit issued, such equipment must not be made live or electrically de-isolated until work has been completed, the permit returned to the issuing authority, the work site, equipment and system have been checked and clearance has been granted by the Permit Applicant and Permit Issuer. The authorized Electrical Person (from KOC) shall raise an ‘Electrical Work Certificate’ in the format as provided in Appendix – C of this procedure giving all the specified details. The certificate shall be attached to the respective Permit as an additional check prior to commencing the work as well as for convenient reference while de-isolating or commissioning the equipment. The Electrical Work Certificate shall be cross – referenced with the associated work permit. The electrical isolation record shall be maintained at Sub-station / Switchgear Room in compliance with “Electrical Multi-lock & Tagout Procedure” (KOC.SA.022) which is to be referred for further detail on this issue .

5.14.3 Safety / Instrumentation Overrides The requirement and implementation of instrumentation overrides, defeats and inhibits (such as inhibiting - equipment safety switches, ESD switches, Fire & Gas detectors, plant alarm Control Tier 3



system etc) for safe work execution shall be the responsibility of the Permit Issuer in liaison

with the Permit Applicant. The necessary detail such as inhibited device tag number, equipment number and instrumentation overrides or defeats shall be clearly recorded in the respective isolation / de-isolation box of Work Permits and these overrides and defeats shall be authenticated by the concerned authority in this regard. It is also required to record such overrides separately in the Override Record Register maintained in the Control Room to prevent inadvertent removal or normalization of inhibited switches. The process and equipment protection alarms (on DCS or Plant Shutdown System as well as Fire & Gas Detection panel) due to such overrides shall be checked and corrective actions taken before normalizing the inhibited switches or device to rule out the possibility of any adverse effect on the system or facility in the plant. Moreover, any override / normalization of ESD Trip or Safety Critical Equipment or Fire & Gas Detectors requested by Contractor, has to be risk assessed, by KOC Instrument Engineer before it is reviewed by Opeartor-1 and approved by Shift Controller. Any override or its normalization must be communicated during the shift handing over. Additionally, at the beginning of each shift, the Control Room Operator and Shift Controller must check the Override Registration Log-sheet for self-information as well as communication to other personnel such as maintenance crew in the shift. For further detail on this issue, Plant Safety Override Registration Procedure (KOC.SA.020) may please be referred. 5.14.4 Long Term Isolation If work is completed or suspended beyond the work permits period of validity, but the worksite requires continued protection of an electrical, mechanical or instrument system isolation, it shall be indicated in the work permit stamping ‘LONG TERM ISOLATION’ in bold letters. Such long term isolation must be risk assessed, approved and recorded as well as widely brought to the notice of all concerned supervisors in the plant or facility .

5.15 Gas Tests for Work Gas testing is essential prior to and during any work activity that may expose personnel to risks from fires, explosions, chemical or other toxic substances. The methods and equipment used for testing atmosphere must be selected with regard to contaminants, which are or may be present at the worksite. In oil & gas industry, gas tests are carried out to determine the presence or absence of the following gases: 

Oxygen (deficiency or enrichment)



Flammable Gases (Usually hydrocarbon)



Hydrogen Sulphide (H2S)



Other toxic substances (such as welding fumes, chemicals, solvents or dusts)

Personnel must be fully trained to understand the methods, equipment and procedure for frequent monitoring throughout the work duration. Even if a particular atmosphere has been declared safe, continued monitoring is necessary particularly for Hot Work & Confined Space Entry to ensure that it remains safe during the entire work period. Gas tests should be conducted each day or shift prior to starting the work activity, and always after any break or interruption of work. In special circumstances (such Confined Space Entry, Hot Work) the frequency of such gas tests can be mentioned in the work permit. Additionally: a) Gas tests are mandatory prior to authorizing any – Hot Work, Confined Space Entry and Vehicle / Mobile Plant Entry – permits. Gas test may also be required sometimes for cold work, radiography work and excavation notification depending upon potential hazards as well as work location such as working in H 2S prone area or near a gas Control Tier 3



pipeline. Gas tests must be carried out by an authorized gas tester & test results must be recorded in the appropriate section of the work permit. If the work has not started within 2 hours from the time of a gas test, the gas free certification will become invalid and a new test must be carried out. b) All gas detectors must be checked, inspected and tested prior to use. Depending upon the type and nature of contaminants, tests should be conducted by certified personnel using specific instruments. This is necessary to ensure accuracy in the testing and in the interpretation of test results. As and when needed the opinion and assistance from HSE personnel can be sought to ensure the gas test certification. c) In case of Confined Space Entry, the initial tests for flammable vapour, toxic gas and oxygen deficiency should be made from outside the confined space, using a long probe. If the initial tests indicate a concentration above the permissible levels, further gas freeing and tests will be necessary until the gas concentration falls within permissible limits. d) For testing of flammable gases & vapours, electronic monitor or detector tubes should be used. Portable gas detectors are used to determine the concentration of flammable gas, whereas detector tubes may be used to identify a particular gas and find out approximate concentration. e) Tests for Hydrogen Sulphide should be conducted using detector tubes or an electronic sensing & measuring device. Personnel conducting H 2S tests in H2S prone area shall wear self – contained or air supplied breathing apparatus preventing exposure to toxic environments.

5.16

Fire Protection during Work a) Where the hot work is to be carried out , a minimum of two fire extinguishers (of capacity 9 Kg Monnex or 12 Kg DCP) shall be available within 7.5 meters from each hot / flame / spark potential work location. b) In addition to the above for hot work in hazardous area, there shall be a 2 ½ “diameter duly pressurized water hose capable of reaching a minimum distance of 30 meters from the hot work location. The firewater hose shall be properly connected to nearby fire hydrant (with approval from Permit Issuer) and a continuous flow of water shall be maintained through the delivery nozzle (fitted with shut off valve) while hot work is in progress. In situations where fire hoses cannot be connected to fire hydrants, a separate source for firewater supply shall be made available at hot work location c) Fire Team may be requested to provide additional support or equipment depending upon the criticality and hazardous nature of work. d) One person may be deployed for directing water from the hose to the area where sparks or hot debris may fall. It is also recommended to deploy a fire watch for all hot work activities. e) While working at heights, silica / fibreglass blanket soaked with water shall be provided in order to kill falling sparks and to prevent scattering on to other unprotected areas. f)

The worksite supervisor shall ensure that no combustible material or refuse is collected adjacent to the work area. The worksite shall be kept clean, tidy and free from obstruction.

g) In case the General Alarm or Fire Alarm is sounded, all work will immediately cease, machinery stopped and worksite made safe prior to reporting at assembly point for further instruction. The firewater hose shall also be isolated from the hydrant before leaving the area. h) Any pyrophoric refuse shall be made wet and disposed of immediately according to approved KOC waste management procedure. The equipment and components Control Tier 3



contaminated with combustibles such as pyrophoric material shall be always kept wet with water.

5.17

Permit for Wireline Operations All wireline operations require a ‘Permit to Work’. Wireline activity can be permitted at night only if the Permit Issuer agrees with the Work scope & is satisfied all potential hazards have been considered & adequate precautions taken. The Permit Issuer shall take into account the adequacy of lighting at the worksite for the job to proceed safely. The following procedure will apply for wireline activities at W ellhead locations: 









5.18

In normal operations a Work scope must be received by the Permit Issuer 24 hours prior to commencing of wireline activities. The representative from Well Surveillance Team shall be the Permit Applicant and is also responsible for all down-hole technical aspects of the wireline program. The Permit Issuer in liaison with the Permit Applicant shall ensure the isolation and preparation of the worksite as specified on the permit. When the work is completed, the Permit Issuer shall ensure that everything is in order at the wellhead location before reinstating the well back to production. For further detail refer HSE Procedure for “Exploration, Drilling and Work over Operations” (KOC.GE.011).

Permit for Shared Areas The permit for worksites shared between KOC & other external agencies (such as KNPC, MEW, Municipality etc.) shall be routed through Local Relation Team to the respective asset owner for either endorsement or authorization of the permit. Local Relation Team will act as the contact medium for external agencies whereas the permit application, endorsement & authorization will be the responsibility of respective asset owners.

5.19

Permit for Hydrocarbon / Services Free Facility under Construction (Green Field Projects)

The permit for a new facility under construction or Contractors Site Office / Layout Areas (at a location free from underground / above ground hydrocarbon carrying pipeline / flow line / vessel / equipment and / or services such as electrical / instrumentation / telecom / network / cathodic protection cables or wirings etc.) can be issued by respective Project Controlling

Team after the location has been officially released by the Asset Owner assuring it a Green Field worksite. Such ownership transfer between the Asset Owner & respective Project Controlling Team / Group shall take into account contractual, commercial, legal & administrative liabilities, which may arise from the arrangement. In such situation, the Project Controlling Team / Group can delegate the permit issuance responsibility to PMC (Project Management Consultant for Major Project Team’s worksites) or Construction Team (for Project Management Team’s worksites) as their representative. Moreover, for Green Field Projects, PMC personnel can be authorised as Gas Tester including for Confined Space Entry Gas Tests once they are trained on “Gas Testing & Confined Space Entry’ by third party training agencies approved by KOC (T&CD) for this purpose. Consequently, under such circumstances the Main Contractor personnel will be the Permit Applicant and Sub-Contractor personnel will be the Worksite Supervisor. However, the Permit Issuer, Permit Applicant and Worksite Supervisor shall be authorized by the Controlling Team as per procedure.. The transit ownership shall be returned to the original asset owner at pre-commissioning stage of the project prior to Introducing hydrocarbon in the facility.

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5.20

Permit to Work for Contractor Owned Facilities: The KOC permit to work procedure shall be applicable to Contractor owned facilities (such as EPF / GSF) also. However in such situation KOC Permit to Work shall be managed by the respective contractor who owns as well as operates that facility. Under such circumstances the Permit Issuer and Permit Applicant from Contractor shall be authorized by the Controlling Team considering their competency and skill requirement for the job as per procedure.

5.21

e-WP (Electronic Work Permit): KOC introduced e-WP system based on this procedure to replace in phases the manual issuance of work permit. The e-WP system is in the process of testing / trial implementation across asset / directorate after extensive training and roll – out sessions. Additionally a User Manual on KOC e-WP has been also distributed explaining electronic features applicable to KOC Permit to Work System. The trained and authorized personnel associated with e-WP have been issued specific Username and Password which allows them to access e-WP portal for their assigned roles & responsibilities as per KOC Permit to Work Procedure. The electronic management of work permit including its application, issuance, execution, distribution, suspension and close – out process have been explained in the User Manual which is available on e-WP portal.

6.0 Key Documents / Tools / References 

KOC HSEMS Procedure “Entry into Confined Space” (KOC.SA.007)



KOC HSEMS Procedure “Plant Safety Override Registration”(KOC.SA.020)



KOC HSEMS “Welding & Cutting Procedure”(KOC.SA.021)



KOC HSEMS Procedure “Electrical Multi-lock & Tagout” (KOC.SA.022)



KOC HSEMS “Excavation Procedure” (KOC.SA.026)



KOC HSEMS “Electrical Work Safety Procedure” (KOC.SA.027)



KOC HSEMS Procedure “Job Safety Analysis”(KOC.SA.024)



KOC Electronic Work Permit (e-WP) User Manual



KOC HSE Procedure for Rig Move Operations (KOC.GE.037)



KOC Standard for Hazardous Area Classification (KOC.G.002)

6.1 Appendix

7.0



Appendix A: Permit Compliance for Ahmadi Area.



Appendix B: KOC Permit Compliance for Rigs



Appendix C: Specimen Forms of Permit to Work



Appendix D: e-WP User Manual



Appendix E: PTW Flow Diagram

Abbreviations          

e-WP e-BEAMS PA PI WS PTW JSA LEL UV DCP

-

Electronic Work Permit Electronic Business & Enterprise Asset Management System Permit Applicant Permit Issuer Worksite Supervisor Permit to Work Job Safety Analysis Lower Explosive Limit Ultra Violet Dry Chemical Powder

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KOC.SA.004 - Permit to Work Procedure Page 22 of 55  

8.0

P&ID ID. No.

-

Piping & Instrumentation Diagram Identification No.

HSE Records (Retention Time) 



Electronic - Work Permit / Excavation Notification / Isolation & De-isolation Record / JSA Sheets (Indefinite) Hard copies of Work Permit / Excavation Notification / Isolation & De-isolation Record / JSA Sheets (5 years)

Review & Revision Log Review / Revision Date May 4, 2004

Revision Details Draft for internal review

July 27, 2004

Issued after review by HSEMS Implementation Committee

July 27, 2005

Updated after internal review

September 10, 2005

Updated after internal review & feedback from PTW Pilot Exercise

September 5, 2006

Updated on suggestion / comments received for Annual Review

November 15, 2006

Included Appendix - A for Work Permit in Ahmadi Area

January 27, 2008 May 17, 2009

February 21, 2011

March 10, 2012

Reviewed by HSEMS Implementation Committee Appendix - B ‘Permit Compliance for Rig’ after review from HSEMS IC Clause 2 eWP definition added, Authorized Gas Tester Definition & Work Permit Authorization Card ‘Industrial Hygienist’ deleted, Clause 5.0 Clauses re-numbered, Clause 5.19- Added PMC as delegated Permit Issuer for Green Field, New Clause 5.20 PTW for Contractor Operated Facilities added, New Clause 5.21 for eWP added, Clause 6.0, 7.0 & 8.0 renumbered for alignment with Document Control Procedure. Appendix A – 6th bullet point added. Added Appendix E Flow Diagram Clause 5.19 amended for Green Field Following Appendixes were revised

June 12, 2013

Appendix A – Permit Compliance for Ahmadi Area Appendix B – PTW Process for Drilling & Workover Operations Ahmadi Area Work Permit Form has been revised.

Jun 17, 2015

Amended Clause # 1, 2, 3, 4.1, 4.3, 4.4, 5.2,, 5.5,, 5.8, 5.13.2, 5.13.4, 5.13.6, 5.14, 5.14.1, 5.14.2, 5.14.3, 5.14.4, 5.16, 5.19, 6, 7 and Appendix B as per suggestions brought forward and to align with Facility Insurance Recommendation.PTW specimen forms updated as per agreed suggestions from Shell and Asset / Directorate.

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Appendix –

A “Permit to Work Procedure (KOC.SA.004)”

Permit Compliance for Ahmadi Area It is obvious that Ahmadi Area does not pose the same level of risk as eviden t in KOC restricted premises or hazardous area facilities. However the recent increase in various non – routine activities such as construction; installation, up-gradation & excavation work have brought forward the need of work permit compliance in Ahmadi Area also with the aim of hazard control and safe work execution. As directed by top management during HSE Management Committee Meeting No. 90 dated 11th July 2006; a simplified “Work Permit” has been drafted specifically to control the hazard associated with non – routine activities being carried out in Ahmadi Area. Hence, this appendix is intended to establish & support the practice of “Work Permit Procedure” in Ahmadi Area complying KOC HSEMS Procedures. Accordingly, the following additions have been made keeping in view the work permit requirement for Ahmadi Area:

(i)



Single form Permit for Cold / Hot Work



Non – routine work requiring permit



Location / Premises requiring permit



Exemption of Permit for routine activities & its location



In case of unspecified ownership for the location where the work to be carried; the respective Controlling Team may assign Permit Applicant & Permit Issuer from their Team itself, who could be the same person.



Permit Issuer will be KOC Employee from respective Controlling Team



Permit Applicant will be KOC Supervisor or Snr. Foreman or Foreman from respective Controlling Team



Worksite Supervisor will be contractor personnel representing the respective Controlling Team



The personnel having PTW roles & responsibilities must have authorization card issued by their Controlling Team as per Permit to Work Procedure.



The Controlling Team responsible for the work shall obtain asset owner signature before starting the work and also after completing the work.



For works to be carried out in Government owned buildings at Ahmadi, the concerned KOC Controlling Team responsible for the work can issue the permit after obtaining signature of the asset owner for the building.



For works to be carried out in Ahmadi areas / buildings owned by other KCompanies, PTW form for that Company to be used.

Single Form for Hot / Cold Work: A single form for Hot / Cold work has been developed specifically for use in Ahmadi Area only. The Permit Applicant shall tick the relevant box to select the category of permit depending upon the nature of work to be carried out. However, different categories of work (such as Hot / Cold) cannot be authorized in the same permit. A separate permit has to be applied for each type and category of work after identifying & controlling the potential hazards. It is to note that Radiography Permit, Confined Space Entry Permit & Excavation Notification remain the same as for other area; whereas Vehicle / Mobile Plant Entry permit is not required for Ahmadi Area.

(ii)

Non – routine Works requiring Permit: The following non – routine work in Ahmadi area will require a duly authorized work permit: Control Tier 3


KOC.SA.004 - Permit to Work Procedure Page 24 of 55 









(iii)

Construction, demolition, excavation, installation; repairing, working at height, entry into confined space at location identified in this document. Maintenance work on underground services such as Gas, Steam or Water carrying pipelines, Electrical / Telecom Cables Maintenance Work inside Electrical Substation including isolation of High Voltage / Low Voltage Equipment. Project related activities in Ahmadi Area Jobs where two or more individuals or teams need to co-ordinate activities to complete the job safely.

Location / Premises requiring Permit: Any non – routine activity at the following location in Ahmadi will require a work permit to be authorized by respective Asset Owner 

Petrol Filling Station



Chiller Plants



Telecommunication Facility Centre (Radio Room or Telecom Room in any building)



Computer Centre



KOC Industrial Area



Drilling Workshop



Mobile Plant Workshop



Ahmadi Hospital



Ahmadi Roads,



Water Filling station,



Sewage Plants



Booster Pumps Station,

Warehouses,





Central Workshop,



Domestic Areas (Occupied / Vacant Houses, Bachelor / Guest Houses, Sports Centers, Clubs. Etc)



Works inside and outside the fenced area around Ahmadi houses.



Works at Community Services Centers



(iv)

Works at Roads, its shoulders & adjacent open areas in Ahmadi township



All open areas in Ahmadi Township



Existing gas and water facilities

Permit Applicant, Permit Issuer & Worksite Supervisor: The persons from the respective Teams against the identified location as tabulated below shall be responsible as Permit Applicant, Permit Issuer & Worksite Supervisor in compliance to job competency and nature of work.

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Location

Permit Applicant

Permit Issuer

Worksite Supervisor

Petrol Filling Station

The respective Project Controlling Team

Transport Operations Team

KOC or Contractor personnel under respective Project Controlling Team

Chiller Plant

Do

Utilities Team

Do

Telecom Centre / Radio Room / Main Telephone Exchange

Do

Communication & Networks Team

Do

Computer Center

Do

IT Operations

Do

KOC Industrial Area & Offices in Ahmadi

Do

Nominated representative of the Project / Maintenance Controlling Team

Do

Drilling Workshop

Do

Drilling & Workover Services Team

Do

Mobile Plant Workshop

Do

Mobile Plant Maintenance Team

Do

Central Workshop

Do

Central Workshop Team

Do

Ahmadi Hospital

Do

Medical Services / Nominated representative of the Project / Maintenance Controlling team

Do

Al –Tameer Building

Do

Project Control Team

Do

Warehouse

Do

Warehouse Team

Do

Works inside & outside the fenced area around Ahmadi houses.

Do

Nominated representative of the Project / Maintenance Controlling Team

Do

Works @ Community Services Centers

Do

Do

Do

Works @ Roads, its shoulders & adjacent open areas in Ahmadi township

Do

Do

Do

All open areas in Ahmadi Township

Do

Do

Do

Existing gas & water facilities

Do

Utilities Team

Do

The criteria, competency, nominations, authorization, roles and responsibilities for Permit Applicant, Permit Issuer & Worksite Supervisor shall conform to respective clauses in “Permit to Work Procedure; (KOC.SA.004)”. Similarly, worksite preparation Control Tier 3



for different category and nature of work (such as Hot, Cold, Radiography, & Confined Space Entry) shall be dealt as stipulated in Permit to Work Procedure. Additionally for permit administration ‘involving application, authorization, issuance, cross referencing, distribution & close out etc’ it is required to refer the relevant clause from ‘Permit to Work Procedure’ (v)

Exemption of Permit for Routine Activities: Exemption of permits for routine activities will be in compliance to Memo dated 10 th October 2012 issued by TL – AHM / TL – HSE (A&F).

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Appendix –

B “Permit to Work Procedure – (KOC.SA.004)

Permit To Work Process for Drilling & Work over Operations Background: A decision was taken in the leadership meeting No.152, dated 09.11.2010 and meeting No. 159, dated 12.07.2011 on the process of Work permits system at Drilling Operations based on International Practices. Following are t hese directives in principle: 



To implement Drilling Contractor PTW system in the KOC Drilling Operations. To validate the Contractors PTW system with respect to KOC PTW System by carrying out Gap Analysis. If the Contractor PTW system meets or exceeds the Company’s requirements, then contractors may be allowed to use their own PTW system with countersignature of Company representative on PTW Forms







To identify and list the non-routine Critical activities that requires permit to work. The Task force shall develop a unique PTW process that is specific to Drilling Operations and incorporate relevant clauses in the KOC HSEMS procedure KOC.SA.004 “Permit to Work Procedure” as an appendix in liaison with HSEMS Implementation committee. Such system shall define non routine activities and level of approval. The drilling area (asset) shall be officially handed over from operations Group to the pertinent Drilling Group for Drilling operational activities through regular KOC permit.

The ‘Appendix – B’ of Permit to Work Procedure is based on the leadership committee directives and PTW IC recommendations focusing on the following issues for Work Permit process at Drilling Rig: 

General requirements of Drilling Contractor PTW system



Ownership of Drill Site / Well Site Location



Work Permit process for Drilling Operations.



List of activities of Drilling Contractor that needs PTW



List of PTW activities of Drilling Contractor that need KOC Rig Supervisor counter signature.



Work permit process for Service Contractor Operations at Drilling Rigs



List of Service Contractor activities that require Work permits on Rigs



Categories of work permit & process flow chart



KOC Rig Supervisor/ Company Man Roles & Responsibilities



Tool Pusher/ Night Pusher Roles & Responsibilities



Service Contractor In charge Roles & Responsibilities



Work done on or near drilling rigs by departments other than drilling



Gas Test Requirement at Drilling / Work - over Location

It is to be noted that the purpose of this Appendix ‘B’ is to ensure that the non - routine critical activities which are in the high hazard category as per clause IV & V are carried out by the contractors at the Drilling & W ork Over locations with adequate controls for the risk mitigation, by means of a structured PTW Process. The contractor shall bridge the gaps on their PTW procedures with respect to applicable KOC PTW procedure requirements. Accordingly all involved in KOC Drilling & Workover operations must comply with all applicable HSEMS Control Tier 3



Procedures including Appendix ‘B’ of this “Permit to Work Procedure”. The Drilling Contractors may approach their Controlling Team / Group for clarification and assistance on this issue. I.

General Requirements of Drilling Contractor PTW system The following is the process for review of Drilling Contractor PTW System.

II.

a)

All Drilling Contractor working for KOC shall conduct Gap analysis of their PTW system with respect to the KOC HSEMS Procedure on Permit to Work (KOC.SA.004).

b)

All the Drilling Contractors shall submit their PTW system along with gap analysis in the template to their respective Superintendent of Contract.

c)

Upon receiving the Drilling contractor PTW system along with the Gap analysis, HSE (E&PD) Team will review the PTW system and gap analysis report submitted by Drilling Contractors and prepares a bridging document, which will be forwarded to the Contractor through Superintend of contract for updating their PTW system.

d)

The updated drilling Contractor PTW system will be reviewed by HSE E&PD Team. If the Drilling contractor PTW system meets or exceeds the KOC PTW System requirements including each type of permit then they may be allowed to use their own system with the approval of Supt of Contract, if not the contractor will be further advised to fulfill the KOC requirements. After the initial approval, the contractors PTW system will be reviewed once in every 3 years.

e)

Drilling contractors will be advised to update their PTW system clauses periodically based on revision of relevant KOC HSEMS Procedures.

Ownership of Drill Site / Well Site Location: For Drilling and Workover activities; the ownership of well site/ Drilling Area shall be officially released / handed over temporarily to respective teams under Drilling Groups from concerned permanent asset owner (controlling teams under Production Operations, Water handling, Exploration, Gas Development, etc. as applicable) through KOC Permit for Drilling operational activities. The expiry of the permit shall be till the end of completion of well and shall carefully be specified and monitored. Once handed over to drilling team; the KOC Rig Supervisor/Company Man will be an authorized representative of respective Team Leader of Drilling / Workover Team (Temporary Asset owner) for well operations. However upon completion of drilling / workover activities, the well site will be handed over /returned to the original asset owner (Operations Group) which is respective Production Operations Team along with permit f or closing.

III.

Work Permit Process for Drilling & Workover Operations: The following is process a)

Upon receiving the ownership of the Well site by KOC Rig supervisor, Permit to Spud / workover the well shall be issued by the KOC Rig supervisor to the Drilling Contractor Representative (Tool Pusher) in KOC prescribed format (Attachement1)for a period till the completion of well. After completion of the well/ job the same permit will be closed prior to rig movement to next location.(Attachment-1)

b)

Later all other permits will be issued by Drilling Contractor in their PTW forms for all non-routine and critical activities (identified in this procedure) carried out by rig contractor and service contractor at the rigs.

c)

For the Drilling contractor non routine activities requiring PTW, Senior Tool Pusher (STP) / Night Tool Pusher (NP) will issue the Permits and Drilling Contractor personnel will apply for the permit.

d)

For the Drilling contractor non routine and critical activities which can affect the well integrity (listed in this appendix B), the PTW form prior to issue will be endorsed

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and counter signed by KOC rig supervisor. In addition, PTW activities which requires overriding of critical safety systems needs to be discussed with operations Team leader (if required TL will discuss with Manager) and upon his approval only the permit can be countersigned by the KOC rig supervisor.

IV.

e)

For the service contractor activities requiring PTW, rig contractor Tool pusher will issue the PTW and service contractor Engineer / Supervisor will be permit applicant and worksite supervisor. KOC rig supervisor will countersign on the PTW forms issued to service contractors.

f)

Permit applicants can apply multiple permits at a time in his area of responsibility but shall not supervise more than one work at a time.

g)

Each well location shall have dedicated supervisors and they shall not supervise multiple works / worksites at a time where jobs with PTW are in place.

h)

For all permits issued by drilling contractor, a copy shall be submitted to KOC Rig Supervisor.

List of Activities of Drilling Contractor that needs PTW Activities for which drilling contractor work permits to be issued by senior Tool pusher / Night pusher of the rig. a)

All hot work involving welding, burning, heating, any other spark producing activity generating a potential source, except when done in the approval rig site welding workshop.

b)

Isolation/Override/Disabling/Removal of rig safety critical equipment/ systems.

c)

High pressure testing of rig equipment such as piping, vessels, well control equipment/manifolds/lines etc.

d)

Man-riding & personal basket hoist operations.

e)

Use of non-intrinsic electrical equipment in hazardous area at the rig site (cameras / mobiles / radios / portable non-intrinsic gas detection systems etc.)

f)

Work on electrical equipment in hazardous areas that can generate sources of ignition.

g)

Working on equipment which requires Energy isolation. (Pneumatic & Hydraulic, electrical, spring loaded etc.)

h)

Working on equipment which requires Isolation from hazardous substances (hydrocarbon, flammable materials, toxic materials, etc.)

i)

Charging of accumulator bottles & pulsation dampeners.

j)

Scaffold erection on rig or camp site.

k)

All non-routine inspection & maintenance activity on critical rig equipment such as mast, substructure, draw works, rotary, mud pump, BOP control unit, crown block, BOP, top drive, travelling block, load bearing equipment and other fixtures on mast & substructure during routine rig operations.

l)

Commissioning of new machinery during routine rig operations.

m) Installing of third party contractors equipment on the rig (other than drilling contractors) n)

Handling materials weighing more than 85% of SWL of the lifting equipment.

o)

All contractor, service contractor & 3rd party vehicle entry to the under hazardous area conditions.

p)

Work on / or near moving equipment where safety barriers and guards have to be bypassed / removed.

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q)

Working at height (more than 2 meters), except on mud tanks, generator skid, SCR skid, rig floor, monkey board & stabbing board during routine operations.

r)

Operations where heavy machinery (e.g. cranes, mechanical excavators, trucks etc.) could pass over live hydrocarbon systems or come into contact with overhead power lines (within approximately 10ft)

s)

Use of temporary mobile equipment in hazardous areas (crane, Snorkel Lift, Forklift)

t)

Use of portable diesel engines in hazardous area conditions.

u)

Any work generating ignition sources inside hazardous area.

v)

Operation of permanently installed approved equipment which produced an ignition source or open flame when it operates in hazardous areas.

w)

Major work on Xmas tree at rig site while Rig rigging up / down.

x)

Work/Entry in the confined spaces where there is a risk from toxic and hydrocarbon fumes or oxygen depletion.

y)

Work in contaminated or possibly contaminated atmosphere or in an atmosphere where TLV of a toxic gas is exceeding the acceptable limits.

z)

All operations involving X-ray, radioactive & explosives sources.

aa) Working during blow out and serious well control situations. bb) Transfer of flammable hydrocarbon from trucks (Diesel, OBM etc.). cc) Rig Move activities dd) Any other activities which deviate from regular procedures having potential for high risk where JSA alone cannot provide adequate risk mitigation. V.

List of Activities that need KOC Rig Supervisor Endorsement & Counter Signature on the Contractor PTW Form a)

Isolation / removal of safety critical equipment during normal rig operations (emergency power shutdown system, crown saver systems, derrick man’s emergency escape devices, fire pumps, LEL & H2S detection and alarm systems, audio visual alarms at drillers console / BOP control panels, BOP & well control equipment, critical driller console instrumentation systems, Respiratory protective systems (air cascading system, SCBA sets, EEBA sets)

b)

All activities mentioned in clause IV of this Appendix-B, when carried out in classified hazardous areas, which has the potential to affect the well condition & which has the potential to damage well head, X mas tree & valves.

c)

High pressure testing and major work on Xmas tree at rig site while Rig rigging up / down.

d)

Man riding & personnel basket hoisting operations above monkey board level.

e)

Pressure testing of well control equipment when BOP stack is rigging up on well head.

f)

All operations involving X-ray, radioactive & explosives sources.

g)

Replacement or repair of well head at rig site.

h)

Swabbing at night.

i)

Working during blow out or serious well control situations.

j)

Un-setting packer operations.

k)

Welding/Cutting jobs on casing while fitting float shoe and float collar.

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l)

High pressure testing of well head and casing.

m) All jobs of service contractors on the rig under clause VII. VI.

VII.

Work Permit Process for Service Contractor Operations at Drilling Rigs a)

Permit to Work form of the Drilling Contractor will be used for generating a PTW.

b)

Service contractor engineer / supervisor shall be the permit applicant.

c)

The permit will be issued by the Drilling contractor senior tool pusher / night tool pusher.

d)

For the jobs carried out without the assistance of the rig crew, worksite supervisor shall be the service contractor engineer / supervisor.

e)

All simultaneous jobs carried out at the rig by the Drilling contractor and service contractor, the service contractor will be the PTW worksite supervisor. Tool pusher will issue the permit in consultation with Driller / Assistant Driller.

f)

The service contractor who applies for permit is also responsible to initiate the process to close the permit as per drilling contractor PTW process

g)

Service Contractor shall have the responsibilities of Permit Applicant & Work Site Supervisor & Rig contractor personnel shall have the responsibilities of Permit issuer as per their role in the PTW process in line with KOC PTW procedure & Rig contractor procedures respectively.

h)

All the Service Contractor Permits need Rig Supervisor counter signature on the form.

List of Service Contractor activities that require Work permits on Rigs All the following service contractor activities require PTW and endorsement & counter signature from KOC Rig Supervisor on the permits issued by Tool pusher/ Night pusher a)

High pressure testing of service contractor piping, vessels, BOPs etc.

b)

All operations involving X-ray, radioactive, explosives sources.

c)

Cementing jobs and associated pumping and pressure testing.

d)

Installation and subsequent testing of well heads by service contractors.

e)

High pressure stimulation jobs.

f)

Coil tubing jobs.

g)

Acid jobs

h)

Well killing jobs

i)

Swabbing operations.

j)

Well testing & flaring

k)

Replacement or repair of well head at rig site.

l)

Wire line / Slick line jobs at rig.

m) All well surveillance / testing / artificial lift jobs using rigs. n)

Working during blowout & well control situations.

o)

All applicable activities involving service contractor when carried out as per activities under Clause No. V of this Appendix-B.

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VIII. Categories of Work Permits & Process Flow chart Tier

Description

1

Work Permit for non-routine activities carried out by the Drilling Contractor

2

3

Work permit for non-routine activities carried out by the Service Contractor

Work Permit for non-routine activities (critical) carried out by the Drilling Contractor

Activities

Clause IV

Roles & Responsibilities

Clause X

Clause IX/ Clause VII

Clause X/ Clause XI

Clause IX/ Clause V

Clause X

Job Supervisor

Permit Applicant

Permit Issuer Drilling Contractor Sr. Tool pusher / Night pusher

Drilling Contractor representative

Service Contractor Supervisor

Drilling Contractor Sr. Tool Pusher / Night Tool Pusher.

Service Contractor Supervisor

Drilling Contractor representative

KOC Company Man will only endorse for item listed in clauses V & VII Drilling contractor Sr. Tool Pusher / Night Pusher. KOC Company man will only endorse for item listed in clause V

PTW Process Flow Chart KOC Rig supervisor applies for permit to Asset through KOC PTW system. Then the Well site shall be officially released / handed over temporarily to respective teams (Temporary Asset Owners) under Drilling Groups from concerned Assets Teams (Permanente Asset owner) through KOC Permit for Drilling operational activities for the period till completion of Well.

Blanket Permit to Rig move and Spud / work over the well shall be issued by the KOC Rig supervisor to the Drilling Contractor Representative (Tool Pusher) in KOC prescribed format (Attachement-1 of Appendix-B) to issue all permits for a period till the completion of well.

TIER – 1

TIER – 2

TIER – 3

Drilling contractor non routine activities requiring PTW, senior tool pusher (STP)/night pusher (NP) will issue the Permits and Drilling Contractor personnel will apply for the permit in the Drilling contractor Permit form.

Drilling contractor non routine and critical activities which can affect the well integrity the Drilling Contractor PTW form prior to issue as under Tier-1 will be endorsed and counter signed by KOC rig supervisor.

Service contractor activities requiring PTW, rig contractor Tool pusher will issue the PTW in Drilling Contractor PTW Form and service contractor Engineer/supervisor will be permit applicant and worksite supervisor. KOC rig supervisor will countersign on the PTW forms issued to service contractors.

After completion of the well/ job, the blanket permit issued at the beginning will be closed prior to rig m ovement to next location by the Drilling Contractor Representative (Tool Pusher) and KOC Rig supervisor in KOC prescribed format (Attachment-1 of Appendix-B).

Upon completion of drilling / work over activities, the well site will be handed over /returned to the permanent asset owner (Asset Teams) along with KOC permit for closing.

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IX.

KOC Rig Supervisor/ Company Man Roles & Responsibilities: 1. KOC Rig Supervisor/ Company man will endorse & counter sign the rig contractor PTW for identified drilling contractor activities’ as listed in clause V under following conditions: a) Agreeing that the work shall be done by Drilling Contractor personnel on the equipment involved at the proposed time as per the contractor Standard Operating Procedures. b) Ensure JSA carried out by the rig contractor is attached along with the permit and the hazards identified in the JSA are specific to the job. Ensure pre-job safety meetings are conducted by the rig contractor. c) KOC rig supervisor may provide additional recommendations as required on necessary worksite preparations and safety precautions. d) The Drilling contractor personnel has all the responsibilities listed in the Drilling contractors PTW & HSEMS procedures as work site supervisor, permit applicant & permit issuer. e) All permits will be withdrawn and closed immediately upon any emergency at rig during operations. 2. KOC Rig Supervisor will counter sign the Rig contractor PTW form for service contractor activities listed under clause VII, which is issued by Rig Contractor Tool Pusher/ Night Tool Pusher and applied by Service Contractor at rig site under following conditions: a) Agreeing that the work done by service contractor personnel who will be responsible & accountable for the work being done on the equipment involved at the proposed time as per the service contractor procedures. b) Service contractor is responsible & accountable for the identification of all hazards related to their equipment and task and application of risk mitigation measures while generating permit to work. c) JSA carried out by the service contractor shall be attached along with the permit application with the signature of the service contractor engineer or supervisor. The hazards identified in the JSA shall be specific to the job. d) Service contractor is responsible & accountable for t he implementation of their HSE MS, JSA & Standard operating procedures for the jobs carried out by them at the rig sites and ensure the PTW process is being carried out in line with KOC PTW procedure (conducting Job risk assessment, JSA, Safety meetings / T BM etc.)

e) Rig contractor STP / NTP & KOC Rig supervisor may provide additional recommendations as required recommending on necessary worksite preparations and safety precautions. f)

All permits will be withdrawn and closed immediately upon any emergency at rig during operational activities.

g) For the purpose of tracking, KOC Rig Supervisor shall maintain a register/ tracking sheet of the permits endorsed by him (for rig contractor & service contractor activities) mentioning the jobs for which the permit, permit endorsement date & time of issue and closure of the permit. X.

Tool Pusher/ Night Tool Pusher Roles & Responsibilities: 1. Tool pusher/ Night Pusher roles and responsibilities while issuing Work Permits in the Drilling Contractor PTW Forms for drilling contractor identified activities’ at rig site are: a) Shall follow the Work permit process for job activities carried out by rig contractor listed in clause IV as per the process mentioned under clause III of this Appendix-B. Control Tier 3



b) Ensure that the PTW Jobs will be done on the equipment involved at the proposed time as per the contractor Standard Operating Procedures (SOP’s). c) Responsible & accountable for the identification of all hazards related to the equipment and task and application of risk mitigation measures while generating permit to work. d) Responsible & accountable for the implementation of their HSEMS procedures

for the jobs carried out by Drilling Contractor & sub-contractor at the rig sites as mentioned in clause- IV that requires PTW (job risk assessment, conducting JSA, ensuring relevant Operating procedures are followed for the work, conducting pre job safety meeting etc.)

e) Ensure to implement KOC rig supervisor additional recommendations if any during his counter signature as required on necessary worksite preparations and safety precautions. f)

Has to ensure that responsibilities listed in the Drilling contractors PTW & HSEMS procedures as worksite supervisor, permit applicant & permit issuer are complied.

g) All permits will be withdrawn and closed immediately upon any emergency at rig during operations. 2. Tool Pusher/ Night Tool Pusher roles and responsibilities while issuing Work Permits in the Drilling Contractor PTW Forms for Service Contractor identified activities’ at rig site are: a) Shall issue work permits for Service contractor activities at Drilling Rigs as listed under clause VII and as per process mentioned under clause VI of this Appendix-B, in the rig contractor PTW form. b) Ensure that JSA carried out by the service contractor is attached along with the permit application with the signature of the service contractor engineer or supervisor. Also ensure pre-job safety meetings are conducted by Permit Applicant / Work Site Supervisor of Service contractor. c) May provide additional recommendations based on any additional hazards identified as required recommending on necessary worksite preparations and safety precautions. d) All permits will be withdrawn and closed immediately upon any emergency at rig during operational activities. XI.

Service Contractor Engineer / Supervisor Roles & Responsibilities: a) Shall apply for Work permit & supervise for the activities mentioned in ClauseVII and implement the Work permit process for Service contractor operations at Rigs as mentioned under clause VI of this Appendix-B. b) Service contractor personnel will be responsible & accountable for the work being done on the equipment involved at the proposed time as per the service contractor operating procedures (SOP’s). c) Service contractor is responsible & accountable for the identification of all hazards related to their equipment and task and application of risk mitigation measures while generating permit to work. d) JSA carried out by the service contractor shall be attached along with the permit application with the signature of the service contractor engineer or supervisor. The hazards identified in the JSA shall be specified to the job. e) Service contractor is responsible & accountable for the implementation of their HSE MS, JSA & Standard operating procedures for the jobs carried out by them at the rig sites. Control Tier 3



f)

To implement Rig contractor STP/NTP & KOC Rig Supervisor additional recommendations if any as required recommending on necessary worksite preparations and safety precautions.

g) The service company personnel have all the responsibilities listed in the KOC PTW procedure as permit applicant & work site supervisor. h) All permits jobs to be stopped immediately upon any emergency at rig during operational activities and inform to permit issuer. XII.

Work Done on or Near Drilling Rigs by Departments other than Drilling All works on or near the drilling location that are performed by KOC assets or other contractors other than Drilling, e.g. welding and testing GC flow lines, digging pits etc. This work is to be covered by a permit to work procedure. The requirements are as follows: 1. Work within the Drilling Location a) The KOC permit is to be raised by the appropriate KOC asset work site supervisor & permit applicant from asset (Contractor or KOC) and issued by the permit issuer form the asset for the personnel carrying out the work. b) The permit shall be countersigned by the KOC Drilling supervisor. c) Ensure that the permit copy to be submitted to KOC company man prior to start of job & the permit to be closed after safe completion of jobs. 2. Work around the Drilling Location Where the work is done outside the drilling location, but within 100 meters of the well, the following shall apply: a) The KOC permit is to be raised by the appropriate KOC asset work site supervisor & permit applicant from asset (Contractor or KOC) for the personnel carrying out the work. b) The permit is to be Authorized and issued by an Authority, from the KOC asset department for the area. c) The permit copy to be submitted to KOC company man prior starting the job & the permit copy to be taken back after safe completion of jobs. d) For the work over site preparations & back filling which are not carried out by Drilling group, the KOC PTW shall be implemented by the concerned KOC Group controlling the activity. 3. Drilling Location Preparation: a) As per the scope of the contract regarding site preparation & back filling applicable to drilling group, concerned rig contractor to implement the KOC PTW procedures as work site supervisor & permit applicant with the concerned GC personnel as permit issuer. b) Excavation notification for any excavation jobs to implemented as per KOC procedures. The concerned rig contractor personnel shall be the work site supervisor & permit applicant and concerned GC personnel as permit issuer.

XIII. Gas Test Requirement at Drilling / Work - over Location: The responsibilities of carrying out gas test will be delegated to Permit Issuer (Tool Pusher) or rig crew/ service contractor crew holding valid certificate and authorizations. The gas testing at Drilling / W ork – over location must take into account the precautions specified in Clause 8.0 of Permit to Work Procedure as well as other applicable HSEMS Procedure such as “Gas Testing & Gas Test Standards” (KOC.HE .003).

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Attachment - 1

Permit No : Issue Date: Valid up to: WELL SITE SPUD-IN / WORK-OVER PERMIT Permit Applying for

Drilling Operation Workover Operations

Asset details: Well No Location/Asset Asset Owning Team/Group Contractor / Rig details: Contractor Rig name & No. Permit Authorization This permit is being issued to move the Rig from location ………………………………… to well location ……………………………… for carrying out Drilling / Workover operations as per well plan. Name of Issuer (KOC Rig Supervisor): .............................................. ........................... Controlling Team / Group: ................................... . .Signature & Date: ......................... Name of Receiver (Tool Pusher-Contractor): ....................................... ......................... Contractor: .............................................................. Signature & Date: ........................ Drilling & Workover Operations Completion & Permit Closeout Drilling and work over operations has been completed in the well location No ……………….wellsite and hereby closing this permit Name of Issuer (Tool Pusher / Contractor): .................................. .......................... Contractor: ....................................................... Signature & Date: ........................ Name of Receiver (KOC Rig Supervisor): ............................................................ .. Controlling Team/Group: ........................... Signature & Date: ............................... Notes: 

Permit to Spud the well will be issued by the KOC Rig supervisor to the Drilling Contractor Representative (Tool Pusher).



All other remaining permits will be issued as per Drilling Contractor PTW System as following: 



Tool Pusher will issue Permits for all Non-routine Operations (including for Service Companies operations). Non-routine critical operations related to the Well Integrity/ KOC Assets will be endorsed and countersigned by KOC Rig Supervisors.

While issuing permits, the Drilling Contractor shall submit one copy to KOC Rig Supervisor

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APPENDIX – C “Specimen

Forms for Work Permit ”

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Mechanical Isolation & Spading Record Register Facility: …………………… Reference Device / Equipment

Reason of Isolation / Spading

Controlling Team: ……………………………….. Isolation / Spading Record

Permit No. (If Applicable)

Lock / Tag #

Date & Time of Isolation / Spading

Requested Reviewed by by Operator- I

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Normalization Record

Approved by Shift Controller

Date & Time of Requested by Normalization


Reviewed by Operator- I



Mechanical Isolation & Spading Record Register Facility: …………………… Reference Device / Equipment

Reason of Isolation / Spading

Controlling Team: ……………………………….. Isolation / Spading Record

Permit No. (If Applicable)

Lock / Tag #

Date & Time of Isolation / Spading

Requested Reviewed by by Operator- I

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Date & Time of Requested by Normalization



Normalization Record Reviewed by Operator- I



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APPENDIX – D http://mykocportal.kockw.com/sites/TS/ITG/COSOT/Shared%20Documents/ewpDemo/src/E lectronic_Work_Permitv2.6S.pdf

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KOC.sa.004 Permit to Work Procedure

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