KUWAIT NATIONAL PETROLEUM COMPANY
SAFETY REGULATIONS
CHAPTER - 8
WORK PERMIT SYSTEM SYSTEM
IMPORTANT Mandatory rules (or “must”) are characterized by the word “SHALL” throughout the text. Advisory rules or recommendations are indicated by the word “SHOULD”. The words 'shall and and should' have been used to remain in line with the terminology used by American National Standard Institute.
REFERENCES OSHA Regulations, CONOCO guidelines, HRC recommendations, KOC Safety Regulations, ISGOTT (International Safety Guide for Oil Tankers and Terminals), IC-37, API-2217, 2217A, 2031, 2015, 2009, 2077
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PAGE - 1 OF 40 KNPC/S-Reg/ Chapter – 08
Revisi on – 2 Revisi on – 1 Revisi on – 0
Prepared by SRRC
January Januar y 2003 2003 November 2001 2001 Jun e 1994 1994
Checked by STS-SHE
Minor Revisions General Revision for all KNPC MAA/MAB/SHU Unified Chapter
Approved by Manager-SHE
Final Approval EAMD (M)
KNPC SAFETY REGULATION REVIEW COMMITTEE
WORK PERMIT SYSTEM SYSTEM TABLE OF CONTENTS Page 8.1 INTRODUCTION .................................................................. ..................................................................Error! Error! Bookmark not defined. 8.2 WORK PERMIT REQUIREMENT, TYPES & FEATURES..........Error! FEATURES.......... Error! Bookmark not defined. 8.2.1
WORK REQUIRING A PERMIT..................................... Error! Bookmark not defined.
8.2.2
WORK NOT REQUIRING REQUIRING A PERMIT............................. PERMIT ............................. Error! Bookmark not defined.
8.2.3
TYPES OF WORK PERMITS & AUTHORISATIONS......... Error! Bookmark not defined.
8.2.4
FEATURES OF WORK PERMIT FORM........................... Error! Bookmark not defined.
8.3 WORK PERMIT SIGNING .................................................... ....................................................Error! Error! Bookmark not defined. 8.4 WORK PERMIT ISSUER (Issuing Authority) .......................Error! .......................Error! Bookmark not defined. 8.4.1
Issuer (Issuing Authority) .......................................... Error! Bookmark not defined.
8.4.2
Issuer Responsibilities................................................Error! Responsibilities................................................ Error! Bookmark not defined.
8.4.3
Operation Area..........................................................Error! Area.......................................................... Error! Bookmark not defined.
8.5 WORK PERMIT EXECUTOR (Executing Authority) ..............Error! ..............Error! Bookmark not defined. 8.5.1
Executor (Executing Authority) ................................... Error! Bookmark not defined.
8.5.2
Executor Responsibilities............................................ Error! Bookmark not defined.
8.6 WORK PERMIT VALIDITY, RECORDKEEPING & SAFETY FUNCTIONError! FUNCTION Error! Bookmark not d 8.6.1 VALIDITY PERIOD OF WORK PERMIT ......................... Error! Bookmark not defined. 8.6.2
SUSPENSION OF WORK PERMIT ................................ Error! Bookmark not defined.
8.6.3
CLOSING AND FILING................................................ Error! Bookmark not defined.
8.6.4
SAFETY FUNCTION.................................................... Error! Bookmark not defined.
8.7 SAFETY REQUIREMENTS, GAS TEST AND ELECTRICAL ISOLATIONError! ISOLATION Error! Bookmark not de 8.7.1
SAFETY REQUIREMENTS (Section-3) .......................... Error! Bookmark not defined.
8.7.2
GAS TEST FOR WORK PERMIT (Section-4A)................ Error! Bookmark not defined.
8.7.3
ELECTRICAL ISOLATION (Section-4B)......................... Error! Bookmark not defined.
8.8 COLD WORK PERMIT .......................................................... ..........................................................Error! Error! Bookmark not defined. 8.8.1
GENERAL REQUIREMENTS FOR COLD WORK .............. Error! Bookmark not defined.
8.8.2
WORKING WITH RESPIRATORY PROTECTION IN OPEN AREAS Error! Bookmark not defi
8.8.3
WORKING ON OR NEAR EQUIPMENT CONTAINING HYDROGEN SULFIDE Error! Bookmark
8.8.4
WORKING WITH RADIOGRAPHY EQUIPMENT ............. Error! Bookmark not defined.
8.8.5
OIL PIER WORK ........................................................ Error! Bookmark not defined.
WORK PERMIT SYSTEM SYSTEM TABLE OF CONTENTS Page 8.1 INTRODUCTION .................................................................. ..................................................................Error! Error! Bookmark not defined. 8.2 WORK PERMIT REQUIREMENT, TYPES & FEATURES..........Error! FEATURES.......... Error! Bookmark not defined. 8.2.1
WORK REQUIRING A PERMIT..................................... Error! Bookmark not defined.
8.2.2
WORK NOT REQUIRING REQUIRING A PERMIT............................. PERMIT ............................. Error! Bookmark not defined.
8.2.3
TYPES OF WORK PERMITS & AUTHORISATIONS......... Error! Bookmark not defined.
8.2.4
FEATURES OF WORK PERMIT FORM........................... Error! Bookmark not defined.
8.3 WORK PERMIT SIGNING .................................................... ....................................................Error! Error! Bookmark not defined. 8.4 WORK PERMIT ISSUER (Issuing Authority) .......................Error! .......................Error! Bookmark not defined. 8.4.1
Issuer (Issuing Authority) .......................................... Error! Bookmark not defined.
8.4.2
Issuer Responsibilities................................................Error! Responsibilities................................................ Error! Bookmark not defined.
8.4.3
Operation Area..........................................................Error! Area.......................................................... Error! Bookmark not defined.
8.5 WORK PERMIT EXECUTOR (Executing Authority) ..............Error! ..............Error! Bookmark not defined. 8.5.1
Executor (Executing Authority) ................................... Error! Bookmark not defined.
8.5.2
Executor Responsibilities............................................ Error! Bookmark not defined.
8.6 WORK PERMIT VALIDITY, RECORDKEEPING & SAFETY FUNCTIONError! FUNCTION Error! Bookmark not d 8.6.1 VALIDITY PERIOD OF WORK PERMIT ......................... Error! Bookmark not defined. 8.6.2
SUSPENSION OF WORK PERMIT ................................ Error! Bookmark not defined.
8.6.3
CLOSING AND FILING................................................ Error! Bookmark not defined.
8.6.4
SAFETY FUNCTION.................................................... Error! Bookmark not defined.
8.7 SAFETY REQUIREMENTS, GAS TEST AND ELECTRICAL ISOLATIONError! ISOLATION Error! Bookmark not de 8.7.1
SAFETY REQUIREMENTS (Section-3) .......................... Error! Bookmark not defined.
8.7.2
GAS TEST FOR WORK PERMIT (Section-4A)................ Error! Bookmark not defined.
8.7.3
ELECTRICAL ISOLATION (Section-4B)......................... Error! Bookmark not defined.
8.8 COLD WORK PERMIT .......................................................... ..........................................................Error! Error! Bookmark not defined. 8.8.1
GENERAL REQUIREMENTS FOR COLD WORK .............. Error! Bookmark not defined.
8.8.2
WORKING WITH RESPIRATORY PROTECTION IN OPEN AREAS Error! Bookmark not defi
8.8.3
WORKING ON OR NEAR EQUIPMENT CONTAINING HYDROGEN SULFIDE Error! Bookmark
8.8.4
WORKING WITH RADIOGRAPHY EQUIPMENT ............. Error! Bookmark not defined.
8.8.5
OIL PIER WORK ........................................................ Error! Bookmark not defined.
8.9 HOT WORK PERMIT ............................................................ ............................................................Error! Error! Bookmark not defined. 8.9.1
GENERAL REQUIREMENTS FOR HOT WORK................ Error! Bookmark not defined.
8.9.2 VEHICLE ENTRY ........................................................ Error! Bookmark not defined. 8.9.3
USE OF PORTABLE INSTRUMENTS ............................. Error! Bookmark not defined.
8.9.4
CONTROL OF IGNITION SOURCES ............................. Error! Bookmark not defined.
8.9.5
OFFSHORE / OIL PIER HOT WORK ............................. Error! Bookmark not defined.
8.10
CONFINED SPACE ENTRY AUTHORIZATION.................Error! AUTHORIZATION.................Error! Bookmark not defined.
8.11
EXCAVATION AUTHORIZATION .................................... ....................................Error! Error! Bookmark not defined.
APPENDIX - A “ COLD WORK PERMIT”.....................................Error! PERMIT”.....................................Error! Bookmark not defined. APPENDIX - B
(Back Of Cold Work Permit Permit Form) ..................Error! ..................Error! Bookmark not defined.
APPENDIX - C “ HOT WORK PERMIT”.......................................Error! PERMIT”....................................... Error! Bookmark not defined. APPENDIX - D
(Back of Hot Work Permit form).....................Error! form).....................Error! Bookmark not defined.
APPENDIX - E
“INSTRUCTIONS FOR FILLING WORK PERMIT” Error! Error! Bookmark not defined.
APPENDIX - F SAFETY AUTHORISATION AUTHORISATION CARDS ............. ................... ........ ..Error! Error! Bookmark not defined.
WORK PERMIT SYSTEM SYSTEM 8.1 8.1
INTRODUCTION
8.1.1
8.1.1 Working in a petroleum refinery or distribution facility plant involving hydrocarbon and toxic material presents various risks. In order to provide safe-working conditions, a Work Permit System shall be followed. The Work Permit specifies the conditions and procedures for safe execution of the work and allows the work to be carried out under controlled conditions.
8.1.2
8.1.2 The basic purpose of the Work Permit System is to assign the responsibility of each party for the safe execution of the work; i.e. prevent injuries to personnel, protect property from damage, avoid fire/explosion and ensure that all work is carried out in the safest possible manner.
8.1.3
8.1.3 The Work Permit authorizes specific work to be carried out in Work Permit Area (KNPC premises) and serves as an official document of conditions and requirement as agreed upon between Issuing and Executing Authorities (defined in 8.4 & 8.5).
8.1.4
8.1.4 The conditions set out on the Work Permit are meant as general guidelines and shall not be assumed to cover every condition or circumstances that may be present or may arise during the course of the work. The Permit in itself does not make the job safe but shows to what extent the job has been made safe.
8.1.5
8.1.5 Confined Space Entry and Excavation Authorisations, which are associated with work permits, are discussed in Chapters 7 and 13. Special precautions for specific type of work are mentioned in other relevant chapters.
8.1.6
8.1.6 Issuers, Executors and their superiors are responsible & accountable to ensure strict compliance at all levels to all clauses of the work permit system.
8.2 8.2
WORK PERMIT REQUIREMENT, TYPES & FEATURES
No work shall be carried out without a proper Work Permit unless such work or area has been declared permit free (see Ch-1, 1.3). 8.2.1
8.2.1
WORK REQUIRING A PERMIT
A Work Permit is required for jobs including, but not limited to the following:
a. b. c. d. e. f. g. h. i. j. k.
a. Maintenance Work (mechanical, electrical, instrument, civil, etc.) b. Construction and project work c. Alterations/modifications d. Process equipment cleaning activities e. Inspection and condition monitoring f. Work inside Confined Space g. Excavation h. Vehicle/mobile equipment entry into Hazardous Areas i. Underwater maintenance, marine construction j. Other Activities serving the refinery operations k. Non-routine work in workshops, warehouse, etc. other than those excluded under 8.2.2 d (ex. Building modification, civil/mech/elect/AC work in these buildings)
8.2.2
8.2.2
WORK NOT REQUIRING A PERMIT
A Work Permit is NOT required for following routine work, when carried out by the respective craft:
8.2.3
a.
a. Routine work carried out in established workshops and adjacent yards with fixed boundaries
b.
b. Routine material handling work in established warehouses and adjacent laydown yards with fixed boundaries
c.
c. Routine office work including cleaning, servicing of office equipment, communication equipment, and furniture
d.
d. Maintenance cold work in buildings outside hazardous area (other than control rooms), which does not exceed climbing of ladder or scaffold over 2 meters. Ex. hand tool work, relamping, servicing of air conditioners, painting.
e.
e. Visual inspection or checking without using any tools in operation areas with verbal permission of the asset custodian (if such work involves confined space entry, confined space authorisation is required)
f.
f. Work carried out by Operations Dept. personnel as part of their routine operations, start-up and shutdown (ex. operating valves, pumps, etc)
g.
g. Work carried out in areas designated as 'permit free' by written approval from KNPC Safety (See Chapter-1, Section 1.3.2)
h.
h. Any other work approved by KNPC Safety as permit free upon written request from the concerned Department. 8.2.3
TYPES OF WORK PERMITS & AUTHORISATIONS
There are two types of Work Permits at KNPC with specific colors assigned for easy identification. Other "Associated Authorisations" are also required depending on the nature of work. a. a.
Cold Work Permit (green permit) is required for any work that does not involve use of or generate a source of ignition (see Section 8.8 and Appendix - A).
b. b.
Hot Work Permit (red permit) is required for any work that involves use of or generates a source of ignition capable of igniting a flammable mixture or combustible material (see Section 8.9 and Appendix - C).
c. c.
Confined Space Entry Authorization (yellow permit) is associated with work permit for personnel entry into a confined space (see Section 8.10 and Chapter-7).
d. d.
Excavation Authorization is associated with work permit for excavation work (see Section 8.11 and Chapter-13)
e. e.
Other Authorisations such as Vehicle Safety Certificate (see Chapter-18), Electrical Isolation Tag (see Chapter-14), etc shall also be required as applicable.
8.2.4
8.2.4
FEATURES OF WORK PERMIT FORM
Work Permit form consists of the following features: a.
a.
The original and 3 copies:
-
Original marked (belongs to executor)
"DISPLAY
-
1st copy marked
"ISSUER copy"
-
2nd copy marked
"Field Operator copy"
- 3rd copy marked box) b.
b.
AT
"SAFETY copy"
WORK
SITE"
(inserted in the
The following appear on the original and the 3 copies:
- Printed serial number on the top left hand corner - Latest revision date of the Permit form on the lower left hand corner - Arabic translation of the English text side by side - General and Special Conditions of the permit on the back of the form. c.
8.3 8.3
c. One hard sheet of “HOW TO FILL WORK PERMIT FORM” in English with Arabic translation with each work permit pad (Appendix – E). WORK PERMIT SIGNING
The eligibility and training requirements for personnel eligible to sign a work permit as issuer or executor are described in the following sections. 8.3.1
8.3.1 The Department Head shall ensure that personnel nominated to attend training for signing work permit meet the following requirements.
a. a. Has basic safety knowledge: attended training courses in this regard which should generally cover basic safety at work, PPE, emergency actions, first aid fire fighting, basic awareness of work permit system, work place hazards, etc. b. b. Has craft specific safety knowledge: attended training courses covering the safety aspects of employee’s craft. He(she) shall be fully conversant with this chapter, Confined Space Entry (Chapter7), PPE (Ch-5) and other chapters relevant to the particular craft. c. c. Is technically competent (qualified and experienced) to fully appreciate the potential hazards of the work, the site conditions under which the work will be performed and the safety requirements. 8.3.2
8.3.2 The respective KNPC Safety Division shall train, test and certify the nominated person for signing the Work Permit as Issuer or Executor. Validity of certification (see Appendix-Fi & Fii) shall be a maximum of 2 years for KNPC personnel and 2 years or till the end of the contract, whichever is less for the secondment and service contractor personnel. Acting personnel also can be given 2 years or temporary authorisation for the acting period as per Dept head’s request.
8.3.3
8.3.3 Each Division Superintendent shall maintain a record of Certified Issuers/Executors and apply for timely renewal or new authorisations. KNPC Safety shall maintain a central database of work permit training and issuance of authorisations.
8.3.4
8.3.4 KNPC Supervisor (Oprn.)/ KNPC Foreman (Maint.) including secondment personnel shall be the lowest level to sign a work permit. However, the Department Manager may request for approving lower level as explained in Sections 8.4 and 8.5.
8.3.5
8.3.5 Critical Work: Some hazardous work, which has the potential to cause fire/explosion, toxic release or immediate danger to life or property, is considered critical (ex. welding in process area, most of confined space entries, hot tapping, opening flanges on lines containing H2S and volatile hydrocarbons, blinding flare line, radiography, etc).
8.3.6
8.3.6 Both issuer and executor shall make sure that all relevant sections from 1 to 4 have been properly filled before signing section-5.
8.3.7
8.3.7 In case if the executor and issuer disagree on safety matters, it should be raised to KNPC Safety (ex. Inadequate preparation before hand-over of equipment, permit conditions such as specifying excessive protective measures).
8.4 8.4 8.4.1
WORK PERMIT ISSUER (Issuing Authority) 8.4.1
Issuer (Issuing Authority)
a.
a. Operation Issuers: The Shift Supervisor or above shall only be granted authority to issue all types of work permits in operation areas. Control Room Operators may be authorised as issuers for special circumstances such as shutdown. However, Operations Manager may authorise lower level personnel subject to the conditions in 8.3.1.
b.
b. Other Issuers: Other asset custodians or technical personnel in office buildings can be authorised to issue all types work permits in their respective areas. •
•
Shift Fire officer, Lab Shift supervisor and
above •
•
Supervisor level or above of workshop, warehouse (normal work-hours) •
Supervisor or above person with technical background, assigned as custodian for an office building (ex. One of the engineers in Operation or Maint. Bldg.) •
c.
c. Shift Safety Engineer/ Shift Leader shall issue permits for areas without designated asset custodian (ex. Main roads, main substations, scrap/salvage yards, etc). He shall also issue permits for areas with custodian issuers outside their work-hours.
d.
d. Authorised Projects personnel shall issue permits for fenced Project sites outside unit boundaries.
e.
e. If the work affects or can impact safety of adjoining/other Unit/Department, the other affected Unit/Department Issuer shall countersign the permit to indicate awareness of the job. (ex. Work on Unit-A pipeline crossing Unit-B, supervisor of Unit-B also should countersign in issuer column).
f.
f. Issuer’s Division Supdt should ensure the number of permits to be signed by one issuer in a day/shift does not hamper his primary duty of running the plant safely. If overloaded other issuers such as shift controller or section head should cover to have effective control of work.
8.4.2
8.4.2
Issuer Responsibilities
a.
a. Issuing authority is responsible for preparation and handing over of the equipment in safe condition to perform the work. His signature as issuer shall mean understanding the job, safe handing over and monitoring of site conditions.
b.
b. Issuer shall fill Sections 2 and 3 of the work permit form (Issuer or executor may fill Section-1). He may sign Section 4(A) or delegate the gas test responsibility to an authorised gas tester working under his supervision (see 8.7.2). He may tick “Not Required” or arrange necessary signatories for Sections 4(B): Electrical Isolation (see 8.7.3).
c.
c. Issuer shall decide whether the work is critical and inspect the work site with the executor before issuing the permit. He shall inform ECCC about all critical work (see 8.3.5). He shall also inform ECCC about road closures (see also Ch-13.10). ECCC shall log it and inform KNPC Safety.
d.
d. Immediately after signing, Issuer shall drop the safety copy in the box provided.
e.
e. The Field Operator shall read the work permit, check the site compliance to permit conditions and sign original permit with field operator copy (signing issuer copy is optional). He shall monitor the site conditions and executing group’s compliance to permit conditions. He shall register the work in his log. He shall have valid “work permit awareness” training card (Appendix- F).
8.4.3
8.4.3
Operation Work Permit Area
a.
a. For work permit issue purposes, Operation Work Permit Area shall include surrounding area at least 15 m from battery limit (or up to the inner boundary fence in MAA), roads, substations feeding the unit, IRT lines and Operation assets outside KNPC premises in addition to the unit area.
b.
b. Operation Manager shall ensure clearly identified boundaries between and beyond units and make each issuer aware of his work permit area.
8.5 8.5 8.5.1
WORK PERMIT EXECUTOR (Executing Authority) 8.5.1
Executor (Executing Authority)
a.
a. Authority to execute all types of work permits shall only be granted to KNPC Foreman level of Maintenance Dept. and above. KNPC Assistant Foreman may be considered for special situations such as shutdown.
b.
b. KNPC Technician level should be considered only for cold work which is not related to opening of vessels, disconnecting lines in flammable or toxic service and radiography. Technicians can also be authorised to sign hot work related to use of portable battery operated instruments (vibration, thickness, multi meters) and for vehicle entry.
c.
c. Separate permits are required for different crafts & jobs. Person holding valid executor card shall only sign permits for crew under his control.
d.
d. Equivalent categories of other Department personnel can be granted similar authority (ex. Admin Services, Projects, KOC).
e.
e. Executing Division Supdt should ensure that each executor is not overloaded with too many permits, which can hamper effective supervision.
f.
f. Contractor’s personnel shall not be considered as executors. However, RM may approve requests for authorising Service Contractor’s personnel equivalent to KNPC Foreman as executors if there is a genuine shortage of KNPC personnel. Executing Division Supdt shall ensure that, such executors are not utilised when there are sufficient KNPC executors for the amount of permits in a given day.
g.
g. Contractor Column – The actual site supervisor of work performed by contractor (contractor or subcontractor person) shall sign this column to indicate understanding of permit conditions for compliance. He shall have valid “work permit awareness” training card (Appendix- F). Executor card is not required for the person signing this column.
h.
h. Responsibility for safe execution of the job primarily lies with the KNPC Maintenance for all jobs carried out by Maintenance Dept including those where contractor’s personnel have signed as executors.
8.5.2
8.5.2
Executor Responsibilities
a.
a. After checking the site, the Executor himself (not the deputies) shall request from the respective issuer, for a work permit to carry out the work (other than those listed in 8.2.2). He shall forward associated authorizations to the issuer (for excavation, hot-tapping, etc).
b.
b. He/She shall indicate the types of tools and equipment necessary for performing the work. He shall forward valid Safety Certificate for vehicles and engine driven equipment.
c.
c. He shall ensure that, the tools, equipment and accessories are in good condition. He shall apprise his workers about job hazards and provide proper PPE (personal protective equipment).
d.
d. His signature indicates understanding and compliance to relevant conditions on (both sides of) the permit. Adequate supervision shall be ensured for all jobs. The work permit with associated authorizations shall be available at work site.
e.
e. Executor shall take “Original” and “Field Operator Copy” to the Field Operator and obtain the signature before starting the work (signing issuer copy is optional).
f.
f. Executor shall display the permit in suitable manner and protected from direct sun and moisture. Appendix – G shows a sample of a permit display board as a guideline. Vehicle entry permit should be displayed on the back of the windshield. If the nature of work involves moving from one place to another, (ex. Thickness or vibration measurement) it shall be displayed centrally and shifted as the work progresses.
g.
g. Transfer of Responsibility of Supervision - Executor of critical work shall remain in the work site. In case he has to leave the site at anytime, the work shall be suspended until the responsibility is transferred to another executor by renewal of the permit. Executor shall not sign more than one critical work permit unless it is in the same location/vicinity.
8.6 8.6 WORK PERMIT VALIDITY, RECORDKEEPING & SAFETY FUNCTION 8.6.1
8.6.1
VALIDITY PERIOD OF WORK PERMIT
a.
a. Maximum validity of initial issue of a Work Permit shall be for the duration of the work or until the end of the shift/ workday, whichever is less. The issuer or executor shall not sign for duration beyond their work-hours.
b.
b. If the work continues uninterrupted, the permit can be renewed twice provided that, the job and surrounding area is re-inspected, gas tests are repeated where appropriate and each renewal is signed by all signatories on the original and field operator copy (signing issuer copy is optional). The renewal of permit is a transfer of responsibility and an affirmation by the issuer/ executor that conditions are safe to continue the work.
c.
c. Extended duration of work permits for special tasks such as major turnarounds and major projects could be considered subject to written approval from KNPC Safety.
d.
d. If work in hazardous area is not started or is stopped for over 2 hours for any reason the permit becomes invalid. It shall be renewed before starting or resuming the work. However the permit shall be closed if the work is not started/ resumed before the end of executor's workday. Non-hazardous area permits can be reused next work day without closing.
8.6.2
8.6.2
SUSPENSION OF WORK PERMIT
a.
a. In case of an emergency, work shall be suspended and validity of any work permit ceases in the affected area.
b.
b. Executor or his crew shall immediately stop work when a fire or emergency alarm is sounded or accident of any kind occurs. Approval from the Incident Controller (definition as per MIPP) shall be obtained after necessary preliminary investigations, to resume such work. The Work Permit shall be renewed to resume the work after the fire or emergency is over.
c.
c. Issuer, his deputy or KNPC Safety is authorized to suspend work and withdraw the Work Permit, if the Permit conditions or Safety Regulations are violated and/or if the site conditions have changed leading to a hazardous situation. Person stopping the work shall immediately inform the reasons for stopping to the Issuer/Executor or their superiors.
d.
d. If work is not started or is suspended due to safety reasons after a Work Permit has been issued, the work shall only be started or resumed after establishing safe conditions and renewal of the Work Permit.
8.6.3
8.6.3
CLOSING AND FILING
a.
a. Executor, Field Operator and Issuer shall fill and sign Section-6 (Permit Closure) on the "Original" and “Field Operator Copy" of the work permit at the completion of work or the end of last renewal whichever comes earlier (closing issuer copy is optional). Objective of closing is, safe handing over of the site.
b.
b. Different types of permits shall be filed separately in chronological (date) order in box files for future reference for at least one month (30 days) from the date of issue/closure.
c.
c. “Original” which belongs to executor shall be filed and available with the KNPC supervisor in charge of execution of the job.
d.
d. “Field Operator copy” shall be filed and available at the issuing office or CCR workstation (filing or retaining issuer copy is optional).
e.
e. “Safety copy” which had been dropped in the permit box by the issuer shall be collected by the Area Safety Engineer every workday and filed. Safety engineer, who is the custodian of this box, shall ensure it is locked and not allowed to overfill.
8.6.4
8.6.4
SAFETY FUNCTION
Safety Section is an advisory and monitoring function. Hence Safety Engineers are not required to sign on the work permit unless he is the issuer or executor. He shall audit the work permit filling and compliance on a daily basis. Safety Engineer shall write his site instructions in the safety log maintained at issuer’s office with date, time & signature or issue official memo. 8.7 8.7 SAFETY REQUIREMENTS, GAS TEST AND ELECTRICAL ISOLATION 8.7.1
8.7.1
SAFETY REQUIREMENTS (Section-3)
a.
a. Operations or the asset custodian shall prepare the equipment for safe execution of the work before handing over to executors. The extent of preparation depends on the nature of work as described in other sections. See cold work (8.8), hot work (8.9) and confined space entry (8.10). (See also Chapter-25: Safe Maintenance Practices)
b.
b. Issuer shall tick all items of Section 3(A) (B) & (C) either 'Y' (yes) or 'N'/'NR' (no/not required or applicable). Executor should assist issuer in ticking section 3(C).
8.7.2
8.7.2
GAS TEST FOR WORK PERMIT (Section-4A)
Gas tests are required for hot work and confined space entry. It may also be required for some cold work and excavations. Section-4(A): Gas Test of Work Permit shall be filled to record results of Combustible, Toxic Gases and Oxygen concentration as applicable to the location of work. a.
a. Issuer shall determine the requirement of gas test, the gases to be measured and frequency of repeating the test or the need for continuous monitoring. Minimum requirement shall be once at the beginning of shift/work.
b.
b. An Authorised Gas Tester, who has been certified by KNPC Safety and holding valid certification card (Appendix-G iii), shall carry out the gas test using an approved gas meter (see Chapter-7 for more details). He/she shall check the meter in fresh air and keep it on before actual test.
c.
c. Combustible gas is measured as a percentage of Lower Explosive Limit (%LEL, definition in Chapter-20). For hot work, the reading at the point of work shall not exceed 1%, preferably 0%. For cold work without respiratory protection, breathing area LEL shall be less than 10%.
d.
d. At least 13% Oxygen is required to obtain an accurate LEL reading from a combustible gas meter. Hence, these cannot give a proper reading in inert atmospheres (ex. system purged with nitrogen or steam). Special test methods shall be adopted in such situations (as per instruction manual of the gas meter or lab analysis).
e.
e. Moisture/dust filter and/or liquid trap is required when measuring probe comes in contact with excessive moisture/dust and liquid to prevent sensor damage.
f.
f. Gas meters used for leaded gasoline shall be equipped with special filters to prevent damage to the sensor by lead resulting in reading errors.
g.
g. Gas tester wearing SCBA or carrying an escape mask shall test for Toxic gas, if the presence of toxic vapor or gases is known or suspected.
h.
h. Temperature and humidity are related to each other and do not have fixed limits. Precautions shall be taken such as air conditioning, work time adjustment, or special clothing depending on each situation.
8.7.3
8.7.3
ELECTRICAL ISOLATION (Section-4B)
a.
a. Before a Work Permit can be issued, it is essential to ensure that the equipment / facility to be worked on is electrically safe by isolating power to the extent necessary for the safe execution of the authorized work.
b.
b. Issuer, Executor and Electrical Maintenance shall jointly decide the extent of isolation required (see Chapter-14 for further details) and fill Section (4B) of the Work Permit for electrical isolation.
c.
c. Authorised person from Electrical Maintenance shall isolate electrical power of the circuit/equipment to be worked on after obtaining a separate permit, then close that permit and sign Section 4(B)i.
d.
d. “Not required” option can be used when the isolation is not applicable (i.e. the work is not connected to an electrical power supply) or when the particular work requires the power to be ON (ex: vibration monitoring, instrument checking, etc).
e.
e. “Use DO NOT OPERATE tag” option shall be used when isolation by local switch is decided as adequate protection. Executing authority shall fill and hang this tag at the switch (see Chapter-14, App-B).
f.
f. MULTILOCK SYSTEM shall be used when different crafts are involved. This is the safest way of ensuring protection from electrical hazards. If only Electrical Maintenance Division is involved they may use single lock. After installing locks and signing the permit, the keys of the locks shall be retained by the respective locking authorities until the job is completed.
g.
g. Keys shall be transferred and multilock signatures renewed when the permits are renewed. On completion of work, executor shall remove tag/lock and close the permit. Circuit shall not be re-energised until the permit is closed.
h.
h. WORK ON CATHODICALLY PROTECTED EQUIPMENT: Before any work is carried out on impressed current cathodically protected pipelines or tanks, prior notice shall be given to Corrosion Section who shall isolate the electrical current at least 24 hours in advance and bond/ground the equipment as necessary. Due to residence time, disconnecting the system will not immediately reduce the electrical potential to zero. No work shall be carried out until
Corrosion Section has declared it safe to avoid risk of sparking and consequent danger of fire. 8.8 8.8
COLD WORK PERMIT
A Cold Work Permit shall be obtained for all general work that does not involve activities related to hot work, i.e. the tools and equipment used or the work itself do not generate any spark. Ex: Routine maintenance, inspection and condition monitoring activities using non-sparking hand tools, intrinsically safe instruments or explosion proof equipment.
-
-
-
Excavation by hand tools, erection of scaffolds & barricades, chemical cleaning and use of air driven power tools which do not generate sparks during use.
-
Opening of process equipment such as, vessels, towers, pumps, compressors, heat exchangers, filters, tanks, etc.
-
Blinding (Spading), blanking, breaking of flanges and unions, tightening of flanges, hot bolting, tapping, cold cutting, hot work preparations, etc.
-
-
8.8.1
Industrial radiography using ionizing radiation source (excluding X-ray generators). 8.8.1
GENERAL REQUIREMENTS FOR COLD WORK
a.
a. Issuer shall ensure that, before issuing a Cold Work Permit, all necessary preparations are done to ensure that the work can be undertaken in a safe manner. These shall be ticked and/or stipulated in Sections 3 & 4 of work permit.
b.
b. Executor shall ensure that tools used do not produce any spark (ex. brass hammer, running water while concrete chipping, cold cutting or cold drilling with pneumatic drill).
c.
c. Executor shall indicate to issuer that his battery/electric-operated items are intrinsically safe or explosion-proof. Such certification shall be marked on the equipment by the manufacturer (Ex. suitable for use in Class 1, Div 1 or 2, Ex-i, Ex-d).
d.
d. Extra precautions for special or critical cold work are described in following paragraphs.
8.8.2 8.8.2 WORKING WITH RESPIRATORY PROTECTION IN OPEN AREAS Respiratory Protection section of chapter-5 (Section 5.11) shall be referred for further details on following clauses. a.
a. Respiratory protection will be required while working in open areas due to presence or the possibility of release of toxic/flammable gas during the course of work. Only trained personnel shall wear appropriate respiratory protection.
b.
b. Gas masks (canister/cartridge respirators) can be worn if the toxic concentration is known and not Immediately Dangerous to Life
or Health (IDLH, see Ch-20). Escape air mask or self-contained breathing apparatus (SCBA) shall be available for emergency use. c.
c. Airline Mask with escape cylinder shall be used if toxic concentration exceeds IDLH level. An attendant (standby man) ready with SCBA/ Air Mask shall remain in a nearby safe area, upwind of the job site and in line of sight of the work area, to undertake any rescue if required. He shall be equipped with proper means of communication with workers.
d.
d. The work area shall be barricaded with rope and warning signs shall be posted. The issuer shall inform ECCC operator prior to start of the work.
8.8.3 8.8.3 WORKING ON OR NEAR EQUIPMENT CONTAINING HYDROGEN SULFIDE Work on or near (but not inside) any vessel, pipeline, pump, etc., which had been in the service of products containing Hydrogen Sulfide (H2S) shall be handled with additional precautions. a.
a. All personnel working in an environment likely to be contaminated with H2S shall be trained and certified on emergency actions, use of respirators and their limitations.
b.
b. After the equipment has been depressurized and purged free of H2S, the flange, valve or manhole, as the case may be, shall be opened by persons wearing airline mask (or SCBA). After opening the flange, valve or manhole, the area in the immediate vicinity of the opening shall be checked for the presence of H2S.
c.
c. If the H2S reading is above 10 ppm, the use of airline mask or SCBA shall be continued during the work. If H2S is above 100 ppm, SCBA or “airline mask with escape cylinder” shall be used.
d.
d. If no H2S is detected in the vicinity of the opening, the enclosed space shall be checked for H2S using a long probe. H2S shall be less than 10 ppm for people to work without respiratory protection. Personal H2S alarm shall be used during such work.
8.8.4
8.8.4
WORKING WITH RADIOGRAPHY EQUIPMENT
a.
a. When an ionizing radiation source other than X-Ray generator is being used for industrial radiography, or while handling a radioactive source a Cold Work Permit is required in order to protect personnel from the hazards of ionizing radiation. X-Ray generators constitute a source of ignition and hence a hot work permit is required. See Chapter-20 and Inspection Procedure IC-37 for further details.
b.
b. Boundaries, based on maximum allowable radiation level of 0.25 mrem/hr (2.5microSV/hr) shall be defined and roped off. All personnel shall clear the roped area. Work shall be scheduled when the number of people are minimum in the area such as weekend, night or break times.
c.
c. Adequate warning signs on the outskirts of the roped area shall be provided. Warning flashlights shall be provided for night radiography.
d.
d. Authorised person shall announce start of the job and the duration, using plant paging/PA system and monitor the radiation at the boundary limit during radiography.
e.
e. Authorized person shall at all times be present on site in a safe area during radiography and the equipment shall never be left unattended.
f.
f. Personnel handling radiography equipment shall wear film badges and Dosimeters. Dosimeter readings shall be checked prior to and following the exposure in addition to weekly checks. All readings shall be properly recorded.
8.8.5
8.8.5
OIL PIER WORK
a.
a. Employees working on oil pier/ offshore shall wear life jackets wherever proper working platforms with guardrails are not provided (see Chapters 5 & 22).
b.
b. During mooring of a ship any person other than those required for mooring shall not be allowed to remain within ropes area.
c.
c. Any employee working below deck and away from proper platform shall be equipped with lifeline and safety harness/belt in addition to life jacket.
d.
d. Life buoys with 90 feet (27m) rope line shall be available or arranged at work location.
e.
e. Diving: Executor shall ensure that divers are qualified, trained and medically certified for diving with valid certifications. SCUBA diving should not be carried out in nighttime. In restricted water such as beneath pier structure, either a lifeline or the buddy system must be used (see Chapter-22).
8.9 8.9 8.9.1
HOT WORK PERMIT 8.9.1
GENERAL REQUIREMENTS FOR HOT WORK
a.
a. The issuer of the Hot Work Permit is responsible for ensuring that the site and the equipment (vessel, piping, etc) are properly prepared to prevent the danger of fire & explosion involving flammable material.
b.
b. Issuer shall ensure that, the equipment is emptied, cleaned of flammable materials and isolated from sources of hydrocarbons by means of disconnection, blanking or insertion of blinds. Isolation by closed valve only is allowed if, there is no other possible way of isolation and this has been approved by KNPC Safety.
c.
c. Issuer & executor shall ensure that, within 15 meter of a hot work site, any sample point, drain, surface manhole cover or relief valve outlet are covered to prevent the escape of flammable gas and vapors (sealed using flame-retardant tarpaulin, wet rags or metal plate). They shall also ensure that, these seals are maintained in good condition.
d.
d. If there are any open drains or ditches into which flammable liquid can escape, the same shall be dammed and pumped dry.
Outlets of all unit drains shall be plugged to isolate them from the rest of the sewer system. e.
e. Authorised Gas Tester shall conduct the test for flammable gases (%LEL) in a radius of 15 meters at location of work. (LEL 1% or less, see 8.7.2). LEL test is a must for all hot work including vehicle/equipment entry and use of battery/power operated ordinary equipment in hazardous area.
f.
f. Before hot cutting a long pipe, cold cut or hole shall be made to test combustible gases at the point of cut.
g.
g. Issuer & executor shall ensure that, heavy oil deposits, dried vegetation or other flammable/combustible materials within 8 meters of a hot work site are cleared.
h.
h. If hot work is to be done at height, then precautions shall be taken to prevent the spread of sparks and molten metal by surrounding the work area with fire-resisting/flame-retardant tarpaulin or metal sheets (more details on welding, cutting & hot tapping in Chapter-11). Proper ventilation/ air circulation for the welder should be ensured. Barricade should also prevent direct eye contact of others with welding arc.
i.
i. Executor shall arrange water for quenching sparks or molten slag and minimum of 2 fire extinguishers within 8 meters from the place of hot work. Extinguishers, hoses and nozzles in process area shall not be used for this purpose.
j.
j. Executor shall ensure grounding/bonding to avoid static (sand blasting, spray painting, refueling, etc.)
k.
k. Issuer shall inform the Fire Station (ECCC) about critical hot work (ex. welding in process area).
l.
l. Executor shall ensure that the work area be made safe at the end of the job/work-day.
8.9.2
8.9.2
VEHICLE ENTRY
a.
a. A Hot Work Permit is required for entry of all vehicles or mobile equipment into Division 2 hazardous areas. Such areas shall be clearly demarcated with signs indicating “No Entry of Vehicles without Permit” and/or with removable chain barriers.
b.
b. Executor shall ensure that all vehicles/equipment are fitted with exhaust spark arrestors of approved type and fire extinguishers with valid certification (see Ch-9, App-D).
c.
c. KNPC owned or leased equipment/vehicles or contractor's vehicle/equipment shall have a safety certificate when applying for a permit to enter or use in Hazardous Area. Certificate (or copy) shall be available with the equipment/vehicle (see Chapter-18).
d.
d. Issuer shall verify the validity of the safety certificate (Appendix3) and, indicate its number on the permit.
e.
e. Engine driven vehicles or mobile equipment shall not be allowed to enter Division 1 Areas (defined in Chapter-1). Use of gasoline or
gas powered engines shall be minimised in Division-2 Areas due to higher spark risk. f.
f. Driver should be given clear instructions on which route to follow and the field operator initial shall be obtained on the work permit before entering hazardous area.
g.
g. Assigned or pool cars, buses and other passenger transport vehicles shall not be allowed to enter hazardous area. Mobile equipment, lifting appliances and vehicles to load or unload material shall only be allowed.
8.9.3
8.9.3
USE OF PORTABLE INSTRUMENTS
a.
a. Electrical, Instrument, Inspection, condition monitoring and some other activities require use of battery operated portable instruments (meters). User Divisions should procure intrinsically safe instruments to carry out the work with a Cold Work Permit.
b.
b. Ordinary equipment is treated like any other source of ignition. These can be allowed for use in hazardous area with a Hot Work Permit, if intrinsically safe instruments for that particular application are not available in the market.
c.
c. Gas test shall cover entire area of use of such instrument. User of the instrument shall know the location of the nearest fire extinguisher. Requirement of dedicated fire extinguisher, tarpaulin barricade, water hose, covering drains, etc can be waived.
d.
d.
8.9.4
Users are recommended to carry personal LEL detector/alarm.
8.9.4
CONTROL OF IGNITION SOURCES
Use of lighters, matches, non-intrinsically safe personal pagers, mobile telephones, cameras, calculators and any other ordinary battery operated appliances are prohibited in hazardous areas unless approved by KNPC Safety/Security and a Hot Work Permit obtained. 8.9.5
8.9.5
OFFSHORE / OIL PIER HOT WORK
a.
a. In addition to requirements in (8.9.1) and (8.8.5), high degree of control and supervision is required to carry out hot work at the loading berths in the ports (oil piers and Sea Island).
b.
b. Hot work shall be prohibited within 30 meters of a ship being loaded, unloaded, or gas freed/ inerted.
c.
c. Issuing Authority shall liaise with the Captain if a ship has been berthed (but not engaged in loading/ unloading) within 30m of work site.
d.
d. The frequency of flammable gas monitoring should be established and portable continuous gas detector alarms shall be used if necessary.
8.10
8.10
CONFINED SPACE ENTRY AUTHORIZATION
A Confined Space is any space large enough for a man to enter where, there could be presence of hazardous material, or there is likelihood of deficiency of oxygen, or access or exit is difficult or restricted. Ex. vessels, tanks, furnaces, pits, manholes, sewers, excavation deeper than 1.2 meters, entry on floating roof tanks when the roof is more than 3 meters down from the top, etc. Work within a confined space requires a Confined Space Entry Authorisation in addition to the hot or cold work permit (see Chapter-7 for details). Serial number of work and entry authorisation permits shall be cross-referred in each permit. 8.11
8.11
EXCAVATION AUTHORIZATION
a.
a. An excavation authorization associated with the work permit is required for all excavations (see Chapter-13: Excavation and Civil Work for details). Copy of authorisation shall be attached to the work permit. Serial no. of authorisation shall be written against associated Excav no.
b.
b. A Cold Work Permit is required if non-sparking hand tools are being used for excavation and a Hot Work Permit if powered tools or mechanical equipment are being used (ex. jackhammer, backhoe).
c.
c. For excavations more than 1.2 meter deep a Confined Space Entry Authorization is also required (see Chapter-24).
d.
d. WAIVER : In emergency situations (e.g., rupture of a pipeline) an excavation may be required beyond the normal working hours or on weekends/holidays. In such cases the Shift Leader can waive the requirement for obtaining an Excavation Authorization for carrying out urgent repairs. He shall advise the issuing authority to issue Cold Work Permit without excavation authorisation to contain the emergency. “Waived” shall be mentioned against “Associated Excav No.” He shall inform the concerned Operation Supdt. (or GS) and KNPC Safety. Shift Leader shall countersign on the relevant permits. No mechanical excavations are permitted in such cases except, for the removal of concrete or asphalt.
APPENDIX - A “ COLD WORK PERMIT” (Color: light fluorescent green)
Ser. No:
Associated Excavn./Entry No.:
Continues from permit:
(. . . COLD WORK PERMIT
)
KUWAIT NATIONAL PETROLEUM C
1.(A) Exact Location (Area / Unit / Equip /etc.)................................................................................…….......... MAA MAB SHU LM Other….……….… (B) Description of Work (attach sketch if required)
(
... /
/
/
(
)
Using
(mention tools/ equipments) (
/
) ( )
(C) Issued to
Dept./ Div./
/
Craft/Contractor 2. Work is Critical Fire Station informed Issuer & Executor jointly checked work site
/
Tele:
/
Yes
No
Yes
Not
Required Yes Not Required 3 (
)
3. Safety Requirements (USE OF SAFETY HELMETS, SPECTACLES AND BOOTS IS MAN () ( ) Y (A) has the equipment Y (B) expected residual hazards Y NR (C) protection m NR been ? N /
/
/
isolated from power/steam/air
combustible gas &/or liquid
(
)
gloves (type.......….......... /
isolated from liquid or gases
lack of O2
/
ear plug / muff
/
depressurised &/or drained /
/
H2S/toxic gases...............
corrosive chemicals
goggles (....……... shield
/
blanked/ blinded/ disconnected / flushed / purged
( / ) ventilated (natural/mechanical)
/
pyrophoric iron / scales / electricity / static
protective clothin (..…............) /
dust / gas / air line safety harness & lifeli
/
cont. inert gas flow arranged
/ / heat/ steam / frost
/
standby mask
with
adequately cooled (
)
approved by Inspection
high humidity ionizing radiation
(see below)
......................................
......................................
liquid collector un /
fire extinguisher/ non-sparking tools / / barricade with tap /tarpaulin./............
Others / Details:................................................................................................................................................................... …............................................................................................................................................................................ See the back of this permit for additional requirements and other conditions. Inspection approval paper shall be attached for work on a corroded tank roof.
Not Required See associated Entry Authorisation
4.(A) Gas Test Comb Shift
H2S O2 % >19.5
LEL <10%
CO
ppm <10
SO2 ppm <2
ppm <25
Others
(B) Electrical Isolation Not
Required (or N/A)
Use
single lock (i) All electrical circuits / equipment have been isolated by: Emp. Name.
Us
Us
Emp. No
D
(ii) Multi Lock System Signature/Emp. No. Shift
Electrical Maint.
Mechanical Maint.
5. Authorization / Renewal (It is safe to proceed with this job) / Time Date / Shift From To
Issuer
6. Permit Closure
(A) Work Site handedover
Yes
Housekeeping done
No
in safe condition
Executor name
completed
Multilock Removed Emp.No.
Not applicable
Designation
Yes
No
stopped
No
Signature
Time
Date
Remarks:...……........................................................ ...............................................................................………………….
Tele.
(B) Agreed to above. Site was checked and found safe.
No
)
Yes
Field Operator signature/ Emp. No............................……………………
Issuer name
(
/
Designation
Signature
Time
Date
Tele.
Emp.No.
REV-1a/Sep 2002 "
DIAL " 888" IN ANY EMERGENCY "
APPENDIX - Bi (Back Of Cold Work Permit Form) GENERAL CONDITIONS OF PERMIT 1
1
Display the p ermit at work site with assoc iated authorisations.
2
2
Separate permits are required for different Maintenance crafts & jobs.
3
3 Only authorised personnel holding va lid "Work Permit Issuer/Exec utor" card can sign permit.
4
4 Only field operators/contractors with valid “work permit awareness training" card can sign respective column.
5
5 Only authorised ga s testers holding valid c ertification for gas test c an sign gas test.
6
6 Issuer may authorize work, only if the gas tests results are within the permissible range.
7
7
Me ntion C lear description of the work. Issuer or executor may fill Sec tion-1.
8
8 Issuer must fill or tick a ll relevant items from Sec tions 2 to 4. Spec ify add itiona l requirements under rema rks. Inform critic al work and roa d c losures to EC C C . (EC C C will inform Safety)
9
9 Operation's Issuer is responsible for safe ha nding o ver of equipment to Maintenance.
10
10
Field operator must check site and sign the permit before start of the work.
11
11 Exec utor must not start work before getting permit or on an inc omplete work permit.
12
12 Executor must provide adequate supervision and must be always present during critical work.
13
13 Exec utor must ensure providing a ll rec ommend ed protec tives before starting work and compliance to all permit conditions. He must ensure his people are wea ring appropriate PPE.
14 15 16 17
14
Suspend a ll work in ca se of plant emergenc y or ac cident.
15 Issuing Division a nd Safety personnel have the right to stop the job any time on safety reasons. 16
Field operator shall monitor permit conditions and site c onditions frequently.
17 Exec utor must rene w the permit if the work is 'stop ped ' or 'not started ' for over 2 hrs.
18
18 C lose the p ermit by co mpleting Sec tion-6 of original and field op erator copy. Keep in file for 1 month.
19
19 All tools and equipment shall be sec ured and personnel protec ted from falling objects.
20
20
Do not anc hor to or suspend loa ds on proc ess piping.
21
21
Do not use sca ffolds without valid green scaffold tag .
22
22
Do not use wood en p lanks in running units.
23
23
Any exemption shall be with prior approval of KNPC Safety.
SPECIAL PRECAUTIONS FOR COLD WORK 1
1 When using g as mask (Chemica l ca rtridge) in op en a rea , Esc ap e set or SC BA must be ava ilable for emergency.
2
2 In da ngerous (IDLH) atmospheres, use a irline ma sk (BA) with esca pe cylinder and attenda nt having BA.
3
3 Always wea r BA when disconnec ting flanges or opening manwa ys in lines/eqp t. containing H2S.
4
4 Radiographers must wear film badges and dosimeters. Provide radiation survey meter and ba rricade 0.25 millirems/ hr level a rea with warning signs.
5
5 Oil pier workers must wea r life jac ket wherever prop er platforms with guardrails are not provided.
. . .
-
-
-
-
-
-
-
-
-
-
-
-
-
-
/
.
. . . . -
.(
) . .
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
. . .
, .
. . . . .
.
. . . . .
( .
)
-
-
(IDLH)
-
-
-
-
-
-
-
-
. (
) . . .
/ .
APPENDIX - C “ HOT WORK PERMIT” (Color: light fluorescent pink-red)
Ser. No:
Associated Excavn./Entry No.:
Continues from permit:
(. . . ) HOT WORK PERMIT
KUWAIT NATIONAL PETROLEUM CO
1.(A) Exact Location (Area / Unit / Equip /etc.).......................................................................................……... MAA MAB SHU LM Other….………..… (B) Description of Work (attach sketch if required)
(
... /
/
(
)
Using
(mention tools/equipment & Safety Cert. No. if applicable) (
/
)
( )
(C) Issued to
Dept./ Div./
/
Craft/Contractor 2. Work is Critical Fire Station informed Issuer & Executor jointly checked work site
/
Tele:
/
Yes
No
Yes
Not
Required Yes Not Required
3 (
) 3. Safety Requirements (USE OF SAFETY HELMETS, SPECTACLES AND BOOTS IS MA () ( ) Y (A) has the equipment Y N (B) expected residual hazards Y NR (C) protection NR been ? /
/
/
isolated from power/steam/air
combustible gas &/or liquid
(
)
gloves (type.......…....... /
isolated from liquid or gases
lack of O2
/
/
depressurised &/or drained /
ear plug / muff /
H2S/toxic gases...............
corrosive chemicals
goggles (....… shield
/
blanked/ blinded/ disconnected / flushed / purged ( / ) ventilated (natural/mechanical) sewers & drains covered
/
pyrophoric iron / scales / electricity / static / / heat/ steam / frost
protective clothi (.….............) /
dust / gas / air li safety harness & li
/
eqpt. grounded/
combustibles removed from area
cont. inert gas flow arranged (
high humidity
fire extinguishe
ionizing radiation
fire watch
)
/
appr’d by Inspection (see below)
........................................
running/press /
engine with exhaust spark arrester & valid safety certificate
......................................
barricade retardant tar
Others / Details:................................................................................................................................................... .............................................................................................................................................................................. See the back of this permit for additional requirements and other conditions. Inspection approval paper shall be attached for hot tap, patch work on live lines and work on a corroded tank roof.
LEL TEST IS MANDATORY FOR ALL HOT WORK INCLU Not Required (only outside operation area)
4.(A) Gas Test
Continuous
monitoring See associated Entry Authorisation Comb Shift
O2 % >19.5
LEL <1%
H2S
CO
ppm <10
ppm <25
SO2 ppm <2
Others
(B) Electrical Isolation Not
Required (or N/A)
Use
single lock (i) All electrical circuits / equipment have been isolated by: Emp. Name. Emp. No
Use “D
Use Mul
Desig
(ii) Multi Lock System Signature/Emp. No. Shift
Electrical Maint.
Mechanical Maint.
5. Authorization / Renewal (It is safe to proceed with this job) / Time Date / Shift From To
Issuer
6. Permit Closure
(A) Work Site handedover
Yes
Housekeeping done
No
Multilock Removed
in safe condition
Executor name
completed
Not applicable
Designation
Emp.No.
Yes
No
Yes
No
Signature Time
Date
stopped
Tele.
Remarks:...……........................................................ ...............................................................................…………………. (B) Agreed to above. Site was checked and found safe.
(
Yes
No
Field Operator signature/Emp. No............................…………………… Issuer name
)
Designation
/
Signature Time
Date
Tele.
Emp.No.
REV-1a/Sep 2002
APPENDIX - D
DIAL " 888" IN EMERGENCY
"
"
(Back of Hot Work Permit form)
GENERAL CONDITIONS OF PERMIT 1
Display the p ermit at work site with assoc iated authorisations.
2
Separate permits are required for different Maintenance crafts & jobs.
3
Only authorised personnel holding valid "Work Permit Issuer/Exec utor" card can sign permit.
4 Only field op erators/ contrac tors with work "permit awa reness training" ca n sign respective column. 5
Only authorised gas testers holding valid certification for gas test can sign gas test.
6
Issuer may authorize work, only if the gas tests results are within the permissible range.
7
Mention C lear description of the work. Issuer or exec utor may fill Sec tion-1.
8
Issuer must fill or tick all relevant items from Sec tions 2 to 4. Specify ad ditional requirements under rema rks. Inform critica l work and road c losures to ECC C . (EC C C will inform Safety)
9
Operation's Issuer is responsible for safe handing over of equipment to Maintenance.
10 Field operator must check site and sign the permit before start of the work. 11 Executor must not start work before getting permit or on an incomplete work permit. 12 Executor must provide adequate supervision and must be always present during critical work. 13 Executor must ensure providing all rec ommended protec tives before starting work and complianc e to all permit conditions. He must ensure his people are wea ring appropriate PPE. 14 Suspend a ll work in ca se of plant emergenc y or ac cident. 15 Issuing Division a nd Safety personnel have the right to stop the job any time on safety reasons. 16 Field op erator shall monitor permit conditions and site c onditions frequently. 17 Exec utor must rene w the permit if the wo rk is 'stop ped ' or 'not started' for over 2 hrs. 18 C lose the p ermit by co mpleting Sec tion-6 of original and field o perator copy. Keep in file for 1 month. 19 All tools and equipment shall be secured and personnel protec ted from falling objec ts. 20 Do not anc hor to or suspend loa ds on proc ess piping. 21
Do not use scaffolds without valid green scaffold tag.
22 Do not use wood en p lanks in running units. 23 Any exemption shall be with prior approval of KNPC Safety.
SPECIAL PRECAUTIONS FOR HOT WORK 1.
Flamma ble Gas Test (LEL) within 15 meters is compulsory prior to any hot work. This includes vehicle entry and use of portable battery operated instruments.
2.
C over and sea l sewers, drains, vents or any other gas escaping po ints within 15 meters. Use flame retardant tarpa ulin for barrica ding.
3.
Issuer must check the Hot Tapping Authorisation form approved by all parties before authorising hot tap ping, pa tchwork on live lines and work on corrod ed tank roof.
4.
Positively isolate the line/ equipment by blinding for welding, cutting or grinding. C losing valve a lone is not ac c eptab le.
5.
C lear comb ustible material and heavy oil deposits within 8 meters.
6.
Ensure 2 fire extinguishers are available within 8 meters. Do not use unit extinguishers. Personnel engaged in the job must know ho w to use fire extinguishers.
7.
C arry out all po ssible fabrica tion and welding outside unit area . Limit site welds to minimum.
8.
Welder and helper must wear eye protection. Welder must use fa ce shield, which can be fitted to the helmet.
9.
Welders must wea r leather or flame resistant gauntlets/ gloves, ap ron and high safety boots.
10. Welder must use leather shoulder covers and ear plugs for overhead work. 11. C hec k the welding ma chine, terminals, cables & ca ble laying before start of work 12. Provide adequate ventilation or respiratory protection against welding fumes. 13. Field operator must guide the drivers on which route to follow when entering a unit. 14. Issuer must check valid safety certificate for mobile equipment and vehicles
15. Vehicle entry allowed only for loa ding and unloading a nd not for remaining in hazardous area or passenger transport.
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APPENDIX - E
“INSTRUCTIONS FOR FILLING WORK PERMIT”
HOW TO FILL WORK PERMIT FORM CW- Cold Work; HW- Hot Work, CSE- Confined Space Entry, P- Permit Fill carefully and accurately in clear handwriting giving all possible details. Permit is not valid unless sections 1 to 5 are filled (or ticked “Not Required”). Continues from Permit:… mention the serial number of previous work permit in this space. Associated Excavn./Entry No:.......... Mention Excavation Authorisation Number and attach a copy of same (and/or) mention Confined Space Entry Permit number and attach it with CWP/HWP. Mention associated CW/HW permit No. on CSEP. SECTION-1: A Mention exact location of work (i.e., name of area, unit and equipment number) ex. (MAA): RMP, CDU-4, V-40-001; (MAB): ARDS, Train-2, V-12-025; (SHU): Area-4, H-Oil, V-07-01A B Give precise description of work. Mention tools and mobile equipment used. Mention Safety Certificate number for engine driven equipment . Attach sketch/work procedure, if needed, to avoid miscommunication ex. Unbolting of bottom manway using Impact Wrench, Air Compressor - SS# 4561 ex. Blinding upstream of valve using hand tools C Write Executor’s Dept, Division, Craft and Contractor company name. Also write the telephone number of the executor. Issue separate permits for different crafts (electricians, scaffolders, fitters, etc). ex.(MAA): Maint. Zone-1, Utility, Kremenco; (MAB): Maint., Elect. Motor, IMCO; (SHU):Maint. Field, H-Oil SECTION 2 Issuer to inform location, description and commencing time of any critical work and road closures to ECCC (Fire Station MAA-1336; MAB-4111; SHU5517: LM-6500) who will inform the Shift Fire Officer and Shift Safety Engineer for necessary advice or assistance. Critical Work : hazardous work, which has the potential to cause fire/explosion, toxic release or immediate danger to life or property (ex. welding in process area, confined space entry, hot tapping, opening flanges on lines containing H2S and volatile hydrocarbons, blinding flare line, radiography, etc).
SECTION 3 A. A. Tick Y (yes) for the safe conditions that are required and already prepared for the intended job. Tick NR for the rest (means not required or not applicable). B. B. Tick Y (yes) for the residual hazards, which might be expected even after above preparation. Tick N (No) for rest.
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C. Tick Y (yes) for the appropriate protective measures. Strike off unwanted choices (Ex. dust/gas/airline mask). Write the specific type of protective equipment in the blanks, ex. gloves (..rubber..). Get help of executor for precautions on specialised jobs (ex. hot tapping, radiography, diving). Tick NR for rest.
Fill (or renew) Name & Employee No. of the standby person for Confined Space Entry Write additional remarks or requirements against “Others/ Details”. SECTION 4 (A) GAS TEST If gas test is "not required" tick the box and leave the rest blank (for hot work in non-hazardous areas only or for cold work ). For CW or HW associated with Entry, tick the box "See Associated Entry Authorisation" Tick box if continuous monitoring is required. Specify period (ex. every 2 hrs) when test are to be repeated during permit validity period In entry permit tick “pre-entry gas test” when entering for gas testing at 1 st entry. Values below each gas are limits you can allow people without respiratory protection except in HWP, where LEL limit is a requirement for allowing hot work. Issuer (if authorised) or any authorised gas tester under him can sign this section. SECTION - 4 (B) ELECTRICAL ISOLATION If isolation is “Not Required” or not applicable tick this box and leave the rest blank . If tagging is adequate tick “Use DO NOT OPERATE Tag”. If only electricians are working tick “single lock” and if other crafts are involve tick “multilock” i. Electrical Maintenance Division authorized person to isolate i. electrical power of circuit/equipment from main Distribution Panel/Substation, fill the relevant boxes and sign. ii. ii. If multilock system is used, each concerned person to sign his name and employee number after installing the lock. SECTION - 5 AUTHORISATION & RENEWAL Initial issue: Maximum validity must be for duration of work or until the end of the shift/ workday whichever is less. Issuer signs first followed by executor & contractor (if applicable). Then issuer must drop “Safety Copy” in the box provided. Issuer & executor must check readiness of the site before signing for critical work. Executor to take “original” & “Field Operator Copy” with or without “Issuer Copy” to obtain field operator signature (his signature on “Issuer Copy” is optional). Operator must check site, sign the permit and log it. All signatories: Clearly mention employment number. Make sure your authorisation/ awareness card is valid. Do not sign for duration beyond your work-hours. Renewal: Use the two renewals if the work continues and any of the signatories change shift or handover responsibility. Also renew if work in hazardous area is not started or is stopped
for over 2 hours within the executor’s workday. Incident Controller/SH&E clearance required for renewal after an incident/ stoppage due to safety reasons. Recheck site conditions and renew Sections 3 & 4 as applicable before signing this section of original & Field Operator Copy (issuer copy optional). Non-hazardous area permits can be reused next work day without closing.
SECTION - 6 PERMIT CLOSURE Fill this section both on the original and field operator copies (issuer copy optional). A To be filled by the executing authority (of last renewal). Tick appropriate boxes. Permit must be closed in hazardous area even if work is not completed and site must be left in safe condition. B To be filled by issuing authority (e.g. Operations Supervisor of last renewal) confirming that area has been cleaned and made safe from any hazard. CLOSED PERMIT TO BE FILED FOR AT LEAST ONE MONTH FROM DATE OF CLOSURE Rev2/Jan 2003
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APPENDIX-F
SAFETY AUTHORISATION CARDS
