Permit To Work: Practical Aspects

Learning objectives

Enabling Objectives:

At the end of training program participants would be able to:

›Understand the need & importance of PTW system.

›Differentiate between various PTW & choose right PTW for any work
›Understand role of different staff handling the PTW
›Understand various safety measures required for PTW for any work
›Understand Lock out Tag out (LOTO) system

Terminal Objectives:

›At the end of training program participants would be able to develop comprehensive
knowledge about PTW system , choosing right type of PTW & incorporating safety
measures to maintain safe environment .

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Road Map

›Introduction
›Elements of Permit to Work system
›Types of Permit to work
›Protection measures
›Lock out Tag out
›Conclusion

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Introduction

What is Permit to Work?

› It is a formal written system used to control certain types of work that are potentially hazardous.

Purpose of Permit

› Permit to work is plant operational safety management system

› It lay down specific procedures to achieve safety from the system
› Ultimate aim is to generate electricity in most reliable manner
› Maintenance & testing function carried out in safest possible manner is prime purpose of Permit to Work
system.
Simply put , purpose is to to provide safe system of work applied to individual task.

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Why work permit?

› Maintenance Personnel may not adequately familiar with process conditions.

› Basic purpose of permit system is to prevent injuries to personnel.
› Protect property from damage
› Avoid fire
› Ensure that all work is carried out in safest possible manner.
› permit specifies the conditions and procedure for safe execution.

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Applicability of Permit system

› Permit to work system apply to New plant & apparatus subject to safety rules clearance certificate has
been issued by responsible official & necessary instruction in this regard issued by management.

When Permit to work not required

› Works carried out by Operation Dept. as a part of routine operation.

› Fire station & Fire training

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Road Map

›Introduction
›Elements of Permit to Work system
›Types of Permit to work
›Protection measures
›Lock out Tag out
›Conclusion

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Elements of Permit system

In a good PTW system three elements are involved

› Safety documents & supplementary terms

› Identification of the persons & their responsibilities
› Full proof isolation system for work

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Safety document

PTW Safety documents are used for controlling maintenance or testing

PTW documents contain the following :

› Type of PTW
› Identification no of PTW
› Date & time of issue
› Clear identification of Plant , Unit , system & equipment on which maintenance or testing to be done
› Identification of all isolations required to safely carry out the maintenance or testing work
› Declaration about isolation & sign of Issuing authority.
› Acceptance with sign by Executing authority.
› Declaration of work completion by Executing authority with removal of Men & materials.
› Closure of PTW with sign & time & date.
› Provision of suspension of PTW.

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Safety Documents

PTW document may be supplemented as appropriate by some of the following forms:

› Selected person report.
› Earthing schedule
› Approved ROMP procedure
› Switching/isolation /earthing instruction sheet
› Safety precaution list

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Safety Documents -Supplementary forms

Selected persons report

› A report on the standard form giving specialist advises to the senior authorities persons preparing a safety
document where special hazardous exist. the report is only called foe by a senior authorities person and
prepared by a selected person.

Earthing schedule

› A standard form to be issued with any safety document where drain earths are also issued with the
document . the purpose of the schedule is to specify where & when drain earths are to be applied by
the competent person incipient during the course of work for which the document is issued.

Approved ROMP procedure

› A procedure detailing the approved method of restoring motive power during the course of the work for
which a permit to work with romp has been issued.

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Supplementary forms

4. Switching /isolation /earthing instruction sheet

› A standard form to be used when person are giving & receiving switching /isolation /earthing instruction.

5. Safety precautions list

› The safety rules call for a record of the safety precautions taken by an authorized person acting under
instructions from a control person to be recorded before the permit to work is issued. the authorized
person shall sign the record of the safety precautions & shall inform the senior authorized person of the
detailed safety precautions so that the permit to work can be prepared.

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Persons and Responsibilities

› Success of PTW system depends upon person involved in it.

› Identification of persons & their responsibilities is very essential.
› The range of persons recognizes in the safety rules is as follows:
• Competent person
• Authorized person
• Senior authorized person
• Control person
• Extra nominated person

Competent person

› Person having sufficient technical knowledge and/or experience to enable themselves to avoid danger
when nomina­ted may receive/transfer/clear specified safety documents. the departmental internal list
provides persons named have received the necessary training & can carryout the specific tasks
satisfactorily without danger to themselves or others.

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Persons and Responsibilities

Authorized Persons :

› Authorized person are competent persons .who have been further trained & then authorized by the
general manager or deputy general manager in writing to carry out duties specified in writing.

Senior Authorized Persons:

› A senior authorized person is an authorized person who has been nominated by the top management & is
trained person to carry out duties specified in writing including the preparation, issue cancellation of
specified documents on plant & apparatus within his area of authorization.
He shall decide which type of safety document to be issued depending upon the nature of work & decide
what category of person shall provide personal supervision when if is required.

Control persons:

› A control person is a person who has been nominated by the top management to be responsible for
controlling & coordinating safety activities necessary to achieve safety from the system. a Senior
authorized person shall also be a control person within the particulars plant/apparatus area of
authorization and to the limit of his authorization.

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Isolation for work

Isolation for work

PTW safety rules calls for

› The locking of breakers, valves, and dampers for the purpose of isolation .whenever required.
› This is to ensure the equipment is in operable and in turn to make the equipment/system safe for work to
be carried out on it.
› For this a locking system is to be made available.

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Persons and Responsibilities

Safety Locks:

› These are locks used for securing plant and/or apparatus in an isolated or earthed state.
› Each lock will be allowed to have only one key in' current use.
› Spare keys will be kept by Operation Incharge & will only be issued on positive proof of the absolute
necessity to do so.
› The point of issue of the safety documents will be the centre of use & control of these locks.
Key Safes (Lock out boxes) :
› These are an approved safe which is used to retain safety keys & some cases electrical fuses which are
forming part of an isolation within an adjacent control boundary
› The safes are numbered & each has fitted lock which are unique. the locks are identified along with then
keys safes are located at the parks which issue safety documents.

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Preparation of the equipment

› Equipment to be electrically isolated

› Inspection & testing for specified PTWs
› Isolated from water , steam, air & gas
› Steam , water, chemical etc flushed
› System to be depressurized
› System to be drained
› System positively isolated/blinded

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Roles in Preparation of the equipment

› Preparation, issue & cancellation of all documents is by senior authorized person.

› Transfer & suspension of any document (except Sanction for Test which not to be suspended) is also by the personal
supervision of senior authorized person.
› Sanction for test may be issued only by the senior authority person who prepare it & can be received only by an
authorized person.
› Hot work PTW is to be issued by Senior authorized person of SCE level.
› All other documents can be prepared by one sr. authorized person & issued by a different senior authorized person.
additionally all documents other than a sanction for test can be received by a competent person.
› Register of the preparation & issue of all safety documents will be kept at the points from which permits are issued.
The register will also contain the details of all document cancellati­ons. i.e. plant title & key safe & key no. will be in the
entry in the register along with the safety document number

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PTW Preparation : Key Points

In order to avoid misunderstanding which may endanger safety of persons :

› Legibility of safety documents at all times is of prime importance.

› The use of abbreviations on safety documents is restricted to these used in the actual plant labeling so
that the letters appearing on the document are the same as there on the plant.
› When completing the section of the safety document “state safety precautions applied" the individual
points of isolation must be detailed. the fixing of caution notices required by the safety rules must be
included in the appropriate section of the safety document.
› All PPE’s required for carrying out the job must be mentioned in PTW document
› PPE : Earthing equipments , safety belts, safety helmets, face shields, electrical gloves, gumboots,
breathing apparatus sets and others as per need.
› Request for a work permit is to be by executing authority. He shall indicate types of tools and equipment
necessary for performing the work.

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Basic responsibilities of issuing authority

› Authorized to issue and approve the permit.

› Fully aware of site conditions and permit requirements.
› Consult with Safety Dept. for safety requirements if required.
› Responsible to check all safety measures before signing the permit.
› Prior to approval the permit, Issuing Authority must visit the site along with Performing Party and ensure
that the site condition is safe for the work and fulfill all safety requirements.
› Can withhold the approval of the permit, if safety requirements are not fulfilled.
› To prepare the equipment and properly tick the checklist items
› To identify & indicate any residual hazard in PTW document.
› To advise on protective measures & mention in PTW document.
› To carry out all specific requirement of specified PTW and enter the result with sign, date & time
› To discuss & explain with/to executing authority all safety related salient points.
› Carry out electrical isolation whenever required.
› Close the permit when the job is complete or end of permit duration, which one is earlier.
› To preserve the permit for next one month at assigned place.
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Responsibilities of executing authority

› The recipient of the safety document shall sign the appropriate section & take it into the safe custody
together with the appropriate items issued with and listed on the document.
› It must be readily available for reference by himself & other possi­ble working parties.
› For work by competent person of different departments on one job, a separate document will normally be
issued. They may be issued different keys of key safes. This provides extra safe guard as plant/apparatus
can not be normalized till all keys of, key safes returned by all recipient.

Responsibilities of executing authority:

› To understand all safety measures required for carrying out assigned maintenance work or testing.
› To clearly understand the conditions of the equipment and residual hazards
› To discuss the with issuing authority and decide upon the protective measures.
› To describe the job and associated hazards to the workmen
› To ensure that all required PPE are being used while execution of work
› To ensure that safe procedure of execution are being followed
› To make the permit available at work site all the time
› To close the permit when the job is over or at the end of permit duration, which one is earlier.
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PTW transfer , cancellation & suspension

Transfer of document:
› Transfer of safety document from one recipient to another will be enacted by Sr. authorized person only
after making proper entry in PTW register.
› This is to ensure that the new recipient is made aware of any hazards or dangers existing.
Clearance and Cancellation:

› When work or testing has been completed or when a Senior authorized person requires a document to be
cancelled a competent person shall sign the clearance section confirming that all persons working or
testing under the document have been withdrawn & warned of not to continue.
› He will also certify whether or not the work place has been cleared of all tools, gear & loose material &
whether not all guards & access doors have been replaced.
Suspension of work permit

› All work shall immediately stop when a fire or emergency alarm is sounded or accident of any kind occurs.
› Approval from the Safety shall be obtained after necessary preliminary investigations, to resume such
work.
› The Work Permit shall be revalidated to resume the work.
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Validity of permit

› Work permit shall be initially issued for a period of 8 hrs. and shall be renewed for one more shift .
› On need basis , particular permit can be given for max. 7 days period.
› Clearance to be obtained in every shift.
› Clearance to be given after physically checking the site.

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Road Map

›Introduction
›Elements of Permit to Work system
›Types of Permit to work
›Protection measures
›Lock out Tag out
›Conclusion

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Basic type of permit to work

1 Work on or adjacent to plant 3and or HV apparatus with means Limited work certificate
of activity safety from the system by limiting the work or the
work area with instructions clearly defining the limits to that
require to be confirmed in writing.

2 Work when limiting the work as area is insufficient to achieve Permit to work
safety from the system permit o work

3 Work where limiting the work as work area is in sufficient to permit to work
achieve safety from the system & where it is essential to with restoration of motive
restore motive power supplies for certain approved work. power (ROMP)
permit to work with restoration of motive power (romp)

4 Testing plant and or HV apparatus where limiting the testing is Sanction for test (SFT)
insufficient to achieve safety from the system.

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Specific types of PTW

Hot work permit :

For welding and cutting, working with open flames or sparks due to grinding,
chiseling etc., or where hot work is dangerous or my cause fire, hot work or fire
permit is necessary.
› All flammable materials to be removed from the area, if not possible to be covered with tin sheets.
› Tests for explosive air mixture or possibility should be done.
› Sufficient vents and light shall be provided.
› Basic fire fighting equipments to be kept near the work area
› Return earthing cables to be provided along and insulated welding cable.
› Area to be barricaded ensuring good housekeeping
› All desired PPE’s should be provided to the workforce.
› Work should be carried out in presence of Fire staff

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Special requirements for hot work permit

› The person who authorizes the Hot Work Permit is responsible for ensuring that the site and the
equipment are properly prepared to prevent the danger of fire & explosion involving flammable material.
› The equipment shall be emptied and cleaned of flammable materials and isolated from sources of
hydrocarbons or explosive mixture.
› Equipment and surrounding areas shall be checked to ensure that they are free from any combustible gas.
Carry out gas test.
› Any heavy oil deposit, dried vegetation or other flammable / combustible materials within 8 m of a hot work
site shall be cleared away.
› No hot work shall be allowed within a radius of 15 m of any sample point, drain or relief valve outlet unless
precautions have been taken to prevent the escape of flammable liquids and vapors.

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Requirements for confined space permit

The “Confined Space Entry Permit” is another form of safe work permit
regulating entry into pits, tanks, and vessels.
› The process vessel / equipment is to be positively isolated if required by blinding.
› Shall be made safe for entry by depressurizing, venting, draining, steaming, washing and ventilating.
Radiation sources ,if any, shall be removed.
› The atmosphere within the confined space shall be checked initially and periodically. No toxic gas should
be present in confined space.(gas test).
› Equipment / Area to be made spark free particularly Electrical installations.
› O2 level to be measured & to be ensured to be adequate.
› Supervisory person needs to be stationed outside confined space.
› All desired PPE’s should be provided to the workforce & their use to be ensured.
› Work should be carried out in presence of responsible person
› Confined space trained person will only be allowed to enter inside.
› Entry and exit of the personnel must be monitored by a checker (Maintain Register).
› Emergency procedure required with every confined space permit.
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Test for hot work permit

Why gas test is required ?

› Most of the gases are unwanted

› Hazards involved ­
› Flammability(Fire & Explosion)
› Toxicity(health hazard)
› Oxygen Deficiency

For hot work :

› Combustible ­ Preferably NIL

For confined space entry :

› Oxygen ­ 19.5% minimum

› Toxic gases ­ Nil

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Test for hot work permit

All necessary test to be carried out to eliminate the following :

› Lack of oxygen
› Toxic gases
› Combustible gases
› Corrosive chemicals
› Steam / Condensate

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Permit for working at Height

› Proper staging and work platforms to be provided to work at height.

› Good quality Safety Belts, Helmets and shoes to be provided & being properly used.
› Please ensure safety belts are properly fixed.
› Safety net to be provided below work area.
› Minimum required persons should be on working platform.
› Person working at height should be medically fit to work at height.
› Area below should be barricaded,& in any case no work should be allowed to be carried out below during
height work in progress.
› Work should be carried out in presence of responsible person

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Excavation Work Permit

› Excavations can result in: Head Injuries from materials falling from overhead surfaces, rupture of high
pressure hydraulic lines used on backhoes, shovels, and drills or side walls can fall.
› Excessive noise from concrete breaking and cutting equipment, and collapse of excavation walls and piles
due to poorly secured soil, sudden weather changes, or other factors.
› Permits are written to ensure that necessary equipment is present and in good working order.
› Poorly planned excavations can result in damage to underground services, such as electrical lines, natural
gas lines, water lines, sewers and drains.
› All protective measures must be taken.
› Work must be performed in presence of responsible person.

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Road Map

›Introduction
›Elements of Permit to Work system
›Types of Permit to work
›Protection measures
›Lock out Tag out
›Conclusion

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Protection Measures

› Protective clothing
› Hearing protection
› Safety Helmet
› Safety belt
› Eye protection
› Face protection
› Respiratory protection
› Keep fire equipment stand­by
› Barricade the area

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Protection Measures

› Remove flammable and combustible

› Cover with fire retardant tarpaulin
› keep man ways open
› Allow minimum possible no. of persons at work area particularly in case of hot work , work at height ,
inside confined space
› To ensure positive isolation & maintain it all through
› Ensure adequate ventilation all through
› Keep copy of permit handy at work area.

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Road Map

›Introduction
›Elements of Permit to Work system
›Types of Permit to work
›Protection measures
›Lock out Tag out
›Conclusion

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Why Lockout/Tag out?

When someone will be servicing or repairing machinery or equipment

And

The unexpected machinery start­up or release of stored energy could cause injury

Lockout / tag out is performed to prevent injury to personnel or damage to property and or environment by
the unexpected release of hazardous energy / materials.

When planning a lockout, it is important to consider the nature of all hazardous energy / materials that may
be present.

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What is an energy-isolating device?

A device that physically prevents transmission or release of energy such as:

An electrical circuit breaker,

A pipeline valve,

A machine block

Anything else that positively blocks or isolates energy.

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Electrical lockout devices

Locked out circuit breaker

Locked out electrical panel

Locked out electrical plug 39

Fluid & gas lockout devices

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Pipe lockout examples

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Group lockout devices

Used when more than one person doing

maintenance or repair on same machine or
equipment.

Machinery or equipment can’t be started up until all

locks are removed.

Each person places and removes their own lock.

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Electrical isolation from energy

Lock Placement ­­ Locks must be placed on

main disconnect switches

NOT on control circuits

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Isolation from processes

Isolating Devices 44
LOTO - Devices

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LOTO - Devices

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LOTO - Devices

For a group lockout, each

authorized person must affix his or
her personal lock and tag before
beginning any work activity. All
authorized personnel must be
familiar with the deenergization
procedure.

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Isolation

› Separation of the equipment, machinery or area where

work is to occur, from sources of hazardous energy or
materials in such a way that only a conscious and
deliberate act can restore the connection.
› Confined spaces must be isolated from all external sources
of energy and materials.
› Pipelines attached to the vessel must be disconnected or
have a physical barrier present (e.g., blank or blind flange).
› Power­driven equipment that affects the space (e.g., an
agitator) must be mechanically and electrically
disconnected from the power source (e.g., physical
disconnection of motor leads) and tagged if the equipment
can feasibly pose a hazard during the entry, regardless of
whether the work involves that particular piece of
equipment.
› Tagging and Isolation is an extremely important part of
safely accomplishing a vessel entry. The vessel must be
completely isolated from all lines entering/exiting the vessel
and all moving/ rotating equipment must be de­energized 48
and disconnected.
Isolation

Agitators and fans must be secured from rotating and disconnected

from their drive mechanisms by one of the following:
Disconnect the drive coupling
Remove drive belts
Disconnect motor leads at the motor
The appropriate prime mover must be properly tagged.
The preferred method of isolation is that pipelines attached to
vessels shall be disconnected and blind flanged or capped.
The following alternatives are acceptable when approved by
the owner group and work group supervision.
Disconnection with full line diameter offset or frying pan
blanking is sufficient for lines carrying air or water at non-
hazardous conditions (less than 95F and 150 psig) or for
exhaust ducts and vent stacks.
Frying pan blanking alone may be used for isolating lines
provided that (a) the valve in the piping upstream of the blank
is closed and locked, and (b) the piping between the blank and
locked valve is vented by opening and locking a vent valve or
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disconnecting appropriate piping.
Isolation

Each person entering a vessel is required to place an individual

tag and lock at the lock out box for the inner circle and the
physical disconnect of any power drive that is not included in
the lock out box.
NOTE: When there are no locks in the inner circle it may not be
necessary to establish an inner circle lockbox. In this case all
entrants should hang a personal lock and tag on the outer
circle box.

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Lockout/Tag out & Confined Spaces

Lockout/Tag out is important in confined spaces

since it is easy to get trapped and hard to escape.
Pipelines leading into tanks must be blanked off
before entering the space.
All electrical and mechanical hazardous energy
must be addressed and locked out or tagged as
needed.

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Electrical energy isolation method

SL Electrical Energy Location of LOTO LOTO Isolation method

Source point
1 220KV source Breakers/Isolators on Lock Out & Switch Off and Isolate Control
respective panels Tag Out Supply
2 132KV source Breakers/Isolators on Lock Out & Switch Off and Isolate Control
respective panels Tag Out Supply
3 33kV, 6.6KV source Breakers on respective Lock Out & Rack out
panels Tag Out
4 415V Source MCC / PDB feeder Lock Out & Rack out / Fuse removal
Tag Out
5 415V or less Source DB / Power points / Lock Out & Fuse removal
with LO provision Control Panels Tag Out
6 415V or less Source DB / Power points / Lock Out & Switching OFF power from
without LO provision Control Panels Tag Out MCB/ELCB/ Isolator
7 Lighting circuit LDB Lock Out & Switching OFF power from
Distribution (230V) Tag Out MCB/ELCB/ Isolator
8 415V / 230V/110V Socket Lock Out & Removal of plug
sockets Tag Out
9 220V DC MCC / PDB feeder Lock Out & Rack out / Fuse removal
Tag Out
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Conclusion

› PTW system is very important for ensuring safety while carrying out any maintenance work or
testing.
› Role of all concerned in PTW system is equally important.
› Every particular job or testing require specific type of PTW.
› Identification & incorporation of specific safety measures for carrying out any particular
maintenance or testing is must.
› Specific types of PTW like Hot work , Working at height , Working in enclosed vessel etc require
specific safety measures & precautions.

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Any Questions Please

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Thank
You
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