Permit To Work Standard (PTW)
Training Module
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Safety Contact
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Work Permit System
ü Work Permit is a formal system used to control
certain types of work which are potentially
hazardous.
ü Work permit is a mean to communicate safe
working practices among site personnel to ensure
all necessary safety precautions are taken before
starting such work.
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Intent
To ensure that hazards are identified by area owners and necessary control
measures are implemented by executing agencies (KFIL / Contract) for safe
completion of work
Purpose
a) Ensure Safety of personnel
b) Avoid Damage to environment and assets
c) Comply with Statutory Requirements
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Concept of PTW
§ System is based on Custodian concept
§ Custodian is one responsible for operation
§ Custodian must know each & every activity being done in the custodian
area.
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Permit to Work – Why?
§ To identify HSE critical operations and installations
§ Control the risks through Risk Analysis and implementing preventive measures
§ To provide carefully planned system of checks and authorizations prior to carrying
out actual work.
§ All the work done in that functional area should have authorization of the
custodian.
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Scope
§ ‘Routine jobs’ that are potentially hazardous (viz., Preventive/
Breakdown maintenance),
§ Routine Jobs having no SOPs and SMPs in place that clearly identifies
the hazards involved and the controls steps to mitigate
§ Routine Jobs involving High risk activity viz.,
* Working at height
* Hot work
* Confined space entry
* Rigging and crane operation
* Working on electrical system
* Shutdown operations
§ Non -routine work viz., Modification, Projects etc.
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Exclusions:
§ Each unit shall prepare ‘list of activities’ where PTW not required and ratify
by SBU APEX Committee.
§ List of activities exempted for PTW shall be approved by Business Steering
Council (BSC).
§ PTW will not be required for works listed in the ‘Exception List’
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Guidelines for ‘Exception List’
§ Tasks considered so straight forward and low risks that are covered by
the general risk assessment (example: simple cleaning tasks).
§ Tasks formally risk assessed, procedure exists, personnel trained and
tested as competent to perform such tasks.
§ Such tasks can be carried through Limited Work Certificate (LWC)
without isolation.
§ Example-Trouble shooting, Testing LT current / Voltage, Vibration
Analysis, Lubrication, Checking molten metal temperature with
pyrometer, collecting sample
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Limitations:
§ Permit-to-work is NOT permission to carry out a dangerous job.
§ It should not be regarded as a way of avoiding the need to eliminate hazards and
reduce risks.
§ The issue of work permits does not, by itself, make a job safe or guarantee safety.
§ Safety Checks stipulated in a work permit are normally addressing those
foreseeable risks or hazards and they are by no means exhaustive.
§ Safety can be achieved : By preparing work procedure, methods, use of right
tools and use the right judgment for which they have been trained.
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The types of work permits
1. General Work Permit
It is the permit issued for jobs of general nature that do not involve any additional
high-risk activities like hot work, working at height, electrical work etc.
2. Special Work Permit : It is a supplement to general work permit
a. Hot work permit
b. Height work Permit
c. Confined space entry permit
d. Floor Opening / Hand Rail removal permit
e. Excavation Permit
f. Chemical work permit
g. Electrical Work Permit
h. Temporary Energization of Equipment/System
i. Emergency Deviation Approval
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Definitions
§ Initiator: Usually the Person-in-charge from the job executing/ working
agency having relevant educational background and total experience in the
trade,
§ Custodian: On-site senior employee, who is designated by the Plant Apex
committee, as an owner of a given unit / sub-unit
§ Issuer: An employee designated by custodian with relevant job experience
& authorized by Apex committee who will issue work permit for respective
area.
§ Authorized isolator is a person identified and authorized as per the
requirements in the LOTO standard.
§ Co permitee (permit holder) shall be a person from the work group
carrying out the job at site and who holds a copy of the PTW at site.
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Definitions ……….contd.
Competent person; Person having validated skills, knowledge, ability, training
and experience to perform the job safely and to recognize personal limitations in
these areas.
A competent individual has the following characteristics
Ø Knows the Construction and principle of operation of the equipment
Ø Knows and is skilled in the use of the work methods and safe work practices for
performing the task.
Ø Understands & recognize the hazards associated with the equipment.
Ø Is able to recognize and manage charging conditions of equipment or operation
Ø Knows the local legal requirements
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Obtaining a General Work Permit
Fills in PTW Section “A”, Job Details,
Initiator Time and duration, Equipment
Isolation required and other details.
Goes through list of isolation,
Identifies additional isolation /
safety measures, directs issuer to
Custodian provide required isolations & issue
permit to work
Goes through list of isolation,
Identifies additional isolation /
safety measures, Carry out
required isolations as per Section
Auth. Isolator Issuer “C” from authorized isolators.
Gives clearance to start the work
Briefs the job SOP, hazards, safety
Carry out actual isolations as per measures taken etc. to the work
Section “C” and as directed by issuer group along with the Co permitee
Initiator (permit holder). Handovers the
permit to the Co permitee (permit
holder) and allows the work to
Ensures all safeguards and control
proceed.
are maintained throughout the
duration of the job. Stops work
when conditions change or work
scope has changed. Carries out job Co
permitee(permit
holder)
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Closing a General Work Permit
Removes men and material from job
site. Takes sign of co-permittee and
put own signature (all copies).
Declare safe to restore isolation.
Initiator
Asks Respective Authorised Isolators
Issuer to restore Isolation as per Section “C”
General Work
Permit
Auth. Isolator
Ensures all isolations are restored.
Issuer Confirms restoration in Section “H”
& “I”; Closes the permit. Informs
custodian.
Files PTW for record as needed.
Carry out restoration isolations
as per Section “C” and as
directed by issuer
Initiator Files PTW for record as needed.
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Roles & Responsibilities - Custodian
He is responsible for the following:
§ Knowing the hazards including potential hazards and confirming that all
hazards associated with the work have been identified, assessed and
managed and all relevant agencies have provided their input and agree
with the precautions.
§ Knowing how to control and manage hazards.
§ Confirming that the permit accurately details the scope of works and that
the documented controls are adequate to ensure the work can be
undertaken and completed in a safe manner.
§ Signing the permit.
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Roles & Responsibilities – Permit Issuer
Responsible for the following:
• Knowing the hazards including potential hazards
§ Evaluating changes to conditions as a result of the work being performed
within the area
§ Verifying that the work area is safe to commence and carryout work, including
checking
§ Arrange for Authorized Gas Tester for Hot Work or Confined Space Entry
Permit
§ Ensuring that the permit accurately details the scope of works and that the
documented controls are adequate to ensure the work can be undertaken
and completed in a safe manner.
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Roles & Responsibilities – Permit Issuer Contd..
§ Ensuring that all necessary supporting permits, JSA etc are attached and
referred to in the permit.
§ All operational preparations, including process clearance have been
completed.
§ Communicate to those who may be affected by the work
§ Signing and issuing the permit.
§ Knowing the status of the work at all times.
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Roles & Responsibilities – Initiator
§ Permit acceptor shall be responsible for executing the entire work in full
Compliance with the permit requirements.
§ Understanding the potential hazard
§ Understanding how the hazards are controlled
§ Knowing the emergency situations likely to occur in the work area and actions
to be taken including evacuation procedure.
§ Ensuring that the Co permitee (permit holder) understands all the hazards and
controls,
§ Informing all people who may be directly affected by the work.
§ Play the role of Person-in-charge if LOTO is involved
§ Signing the permit, and also the ‘Declaration Form’ for LOTO, as required.
§ Knowing the status of the work at all times,
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Roles & Responsibilities – Co permitee /permit holder
§ The permit holder and the Work group member(s) who carry out the work
shall be responsible for commencing and completing the authorized
task
§ Knowing and understanding the potential hazards
§ Knowing and understanding how the hazards are controlled
§ Knowing how to use PPE and complies with the same
§ Knowing the emergency situations likely to occur in the work area and
actions to be taken including evacuating the area
§ Knowing the terms and conditions of safe work
§ Informing all people who may be directly affected by the work.
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Roles & Responsibilities – Authorized Gas Tester
& Fire Watch
§ Authorized Gas Tester and Fire Watch are required when performing Hot
Work and or Confined Space Entry
§ Authorized Gas Testers are additionally required to check atmosphere when
entering confined spaces which may have hazardous atmosphere (Oxygen
deficient, Toxic or Flammable).
§ Authorized Gas Tester
- Carrying out gas tests (oxygen, toxic and flammability % LEL) at the
frequency specified on the permit and supporting certificates.
§ Fire Watch
- Trained in Fire Fighting and fully competent to raise emergency response
in case of fire
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Temporary removal of Lockout and Tag out devices
(Energizing of equipment for test & trial)
If any equipment is required to be temporarily energized for test & trial, the steps
outlined in LOTO procedure(section 7.6) shall be followed.
§ Annexure – III shall be used for “Temporary removal of LOTO” for Test & Trial.
TEE
Please take note that:
§ The scope of General Work Permit should include “Test & Trial” when initiating
the PTW. If it is a change of original scope of the PTW, a fresh PTW shall be
issued.
§ Verbal Instructions shall not be accepted for temporary energizing of
equipment.
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Validity & Renewal of work permit
§ Permit shall remain valid for the duration of maximum 8hrs or end of shift
whichever is earlier
§ All previous day(s) or shift work permit need to renew at the start of the
shift.
§ General Work Permit shall be renewed whenever Issuer, Initiator or Co-
permitee (permit holder) are changed
§ While a permit is due for renewal and/or the permit is under renewal
process, Initiator shall not start working on the job.
§ Important: The validity of the special work permits will expire along with
the general work permit
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Cancellation of Work Permit
General Work Permit can be canceled by the Permit Issuer when:
§ Change of scope
§ Violation of permit conditions & safety requirements
§ Plant emergency
§ When canceling General Work Permit, the Special Work Permit
associated with the General Work Permit is automatically canceled.
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Distribution
§ First copy of the work permit and any attached permit(s) shall be with
initiator / Co permitee (permit holder) and shall be at job site.
§ The second copy shall be with Issuer displayed at Issuer’s designated area.
(Control room).
§ On completion of the work, both the copies shall be signed by the
concerned persons
§ The completed copy of the permit shall be retained in the permit file for 1
year for records.
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Permit Formats
General Work Permit Electrical Work Permit
General Work Electrical Work
Permit Permit
Hot Work Permit Excavation Work Permit
Hot Work Permit Excavation Work
Permit
Confined Space Entry Permit Working at Height Permit
Height Work
Confined Space
Permit
Entry Work Permit
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Exercise 1
Job Title – Ball Mill inside liner repair
Description – Mechanical personnel have planned
to inspect the entire liner inside ball mill for repair
purpose. The Ball mill has only one manhole for
entry. The Mill is driven by Electrical motor. The mill
is filled with 60% balls inside it. So, for inspection of
liner these balls have to be removed from Mill by
process department. The liner which are to be
repaired are made of steel plate which are welded
from inside.
Task – Take appropriate permit as per PTW
standard.
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Exercise 2
Job Title – Duct replacement
Description – Mechanical personnel have planned to
replacement MS duct of vessel located at 25M height
from ground level. The medium present inside duct
was SO2 gas. The duct weight which is to be replaced
was 10 Ton. So, crane was called for lifting activity.
Task – Take appropriate permit as per PTW standard.
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Exercise 3
Job Title – Fire Hydrant line replacement
Description – Under ground fire hydrant pipeline was
leaking near by IT department. So, fire department
had planned to be repair the pipeline which is 3 feet
below ground level near IT office.
Task – Take appropriate permit as per PTW standard.
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Exercise 4
Job Title – Gas duct cleaning in gas cleaning plant
Description – Mechanical personnel have planned to
clean inner surface of Equalization line which is at 22mtr
height having platform one side of the line. The medium
present inside was CO gas. The duct size is 800mm
diameter.
Task – Take appropriate permit as per PTW standard.
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Exercise 5
Job Title – Relining of blast furnace
Description – Plant is planning to repair / reline
the brick work inside the blast furnace. Blast
furnace height is 40Mtr and the inner diameter
5Mtr.The medium present inside the BF was CO
gas.
Task – Take appropriate permit as per PTW
standard.
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PTW Task Team
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