WORK

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

RADIATION WORK PERMIT( PINK & WHITE) BR:F&S:FR:18

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

Ventilated & gas freed

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

To ensure positive isolation & maintain

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

UEL(Upper Explosive Limit) :

The maximum vapor to air conc.above
which propagation of a flame will not
occur(will not ignite).
 GAS TEST CONTD.
Material LEL UEL F Pt.(C) AIT(C)
Hydrogen 4 75 Gas 585
Methane 5 15 Gas 538
Propane 2 9.5 - 104 466
Naphtha 1.1 5.9 - 18 288
ATK/ATF 0.7 5.0 35-50 210
Diesel 0.7 5.0 32-96 256
Fuel Oil 1 5.0 66 262-407
 GAS TEST CONTD.
Toxic substances :
TLV (Threshold Limit Value /
PEL(Permissible Exposure Limit) :
The maximum permissible conc. of a toxic
substance to which exposure of a person
will have no adverse effect on health for
working 8 hrs per day.
STEL(Short Term Exposure Limit) :
Maximum conc. to which worker can be
exposed for a period of 15 mins. without
any adverse effect to health.
 GAS TEST CONTD.
IDLH(Immediate Danger to Life & Health)
A maximum conc. from which one can
escape within 30 mins. without
irreversible health effect.

HYDROGEN SULPHIDE (H2S)

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

Fatal emergency over 700

Explosive limits : 4.6 to 46%, it gives blue

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

TOXIC GAS TLV STEL IDLH

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

Risk assessment through checklist

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

Permit has been closed by both issuing &

executing authority with date & time
Closed permits has been kept properly filed
and being preserved for next one month
 OPEN FIRE

PERMISSION-WEST SIDE OF RD.1 OR OUTSIDE

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

for hot /cold work

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

Request by executor(A grade and above) by filling all

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

Request by executor(A grade and above) by filling all

the entries clearance from EL maint./ Telecom.
Critical evaluation of 27 checklist items./ticking
Approved by GSI
Clearence from PN/Area in charge
On completion , permit closure and return to Fire
Station/ Area in charge.