PERMIT TO WORK SYSTEM

PERMIT TO WORK SYSTEM

INTRODUCTION:

On July 6, 1988, 167 men lost their lives as a result of an explosion and fire on board the Piper Alpha platform of the Occidental Oil Company in the North sea. UK. A public inquiry was set up, headed by Lord Collen to investigate the causes of the accident and make recommendations to prevent a repeat of such in the future. Lord Cullen concluded with 106 recommendations and located that the failure of proper management of the Permit To Work (PTW) was a major cause of the disaster.

The Petroleum Industry and many Chemical industries handle large quantities of flammable and toxic materials, so they  have very high potential for serious accidents. Safe system of work must then be in place.

Permit To Work (PTW) system  is not simply permission to carry out a dangerous job; it is part of as system which determines how a job should be done safely. A part of the HSE management system.

DEFINITION:

WHAT ARE PERMITS-TO-WORK?

A permit-to-work system is a formal written system used to control certain types of work that are potentially hazardous.

 A permit-to-work is a document which specifies the work to be done and the precautions to be taken. Permits-to-work form an essential part of safe systems of work for many maintenance activities.

 They allow work to start only after safe procedures have been defined and they provide a clear record that all foreseeable hazards have been considered.

PTW gives a clear indication of who may authorize particular jobs, the limit of their authority, and who is responsible for specifying the necessary precautions.

It covers training and instructions in the issue and use of permits

It also incorporates monitoring and auditing to ensure the system works as intended.

It ensures that there  are clear identification of who is responsible for specifying the necessary precautions (eg isolation, emergency arrangements, etc.)?

A permit is needed when maintenance work can only be carried out if normal safeguards are dropped or when new hazards are introduced by the work. Examples are entry into vessels, hot work and pipeline breaking (like hot tap).

THE PROBLEM

An HSE survey showed that a third of all accidents in the chemical industry were maintenance-related, the largest single cause being a lack of, or deficiency in, permit-to-work systems.

In a study of small and medium-sized chemical factories:

·          two-thirds of companies were not checking systems adequately;

·          two-thirds of permits did not adequately identify potential hazards;

·          nearly half dealt poorly with isolation of plant, electrical equipment, etc;

·          a third of permits were unclear on what personal protective clothing was needed;

·          a quarter of permits did not deal adequately with formal hand-back of plant once maintenance work had finished;

·          in many cases little thought had been given to permit form design.

While aimed primarily at the chemical industry the guidance provided may have application in other industries.

ASK THE FOLLOWING QUESTIONS IN YOUR PLANT: 

1.       Is the permit-to-work system fully documented, laying down: - how the system works; - the jobs it is to be used for; - the responsibilities and training of those involved; and how to check its operation?

2.       Is there clear identification of who may authorize particular jobs (and any limits to their authority)?

3.       Is the permit form clearly laid out?

4.       Does it avoid statements or questions which could be ambiguous or misleading?

5.       Is it designed to allow for use in unusual circumstances?

6.       Does it cover contractor selection and training?

7.       Are those who issue permits sufficiently knowledgeable concerning the hazards and precautions associated with the plant and proposed work? Do they have the imagination and experience to ask enough ‘what if’ questions to enable them to identify all potential hazards?

8.       Do staff and contractors fully understand the importance of the permit-to-work system and are they trained in its use?

Description of the work

·         Does the permit clearly identify the work to be done and the associated hazards?

·         Can plans and diagrams be used to assist in the description of the work to be done, its location and limitations?

·         Is the plant adequately identified, eg by discrete number or tag to assist issuers and users in correctly taking out and following permits?

·         Is a detailed work method statement given for more complicated tasks?

Hazards and precautions

·         Does the system require the removal of hazards and, where this is not reasonably practicable, install effective control? Are the requirements of The Control of Substances Hazardous to Health Regulations 1999 (COSHH) and other relevant legislation known and followed by those who issue the permits?

·         Does the permit state the precautions that have been taken and those that are needed while work is in progress? For instance, are isolations specified and is it clear what personal protective equipment should be used?

·         Do the precautions cover residual hazards and those that might be introduced by the work, eg welding fume and vapor from cleaning solvents?

·         Do the Confined Spaces Regulations 1997 apply? If so, has a full risk assessment identified the significant risks and identified alternative methods of working or necessary precautions?

 Major hazards could arise from the following:

·         Wrong type of work permit used;

·         Wrong information about work required on the work permit;

·         Failure to recognize the hazards where work is carried out (e.g. flammable substances);

·         Introduction of ignition source in controlled flameproof area (e.g. welding, non spark-proof tools, non-intrinsically safe equipment used in intrinsically safe zones);

·         Terms of work permit not adhered to (e.g. failure to isolate plant and/or drain lines of hazardous substances);

·         Failure to hand-over plant in safe condition on completion of work/cancelling of work permit;

·         Unauthorized staff performing work permit functions;

·         Poor management of the work permit system; and

·         Insufficient monitoring of the work permit system.

PROCEDURES:

1.       Does the permit contain clear rules about how the job should be controlled or abandoned in the case of an emergency?

2.       Does the permit have a hand-back procedure incorporating statements that the maintenance work has finished and that the plant has been returned to production staff in a safe state?

3.       Are time limitations included and is shift changeover dealt with?

4.       Are there clear procedures to be followed if work has to be suspended for any reason?

5.       Is there a system of cross-referencing when two or more jobs subject to permits may affect each other?

6.       Is the permit displayed at the job site?

7.       Are jobs checked regularly to make sure that the relevant permit-to-work system is still relevant and working properly?

ESSENTIALS OF THE PERMIT-TO-WORK FORM

·         The permit-to-work form must help communication between everyone involved. It should be designed by the company issuing the permit, taking into account individual site conditions and requirements. Separate permit forms may be required for different tasks, such as hot work and entry into confined spaces, so that sufficient emphasis can be given to the particular hazards present and precautions required.

·         When a large number of active permits are in force, then the administration of the permit system and control of work may be enhanced by color combinations.to distinguish between the permits issued for different types and degree of potential hazard. It is recommended that the method of differentiation adopted should be consistent within the company.

·         Keep the form simple and user friendly

·         The essential elements of a permit to-work form are listed in the diagram. If your permit does not cover these it is unlikely to be fully achieving its purpose.

PERMIT TITLE		PERMIT NUMBER: Reference to other relevant permits or isolation certificates
3	JOB LOCATION
4	Plant Identification
5	Description of work to be done and its limitations.
6	Hazard identification - including residual hazards and hazards introduced by the work
7	Precautions necessary - person(s) who carries out precautions, eg isolations, should sign that precautions have been taken
8	Protective Equipment
9	Details of work party and tools to be used
10	Details of potential hazards and precautions taken
11	Authorization - signature confirming that isolations have been made and precautions taken, except where these can only be taken during the work. Date and time duration of permit
12	Acceptance - signature confirming understanding of work to be done, hazards involved and precautions required. Also confirming permit information has been explained to all workers involved
13	Extension/shift handover procedures signatures confirming checks made that plant remains safe to be worked upon, and new acceptor/workers made fully aware of hazards/precautions. New time expiry given
14	Hand back - signed by acceptor certifying work completed. Signed by issuer certifying work completed and plant ready for testing and recommissioning.
15	Cancellation certifying work tested and plant satisfactorily recommissioned

PERMITS  SAVE  LIVES - GIVE THEM PROPER  ATTENTION

RESPONSIBILITIES:

Installation owners should ensure:

·         An appropriate PTW system is introduced

·         Training programs and competence standards are established and maintained

·         Monitoring and auditing and reviewing of PTW system is established and maintained.

Installation Managers should ensure:

·         All personnel who operate PTW system are competent to do so

·         Proper coordination of planning and issue and return of permit.

·         Secure methods of Electrical, process and mechanical isolations

·         Effective transfer of information on outstanding permits during shift change

·         PTW system is monitored regularly and system implemented effectively.

Contractor’s Management should ensure that:

·         They are informed of and understand the broad principles of the PTW for the location

·         Their employees have been given appropriate training and understand the operations of the PTW system and their specific responsibilities.

·         They monitor the training of their employees.

THE PERMIT ISSUER should ensure:

·         All understand the nature of the work

·         All hazards associated with the job are identified

·         All necessary precautions are taken

·         All isolations are effected before work begins

·         All who could be affected by the work are informed before the work starts

·         All who could be affected by the work are informed when the work is suspended.

·         All who could be affected by the work are informed when the work is completed.

·         That where permits interact they are cross referenced

·         That work site is inspected before work begins and if suspension occurs and when work is completed.

·         During Shift hand over sufficient time is given for discussion of all on going or suspended permits with the on- coming permit issuer.

Person in-charge of the work (SUPERVISOR) should ensure:

·         They have been well trained in PTW as applicable to that location

·         They discuss the job thoroughly with the person issuing the permit

·         Adequately instructs his workers. Briefs them on the details of the permit including any potential hazard and all the precautions taken or to be taken

·         That the precautions are maintained throughout the work duration

·         The permit is posted at the work site

·         The workers understand that if conditions change, the work must be stopped and advice sought

·         The work party stays within the limitations of the permit-Physical boundaries, type of work and validity time.

·         On completion or suspension  and the permit issuer informed of work, the site is left in a safe condition

INDIVIDUALS WORKING within the PTW system should ensure:

·         That they have received instructions and have good understanding of the PTW system at the installation where they work.

·         They do not start a job that requires a permit until they have been properly authorized.

·         They receive briefing from the supervisor on the particular task and they understand the hazards and precautions taken or to be taken

·         They follow the instructions specified in the permit

·         When they stop work, the site and equipment they are using are left in a safe condition.

·         If in any doubt or if circumstances change, they must stop work and consult with their supervisor.

 CASE STUDIES TO BE DISCUSSED.