Work Permit System Conversion Course--Final.pptx

2
Simplifying the process
Course Objective
To train existing Issuers & Executors
regarding changes on the revised Work
Permit & Risk Assessment procedure (revision
# 6A of ‘SWP on Work Permit System & Risk Assessment’)
At the end of this training a test will be
conducted (duration: 10 minutes);
Passing marks: Min. 80%
Validation

3
Instruction design
Sr.# Topic Time
1. Risk picture 3 min.
2. Recap of Work Permit System 3 min.
3. Revised Work Permit form – ‘Find the change’ Exercise 7 min.
4. Significant Changes 95 min.
a) Risk based categories of work 5 min.
b) Definition of ‘Medium Risk Work’ category & list of
works predetermined as medium risk works
7 min.
d) ‘SWP Checklist format’ 5 min.
e) Definition of ‘Critical Work’ & list of works
predetermined as critical works
6 min.
f) Supervision of Medium Risk Works 7 min.
3 min.
g) Supervision span for Critical Works

4
Instruction design
Sr.# Topic Time
h) Extended validity of work permits during shutdown &
for special tasks
6 min.
4 min.
i) Continuation of work (for 2 hrs.) during renewal when
Issuer change
j) Authority to approve Contractor personnel as ‘Work
Permit Executors’
5 min.
Break (optional) 10 min.
k) Exercise—SWP Checklist 10 min.
l) Case Study &
Improved CTRA (WPRA) Procedure & Exercise
20 min.
m) Other minor changes 7 min.
6. Review & Conclusion 2 min.
7. Test 10 min.
Total --- 120 min.

5
Risk picture Enterprise risks
Operational risks
HSE risks
OHS risks
OHS risk control tools
WPRA
(Changed to
CTRA)
Work
Permit
SWP
OHS RR

6
Hazard Identification & Risk Assessment tools
Hazards &
risk
controls
for all
activities
(routine &
non-
routine)
Hazards
associated
with a specific
activity & risk
control
measures for
the same
(generic)
Hazards
associated
with a specific
activity
(maintenance /
construction
activities) & risk
control
measures for
the same
(specific to location /
equipment)
Additional
HIRA tool
for critical
works
WPRA
(Changed
to CTRA)

7
Introduction & Background
A set of risk control tools (explained in previous slide)used @ KNPC
for carrying out routine & non routine activities
All these four tools are closely interconnected
Work Permit system is one of the key risk control tools
KNPC Work Permit System is unified across the refineries
Work Permit document revised recently with the objective of simplifying
the work permit procedure
This course covers changes done in the revised document ‘SWP on Work
Permit system & Risk Assessment

8
Work Permit system --- Recap
Work Permits /
Authorizations/
Certificate
Cold Work
Permit
Hot Work
Permit
Confined Space
Entry
Authorization
Excavation
Authorization
Vehicle
Safety
certificate

9
Work Permit system --- Recap
Work
Permit &
Risk
Assessment
procedure
Work
requiring
Permit Work not
requiring
Permit
Signing
permits-
Basic
requirem
ents
Who can
be the
Issuer /
Executor
Issuer &
Executor
responsib
ilities
Gas
Testing
?
Electrical
Isolation
Cold Works
& Hot
Works-
General
requirement
s
Confined
Space
Entry &
Excavation
Radiograp
hy, Oil
Pier work
WPRA
(renamed
CTRA)
procedure

10
Work Permit---Revised format
Can you identify the changes / addition in the revised format?

12
‘Find the change’---Group exercise

13

14

15

16

17

18

19

20

21

22

23
Significant changes
1. Risk based categories of works (maintenance / construction
works)
2. Definition of ‘Medium Risk Work’ category & list of works
predetermined as medium risk works
3. ‘SWP Checklist format’
4. Definition of ‘Critical Work’ & list of works predetermined as
critical works
5. Supervision for medium risk works
6. Supervisory span for critical works

24
Significant changes (contd.)
7. Extended validity of work permits during shutdown & for special
tasks
8. Continuation of work (for 2 hrs.) during renewal when Issuer
changes
9. Authority to approve contractor personnel as work permit
Executors
10. Improved CTRA (WPRA) procedure & compliance to KPC HSSE
Risk Assessment Matrix
11. Other minor changes

25
1. Risk based categories of work
Low Risk
Works
Medium
Risk Works
Critical
Works (i.e.
High Risk)
WP
WP +
SWP CL
WP —Work Permit
SWP CL — SWP Checklist
CTRA — Critical Task Risk Assessment
WP +
SWP CL+
CTRA

26

27
All works (maintenance, construction & non-routine
works)
• with a potential risk level of ‘Medium’ as defined in
the Risk Assessment Matrix and
• with hazards whose consequences are comparatively
severe even though the ‘likelihood’ is low (A list of such
predetermined works is listed in the next two slides)
2.Medium risk works

28
1. Lifting activity (for non-critical lifts as defined in SWP on Lifting Appliances & Tackles)
2. Hydro testing
3. Excavations-less than 1.2-meter depth, if they are decided as
‘medium risk’ & not ‘Critical’ by the asset custodian
4. Line breaking where there is no potential for IDLH exposure to
toxic gases, fire, explosion, injury
5. Working at height below 6 feet fall possibility
6. Welding, grinding, hot cutting in process units (where the line / equipment is
positively isolated, gas freed and the precautions in hot work permit & SWP checklist are sufficient)
7. Preheating and Heat Treatment (Stress Relieving)
8. Radiography
9. Abrasive blasting
10. Hydro jetting / Hydro blasting
2.Predetermined Medium Risk Works

29
11. Initial entry into any confined space is always considered a Critical
work. After the initial entry, entry into any confined space which
meets the following criteria may be downgraded from critical work
to medium risk work
 The space is positively isolated & fully cleaned
 The atmosphere in the space is not hazardous and it has no potential to contain a
hazardous atmosphere due to its contents
 There is no potential for a hazardous atmosphere to develop due to the nature of work
to be done (i.e. adequate control measures in place to avoid a hazardous atmosphere)
Downgrading of confined space entry from critical work to medium
risk work shall be decided by a team consisting of Section Head /
Senior Engineer and Area Safety Engineer.
12. For any other activity for which it is determined by the Issuing
division or executing division that a checklist is required
• Filling & signing of SWP checklist by Executor to be done at least once a day
• Whenever the compliance to control measures in SWP checklist becomes not
possible, the work becomes ‘Critical Risk work’.
2. Predetermined Medium Risk Works (contd.)

30
3. Safe Work Practices Checklist

31
Works (maintenance, construction & non-routine works)
• with a potential risk level of ‘High’ as defined in the
Risk Assessment Matrix and
• with hazards whose consequences are most severe
even though the ‘likelihood’ is low (A list of such predetermined
works are listed in the document)
4.Critical Works (High risk works)

32
1. All confined space entries, from the first entry till they meet the
criteria to declare them as ‘medium risk works’
2. All inert confined space entries
3. All pneumatic testing
4. Hot tapping & Welding on live piping and equipment
5. On line leak arresting
6. Tie-in (by hot work) on hydrocarbon contaminated lines
7. Working at height over 6 feet fall possibility
(such as scaffold erection, de-erection, working on pipe rack without working
platform & without scaffold, working on crane man basket & man lift)
8. All excavations whose depth is more than 1.2 meter and excavations
where live underground installations are detected / located
4.Predetermined Critical Works

33
4.Predetermined critical works (contd.)
9. Any work such as opening flanges where there is a potential for oil
spill / leak, injury to personnel, fire, explosion, exposure to toxic
gases at IDLH concentration, exceedance of legal limit
10. Blinding flare line
11. Critical lifts (simple, complicated & complex critical lifts as defined
in SWP on Lifting Appliances & Tackles)
12. If the hazards associated with any activity are not known (and if the
hazards covered by the work permit & checklist are not
comprehensive), then that activity shall be considered as critical
work
13. Any work which is not done before & which is not covered by any of
the existing KNPC Safe Work Practices / Guidelines
14. Any other activity (other than the above) which is determined by
the issuing division or executing division as critical work

37
As per revised procedure (Rev. # 6A)
For Medium risk Work:
For medium risk works the Executor shall assign a person in the working crew
(to supervise the work, whenever the Executor is required to move to other job locations within in the vicinity),
with the following conditions: He shall
• be at the level of foreman or below (in any case not below GFT level)
• be the one who can understand permit conditions, control measures, who
can recognize abnormal condition developing and emergency situations
• be capable of communicating with others in case of abnormal condition
/emergency
• be approved by executing division Team Leader
• have completed work permit level-II training and shall hold a valid training
card for the same
• Shall be explained by the Executor about the requirements of the issued
work permit before start of the work
• be named in the permit
5. Supervision of Medium Risk Works

38
6.Supervisory span of critical work
As per current procedure (Rev. # 5) As per revised procedure (Rev. # 6A)
For Critical Work:
• Executor shall not sign more than one
critical work permit unless it is in the
same location/vicinity.
For Critical Work:
• One Executor can sign only one critical
work permit.
• Any increase of this number to be
decided by CTRA team
• Can be increased up to a maximum of 3
critical work permits per Executor.

39
7.Extended validity of work permit
This procedure may be utilized during:
• Turnarounds
• new projects (in green field & PD controlled fenced area--on a case to case basis after approval
of TL, Safety Projects)
• long term works like tank maintenance (on a case to case basis after approval of TL, Safety)
This procedure is not applicable to Confined Space Entry authorization

40
Permit renewal sheet

41
Permit renewal sheet (contd.)

42
change
During turnarounds when the Issuer changes, the following procedure may be
utilized, with the conditions given below:
 the outgoing Issuer shall inform the incoming Issuer about the works which will
continue without renewal for 2 hours, as part of the relieving; such works will be
mentioned during shift relieving and the same shall be logged in their log book
 the Executor can continue the work for a maximum period of 2 hours, without
renewal
 the incoming Issuer who takes charge shall renew such permits by visiting the
site within 2 hours
 utilization of this procedure shall be only for specific low & medium risk works
 such specific works for which this procedure may be applied shall be approved
by the Section Head in consultation with the Area Safety Engineer
This procedure is not applicable
 during normal running of units
 is not applicable for critical works
 when both the Issuer & Executor change or only when the Executor change

43
9. Authority to approve contractor personnel
as work permit Executors
Approving authority
As per current procedure As per revised procedure
(Rev. # 6A)
DCEO of the respective
directorate DCEO of respective directorate
or
a person delegated by DCEO
(Manager or Team Leader level and not
below Team Leader level)
Dept. Manager (in case of
Projects directorate only)

44
SWP Checklist (sample)

45

46

47
SWP Checklist

48
SWP Checklist (example checklist)
SWP checklist for hydro blasting to be filled

49
Case Study-I
FATAL INCIDENT AT TK-61-668-- MAA REFINERY
19.202
M
58.12 M

50
Location of Incident : KNPC - MAA Refinery
Exact Location : Tank TK-61-668
Date of Incident : Saturday, 16th January 2016
Time of Incident : 12:45 hrs.
Type of Incident : Fatal injury due to fall from height
Designation : Scaffold Erector of M/s. Almen
Brief description :
At around 12:45 hrs. the deceased person (not having CSE authorization card) who was
working inside the tank fell 18 meters through an unprotected opening on the top
platform of the scaffolding to the bottom plate and was seriously injured.

53
Case Study-II
FIRE AT SEA COOLING WATER RETURN BASINS AT MAA REFINERY (AUGUST 2014)

55
CTRA shall be done each time the work is done. This is necessary
because this will
a) provide an opportunity for identifying any changes in the site condition
(i.e. work environment)
b) provide an opportunity for identifying hazards which are not identified
earlier
Old CTRA can only be referred in future if the same job is repeated
When the site condition changes or in case of any emergency,
continued compliance to CTRA conditions shall be reconfirmed by
Issuer & Executor before recommencement of work.
Wok Permit Risk Assessment (WPRA) is renamed as
Critical Task Risk Assessment (CTRA)
10. Improved CTRA (WPRA) procedure

56
CTRA (WPRA) steps
Identify the hazards
Specify existing controls
Assess initial risk
Determine additional controls if
risk is medium or high
Reassess risk with additional
controls in place

57

58
CTRA (WPRA) Matrix – Likelihood descriptors

59
CTRA (WPRA) Matrix – Consequences Descriptors

60
CTRA – Actions for Different Residual Risk Level
Residual Risk Level Action Required
Low One can proceed with the work
Medium CTRA Team leader to consult
his/her superior, reassess &
determine further additional
control measures which may
reduce the risk to low. If risk is
reduced to low, then do the job.
High Stop the Job; It is too dangerous;
find out some alternate safe
method/safe timing (such as during
shutdown) doing the job

61
CTRA shall be reviewed when
1. when the scope of the job changes
2. when the site condition changes
3. when any new hazard (which is not identified during the
CTRA) is identified during the course of the job
4. when any accident happens during the job
5. as per the review frequency decided by CTRA team for long
duration critical jobs
CTRA (WPRA) review

62
Responsibility For Conducting CTRA
For Planned Jobs :
Sr. Level are Leader of CRTA Team & Team Members are Engineers,
Controllers, Supervisors, Safety Engineers, Contractors Representatives,
Rescue Coordinator for CSE works and any other personnel
For Unplanned Jobs:
Controller –I – Leader of CRTA Team, Controllers, Supervisors, Safety
Engineers, Contractors Representatives, Shift Fire Officer for deciding
Rescue Team requirement and any other personnel

63
CTRA format

64
CTRA format (contd.)

65
Long duration critical works
• Any critical work (such as erecting scaffold inside storage tanks, tank
reconstruction activity, erection of Pipe Rack, etc.), which exceeds 4
weeks, shall be declared as a long duration critical work. CTRA team
may declare certain critical works which may be executed &
completed in less than 4 weeks also as ‘long duration critical works’.
• CTRA review frequency for long duration works shall be decided by
the CTRA team but it shall not exceed 3 months.
• CTRA for long duration critical works shall have
 part-A (CTRA) &
 part-C (compliance checklist for CTRA mitigation measures)
Issuer & Executor shall sign the checklist at least once in 7 days or as
per the frequency decided by CTRA team, whichever is less.

66
Long term Critical Work-Compliance Checklist

67
CTRA -exercise

68
a) Inspection of work site by Issuer during turnaround
(for low risk works)
Issuer shall inspect the work site with the Executor before issuing
the permit for all works (low risk, medium risk & critical works)
during normal running of the plant
It is not mandatory for the Issuer to visit the job location for low risk
works
• during turnarounds (when number of permits to be issued is high)
• he shall sign / approve the low risk work permits only after getting
the feedback regarding site / equipment condition from Field
Operator
• he shall indicate the same (that he has not visited the site & he has taken
feedback from Field Operator before issuing the permit) on the work permit

69
Other changes (contd.)
b) Executor of the work permit shall be of the same craft for which he will be
signing the work permit
(i.e. a Mechanical Maintenance person shall not sign as Executor for lifting
activity; a rotating equipment maintenance person shall not sign a permit
for electrical work)
c) List of Work permit Issuers & Executors
• Only specifically authorized personnel shall be Issuer / Executor
• Respective division Team Leader shall maintain a live list of work permit
Issuers in his / her division by name & their signature
• A list of authorized personnel shall be maintained by the division in their
department website. This list shall be reviewed & updated every quarter

70
d) Work Permit Level-II training:
The following personnel shall undergo ‘Work Permit Level-II’ training (competency
level-II training) and a test (written or verbal test)
Field Operator
Person signing in the contractor column
Person below Executor who is assigned to supervise the ‘Medium Risk’ works
e) Electronic work permit system & manual work permit system:
Whenever electronic work permit system is not working, manual work permits can
be used by following the procedure given below.
• Take a screen shot of the message appearing on the system
• Send it by e-mail to Team Leader through Section Head (or through Senior
Engineer of the permit issuing division) and get his approval for using manual
work permit
• Users shall make necessary efforts to get the electronic work permit system
restored as early as possible

71
f) ‘Work Permit Issuers for non operational areas / areas without
designated custodian:

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g) Operations work permit Issuers:
Operator I Control Room Operator-Grade 14 (Operator I),
Operations Controller (old title: Shift Supervisor) or above
are eligible to be authorized as issuers of all types of work permits in
operations areas
Control Room Operators in Grade-13 are also eligible to be authorized as
Issuers for special circumstances such as shutdown subject to approval by
Operations Manager.
The above-mentioned personnel shall satisfy the conditions in sec. #
9.1 and shall attend Work Permit authorization training and pass the exam to get the authorization.
In case of multiple Issuers at the same location, it needs to be ensured that
all the Issuers are fully aware of various permits issued.
h) Work not requiring a permit:
For activities not requiring permit, other alternate risk control measures
and other requirements specified elaborately

73
Significant changes---Review
1. Risk based categories of works (maintenance / construction
works)
2. Definition of ‘Medium Risk Work’ category & list of works
predetermined as medium risk works
3. ‘SWP Checklist format’
4. Definition of ‘Critical Work’ & list of works predetermined as
critical works
5. Supervision for medium risk works
6. supervisory span for critical works

74
Significant changes---Review (contd.)
7. Extended validity of work permits during shutdown & for special
tasks
changes
9. Authority to approve contractor personnel as work permit
Executors
10. Improved CTRA (WPRA) procedure & compliance to KPC HSSE

75
AUTHORIZATION TEST

Work Permit System Conversion Course--Final.pptx

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