Sudarshan Singh Shekhawat - AGM HRD - WORK PERMIT SYSTEM - 29-06-2012

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Presentation Description

A Safe Work Permit is a written record that authorizes specific work, at a specific location, for a specific period of time. A Safe Work Permit is an agreement between the issuer and the receiver, which documents the conditions, preparations, precautions and limitations before work commences.

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“THE WORK PERMIT SYSTEM” :

“THE WORK PERMIT SYSTEM” SUDARSHAN SINGH SHEKHAWAT ASSTT. GEN. MGR. [HRD] AN INTRODUCTORY CUM OPEN SESSION

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2 Why is one sign often ignored, the other one often followed?

Injury Statistics . . . In INDIA:

Injury Statistics . . . In INDIA 124 people die at workplace everyday 46575 people are injured Annually 32% contribution to global fatality at work 37% of global burden of occupational injury Question: Are injuries totally eliminated? WHAT IS MISSING? WHERE IS THE CATCH?

ROAD MAP:

ROAD MAP Presentation on Work Permit system followed by discussion The session will include the following: A work permit system consists primarily of a standard procedure designed to ensure that potentially hazardous routine and non routine work on industrial installations can be carried out safely.

What is a WORK PERMIT SYSTEM ?:

What is a WORK PERMIT SYSTEM ? It is an essential part of a system which determines how that job can be carried out safely, and helps communicate this to those doing the job. The issue of a permit does not, by itself, make a job safe - that can only be achieved by those preparing for the work, those supervising the work and those carrying it out. Other precautions may need to be taken – eg. process or electrical isolation - these will need to be identified in task risk assessments before any work is undertaken. The work permit system should ensure that authorized and competent people have thought about foreseeable risks and that such risks are avoided by using suitable precautions. Those carrying out the job should think about and understand what they are doing to carry out their work safely, and take the necessary precautions for which they have been trained and made responsible.

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6 ■■ Clear identification of who may authorize particular jobs (and any limits to their authority) and who is responsible for specifying the necessary precautions; ■■ Training and instruction in the issue , use and closure of permits; ■■ Monitoring and auditing to ensure that the system works as intended; ■■ Clear identification of the types of work considered hazardous; ■■ Clear and standardized identification of tasks, risk assessments, permitted task duration and supplemental or simultaneous activity and control measures. Essential features of work permit systems : A work permit system is a formal recorded process used to control work which is identified as potentially hazardous. It is also a means of communication between site/installation management, plant supervisors and operators and those who carry out the hazardous work. Essential features of work permit systems are:

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7 A Safe Work Permit must identify: • The work to be done - a brief description of it. • The location where the work will be done - as specific as possible. • The hazards involved in the work - any toxic, corrosive, flammable materials in the work area. • The length of the work - date and time the work will commence and finish. • The precautions to be taken to do the work - equipment and/or procedures that must be worn/followed; isolation, ventilation and testing requirements. • All hazards and precautions related to the work have to be determined before the work starts. A Safe Work Permit is a written record that authorizes specific work, at a specific location, for a specific period of time. A Safe Work Permit is an agreement between the issuer and the receiver, which documents the conditions, preparations, precautions and limitations before work commences.

A Safe Work Permit must also outline: :

8 A Safe Work Permit must also outline: WORK PERMIT SYSTEM is an important and effective tool to ensure safety at workplace. • The date the permit was issued and the name of the issuer. • The date the permit was received and the name of the receiver. • All the steps to prepare the equipment, building or area to be worked on. • The emergency and rescue plan , if it is necessary. • The date and time when the permit was returned and name of the person who signed it off.

Q: Why focus on WPS?..... Benefits:

1) Risk is identified 2) Job is authorized and informed to all the concerned people 3) It is ensured that only trained people are at the job 4) Work area is specified 5) Job duration is specified 6) People doing the job are identified 7) Recorded with the safety department and acts as a help during incident investigation 8) Ensured that people get the required protection 9) Ensured that area is free of hazards 10) Ensured that the work is closed safely Q: Why focus on WPS?..... Benefits Systems’ Benefits

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Course Objective The objectives for this course are: • Be familiar with jobs requiring safe work permits. • Be familiar with the Safe Work Permit system. The basic purpose of the work permit system is to ensure that work is carried out in the safest possible manner to prevent injuries to personnel, protect property from damage, avoid fire and other hazards etc.

Objectives ::

Objectives : The objectives and functions of such a system can be summarized as: Ensuring the proper authorization of designated work . This may be work of certain types, or work of any type within certain designated areas other than normal operations; Making clear to people carrying out the work the exact identity, nature and extent of the job and the hazards involved, and any limitations on the extent of the work and the time during which the job may be carried out; Guidance on permit-to-work systems Specifying the precautions to be taken, including safe isolation from potential risks such as hazardous substances, electricity and other energy forms (for details of isolation procedures and when they are appropriate see guidance Ensuring that the person in direct charge of a unit, plant or installation is aware of all hazardous work being done there; Providing not only a system of continuous control , but also a record showing that the nature of the work and the precautions needed have been checked by an appropriate person or people;

Objectives :…….:

Objectives :……. 6. Providing for the suitable display of permits 7. Providing a process for change , including the evaluation of change on other planned activity, a determination of when hazards need to be reassessed, and a means for controlled communication of change. 8. Providing a procedure for times when work has to be suspended, i.e. stopped for a period before it is complete 9. Providing for the control of work activities that may interact or affect one another; 10. Providing a formal handover procedure for use when a permit is issued for a period longer than one shift; 11. Providing a formal hand-back procedure to ensure that the part of the plant affected by the work is in a safe condition and ready for reinstatement.

Types of Safe Work Permits:…..:

Types of Safe Work Permits:….. 1• Cold Work Permit – used in maintenance work that does not involve hot work. Cold work permits are issued when there is no reasonable source of ignition and all contact with harmful substances have been eliminated or appropriate precautions been taken. 2• Hot Work Permit – used when heat or sparks are present due to the work activities. For example: welding, cutting, grinding, etc. The heat or sparks can ignite flammable or explosive materials/ vapours that may be present close to the work place. 3• Confined Space Entry Permit – used when entering confined spaces. 4• Work Clearance – used when the work to be done requires no preparation by the operations personnel. For example: oiling, greasing, garbage pickup/removal, meter reading, etc.

Types of Safe Work Permits:…..:

Types of Safe Work Permits:….. 5• Excavation Permit and Clearances - Excavation permit is required for carrying out any excavation inside plant. Wherever temporary closure of road / cutting of road or blockage of main roads is required in a section or unit. The necessary approval shall be obtained in proper format for “Road or Site Closure”. 6• Electrical Isolation Permit and Clearances - For all electrical isolation of electrical equipments Permit is required. To work on High Tension (HT) and Low Tension (LT) line and / or equipment is required. For Trip reset of HT and LT equipment, the clearance shall be taken on format. 7• Working at Height Permit - For all working at height (of 2M or above) a permit for “Working at Height” is required. The medical certificate for workmen, required to work at height is required. 8. Special Permits – used to cover special hazards, such as radioactive materials etc.

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15 When are work permit systems required? The following are examples of types of job where additional permits or certificates should be considered: Work of any type where heat is used or generated (eg by welding, flame cutting, grinding etc); Work which may generate sparks or other sources of ignition; Work which may involve breaking containment of a flammable, toxic or other dangerous substance and/or pressure system; Work on high voltage electrical equipment or other work on electrical equipment which may give rise to danger; Entry and work within tanks and other confined spaces; Work involving the use of hazardous/dangerous substances, including radioactive materials and explosives;

When are work permit systems required?:

When are work permit systems required? 7. Well intervention ; 8. Diving, including onshore operations near water; 9. Pressure testing ; 10. Work affecting evacuation, escape or rescue systems; 11. Work involving temporary equipment, eg generators, welding equipment etc; 12. Work at height; 13. Any operation which requires additional precautions or personal protective equipment (PPE) to be in place; 14. Any other potentially high-risk operation. Awareness programs should be arranged in the form of “Refresher Class Room Training” as well as “On the job training” for contractors (Supervisor and their workmen) about work permit system.

WORK PERMIT REQUIRMENT:

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 - PERMIT NOT REQUIRED Works carried out by Oprs. Dept. as a part of routine operation. FIRE STATION FIRE TRAINING GROUND

WHO CAN SIGN A WORK 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.

ISSUING AUTHORITY OF WORK PERMIT:

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 level of OFFICERS and above.

EXECUTING AUTHORITY OF WORK PERMIT:

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:

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. :

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)

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‘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) In case of any accident or fire at the work site, the permit shall get automatically cancelled. Fresh permit shall be obtained for restarting the job.

Limitations of WPS:

Limitations of WPS When the safety officer starts getting too many copies to sign on daily basis, proper hazard identification and minimization gets ignored sometimes. To avoid this situation formation of task force is often suggested. 2) Task force is often from the production departments. It is not always necessary that they follow the complete safety procedures in the absence of the safety officer as they have their production targets as well. 3) In the absence of the safety officer or safety representative, it becomes difficult to start the job. Thus the resultant delay in job is blamed upon the safety officer and the work permit system. To be successful a WORK PERMIT SYSTEM must include all employees, from the top to the floor associates. To achieve changes in system, a change in policy, procedures and/or systems most confidently will also need some change.

Limitations of WPS…:

Limitations of WPS… 4) If the person that has been appointed for signing the work permits is not trained properly it may happen that the hazards remain unidentified. 5) If the proper equipment is not available there is a delay in job. A safety officer has to ensure that the contractor person and the factory people are well aware of the safety requirements so that safety doesn’t clash with company efficiency. 6) Keeping a record is not easy . Work permits that are not reviewed may lead to erroneous information. For example work permit shows the workplace as behind warehouse while the work was being carried out at some other place, then it may be a problem. A Safe Work Permit should be issued only by a competent person, who is completely familiar with the work and the work area. The issuer should review the place where the work will be performed prior to issuing the permit.

The Work Permit System Process:

RESULTS IDENTIFICATION of CRITICAL UNSAFE PROCESS PERFORMANCE OF SET GUIDELINE EXECUTION PERFORMANCE PERFORMANCE IMPROVEMENT PINPOINT EVALUATE MEASURE REINFORCE GIVE FEEDBACK The Work Permit System Process

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WPS has to Succeed then . . . Top Management Commitment is essential Ownership & involvement from all employees Steering WPS Committee to monitor in plants Training to all on WPS & safety practices Effective Feedback – Most important Performance monitoring & frequent improvement in the system

The Work Permit System : Work Planning:

The Work Permit System : Work Planning WORK SCOPE REVIEW DRAWINGS / FLOWSHEETS INSPECT WORKSITE IDENTIFY SAFETY PRECAUTIONS COMPLIANCE WITH REGULATIONS DEVELOP WORK PROCEDURE ASSIGN RESPONSIBILITIES COMMUNICATION PROCEDURES WORK EXECUTION

BASIC RESPONSIBILITIES OF ISSUING AUTHORITY:

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.:

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 :

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:

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:

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 CONTD.:

AUDITOR’S CHECK- LIST CONTD . 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 CONTD.:

AUDITOR’S CHECK-LIST CONTD . 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 CONTD.:

AUDITOR’S CHECK-LIST CONTD . Electrical isolation was required, carried out and documented. Both issuing & executing authority signed mentioning name & signature, date & time. 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

The Work Permit System : Work Execution:

The Work Permit System : Work Execution PREPARATORY WORK ISSUE WORK PERMITS SUPERVISION MONITORING WORK COMPLETED TESTING RE-INSTATE EQUIPMENT RETURN WORK PERMIT HANDBACK PLANT / EQUIPMENT

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39 WPS committee meetings is a requirement FOR CONSTANT IMPROVEMENT IN THE SYSTEM. We can conduct WPS committee meeting a minimum of once in a quarter. The purpose of WPS committee meetings is to discuss the safety related concerns in the presence of representatives of different departments, safety zones and ensure work place safety and proper implementation of WPS. The committee also includes representative of workers as they are better aware of the ground level issues. Importance of WPS committee meeting is that it highlights the safety concern in the eyes of the committee members and the management. This helps ensure that the unsafe acts or unsafe conditions prevailing in some area of the premises don’t repeat in the other area. Committee of WPS Core Elements in Successful Safety System…

Committee …:

Committee … In case there are projects undergoing in the premises there are project safety committees to discuss the safety related concerns with the project supervisors and contractors . The safety highlights need address in the meeting. Incidents also need to be addressed in the meeting so that all come to know how the incident occurred and what were the corrective/preventive actions taken regarding that incident. This is important so that causes of accidents are in the information of everyone as this could help in repetition of similar incidents. In this committee half members are represent from workman side and half from management side out of 08 members including main representative of all tech.

The Work Permit System : In brief:

The Work Permit System : In brief Many accidents have occurred due to lack of Work Permit or non observance of its consigned safety measures. The Safe Work Permit is useful for: The safety of persons in charge of the work The safety of persons in charge of the process The risk management of the process and equipment It is not one more administrative paper! Fill in and follow correctly the work permit, because…. It could save your life!

Are You Ready for Work Permit System Based Safety?:

Are You Ready for Work Permit System Based Safety?

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Are You Ready for Open Discussion? - GROUP EXERCISE – OPEN HOUSE - Feedback & Suggestion

Thank You:

Thank You DWARIKESH SUGAR INDUSTRIES LIMITED There is no limit to what can be accomplished, If it doesn’t matter who gets the CREDIT. HRD TEAM

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