ORISSA POWER GENERATION CORPORATION LTD.

IB THERMAL POWER STATION, BANHARPALI

STANDARD OPERATING PROCEDURE
PERMIT TO WORK
Document No: EM 4 / 35
Filed At: All Departments
The purpose of the SOP Permit To Work is to train and guide operating personnel
for optimum performance of the system.
RESPONSII!I"#
Team Leader (All Departments is responsi!le for implementation of this SOP so
as to ensure safe and efficient operation of the system.
PERMI" "O $OR% PRO&ED'RE
()* PO!I&#
"t is the policy of "# Thermal Po$er Station ("TPS to esta!lish a uniform
Permit to Work Procedure to protect people from in%ury due to electrical
shock& mechanical energy& pipeline product flo$& fire& to'icity and related
potential ha(ards. The policy is also directed at pre)enting inad)ertent start*
up of e+uipment not ready for operation.
SOP Permit To Work
,
+)* IN"ROD'&"ION
This procedure pro)ides "TPS people $ith instructions for starting& initiation
and remo)ing a Permit to Work Order and its associated paper $ork.
3)* DEFINI"IONS
-., S,i-t in &,ar.e. Person ha)ing immediate charge and control of the
po$er plant. /e is responsi!le for ensuring that all procedures are
follo$ed prior to& during and on su!se+uent release of the Permit to
Work Order.
-.0 S,i-t En.ineer. Operations 1ngineer +ualified in the specific area
co)ered !y the Permit to Work Order.
-.- /eri-ication &,ec0. A check must !e made !y the person re+uesting
the Permit to Work and the Shift 1ngineer to ensure all tags and locks
are hung in accordance $ith the Permit to Work Procedure.
-.2 Dan.er "a.. A pre*printed tag stating 3Danger*Do 4ot Operate5 is to
!e used $hen plant e+uipment has !een issued a Permit to Work Order
!y the Shift 1ngineer& prohi!iting energy sources from !eing placed in
an operational mode.
-.6 !oc0. The lock used !y the Shift in 7harge must !e accompanied !y a
Danger Tag.
SOP Permit To Work
0
-.8 Maintenance En.ineer. i.e. electrical& instrument& mechanical
maintenance engineers in)ol)ed in repairing& testing or performing
other $ork on e+uipment.
-.9 Maintenance 1roup. A group or cre$ of more than one craft
$orking on same e+uipment or system ha)ing the presence of
ha(ardous energy.
-.: Sa-e Position. The position in $hich an isolating de)ice has !een
placed to pre)ent the release of ha(ardous energy.
-.; 2a3ardous ener.4. Any chemical& electrical& stored mechanical&
thermal& kinetic or potential su!stance that could harm people or
e+uipment.
4)* RESPONSII!I"IES
2., The Shift in 7harge has immediate charge and control of the
e+uipment re+uiring a Permit to Work& $ill ensure that the Lock& Tag
and Try procedure is follo$ed& authori(e Permit to Work and $ill
ensure that each step of the procedure is follo$ed.
2.,., ",e loc0 5ill 6e remo7ed onl4 a-ter all maintenance/.roups
ha)e signed off the Permit to Work.
SOP Permit To Work
-
2.,.0 The Shift in 7harge<Shift 1ngineer must Lock& Tag and Try to
ensure proper Permit to Work procedure has !een effected. That
indi)idual must !e particularly alert $ith interlocked e+uipment
to ensure it is locked out and not temporarily inoperati)e
!ecause of an interlock.
4OT1. Once the 3try5 phase has !een initiated and the start s$itch
tried. e sure to depress t,e 8S"OP9 s5itc, last)
2.0 =aintenance people must !e a$are of the safety !oundaries offered
!y a Permit to Work Order and may accompany the Shift 1ngineer
$hile tags are placed.
2.0., >pon !eing informed of a Permit to Work& the maintenance
people $ill accept the Permit to Work Order !y signing the
3accept5 column of the Permit to Work.
2.0.0 "f there is a personnel change at shift change or $ork on the
e+uipment is not completed and the e+uipment is not needed for
operations& the Permit to Work $ill remain in force.
2.- 1ach person $orking in a maintenance group on e+uipment or system
containing ha(ardous energy $ill !e gi)en the same amount of
protection as one indi)idual $orking on the e+uipment or system.
SOP Permit To Work
2
2.-., "n a maintenance group situation& one person $ill !e designated
!y the group mem!ers to assume Permit to Work
responsi!ilities for the group.
2.2 All people are responsi!le for honouring all tags and locks.
>nauthori(ed remo)al of a danger tag or lock could result in the
serious in%ury& death or e+uipment damage and may !e cause for
immediate employment termination.
5)* "#PI&A! SI"'A"IONS RE:'IRIN1 PRMI" "O $OR%
PRO&ED'RE
6., Performing maintenance or ser)ices on or around any machine $here
personnel in%ury or e+uipment damage could result from.
6.,., >ne'pected e+uipment starts.
6.,.0 ?elease of stored energy.
6.,.- ?emo)ing a guard or other safety de)ice.
6.,.2 Work re+uiring people to !e situated $here any part of the !ody
could !e caught !y mo)ing machinery.
6.,.6 7losing )al)es $hen the flo$ of air& steam& $ater& flamma!le
li+uids or other chemicals present a ha(ard.
SOP Permit To Work
6
6.,.8 Any situation $here a Permit to Work $ould pre)ent conditions
$hich could cause in%ury& pollution or other undesira!le results.
;)* PERMI" "O $OR% PRO&ED'RE
NO"E: ",ere are si< steps to -ollo5 in controllin. ,a3ardous ener.4.
,. Preparation for shutdo$n 0. 1+uipment shutdo$n& -. 1+uipment
isolation& 2. Application of Permit to Work& 6. 7ontrol of stored 1nergy&
8. 1+uipment isolation 3T?@5 )erification.
;)( Preparation For S,utdo5n =step > (?
1+uipment and<or system re+uiring a Permit to Work Order must !e looked
o)er !efore initiating the Permit to Work procedure. "t re+uires kno$ledge of
the follo$ing.
8.,., The types and amounts of energy po$ering the e+uipment.
8.,.0 Aluids or ha(ardous chemicals associated $ith the e+uipment or
systems.
8.,.- The presence and location of control interlock or Permit to Work
procedure.
8.,.2 People $ho must !e notified !efore remo)ing e+uipment from
ser)ice.
SOP Permit To Work
8
8.,.6 The presence of any secondary (!ack up po$er sources.
8.,.8 The e'istence of any stored energy that must !e !locked and drained.
8.0 E@uipment s,utdo5n =step > +?
=ake certain e+uipment is a)aila!le for shutdo$n.
8.0., Berify that the e+uipment can !e remo)ed from ser)ice considering
operational loss or impacting plant a)aila!ility for a specific time
period.
8.0.0 4otify all necessary people that the e+uipment or system is !eing
taken out of ser)ice& i.e.& maintenance engineers.
8.0.- Berify that normal operating controls can !e used to shutdo$n the
e+uipment.
8.0.2 Take steps to drain& remo)e solids& )acuum out& $ash do$n or cool off
the e+uipment or system !efore or after shut do$n.
;)3 E@uipment isolation =step > 3?
8.-., Place all energy isolating de)ices in a safe position.
SOP Permit To Work
9
8.-.0 1nsure all possi!le alternati)e energy sources are correctly isolated.
Ne7er open isolators under load and Ne7er pull fuses under load as an
isolating de)ice.
The Shift 1ngineer<=aintenance 1ngineer must ensure the necessary
cleaning of pipelines& )essels and the immo!ili(ation of )al)es& electrical
circuits& etc. has !een completed.
8.2 Application o- Permit to $or0 A completin. a Permit to $or0 Order
=step > 4?
Note (. "TPS uses a Permit to Work procedure in $hich !oth locks and tags
are hung on the isolating de)ice. There may !e times $hen tags can !e used
separately $ithout locks& ho$e)er& a lock must al$ays !e used $here)er
possi!le and $ill al$ays !e accompanied !y a tag.
8.2., Shift in 7harge<Shift 1ngineer responsi!le for the Permit to Work
Order must o!tain a Permit num!er from the =aster LogC $rite this
num!er (ne't in se+uence on the Permit to Work Order and on all
tags associated $ith the Permit.
8.2.0 7omplete all information on Permit to Work Order form and Permit to
Work Do! Slip.
8.2.- 4ote special instructions such as special isolating or restoration
re+uirements.
SOP Permit To Work
:
8.2.2 Authori(ation for all Permit to Work Orders $ill !e gi)en !y the Shift
in 7harge after ensuring that the conditions in Section 8.0 1+uipment
Shutdo$n ha)e !een adhered to.
8.2.6 7omplete 3DAN1ERBDO NO" OPERA"E5 tags for all isolating
de)ices associated $ith the Permit to Work Order and fill in !oth the
Permit to Work Order num!er and lock num!er.
8.2.8 Place all isolating de)ices in the safe position as noted on the Permit
to Work Order and hang Permit to Work lock and 3DAN1ERBDO
NO" OPERA"E5 tags.
8.2.9 Shift in 7harge<Shift 1ngineer )erification check of tags and locks&
and 3Try5 (see sec. 8.8 must !e carried out prior to issuing the Permit
to Work.
8.6 &ontrol o- stored ener.4 =step > 5?
NO"E: An4 o- t,e -ollo5in. precautions =indi7iduall4 or in
com6ination? ma4 6e necessar4 to .uard a.ainst residual ener.4 le-t in
t,e e@uipment a-ter it ,as 6een isolated)
8.6., =ake sure all parts ha)e stopped mo)ing.
8.6.0 "nstall ground $ires and<or local earthing if appropriate.
8.6.- ?elie)e trapped pressure. (Lo$ point !leed.
SOP Permit To Work
;
8.6.2 ?elease the tension on springs or !lock the mo)ement of spring dri)en
parts.
8.6.6 #lock or !race parts that could fall !y gra)ity or from hydraulic or
pneumatic pressure loss.
8.6.8 Drain process piping systems and close )al)es to pre)ent the flo$ of
ha(ardous materials.
8.6.9 "f a line must !e !locked& utili(e )al)es& use a line !lank& remo)e pipe
section or misalign a section of pipe.
8.6.: Dissipate e'treme heat& e'plosi)e energy or $ear proper personal
protecti)e e+uipment.
8.6.; "f stored energy can re*accumulate& monitor it to make sure it stays
!elo$ ha(ardous le)els. Al$ays tag lo$ point !leeds if they need to
remain open to pre)ent re*accumulation of energy. The tag $ill ser)e
as a reminder that the )al)e is open $hen putting e+uipment !ack in
ser)ice.
8.8 E@uipment Isolation 8"R#C 7eri-ication =step > ;?
Note: Due to t,e lar.e num6er o- similar pieces o- e@uipmentD s4stem
and isolatin. de7ices 6ein. used in close pro<imit4 o- eac, ot,erD tr4 to
SOP Permit To Work
,E
start t,e e@uipment a-ter Permit to $or0 to insure t,at Permit to $or0
,as 6een ac,ie7ed)
8.8., After all isolating de)ices ha)e !een placed in the safe position and
tags<locks ha)e !een hung& test start the e+uipment or system to
ensure proper control of ha(ardous energy.
8.8.0 The Shift 1ngineer<=aintenance 1ngineer $ill make sure that all
people are clear of the e+uipment or system prior to initiating a test
start (T?@.
8.8.- The Shift 1ngineer<=aintenance 1ngineer must !e particularly alert to
temporarily inoperati)e conditions pro)ided !y an interlock. Once the
T?@ phase has !een initiated and the start s$itch tried& 6e certain to
depress t,e stop s5itc,. 7ontact the Shift 1ngineer to )erify the stop
mode.
E)* PERFORMIN1 "2E $OR%
9., After the e+uipment<system is isolated and the test "R# completed&
notify craft people that the e+uipment<system is ready to !e $orked
on.
9.0 =aintenance people must !e alert not to do anything that could
reacti)ate the e+uipment or system or possi!ly !ypass isolating
de)ices !y installing ne$ piping or $iring.
SOP Permit To Work
,,
F)* REMO/IN1 PERMI" "O $OR%
:., =aintenance 1ngineers $ho finish their assigned task !efore the
entire task is complete $ill notify the Shift 1ngineer or this fact !y
signing the Permit to Work Order in the Permit to Work 3released5
column.
:.0 The Shift 1ngineer $ill ensure that the entire task is completeC all
maintenance people accepting the Permit to Work ha)e signed the
Permit to Work 3release5 column of the Permit to Work Order. The
Shift 1ngineer $ill then thoroughly check the e+uipment<system to !e
sure all safe guard are replaced and the e+uipment<system is ready for
safe operation. The Shift in 7harge $ill then authori(e the remo)al of
tags and check the Permit to Work Order for any special instructions
!efore placing e+uipment !ack into ser)ice.
:.- The Shift 1ngineer $ill then remo)e all locks and tags and& after
assuring that all people are safety clear of the e+uipment& test the
e+uipment for proper operation $here applica!le.
:.2 The Permit to Work Order (tags and locks must !e remo)ed !y the
Shift 1ngineer.
:.6 4otify all operating people associated $ith the e+uipment of its
operating status.
SOP Permit To Work
,0
:.8 ?eturn all tags and locks to the control room from $hich they $ere
issued.
:.9 The Shift 1ngineer $ill complete the Permit to Work Order form.
G)* SPE&IA! SI"'A"IONS
;., "emporar4 P"$ Remo7al procedure =-or testin. and
positionin.?: There may !e occasions $hen to complete repairs&
ad%ustments or perform other $ork on a locked out e+uipment item& a
Temporary Tag ?emo)al procedure is necessary.
;.,., The Permit to Work is the responsi!ility of the Shift 1ngineer
during any Temporary PTW ?emo)al procedure.
;.,.0 Any<All person on the Permit to Work Order $ho re+uests a
Temporary PTW ?emo)al must accept the responsi!ility of
assuring the safety of others signed on the Permit to Work and
also the safety of the e+uipment.
;.,.- The minimum num!er of tags and locks are to !e remo)ed
consistent $ith carrying out any testing<repositioning.
;.,.2 >pon completion of a Temporary PTW ?emo)al function&
return the e+uipment to the original Permit to Work status& i.e.
notify all in)ol)ed people and ensure replacement of all locks
and tags.
SOP Permit To Work
,-
;.0 Emer.enc4 loc0/Permit to $or0 remo7al may !e authori(ed !y a
person accepting responsi!ility for a person $hom has signed
3accepted5 on the Permit to Work Order !ut is off plant site.
;.- 7ontractor personnel $orking $ith "TPS people are su!%ect to Permit
to Work procedure re+uirements. 7ontractor super)isors $ill !e
!riefed as to the procedure and they& in turn& must !rief their people.
;.-.- An "TPS person must ne)er assume that the contractor fully
understands the Permit to Work procedure.
;.-.2 7ontractor person $ill !e issued one copy of the Permit to
Work Do! Slip duly signed !y the "TPS maintenance engineer
and contractor. After completion of the %o!& the same %o! slip
$ill !e returned to the maintenance engineer.
;.-.6 =aintenance<Shift 1ngineer<Shift in 7harge people are
responsi!le for contractor personnel safety and $ell !eing as
they are for their o$n safety.
(*)* ANN'A! INSPE&"ION
I"PSD in accordance 5it, est Mana.ement Practice -or Permit to
$or0 re@uirementsD 5ill conduct an annual inspection o- all Permit to
$or0 paper5or0 and 5ill test selected personnel on t,eir 0no5led.e o-
t,e Permit to $or0 Procedure.
SOP Permit To Work
,2
,E., Annual inspection $ill consist of an e)aluation of Permit to Work
Orders $ritten for that year. Discrepancies $ill !e noted.
,E.0 All Permit to Work Orders& $hich ha)e remained open for a period
e'ceeding three months $ill !e re)ie$ed and any damaged or defaced
tags replaced.
,E.- "TPS Team =em!ers $ill !e randomly selected for testing their
kno$ledge of the Permit to Work Procedure.
,E.2 Selected Team =em!ers $ill !e gi)en a mock situation and a Permit
to Work Order to !e filled out.
,E.6 "n the e)ent that Procedure discrepancies are disco)ered& appropriate
people $ill !e gi)en proper training (training class. "f gross
discrepancies continue after training& additional training $ill !e gi)en
and a 3failure to follo$ and learn procedure5 may !e reason for
disciplinary action.
(()* ENFOR&EMEN"
,,., 1nforcement is di)ided into t$o areas& administrati)e and physical
harm.
,,.,., Administrati)e pertains to any Team =em!ers not adhering to
the application of Permit to Work Procedure.
SOP Permit To Work
,6
,,.,.0 Physical harm pertains to an indi)idualFs failure to follo$
procedure& $hich is the cause of physical harm to another
indi)idual.
,,.,.- 1ach incident $ill !e considered indi)idually and may in)ol)e
an independent in)estigati)e group to pro)ide determination of
fault.
,,.,.2 All safety occurrences $ill !e discussed at the ne't Safety
7ommittee meeting and appropriate actions taken.
(+)* 1ENERA! RE:'IREMEN"S
,0., Locks must !e of common design& su!stantial tamper*proof and
operated !y a single key only.
,0.0 3DAN1ERBDO NO" OPERA"EC "A1S
,0.0., Tags $ill !e a minimum si(e of - inches !y 6 inches.
,0.0.0 Tags $ill !e constructed in a manner that pro)ided easy
attachment to locks& normally $ith a grommet hole larger than
the lock shackle.
,0.0.- A space $ill !e pro)ided on the tag for the custodianFs
signature& date and reason for tag and the Permit to Work Order.
SOP Permit To Work
,8
(3)* APPENDI&ES
,-., Permit to Work =aster Log Sheet
,-.0 Permit to Work Aorm
,-.- "solation ?e+uired 7ontinuation Sheet
,-.2 Permit to Work Do! Slip
,-.6 Periodic Permit to Work<Permit to Work "nspection Aorm.
,-.8 3DA4G1? DO 4OT OP1?AT15 Tag.
Revision No
& Date
Prepared By Verified By
Technical Committee
Approved By
Director (Operation)
SOP Permit To Work
,9
APPENDI&ES
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"EMPORAR# P"$ "A1 RE!EASE S2EE" OF P"$ NO.KKKKKKK
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0. =A"4T14A471 14G"411?S A771PTA471 TA#L1
A771PTA471 A771PTA471
4ame Sign. Date I Time 4ame Sign. Date I Time
-. L"ST OA ALL "SOLAT"O4S TO #1 ?1=OB1D
Description =ade #y Sign. Berified #y Sign. Lock 4o. Tag 4o.
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2. =A"4T14A471 14G"411?S ?1L1AS1 TA#L1
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4ame Sign. Date I Time 4ame Sign. Date I Time
6. "SOLAT"O4 ?1STO?AT"O4 TA#L1
Description =ade #y Sign Berified
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4o.
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0
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SOP Permit To Work
02
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T1A= L1AD1?
SOP Permit To Work
06






SOP Permit To Work
08
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