Safe Systems of Work.

PTW module 1

PTW -

Module1

Objectives of this session

You shall be able to
develop strong understanding of Fatimas SSOW and qualify for Validation &
Qualification test
Understand the different permits used at site.
Understand various requirements of the permits for safe execution of jobs.

It is line managements responsibility to implement SSOW in the field.

The cost of non-compliance to SSOW could be somebodys life.

PTW -

Module1

Objectives of this session

Purpose, scope and definitions SSOW
Permit Preparations
Issuance and Authorization
Permit closure
Isolation standards
Master control sheet
Special cases
Dispensation
HWP
Confined Space Entry
Validation & Qualification test

(PTW, HWP, Vessel Entry, Isolation & Dispensation)

Purpose & Scope of our Procedures

Purpose;
This Procedure defines the arrangements for the issue and acceptance of
Permits to Work, (PTW), and the use of the Master Control Sheet system,
(MCS) at the Fatima Fertilizer Company Limited.

Scope;
This procedure supports Health, Safety and Environmental standard
requirements for safe systems of work to ensure that all jobs are carried out
safely. This procedure applies to Fatima Fertilizer Site, Raw Water Pumping
Station, Natural Gas line, water lines (raw water and plant effluent) and power
transmission lines owned and operated by the company.

Definitions
1. PTW Issuing Authority;
The PTW Issuing Authority is the person nominated by the Production
Manager concerned on Manager HSE recommendation for issuing Permit to Work
(PTW) in his area of responsibility (see Appendix 3).
2. PTW Accepting Authority;
The PTW Accepting Authority is the person nominated by the concerned Maintenance
Manager or concerned E&I Manager, on Manager HSE recommendation to accept
Permit to Work (PTW) in his area of responsibility (see Appendix 4).
3. Inter Plant PTW;
This is another use of the PTW system whereby isolations required to carry out a task
are outside of the control of the Issuing Authority for that PTW. (e.g. on another plant).
The procedure for Inter Plant PTW is attached as Appendix 7 & 8.
4. PTW Exemption List;
A list of simple routine tasks of short duration that the Unit Manager, Maintenance
Manager and HSE Manager have agreed, do not require a PTW.(see Appendix 5).

Definitions
6. Hot Jobs;
A job where the heat generated is of sufficient magnitude and intensity to cause ignition of any
flammable liquids, gases or any other material.
7. Confined Space;
A confined space is defined as any space:
Large enough and so configured that an employee can bodily enter and perform
assigned work.
With limited or restricted means of ingress or egress.
With limited or no natural ventilation.
Not designed for continuous occupancy.
8. Own Isolations;
Term used for isolations carried out by the executor himself for certain E&I jobs. A permit shall be
filled with comments in physical isolation section as own Isolations.
9. Dispensation;
A procedure that defines the steps in case of any deviation/absence of set procedures.

Lets Start
It is important to understand the cycle of any Permit,

Planned/unplanned Jobs
Issuer to make necessary preparations and issue permit

Executor to verify all preparations and take responsibility of safe

execution after acceptance

Both issuer and acceptor to verify job closure, countersign as

job closed and field copy to be retrained with Acceptor and book
copy with Issuer.

PTW Permit to Work

Lets take an insight into our

PTW and discuss step by
step its various sections,
their filling and
responsibilities.

Permit preparations

The PTW Issuing Authority shall ensure before the job is started that:
Accepting authority and Area operator have clear understanding of scope of work, hazards and
precautions.

The job is clearly defined on the PTW in Section-A and tagged. Write tag no. in section-A along
with job description.

There is positive identification of either the equipment to be worked on and/or the area in which
the work will take place.

All isolations shall be adequate, remain secure and are visibly tagged. The Do Not Operate tags
used for this purpose can be signed by PTW issuer or his nominee.

All residual hazards shall be identified in A1 and the necessary Precautions are clearly specified
as PPE's and instructions in A2 and A3

The PTW Accepting Authority has full understanding of the content of the PTW.

Permit preparations
PTW Document - Section A; (see Appendix-1)
This section shall be completed by the Issuing Authority. It records the clear definition
of job to be done in clear and concise manner to avoid misunderstandings.
When a PTW has been issued and accepted, It will be valid for the only distinct, unambiguous and defined
jobs.

Permit preparations (Cont)

Section A1 - Risk Assessment;
Before completing this section the PTW issuer & acceptor shall visit the place of work
to identify any hazards still present. The issuer shall circle those hazards, which exist
or may exist after preparation work is complete.

Permit preparations (Cont)

Section A2 - Precautions Already Taken;
The issuer shall record the precautions already taken such as depressurized, decontaminated, washed, purged, drained etc.

Permit preparations (Cont)

Section A3 Personal Protective Equipment (PPE);
The issuer shall tick mark all the necessary personal protective equipments to
safely carry out this job.
Note; These personal protective equipments shall be in addition to mandatory PPEs
i.e. safety shoes, safety helmet and safety glasses (light eye protection).

Permit preparations (Cont)

Section A4 Physical Isolations
In this section Issuer shall identify the requirement for physical isolations.
a. In case the isolations have been done already on separate PTW, Issuer shall write down the
reference PTW number.
b. All isolations points shall be identifiable through the application of Do Not Operate tags having
specific serial numbers.
c. All isolations that have been achieved by means of inserting blinds shall be identified by Do Not
Remove tags with specific serial numbers.

Permit preparations (Cont)

Physical Isolations Standards

B: Blind;
DBB: Double block & bleed

Mechanical Energy Sources

WHEN there is the potential to be
exposed to Rotating equipment or
machinery

Multi-Hole Hasp

Preferred methods for isolating a gas,

liquid or vapor process stream are :

Isolation Tags

Permit preparations (Cont)

Section A5 Other permit References
The issuer shall record in this section whether an Entry Permit, excavation permit or
scaffolding fitness certificate is required or not. If other Permits are required the
number of the Permits shall be entered.

Permit preparations (Cont)

Section A6 - Electrical Isolation;
a.

The issuer shall identify in this section whether electrical isolation is required or not. In case Electrical
isolation is required he shall coordinate with competent
electrical technician.

b.
Issuer shall also identify what kind of electrical isolation has been performed for the job and tick mark
the relevant.
c.
e.

It is mandatory that concerned trade people put their own lock at breaker after
This section needs to be signed by Electrical technician only, who has been
to perform these electrical isolations.

isolation.
trained and authorized

Electrical Energy Sources

Permit preparations (Cont)

Section A7 - Master Control Sheet;
Where a MCS is in operation the serial number of the MCS shall be entered here.

Master Control Sheet (MCS)

Master Control Sheet (MCS) Permits to Work;

A MCS is a form that records the details of two or more tasks that depend on the
same common electrical or physical isolation (IT IS NOT A PERMIT).

The Issuing Authority shall write in the details of the common isolations in the space
provided.

Brief details of each PTW to be controlled by the MCS shall be entered in column 1.
and the PTW number recorded in column 2.

For a removal/replacement of activity to be carried out the Issuing Authority shall

record in column 4 this requirement.

As tasks are completed and PTW's are handed back by PTW Acceptors the Issuing
Authority shall sign column 3 to record that the job is complete.

Master Control Sheet (MCS) Cont

PLANT ITEM/AREA
DETAILS OF THE COMMON ISOLATIONS
(valves locked off, electrical circuit references, slip-plating etc.)

Certify that all the Permits to Work listed on this Master Control Sheet have been closed and that
Common isolation may now be opened.
*Continued on Master Control Sheet No

Issuance & Authorization

Section B1 - Issue and Receive
When section A of the PTW has been completed the Issuing Authority shall sign in
section B1 in order to authorize that it is safe to carry out the work specified. The
accepting Authority shall also sign in section B1 to indicate that he understands the
job, residual hazards and precautions necessary to carry out the job.
The Issuing Authority shall indicate which Area Operator will monitor the job and ask
him to sign in this section. Area operator shall sign in B1 after carefully reading the
following statement.
I understand the job residual hazards and precautions necessary to carry out the job.
It is my responsibility to audit the compliance in the field.

Issuance & Authorization

Rotation Check Required

Section B2 - Rotation Check Required

a)

If a Rotation Check is necessary to confirm satisfactory task completion then the

Issuing and Accepting Authority shall both sign the PTW in section B2. The electricity
supply may now be restored and the person restoring it shall first sign in section B2.

b)

If further work is required (e.g. coupling up motor), the word Yes shall be crossed
out and the Issuing and Accepting Authority shall sign together with the person who is
re-isolating the electricity supply.

c)

If no further work is required, the word No shall be crossed out, and the PTW can be
signed off as complete and the electrician will sign in section B5 to indicate that the
electrical supply has been restored.

Rotation Check Required

Isolation Standards
1) PTW Issuer shall issue PTW where blinds and/or line breaking and blanking are used
to achieve isolation. Such work shall be considered in three distinct and separate
phases.
a)
b)
c)

Isolation
Main Task
De-Isolation

2) Where it is not possible to meet the relevant standard, PTW Issuers shall obtain
dispensation from the relevant Production Manager.
3) PTW Issuers shall ensure that each isolation is secured and identified (by tagging)
throughout the duration of the maintenance work.
4)

The equipment identification tags detail needs to be put in section A along with
description of job on PTW.

Isolation Standards (Cont)

5) When there is a change of intent, PTW Issuers shall review the adequacy of the isolation
arrangements and issue a new PTW.
6) When maintenance work is complete, PTW Issuers shall assess the hazards of de-isolation
of equipment e.g. trapped materials and take appropriate precautions.
Completion of Job;

When the job has been completed, the equipment is safe to be operated and the work area
is left clean and tidy. The area operator shall sign in section B3 followed by PTW acceptor to
close the PTW.

If the PTW is returned as job incomplete, the Accepting Authority shall sign in section B3 and
indicate what further work is required.

When the work is complete PTW issuer shall then sign in section B3 accordingly.

Completion of Job;

Master Control Sheet (MCS) Cont

When all the PTW's listed on the MCS have been recorded as "Completed" the MCS
can be closed by PTW issuer accordingly.

Master electrical isolations still in operation at this stage can only be reinstated once
the Issuing Authority has signed section B4 on the last PTW.

The electrical Technicians having checked that section B4 has been signed of last
PTW on MCS, can then restore the electrical supply and sign in section B5 on the
original PTW.

Master Control Sheet (MCS) Cont

Isolation and Blind Tag No and

Revalidation

Inter plant permit

PROCEDURE FOR INTER PLANT PERMIT
i)
ii)

All issuers will be acceptors also, for inter plant PTW.

Request for inter plant PTW will be raised before isolation required time,
through Unit Manager or shift co-ordination Engineer in off hours
iii) Requester will be acceptor.
iv) Shift Engineer accepting request will be issuer for inter plant PTW.
v) Issuer will enter inter plant PTW in MCS.
vi) Acceptor will enter Inter plant PTW number, as one of isolation in PTW.
vii) Acceptor will enter this Inter plant PTW in MCS.
viii) Inter plant permit will be in the custody of Acceptor .
ix) When job is completed inter plant permit will be signed off by both issuer
and acceptor, and close respective Master Control Sheets.

Exemption List

PTW Exemption List;

A list of simple routine tasks of short duration that the Unit Manager, Maintenance
Manager and HSE Manager have agreed, do not require a PTW. (see Appendix 5).
Appendix 5
Plant Section ..
Issued By Date ...

Unit Manager: _____________,

Maintenance Manager: __________

Production Manager: ______________

Training, Validation & Qualification test

Training & Validation;

The HSE Manager shall train all Line Managers in the use of this system.

Line Managers with the assistance of the HSE and Training Managers shall train
PTW Issuers and Acceptors and shall validate and authorize their ability to use the
system.

Contractors will receive basic training on the need for PTW's as part of their Induction
Training Package.

Hot work Permit preparations

Hot work Permit preparations

Hot work Permit preparations

Hot work Permit preparations

Issuance & Authorization

Confined Space Entry Permit

Vessel Entry Permit

Tally sheet of Entrants

Vessel registers with rescue

plan