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PETRONAS CARIGALI
PTW STANDARDISATION REV 2.
SEPT 2011
8/3/15
Selamat Datang
Safety Briefing
You are
here
About You!
Your Name :
Your Position:
Your Company:
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Process
Hazard
Job
Hazard
Behavioral
Hazard
HEMP PTW
HEMP - JHA
BBS
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INTRODUCTION
Petroleum industries
handle large quantities
INTRODUCTION
of flammable and toxic materials. Potential
for
is high.
Whyaccident
the need for
a PTW system in PETRONAS
When accidents do occur, root cause - often
due to:
Failure to implement procedures
Lack of training and knowledge in the
application of the PTW system.
The assumption that- The permit when
approved is a confirmation that all
hazards and risks have been eliminated
from the work area
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INTRODUCTION
Why the need for a PTW system in PETRONAS
Many fatalities have occurred. Inadequate
precautions for working in hazardous area and
confined spaces.
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INTRODUCTION
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SCOPE
PTW system is applicable for all activities
carried out at all work locations including
office throughout PETRONAS Carigali global
operations, including Contractors and SubContractors.
Contractors working on their facilities
where
PETRONAS
Carigali
have
the
prevailing influence, may use their own
PTW System; however the PTW system
shall be subject to detail review and
approved by PETRONAS Carigali.
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WHAT IS A PERMIT
An important part of a work system and
guides us how a job shall be carried out
safely.
Is a formal written system and as a means of
communication so that:
Plant management, supervisors, operators
and ALL those carrying out the job are
aware of the work being done.
Only approved people are so permitted to
carry out:
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A
Specific job
At a Specific time
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A PERMIT IS NOT
Permission to simply carry out a dangerous
job.
A confirmation that hazards and risks have
been eliminated.
Security that if you have a Permit, it makes
a job safe.
Those carrying out a work must:
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1. Personnels Safety
2. Environment Prevent polluting the sea,
17
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To protect Environment
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DULANG B PROPERTY
DAMAGE, 1 APR 2009 CRANE
BOOM FALL ONTO MAIN DECK
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DEFINITIONS
AREA CLASSIFICATION
Non-Hazardous Area
An area in which a flammable atmosphere
is not expected to be present.
Hazardous Area
An area in which a flammable atmosphere
is, or may be expected to be present.
Therefore, special precautions for any
work are necessary.
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DEFINITIONS
HAZARDOUS AREAS
1. A4 CWP area classification
2. A3 Permit-To-Work Form - area classification
Zone 0
Flammable gases and vapors are
constantly
present
Zone 1
Flammable gases and vapors are
intermittently
present
Zone 2 Flammable gases and vapors are not
expected to
be present unless conditions
become abnormal.
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DEFINITIONS
Certificat
e
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Hot Work
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DEFINITIONS
DEFINITIONS
Cold Work
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DEFINITIONS
Confine
space
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An enclosed or partially
enclosed space that is at
atmospheric pressure during
occupancy and is
not
intended
or
designed
primarily as a place of work,
and is liable at any time to
have an atmosphere which
contains
potentially harmful
levels of contaminants; have
an
oxygen deficiency or
excess;
or
cause
engulfment; and 27
with
restricted means for entry
DEFINITIONS
Specific
Worksite
Work
Description
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DEFINITIONS
Gas
testing
Hazard
Assessme
nt
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DEFINITIONS
Isolation
source of
Job
Job Hazard Analysis (JHA) is the
Hazard
application of the hazards and
Analysis (JHA) effects
management process
(HEMP) at the job/task level,
identifying and assessing the
hazards of each element of the
task and defining appropriate
controls and recovery measures.
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DEFINITIONS
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DEFINITIONS
Potential
Hazards
An event, circumstances or
condition, if not
controlled,
have the potential to harm
personnel, environment , asset
or reputation
Potential
Preventive
and
contingency
Precautionary steps taken to
ensure a safe
worksite and to prepare for
emergencies
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DEFINITIONS
Validity
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DEFINITIONS
Safety
The period of time during which
Equipment a safety equipment such as PPE
and rescue equipment is valid for
its Validity intended use. Proof
of validity shall be visible by
documents as attached or affixed
on the equipment
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WHAT IS A PTW
The PTW is a written document authorizing
persons to carry out the work concerned,
warning them of possible hazards and Spell out
precautions needed and taken for the job to be
done safely .
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WHEN IS PTW
APPLICABLE
As a general principle, PTW shall be applied for
ALL activities which may harmfully affect the
personnel, environment, asset and reputation
carried out on PETRONAS Carigali facilities.
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Personnel
Competent
Permit Applicant
PCSB/Contractors
Personnel
Offshore/Onshore
Installation Manager
Approving Authority (AA)
(OIM)
Operations Supervisor
/Maintenance Supervisor/
Authorised Supervisor (AS)
Senior Technician /
Technician
Senior
Approving Authority
Representative
Technician/Technician
Competent
Receiving Authority
PCSB/Contractors
Personnel
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Competent
RESPONSIBILITY
Permit Applicant
The person who applies for the PTW e.g.
the foreman/ supervisor / RA responsible
for planning and execution of the work and
may be a Company or Contractor
personnel.
The Permit Applicant shall be responsible for
the following:
Describing in detail the work activity to be
carried out;
Stating the tools and equipment to be used
, the number of personnel to do the work
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38 where the
RESPONSIBILITY
Approving Authority ( AA ) (Offshore/Onshore
Installation Manager)
The person responsible for approving the work
permit, shall ensure all precautions
are
specified, controls in place, and work is
performed in a safe and efficient manner. The
person
shall
verify
and
ensure
the
following:-
All hazards associated with the job are
identified and risks have been reduced to as
low as reasonably practicable;
The authorized work does not endanger other
ongoing operations in the facility;
The AAR is competent and aware of the
conditions as stated in the Permit/Certificate
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RESPONSIBILITY
All supporting certificates and documents
are
attached
and
made
known to
all
concerned parties;
Effective communication to ensure that the
work site is inspected before work begins,
suspended and on completion;
Effective handover for outstanding work after
each shift/crew change; and
The list of authorised PTW signatories is
regularly updated.
Note : Without Approving Authority's
signature you cannot start
a Job
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RESPONSIBILTY
Authority to Delegate
When on a remote facility, the Approving
Authority
may
delegate
his
roles
and
responsibilities
to
an
Authorised
Supervisor/AAR.
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RESPONSIBILTY
Therefore AA has a big responsibility. Simply
said:
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RESPONSIBILTY
Authorized Supervisor (AS)
(Operations Supervisor/Maintenance
Supervisor/ Production Supervisor or any
person
authorized by AA)
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RESPONSIBILTY
The authorized work does not endanger other
ongoing operations in the facility,
All supporting certificates and documents
are attached and made known to all
concerned parties,
All the required equipment and PPE are
adequate for completion of work safely,
Effective handover for outstanding work after
each shift/crew change.
The list of authorised PTW signatories is
regularly updated.
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RESPONSIBILTY
Authority to delegate
When on a remote facility, the Authorised
Supervisor may delegate his roles and
responsibilities to an AAR.
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RESPONSIBILTY
Approving Authority Representative (AAR)
A competent person delegated by the AA
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a remote
facility, I
can be a
3 in 1
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RESPONSIBILTY
Receiving Authority RA
(The RA may also be the Permit Applicant and/or
Work Leader. )
The RA who is responsible for planning and
supervising the safe execution of the work
shall ensure that:
All personnel involved in the work activity
shall receive adequate PTW training;
Job is fully discussed with the AS and AA;
The PTW top copy is displayed at the work
site and the work party briefed on the PTW
The precautions are maintained throughout
the work activity;
The workers understand that if circumstances
change, work must stop and advice47 sought;
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RESPONSIBILTY
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RESPONSIBILTY
Work Leader (WL)
(The WL may also be the Permit Applicant and/or RA ).
RESPONSIBILTY
Work Crew
A team of workers who carryout the job and
shall:
Not start work unless a permit is approved
and issued
Use all the required PPE
Receive briefing from their WL on the
particular task, understand hazards and
precautions to be taken.
Leave the worksite and equipment in a safe
condition upon completion of work.
Stop work if in doubt or if circumstances
change and inform the WL/RA.
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Sec 4 -Pg-4
RESPONSIBILTY
Authorized Gas Tester - AGT
A person who is trained to meet the requirements of
DOSH Malaysia Code of Practice or equivalent Host
Countrys Authority for safe working in a confined space
and industry practices on gas testing, and is authorized
by PETRONAS Carigali to carry out gas testing and
recording in the PTW. If different tests are used, the
authorization may be specific to the type of test. AGT has
the authority to withdraw a PTW if condition is unsafe.
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RESPONSIBILTY
Appointed Person (AP)
A person, especially trained for certain duties (e.g.
isolation/de-isolation
of
electrical
equipment,
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RESPONSIBILTY
Authorised Competent Personnel (ACP)
A person also referred to as the Chargeman,
who is registered with Energy Commission and
authorised by Management. He has sufficient
technical knowledge and experience to enable
him to avoid danger and who can have
authority delegated to him, according to his
knowledge and experience to carry out
operations in power systems and work on
electrical equipment.
He has the authority to issue and cancel
Electrical Isolation Certificate (EIC) and Limit
of Electrical Access ( LoAC ) on Electrical
Equipment/System.
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RESPONSIBILTY
Contractor Management
PTW training is MANDATORY for all
contractor personnel who work under a PTW
system.
Contract Management shall ensure all
their employees who work in PETRONAS
Carigali
facilities
are
trained
and
competent in the PTW system.
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RESPONSIBILTY
Dual Skilled Personnel
A person trained and competent in two work
skills
In the application of this PTW System this
person shall;
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PERMIT
In PETRONAS Carigali there are two different PTW documents :
1.A Cold Work Permit (an A4 document).
2.Cold/Hot Work permit (an A3 document)
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PERMIT
1. A Cold Work Permit (an A4
document).
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COL
D
PTW
57
PERMIT
2.
A3
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PTW58
RA
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SECTION 3
AS to identify with a Y or N all the
worksite preparation / Precautions.
AAR to implement as required and initial.
Write additional precautions
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5
4 the work permit is
AAs signature
to certifies
2
now closed . ( 5 )
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AS writes Y or N.
All boxes must be filled
RA
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Condition compile by RA
AS indicate with a cross (
X ) all the
precautions/conditions
AAR implements all the
specified
precautions/conditions
as identified in the Hot
Work permit and signs
at the bottom of the Hot
Work Permit
Endorsed by
AS
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PTW VALIDITY
1. Permits are valid for the period it is issued
or a maximum of one shift (i.e.) 8 12
hours.
2. Equipment remains the same.
3. Work activity remains the same.
4. Crew/workers remain the same.
5. Work site conditions remain the same.
6. All the required signatures are in place.
Note: A Work Permit may require several
certificates before it may be validated.
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PTW VALIDITY
EXCEPTIONS
EXCEPTIONS
Revalidation can be given for a shift
extension of a cold work permit for a
particular work shift of the same crew.
(Section 7 of the Cold Work Permit)
Note: Extensions granted shall not extend
into the next day
Revalidation for up to seven days ( 7 )
can be given for wireline work, as long as
the work is performed by the same crew
on the same well.
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PTW CANCELLATION
If there is an Emergency Shut Down (ESD),
General Platform Alarm (GPA) INCLUDING
false alarm or an emergency drill,
All work must STOP immediately.
Work sites must be secured and made
safe
All personnel proceed to their designated
muster stations.
Before work activities may resume,
All Hot Work permits and associated
certificates, within the affected areas of the
emergency shall be cancelled and82new
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CERTIFICATES
The PTW system has twelve (12) certificates.
Each is intended for a specific purpose, as the
name implies, and each has a coloured border of
diagonal
stripes.
No Certificates
Color Indication
1 Confined Space Entry Certificate (part of A3 PTW)
2
Purple
Maroon
Excavation Certificate
Lifting Certificate
Radiation Certificate
Dark Blue
Royal Blue
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10
Red
Dark Green
Orange
Yellow
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CONFINED SPACE
CERTIFICATE
Forms part of the A3 PTW. Confirms that a
competent person has:
Checked the work site of a planned
confined space entry.
Identified the hazards within & the controls
to ensure a safe work environment.
An important part of the Confined Space
Certificate is the Confined Space Checklist:
The Confined Space Entry Checklist is a list
of work site conditions that must be
checked by the AS before a PTW can be
issued.
This checklist shall be used in conjunction
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84
SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
The
Safety System Bypass/Override Certificate (SSB
OC
) shall be used for work on process, mechanical
and instrument equipment. A safety system
bypass/override certificate confirms that: One or more of the process control and F&G
safety system have been bypassed to
prevent accidental S/D.
You can carry out the work on that
equipment
process/mechanical/instrument
without an accidental S/D.
Examples of work requiring SSBOC are such
as
1. Hot work in an area with UV/IR detectors
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2. Maintenance of FWP
SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
The bypassing/overriding/isolating/defeating
of Safety Critical Equipment (SCE) MAY BE
ALLOWED for the following reasons:
Maintenance Activities
Faulty SCE
Other consideration
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SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
THE FOLLOWING SCE SHALL NOT BE
BYPASSED:-
Pressure relieve devices e.g. Pressure Relief
Valve, Pressure Vacuum Relief Valve etc;
Thermal relieve devices; and
Electrical overload relay
Risk assessment shall be conducted, prior to
bypass/isolation/defeating of SCE.
Note: The detail requirements of the SSBOC are defined i
n the WW ALL S 04 019 PCSB Bypass of Safety Critical Equ
ipment Guideline.
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SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
VALIDITY AND EXTENSION
Bypass/override/isolation/defeating of SCE should
be allowed for a maximum period of twelve weeks
( 12 ) , subjected to weekly re-validation. In cases
more than 12 weeks, e.g. due to faulty SCE, the
extension should be allowed with the following
conditions:
Maximum cumulative bypass shall not exceed 48
weeks;
A more detail risk assessment required before
the approval beyond 12 weeks;
Weekly revalidation;
The Approving Authority shall be escalated for
each extension as tabulated in Table 1 and Table
2; and
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A
permanent
solution/mitigation
shall
be
SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
90
SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE
Note :
Bypass/override/isolation/defeating
of SCE
should be allowed for a maximum period of
12 weeks, with weekly revalidation.
In
cases
where
bypass/override/isolation/defeating of SCE is
more than 12 weeks, e.g. due to faulty SCE,
the extension shall be allowed for a maximum
period not exceeding 48 weeks.
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ISOLATION CERTIFICATES
The isolation certificate confirms that
the equipment has been drained of liquid,
depressurized of gas and isolated from
other equipment in the operating facility
and from power sources.
Isolation Certificates consist of the
following : Electrical Isolation Certificate
Physical Isolation Certificate
Radiation Certificate
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ISOLATION CERTIFICATES
Energy isolation shall be required during
service, inspection, installation, modification
and/or maintenance of live equipment and/or
pipeline.
Energy isolation may also be required to remain
in place although none of the above being
carried out due to the following reasons:
Mothballed
equipment,
which
may
be
becomes
ISOLATION CERTIFICATES
All energy isolation shall be approved
through
the
application
of
Physical
Isolation
Certificate
(PIC),
Electrical
Isolation Certificate (EIC) and Radiation
Certificate (RC). The energy isolation shall
only be carried out after the issuance of an
approved PIC, EIC or RC.
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ELECTRICAL ISOLATION
CERTIFICATES
The
Electrical Isolation Certificate shall
be
used for work on electrical equipment, and
confirms that an authorized and competent
person has:
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EI PROCEDU
RE
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PHYSICAL ISOLATION
CERTIFICATES
The Physical Isolation Certificate shall
used for work on process lines
equipment, and confirms that :-
be
and
RADIATION
CERTIFICATES
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RC
PROCEDU
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RE
EXCAVATION CERTIFICATES
The
Excavation Certificate shall
be
used
whenever excavation deeper than 150mm is
planned. This certificate confirms that a
competent person:
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EC PROCE
DURE
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LIFTING
CERTIFICATES
ROAD OBSTRUCTION /
CLOSURE CERTIFICATES
The Road Obstruction certificate is used when
the closure of any road may affect the passage
of vehicles particularly for emergency response
vehicles.
ROC PROCE
DURE
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VEHICLE ENTRY
CERTIFICATES
The Vehicle Entry Certificate is used whenever
vehicles are
required to enter process areas that are
controlled by the Permit
to Work system.
VEC PRO
One PTW is valid for more than one certificate
CEDURE
Each certificate is valid for one vehicle
Mechanical Technician must check the vehicle.
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LOEAC PR
OCEDURE
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ELECTRICAL TEMPORARY
INSTALLATION CERTIFICATE
The
Electrical
Temporary
Installation
Certificate is used for control of temporary
electrical installation set up such as
generator set, ELCB and power cable.
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DIVING CERTIFICATE
The Diving Certificate is used for control of
diving activities during inspection and
maintenance of subsurface structures and
facilities.
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DISPLAY BOARD
PTW Display Board
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108
109
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PTW PREPARATION
CO-ORDINATION
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PTW PREPARATION
Proper planning of the work to ensure:
Approval is obtained
All are aware of the safety precautions
All are aware that there shall be no
interaction with other work activities
Adequate time is available for identification of
potential
hazards,
implementation
of
precaution and worksite preparation
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PTW PREPARATION
HAZARD ASSESSMENT
The following shall apply in the assessment of
Hazards
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PTW PREPARATION
TYPES & CATEGORIES OF WORK
The following are some of the work activities
but not limited to:
Maintenance and repair work
Any work that may generate sparks or
ignition
Hook up and commissioning
Well services
Electrical work
Excavation
Diving
Confined space entry
Working at heights
Work on equipment which contains or has
contained flammable or toxic materials
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Work that uses dangerous substances
such as
Preparation
of the Permit
PTW PREPARATION
ISOLATIONS
An essential component of any safe system of
work is the method and integrity of the
isolation procedure.
The isolation principle to be adopted, prior to
carrying out maintenance or repair, shall be
determined by a number of factors, such as
potential for pressure, dangerous substances,
moving machinery and other hazards.
Reference shall be made to WW ALL S 04 018
PETRONAS
Carigali
Energy
Isolation
Procedure.
Plan and record on a working drawing that is
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current and valid
PTW PREPARATION
Ensure
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PTW PREPARATION
Isolations continue
Isolations must be secured and shall be:
Highly visible
Impossible to de-isolate
Simple to apply
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Preparation
of the Permit
PTW PREPARATION
Isolations continue
Padlocks
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PTW PREPARATION
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PTW PREPARATION
ISOLATIONS Lockout Tags
121
PTW PREPARATION
ISOLATIONS Lockout Tags
PTW PREPARATION
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PTW PREPARATION
ISOLATIONS CONTINUE
Operation personnel/AAR shall be the first and
the last person to place/remove LOTO devices.
Exceptions shall be given to electrical isolation
and isolation of ionizing radiation source
where the ACP/AP or RPS/RPO is the first to
install the lockout tags on the isolation device
and last to remove when the job is completed
For any system with positive isolation,
minimum of two (2) Operation personnel shall
present to conduct or to witness the isolation
(in cases where the isolation is carried out by
Contractors).
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PTW PREPARATION
ISOLATIONS CONTINUE
In cases where electrical isolation is required, the
Operation personnel shall accompany the ACP/AP to the
equipment breaker location. The ACP/AP shall then
isolate the breaker and install LOTO devices (red tag).
The Operation personnel shall then place LOTO devices
on the breaker (blue tag). The breaker number and
location including the lock and tag numbers shall be
recorded on the EIC.
For electrical isolation, after the LOTO devices were
placed at the breaker, the Operation personnel shall
conduct equipment testing at the field e.g. local
mounted START/STOP for the particular equipment with
the presence of ACP/AP to confirm energy is isolated.
Once the isolation is confirmed, the isolation point is
then fitted with LOTO devices by Operation personnel
(blue tag).
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PTW PREPARATION
ISOLATIONS CONTINUE
For
physical
isolation,
the
Operation
personnel shall conduct equipment testing to
confirm the energy is isolated for mechanical
and hydraulic equipment. The AA or his
delegates (for remote facilities or satellite
platform) shall present to witness the testing
and verify energy has been isolated. The AA
or his delegates (for remote facilities or
satellite platform) shall then sign on the PIC.
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PTW PREPARATION
ISOLATIONS CONTINUE
Never assume..
127
PTW PREPARATION
ISOLATIONS FOR MAJOR S/D ACTIVITIES AND
SIMULTANEOUS OPERATIONS
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PTW PREPARATION
GAS TESTING
As a minimum requirement, the following shall
apply for work
activity where there may be a hazardous
atmosphere:
Gas testing is done at the workplace, prior to
commencement and during work activities to
check the level of oxygen, flammable and
toxic gases.
This is to alert personnel involved should the
environment become dangerous.
Gas test result shall be recorded 129
and timed
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PTW PREPARATION
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TRAINING AND
COMPETENCE
Training is mandatory for all PETRONAS
Carigali and contractor personnel who
issue, receive and work under a
PTW
system. Written examination and other
suitable assessment shall be carried out
after the training. Records of PTW and
related training should be kept by HR
Department.
Note : The validity of the training shall be
three (3) years.
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TRAINING AND
PTW SIGNATORY MATRIX
COMPETENCE
The minimum training requirements for
different parties in PTW system are:
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LEVEL 1
LEVEL 2
LEVEL 3
MONTHLY PTW
AUDIT BY
DEPARTMENT/ASSET
133
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RETENTION OF DOCUMENTS
Top and Second copy of all completed permits,
certificates and other relevant documents must
be retained for seven (7) years.
The permit, certificate and all relevant
documents relating to any incident shall be
kept throughout the duration of the life of the
plants/facilities
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Audit findings
LEGISLATION
CHANGES
FEEDBACK FROM
OPERATION OF
SYSTEM
PERMIT TO WORK
SYSTEM
AUDIT
FINDINGS
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REVIEW OF
INCIDENT REPORTS
INDUSTRY
GUIDELINES
COMPANY
POLICY
140
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Thank
You
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Process
Hazard
Job
Hazard
Behavioral
Hazard
HEMP PTW
HEMP - JHA
BBS
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