Ptw Slides

WELCOME TO PTW SYSTEM TRAINING WORKSHOP

Aim: To familiarize the participants with the purpose and applications of the PDOC PTW System

Objectives: Upon completion of the session, the participants should be able to: •

• • • •

Know the duties as employer under the OSHA Act Understand the applications of Permits and Certificates Know the responsibilities of various signatories under the PTW system. Understand equipment isolations , system override, atmosphere testing and so on as safe work conditions Complete the various Permits and Certificates for the relevant jobs

Module 1

Legal Requirement for PTW

OSHA • It shall be the duty of every employer to – Provide and maintain the plant and a systems of work that are as far as practical, safe and without risk to health.

Who Is Employer ?

• Employer means the principal employer or the immediate employer or both.

Principal Employer • Principal Employer – Owner of business or process – Not directly dealing with employees but their decision has impact on the employees.

Immediate Employer • A person representing the principal employer in discharging his management duties. • The lowest level of management is the supervisor • Supervisors, superintendent, heads of dept, managers, senior managers and above are all immediate employers.

Supervisor As Employer • A supervisor is an immediate employer as he is directly responsible for the safety and health of those who work under his supervision. • As far as is practical, the supervisor makes sure that the plant and the system of work are safe and without risks of health to all his workers as well as others.

Safe Plant • • • • •

Equipment used for work Equipment where work is performed Area of a plant Unit of a plant Electrical equipment

Safe System of Work • A system to ensure people work safely – – – – – – –

JSA PTW SOP LOTO Lift plan Check list and certificates Tool box talk etc etc

• Safety and health for the people, the plant and the environment are taken into consideration.

Safe Work Documents • SOP – This Safe Operating Procedure is established under the company procedure for a specific activity that is carried out on a regular basis. Requirements are clearly stated for safe work.

• JSA – This document is prepared and approved as a prerequisite to obtain a permit to work. It contains details of job steps, their associated hazards as well as corresponding control measures for each hazard, in order to perform the work without any accident.

Company Procedure • Company procedures should be an instruction to meet regulations and legislations • Standards should be at least the same as the Regulations • More stringent conditions or controls are recommended • Training must be provided to all workers as well as contractors • Compliance is mandatory

More Employer Duties • • • • • •

Provide information Provide training Give instruction Provide supervision Provide PPE Medical surveillance of workers health

As Far As Is Practicable • The equipment and the work methods are so prepared that they are safe • If any thing could be made safer, it was already done as far as practicable. • If any further preventive actions could be taken, they were already taken as far as practicable. • As far as is practicable means that all had been done to the best of our knowledge, experience, and within our available resources and cost.

Penalty • When an offender is prosecuted – The offender is guilty until proven innocent – The offender needs to establish that he had actually done as far as is practicable and he could not have done any further due to certain valid reasons ( which he has to prove )

• If offender convinced the jury, he would be free or otherwise be penalized.

General Penalty • Penalty for employer who offended - A fine not exceeding RM 50K or jail term

not exceeding two years or both.

• Penalty for employee who offended - A fine not exceeding RM 1k or jail term not exceeding 3 months or both

Module 2 What is PTW?

PTW • A safe system of work • Ensure work is carried out without risks to people, plant and environment • Documentation of precautions taken • A document that authorizes work to be carried out from start till completion. • A document to identify persons who are responsible for safe work.

Permits and Certificates • Permit when validated, can proceed with work activity. – it may stand alone or it may be accompanied by certificates.

• Certificate when completed, need to be attached to a permit. It contains details of isolations, tests results etc.It does not authorize work to proceed.

What PTW Contains ? • A work request statement and information • Specification of requirements for safe work • Equipment or area status is made safe and ready for work – Certificates are normally attached

• Names and signatures of those who are responsible. • Permit issue, revalidating and closing out documentation.

What Are Certificates? • A documentation of precautions taken to create a safe plant or equipment for maintenance work to be performed. • Designated Person or competent person perform isolation and precautions and sign for actions done on the certificates. • It is a supporting document to permit. • Certificate by it self is not a permit to work. • Certificates are closed out after permits are closed out.

Module 3

Permits and Certificates

Permit Areas • The permit is required for work activities carried out in the following areas. – Processing areas – Storage areas – Loading areas

Area Classification • Zone 0 – Gas is constantly present

• Zone 1 – Gas is present intermittently

• Zone 2 – Gas is not expected under normal operation

Permits & Certificates • There are FOUR different work permits (each has a solid colored border) • There are SEVEN different certificates (each has a colored border of diagonal strips)

Permits • Hot work permit – For all works that may become source of ignition – Only PDOC Person In-Charge may validate the permit

• Cold work permit – Non routine activity that has no potential for ignition – Only PDOC Person In-Charge may validate the permit

Permits (cont.) • Radioactive work permit (Blue) – Work involving x-rays, gamma ray and other radioactive source – Person In-Charge validates the permit

• Electrical work permit/ isolation certificate – Work on electrical equipment or electrical driven equipment – Person In-Charge /SEAP validate the permit/certificate

Certificates • Safety bypass (purple/white) – Override , forced signals, bypass

• Ground disturbance (brown/white) – Mechanical excavation deeper than 0.5M

• Scaffold (orange/white) – Construct, dismantle or modify temporary platform for work

Certificates (cont.) • Mechanical isolation (green/white) – For process and mechanical isolation – Lock and tags are to be used

• Electrical isolation (yellow) – For work on electrical equipment and electrical driven equipment.

• Lock out Devices and procedure – Application of locks and tags on isolation points.

Certificates (cont.) • Confined space (blue/white) – Preparations for entry of personnel to do work • Gas tests (red/white) – Check for safe atmosphere by trained gas testers

• Lift certificate ( – For lifting activities

/white)

Record keeping • Permits and certificates are to be kept for a period of 2 years • Document is maintained for any would be lesson learnt or investigation. • During the period if nothing is to be traced, they are destroyed

Module 4 Permits Responsibilities

Responsibilities • PTW Validation Authority – Remove or reduce hazards of the plant and equipment for worker’s safety – Protects the plant from risk brought by the work for plant safety.

• PTW Receiving Authority – Protects his workers and others from hazards of the work – Protects the plant and environment in which work is performed

Parties of Responsibilities • Person In-Charge – Managers or Superintendents in charge of the facility. – He validates the Permit

• Safe Work Permit Certified Supervisor – Supervisor who has been certified under the PTW system – He appoints designated person and has overall responsibilities for the job and safety – He specifies requirements

Parties of Responsibilities (cont.) • Permit Applicant – Supervisor , staff or contractor trained under the PTW system – He applies for permit to work and coordinate work activities

• Designated Person – Technician or foreman who carries out the precautionary works – He takes precautionary and preventive measures before and during work.

Parties of Responsibilities (cont.) • Authorized Gas Tester (AGT) – Person trained in use of gas test equipment and the gas testing techniques – He certify acceptable tests results

• Workers/Work Crew – Persons either staff or contractors performing the tasks.

Parties of Responsibilities (cont.) • Senior Authorized Electrical Person (SAEP) – Electrical engineer or superintendent authorized by the company as competent person for high voltage electrical work – He is the only person who may perform electrical isolation for HV equipment

Parties of Responsibilities (cont.) • Authorized Electrical Person ( AEP) – Authorized person is competent person who may perform electrical isolation on LV electrical equipment. – Operator may be competent person and perform isolation and de-isolation as an AEP. – AEP performs work or takes charge of work on electrical equipment.

Module 5

PTW Process

Copies of Permits/Certificates • Original to be displayed at worksite • First copy to be kept at Control Centre • Last copy to be kept by Permit Applicant

Requestor of PTW • Prepare necessary document – – – –

Method statement JSA Plans (if required) Drawing (if required)

• Initiate the permit • Designate a competent person (if deem necessary)

Specifying Requirement • Person In-Charge and SWP CS specify – – – –

Operations requirement Work requirement PPE requirement Special precautions needed

• They need to know the requirements of regulations or company procedures as well as best industrial practices.

Performing Requirement • Designated Person appointed to carry out the necessary requirements. – A certificate or check sheet is used to complete the requirement – Designated Person signed for completion – Details are recorded on the certificates – Certificates are attached to the permit.

Permit Validation • SWP Certified Supervisor verify & confirm completion of precautionary works • Person In-Charge validates

Work In Progress The supervisor in charge is responsible for what the workers do or fail to do. – – – – – –

Pre-work meeting is organized Workers are given information and training Clear instructions and full supervision Work must comply to procedures Work must comply to PTW conditions Safe work practices must be followed.

Re-validation of Permit • All copies required • Applicant, SWP Certified Supervisor request for revalidation • Person In-Charge revalidate permit and certificate. • Reason for revalidation

Permit Re-validation Permits are valid for a period specified – Permit and certificate need revalidation in order to extend the period of work – Revalidation to confirm conditions or precautions taken are still in tact – Worker and work supervisor are the same crew – If work supervisor is changed, a formal handover is required

Reason for Re-validation 1. 2. 3. 4. 5.

Operational conditions caused work to stop Construction conditions caused work to stop Unacceptable conditions had occurred End of work day/shift (normal expire time) Emergency alarm initiated.

Work Completion • • • •

Work site is reinstated back to normal Permit Applicant initiate work completion SWP CS inspect and confirm completion Person In-Charge endorse completion and authorize reinstatement of any isolations .

Module 6

Isolation

Isolation of equipment • • • • • • • •

Prepare for shutdown Shut down Isolation ( valves and switches ) Drain and depressurize Cleaning Testing Positive isolation ( mech.and elect.) Isolation certificates completed. – For confined space entry work – Ventilation and atmosphere testing – Atmosphere test document completed. • PTW authorized

Prepare for shutdown • Planning – Buildup stock – Reduce inventory in the equipment – Inform affected parties

• Shutdown – Stop process flow, close control valves – Stop operating equipment, push stop button – Initiate a shut down sequence button ( gas turbine )

Isolate equipment • • • • •

Close manual valves Close and chain lock valves Hand jack control valves Remove valve handles or hand wheels Switch off field switches

Drain and Depressurize • Depressurize equipment until a few bars left. ( 2 or 3 bar for low pressure flare ) • Drain the liquid till equipment is empty • Fully depressurize the equipment to zero pressure

Removing Process Hazards • Gas – N2 purging • Chemical – chemical wash to neutralize • Oils and greasy – hot water or wet steam wash ( confirm temp spec) • Wet services – water flushing • Wet H/C services - Water displacement

Testing • Sample – pH , lab test, litmus paper

• Atmosphere testing – O2 – Flammable gas

Mechanical isolation • • • • •

Remove spools and install blinds Install end blinds Install in line spades Double block and bleed valves Clamp or pin down moving part

Confirm zero energies before starting work

Electrical Isolation • • • • • •

Lock and tag open circuit Disconnect from power supply source Removal of fuses Discharging capacitors Disconnect battery terminals Testing to confirm circuit dead

Confined Space Work • Ventilation – Natural or mechanical

• Atmosphere tests – O2 – 19.5 - 23.5 % – Flammable gas < 10% LEL – Toxic gas < TLV ppm

Module 7

Permits Details

Section 1 • Facility – The name of the part of the facility in which work is to be carried out

• Equipment No. – Name of equipment, unit number or area specific name

• Date – Date of application

Section 2 • Work description – Direct sentence or phrase – Breakdown into points if possible – Clear and simple description

• Special work instruction – Instruction if not mentioned is not likely to be carried out. Non routine or non standard practice or specific site conditions to look out for.

Section 3 • Applicant’s name and signature • Nominate a designated person to be in charge of the work • Designated Person sign after being briefed about precautions to be carried out. • Specify work area classification by checking the appropriate box

Section 4 • Specifying requirement/precautions • To be completed by Person In-Charge and SWP Certified Supervisor. – All columns to be filled up (yes/no/NA) – Items not available on the list to be specified (4.3) – Specify PPE to be used during work (4.2) Initial column to be completed after the actions are taken by Designated Person. # certificate number to be filled up

Section 5 • Declaration by SWP CS signs the section to authorize the Designated Person to proceed with the precautions/actions required at section 4 • Actions performed by Designated Person – Initial section 4 (column with “yes” only) – Sign declaration at section 5

Section 6 & 7 • Permit Validation – Person In-Charge signs section 6

• Permit Revalidation – If work is not completed within the first validity period, revalidation becomes necessary – If work is interrupted by some reasons, revalidation is required before work may resume – Applicant, SWP Certified Supervisor and Person In-Charge sign section 7 stating the reason for revalidation

Section 8 • Permit close out • Applicant complete the tasks, house-keeping and sign close out section • SWP Certified Supervisor verify worksite ready to return to normal and sign close out section • Person In-Charge signs and authorizes isolations to be reinstated

End of Training

Thank You