WORK PERMIT SYSTEM

By
Narendra Kumar
Deputy Manager (Fire & Safety)
Bongaigaon Refinery
Indian Oil Corporation Limited
Contents :
1. Definition of work permit
2. Terminology
3. Work Requiring permit
4. Work Not Requiring Permit
5. Types of work permit
6. Responsibilities of GSI/FPI/Issuer
7. Responsibilities of Receiver
8. Procedure for Hot Work & General Instruction
9. Procedure for Confined Space Entry & General Instruction
10. Gas test for work permit.
11. Work at height Permit
12. Excavation Permit
13. Radiation Permit
14. Electrical Permits
15. Case Study
16. Any Queries
Definition of Work Permit

 A work permit is a document giving permission for

specific work, at a specific work location, to be carried
out, subject to certain stated conditions and with in a
specified period of time.

 Safety work permit is a written document authorizing

person to carry out work, warning them of the
concerned dangers and spelling out the precautions
needed for carrying out the job safely.

Its an agreement between

two parties i.e Issuer &
Receiver to carry out job
safely.
Terminology Description
Gas Safety GSI means a designated officer authorized to perform all
Inspector / necessary tests before signing a work permit. He must
Issuer satisfy himself by a personal inspection that the tank /
vessel /line /equipment/ any other confined space involved is
safe for the work intended. He can independently issue Cold
work permit and permit for working at height.
Fire Permit FPS means a designated officer authorized to issue work
Signatory / permit. He is ‘Fire Permit Signatory’/‘Issuer’ in case of Hot
Issuer work/ Vessel entry/ Excavation permit and for any other
permit. He issues the permit for the particular job after
addressing the checklist points of permit for the units/ areas,
where he is the in-charge. FPS will sign the permit after
getting satisfied that GSI has carried out all the tests/checks
and signed the permit.
Receiver The ‘Receiver’ the designated person authorized to receive
(Permittee) work permit. Receiver generally is the executing department
officer, who has to execute the particular job for which
permit has been issued. The executing officer can be
Engineer In-charge / Site in-charge of the job or any other
nominated officer for executing dept. (normally service dept).
 WHY PERMIT TO WORK?
 Permit specifies the conditions and procedure for safe execution.

 Basic purpose of permit system is to prevent injuries to personnel

 Maint. Personnel are not adequately familiar with process

conditions.

 Operation will determine that it is safe to perform the designated

job.

 Protect property from damage

 Avoid fire

 Ensure that all work is carried out in safest possible manner.

REQUIRMENT OF WORK PERMIT
Permit is required for the following jobs :

 Major & Minor Maint. work.

 Inspection.
 Construction.
 Alteration.
 Process Equip. cleaning
 Entry into confined space.
 Excavation.
 Electrical job.
 Height jobs etc.
 Work at height
 Handling of materials using mechanized means in
operating areas
 Erection and dismantling of scaffold
 Radiography
 Isolation and energisation of electric equipment/ facilities
 WORK PERMIT NOT REQUIRED

o Routine welding / cutting and similar maintenance / fabrication

jobs carried in Central workshop
o Routine sampling for the purpose of laboratory analysis

o Entry of stores vehicle for loading / unloading of material /

Chemicals at safe place in the plant.

o Jobs carried out during emergencies (fire/ explosion, rescue,

uncontrolled release of hazardous chemicals etc.) to control the
emergency.
o Work carried out at construction site with management approval
(except permit for hot work, radiography and working at height)
Type of Definitions
Permit
Hot Work An activity that can produce a spark or flame or other
source of ignition having sufficient energy to cause ignition,
where the potential for flammable vapors, gases, or dust
exists. This includes all works, which produces spark,
running of IC engine, breaking of concrete, use of ordinary
torches, use of battery operated devices etc.
Cold Work Cold Work is an activity that does not produce sufficient
heat to ignite a flammable air- hydrocarbon mixture or a
flammable substance
Work at Height Any activity that is carried out at 2.0 meters & above on
temporary structure, scaffolds or on a structure not meant
to do particular job safely.
Confined Space It is an enclosure with known potential hazards and
restricted means of entrance and exit. It is not meant for
normal occupancy of people and is usually not well
ventilated such as vessels, boilers, storage tanks, large
diameter piping etc. The excavation more than 1.2 M deep,
entry into floating roof tanks, when roof is more than
Type of Work Definitions
Excavation An Excavation is any man-made cut, cavity, trench, or
depression in an earth surface that is formed by earth
removal. A Trench is a narrow excavation (in relation to its
length) made below the surface of the ground. In general,
the depth of a trench is greater than its width, and the
width (measured at the bottom) is not greater than 15 ft
(4.6 m).
Blanket Permit The hot work permit issued to areas after due consideration
to safety (the fire hazard is minimum and hazards due to
adjoining facilities taken into consideration) with approval
of local management for a maximum period of 1 month.
Such permit shall not need shift-wise renewal, however the
executer has to ensure that permit conditions are complied
throughout the work period.
Radiation Any activity that is carried with a source of ionizing
Work radiation, which does not produce sufficient heat to ignite
a flammable air- hydrocarbon mixture or a flammable
substance.
 Type of Permit

o Cold Work Permit

o Hot work Permit
o Entry into Confined Space Permit
o Working at Height Permit
o Excavation & Dyke Cutting Permit
o Road Cutting & Road Blockage Permit
o Electrical Isolation and Energisation Permit
o Radiation permit
Responsibility of Gas Safety Inspector / Issuer :
 To prepare the equipment/ facility/ area properly prepared before handing
over for Maint./ Repair/ construction / inspection as per written down
procedure.
 Ensure that equipment/ facility and area is safe for particular work.
 Permit is properly filled up and precautions are categorically mentioned.
 Gas test has been carried out, if required. (mandatory for hot work and
entry into confined space).
 Ensure all necessary precautions have been taken so that the
atmosphere remains under control during the work.
 Avoid giving general/ vague remarks on permit, which is not specific.
 For working at height, ensure that there is provision of safe access to the
work site and there is provision of ladder/ platform/ scaffold for safe
execution of work. Check those scaffolds provided are with green tags.
 Ensure positive isolation of energy.
 Close the permit on completion of work and retain the copy for at least
three months.
 Don’t sign the permit without authority.
Responsibilities of Fire Permit Signatory (FPS):
 FPS shall check the permit, submitted by GSI to assess the safety requirement
mentioned in the permit for their adequacy and may check physically
some critical checklist compliance such as gas test, isolation, tagging,
LOTO implementation etc. and recommend corrective measures before
signing the permit.

 For all critical activities, he will thoroughly check the work site condition
(such as hot work in running unit / near OSW lines, working at height,
entry in confined space, radiography etc.) and compliance of permit
conditions at site before signing.

 With his experience he may visualize additional hazards/ risks in jobs,

which needs to be addressed and will add this in permit for compliance.

 Before signing he shall ensure that conditions mentioned in permit by

GSI is fully complied at site.

 He should withdraw the permit, if the conditions in permit/ clearance is

violated or the job is no more safe due to some other reasons. The
information about the withdrawal should be communicated to all
concerned.
Receiver (Permittee) / Executing Authority:

 On issue of permit, Receiver (Permittee) should go through the permit and

pass the instruction down the line as has been mentioned in the permit for
compliance. In case of any doubt, he should clarify from Issuer.
 Ensure that precautions mentioned in the permit are complied at site.
 Ensure that equipment being used is safe to perform the task in particular
area.
 Ensure that all power driven equipment including the cables, insulation of
cables & cable joints etc. are as per standard and are maintained in healthy
condition.
 Make the permit available at work site all the time during the work.
 Work at specified location only.
 Ensure use of approved type of spark arresters on exhaust of every IC
engine.
 The checking and certifying including providing tag on each scaffold shall be
the responsibility of executing authority.
 All jobs shall be done as per established maintenance practices and relevant
safety norms.
 Check and ensure availability of valid medical fitness certificate for
workmen, working at a height of 2M or above under “Work at Height” permit.
 Clear the site on completion of work.
 Close the permit on completion of work and hand it over to issuing authority.
 General Points “Cold Work, Hot Work/ Entry to
Confined Space Permits”
 Equipment / Area inspected: Must to ensure that it is safe to carry out the
work and assess other safety requirements / stipulations.

 Surrounding area checked / cleaned: Unsafe conditions for performance of

work may arise from surrounding area. It should be cleaned-up to remove
flammable material such as oil, rags, grass etc.

 Sewers, Manholes, Closed Blow Down (CBD) etc. and Hot Surfaces
covered:

 Hazard from other routine / non-routine operations considered and

persons alerted:

 Equipment electrically isolated and tagged: LOTO ensured

 Running water hose / Portable extinguisher provided / Fire water system

available:

 Equipment blinded / disconnected / closed / isolated / wedge opened:

Blinds should be installed as close to the equipment as possible. If lines cannot be
blinded, these should be disconnected and the open ends should be made safe by
installing pipe caps / plugs, blind flanges etc.
 Equipment properly drained / depressurized:
 Equipment properly steamed / purged:
 Equipment water flushed:
 Gas / Oxygen deficiency test done
 Shield against sparks provided
 Proper ventilation and lighting provided
 Proper means of exit provided
 Area cordoned off and caution boards provided
 Portable equipment / Hose nozzles properly grounded
 Trained Attendant provided for entry to confined space
 Standby personnel provided for fire watch from Process / Maintenance /
Contractor / Fire Department:
 Iron Sulphide removed / kept wet
 Checked spark arrestor on mobile equipment:
 Checked for oil / gas trapped behind lining in equipment:
 Communication Facility to stand by persons :
 Attendant person with rescue equipment/ SCBA
 POTENTIAL RESIDUAL HAZARD

 Lack of oxygen

 CO, SO2 or any other toxic gases

 Combustible gases

 Corrosive chemicals

 Steam / Condensate

 High humidity

 Any Others
 PROTECTION MEASURES
In addition to standard PPEs like Helmet, Safety Shoes, handgloves
etc, to be mentioned.
 Protective clothing
 Hearing protection
 Safety Harness
 Eye protection
 Face protection
 Respiratory protection
 Keep fire equipment stand-by
 Life Line
 Any Other
Procedure for Hot Work Permit
 General Instruction for Hot Work

Permit shall be valid for a shift only.

For renewal of work clearance, the issuer shall ensure that the conditions are
satisfactory for the work to continue.

Permit shall be considered issued for job after “Clearance renewal” is signed.
This clearance on the same permit can be renewed / extended This clearance on
the same permit can be renewed / extended up to a maximum of seven calendar
days, except in case of plant shutdown, where permit can be issued for a
maximum period of 15 days. Blanket permit may be issued for a maximum
period of 30 days.

Conduct Job Safety Analysis for Critical Equipments.

In case of fire alarm all work must immediately be stopped

Only certified vehicle / engines and permitted type of electrical equipment

operating areas.

Welding machines should be located in non-hazardous and ventilated areas.

Gas test is mandatory. Pre Use check of Gas tester.

 General Instruction for Hot Work…Cont

Daily Toolbox talk / safety briefing to be ensured by the permittee before start
of job and record to be maintained.

Permit issuing authority, RSM & F&S personnel or any authorized person
can check the permit and stop the job and even cancel the permit on safety
norms violation any time.

In case of gas welding/ cutting, cylinders (acetylene cylinder must) should be
kept in upright position and these should be easily identifiable by its colour.

Hose connections of gas cylinders should be checked before starting of hot job.
The hoses must be free from all cuts & kinks and distinct in color (Maroon for
acetylene and black for oxygen).

Executor must ensure use of proper PPEs during hot work.

In case of welding/ cutting/ gauging etc., it should be ensured that spark is
arrested at site only, especially while carrying out hot work at height.

Executer shall ensure use of flash back arrestor in gas cylinders while using
oxy-acetylene sets. Use welding lighters only to light the welding torch.
 General Instruction for Hot Work…Cont

 While carrying out hot work inside confined space, proper ventilation and
illumination should be ensured before start of job.

Electric cable shall be free from joints with sound insulation. Portable
electrical equipment should have no loose connections.

All portable/ mobile electrical equipment shall be connected with ELCB

Executor shall ensure that the lifting machine (Crane), tools & tackles are
properly tested and SWL and date of testing is displayed on equipment.

Barricading of the area below lifting machine (Crane) should be ensured before
carrying out the job.

Executor shall ensure that all vehicles entering inside battery area, spark
arrestor is on exhaust. Vehicle shall move on designated route only.

Executor must know the nearest Fire Alarm point, Fire Order, Fire Station
phone number, nearest safety shower, escape route and siren code of refinery.
 Procedure for Entry into Confined Space

Pre Entry Checklist (Annexure – I)

Entry into Confined Space Permit (Annexure – II)

Attendance sheet for persons inside confined space

(Annexure – III)

Confined Space Box-up Clearance (Annexure – IV)

Dos & Donts for Entry into Confined Space (Annexure – V)

 General Instruction for Entry into Confined Space.

Preparing the equipment & Gas test. Issuing authority shall determine the
requirement of gas test & frequency of re-checking.

Vessel entry, where no hot work is to be carried out, may be permitted if

combustible gases are up to 5 % of lower explosive limit (LEL). Entry with an
air-supplied mask may be permitted with LEL of up to 20%. The Oxygen
level should be at least 19.5% vol. and the concentration of toxic gases below
the threshold limits (TLV of H2S – 10 PPM & CO-50 PPM ).

When a person is entering confined space, the receiver must keep minimum
two trained attendants-designated persons at the manhole or entry point.

Wherever forced ventilation is used. The gas test should be carried out
after minimum 10 minutes of stopping the eductor / fan / blower.

Use suitable respiratory protection for entry in the confined space having
O2deficiency or having toxic gases more than TLV.

Attendant should be available all the times at man way entry for resuce /
till the work is in progress inside. The permit should be available with him
and he shall maintain attendance in prescribed form.
 General Instruction for Entry into Confined Space…Cont

Attendant must be in constant touch with persons working inside and

know the actions to be taken in case of emergency.

The low voltage light limited to 24 V should be allowed inside confined

space. All electric connection shall be provided with ELCB.

 Wherever possible lifelines with safety harness should be used.

Special precautions are required for entry into inert gas atmosphere. It
requires the controlled condition inside confined space as well as mandatory
use compressed breathing air supply to person going inside with alternate
air supply arrangement.

Use Personal gas monitors while entering inside. Use SCBA where there is
likelihood of accumulation of gas during the work such as in severs, OWS
line etc

Carry out regular gas test of confined spaces, where there is possibility of
generation due to nature of work being performed inside line cleaning of
sludge, hot works etc.
GAS TEST FOR WORK PERMIT

Why gas test is required ?

 Most of the gases are unwanted
Hazards involved -
 Flammability(Fire & Explosion)
 Toxicity(health hazard)
 Oxygen Deficiency

Common flammable gases/liquids in refinery are -

 All petroleum products, Crude and intermediates
 Hydrogen
 LPG
 Common toxic gases in refinery -
 H2S, CO,NH3,CL2, etc.
 GAS TEST CONTD.
Terminology Description
Flash Point Minimum temp. at which a liquid gives off sufficient vapor to
form an ignitable mix. It will give a flash, flame will not
continue.
Auto Ignition The lowest temp. to which a substance will ignite without a
Temp. spark or flame.
Explosive Limit The concentration range of vapor in air when propagation of
flame(ignition) occurs in presence of an ignition source.
LEL (Lower The minimum concentration of vapor to air required to
Explosive Limit) propagate(ignite) flame.
UEL(Upper The maximum vapor to air conc. above which propagation of a
Explosive Limit) flame will not occur(will not ignite).
TLV (Threshold The maximum permissible conc. of a toxic substance to which
Limit Value) exposure of a person will have no adverse effect on health for
working 8 hrs per day.
STEL(Short Term Maximum conc. to which worker can be exposed for a period of
Exposure Limit) 15 mins. without any adverse effect to health.
IDLH(Immediate A maximum conc. from which one can escape within 30 mins.
Danger to Life & without irreversible health effect.
Health)
 GAS TEST CONTD.
Gas LEL UEL Flash Point AIT
(% Vol) (% Vol) (degreeC) (degreeC)
Hydrogen 4 75 Gas 585

Methane 5 15 Gas 538

Propane 2 9.5 104 466

Naphtha 1.1 5.9 -18 288

ATK/ATF 0.7 5.0 35-50 210

Diesel 0.7 5.0 32-96 256

Fuel Oil 1 5 66 262-407

GAS TLV STEL IDLH Remarks

Flammable, colorless gas with a strong,
NH3 25 PPM 35 PPM 300 PPM
intense, suffocating odor.
CO 50 PPM 400 PPM 1200 PPM Toxic as well as flammable. Odorless
Highly toxic, combustible, colorless.
Smells like rotten egg. Not detectable to
H2S 1 PPM 5 PPM 100 PPM
nose at higher concentration

SO2 2 PPM 5 PPM 100 PPM Non-flammable and toxic gas

 Procedure for Working at Height

Scaffold Safety (ISMS-1007)

oPre Erection Scaffold Checklist (Annexure – I / II/ III)

oScaffold Pipes, Boards & fittings (Annexure- IV)
oSafe Erection of Scaffold (Annexure – V) – Standard Scaffold
oInspection of Ladder (Annexure – VI)
oTypes of Scaffold (Annexure – VII)
oPersonal Protective Equipment (Annexure – VIII)
oPermit for working at Height & Medical Certificate (Annexure – IX)

This permit will be issued in Triplicate. This permit shall be valid for a period of 8
hours only, unless it is renewed/ extended. This clearance on the same permit can
be renewed/ extended up to a maximum of seven calendar days.
Concerned area HODs & Executing HODs signature is needed for permit beyond
normal working hours (8.00 Hrs to 17.00 Hrs.)/ round the clock/ Sundays &
holidays.
 General Guideline for Working at Height
Risk Assessment by Issuer & Receiver

Fitness Certificate of all workers working at height.

Standard Scaffold erected, checked, certified & tagged (Green) on weekly

basis.

Scaffold erected on firm ground and sole plate & base plate provided.

Hanging baskets used of proper construction, tested and certified for the
purpose.

Work platform made free of hazards of all traps/ trips/ slips & fall.

Edge protection provided against fall from roof/ elevated space.

Ensure use of Fall protection systems.

 General Guideline for Working at Height

Platforms provided with Toe board, guardrail & area below is barricaded.

Checked whether safety harness & necessary arrangement for tying the
life-line, fall arresters etc provided to the worker for working at height.

Have precaution been listed below for safe working at height for source of
energy Such as electricity

Proper means of access to the scaffold including use of standard aluminum

ladder.

The raised work surface properly illuminated

Is the workers are working near unguarded shafts, excavations or hot line?

Provision of collective fall protection such as safety net.

Inspection of Fall protection equipments before use. Ensure Healthiness of

fall protection equipments.

All works at height shall be discontinued during rain/ high wind/ floods.
 PROCEDURE FOR EXCAVATION / ROAD CUTTING /
DYKE CUTTING / ROAD CLOSUREPERMIT
 Initiate Excavation Clearance (Annexure – III) by executor(A grade and above)
by filling all the entries and attaching sketch/indicating on permit form
 Clearance from EL maint./ Telecom,F&S,Civil,PN/Area in charge
 Registered at Fire Station.
 This clearance shall be obtained for a maximum period of 15 days, except at
construction sites, non-operational areas, where it shall be for a maximum period
of 1 month.
 For cutting of road in addition to this clearance, format for Road Closure and
Excavation permit shall be required.
 For Road Cutting, approval of HOD of issuing Dept & for Dyke cutting DGM of
issuing Dept. is required.
 Format for Road Closure (Annexure – IV)
 Format for information about Main Road Closure (Annexure – V)
 On completion , permit closure and return to Fire Station/ Area in charge.
 General Instruction for Excavation

 All excavations and open trenches must be barricaded around the

opening.
 Warning lamp can be used for operating area and roads during darkness
(use FLP type fixture in hazardous area).
 There must be sufficient and safe means of access and escape for
excavated sites.
 Excavation area should be free from fumes/ gases heavier than air
because it may cause asphyxiation or poisoning.
 All excavation of depth more than 1.2 M or more should be treated as
Confined space and permit for entry into confined space should be
obtained.
 Excavation to a depth of 1 M or more shall be cut stepped back to give a
suitable slope or securely held by bracing so as to avoid the danger of
side to collapse.
 All trenches 1.2 M or more in depth shall at all time equipped with at
least one ladder for each 100 feet length of excavation or fraction
thereof. All such ladders shall be extended from bottom of the trench to
at least 1 M above the surface of the ground.
 General Instruction for Excavation..Cont

Barricading of 1M height (with red & white band/ self glowing caution
boards) should be carried out for excavation beyond 1.5 M depth.

All cutting shall be carried out from top to bottom.

Practice to giving permission to cut half road and utilizing half road for
movement of vehicle should be avoided, unless the conditions mentioned in
Sl.–4(Don’ts) is complied.

Use suitable PPE as per job requirement mentioned in work

Excavated earth shall not be dumped within 1 M of the edge of the

excavation or depth the trench whichever is more.

No vehicle should be allowed to go too close to the edge of the excavation
because it may cause side collapse. Maintain at least 2 M distances from the
edge of the excavation.

No mechanical excavation is to be carried out up to a depth of 1.5 M from

the ground level in operating areas. In such cases manual excavation is
required to be carried out up to a depth of 1.5 M from the ground level.
 Procedure for Radiation Permit.

Permit is to be issued by area in-charge and registered at Fire Station).

Part-I to be filled up radiography agency.

Radiation Site Incharge from Inspection dept.

In case of working beyond office hours, HOD/RSM is apprving authority.

Radiography should preferably be carried out at a time, when occupancy

is least

Supervisor must be available at site during the radiography work.

Radiological Safety Officer” designated by the employer and who in the

opinion of the competent authority is qualified to discharge the
functions under Rule-13 of The Gazette of India No.-44, Oct’30, 1971.

The distance for barricading is decided by RSO depending upon on

strength of radiation source, occupancy factor and radiation work load.
Electrical Isolation and Energisation Permit and
Clearances Format

o“Electrical Isolation and Energisation Permit-HT”

o“Electrical Isolation and Energisation Permit-LT”

o“Permit to work on High Tension (HT) Line /Equipment”

o“Permit to work on Low Tension (LT) Line /Equipment”

o“Trip Reset Clearance Certificate for HT Equipment”.

o“Trip Reset Clearance Certificate for LT Equipment”.

 Surrendering the work permit

On completion of a Cold work, Radiation and Working at height,

the permits (original with copies) shall be signed by permittee and
returned to the issuer. The issuer shall retained in chronological
order in folder for a period of minimum 3 months from the date of
closure of permit or from the date of commissioning of facilities,
whichever comes later .

On completion of a “Hot work/ Entry to Confined Space” and

“Excavation”, the permit (original and copies) shall be signed by
permittee and returned to the issuer along with clearance
certificate. The issuer will then send the permits to F&S
Department along with their copies. F&S Department shall record
the completion of the job and keep the permits (with all copies) for
record. Hence, after completion of the job, shift in-charge of F&S
shall retained the copies of various permits in chronological order
in folder for a period of minimum 3 months from the date of closure
of permit or from the date of commissioning of facilities, whichever
comes later.
 Case Study
Incident – 1: In one of the Unit, clearance was given for fixing the
operating wheel on sample line of propylene, but due to wrong interpretation
the bonnet of valve was opened and which led to a major fire accident.

Incident – 2: In one of the Unit, clearance was given for cleaning of

burner in the furnace, but due to miss communication wrong burner along
with the line was opened and due to which there was small flash fire.

Incident – 3: In Shut down clearance was given to carry out hot job at
elevation and at bottom the draining operation was in progress. Due to which
there was small fire. In permit it was clearly mentioned to contain spark
locally.

Incident – 4 : During cutting of over head pipe line in offsite at one of the
refinery due to miss communication wrong naphtha line was cut and there
was fire.

Incident – 5 : During excavation in one of the refinery. The permit was

given on condition that manual digging is to be done, but JCB was used
instead and power cable was cut and there was chance for electrocution.