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Permit To Work System Training

REV 2 SEPT 2011

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PETRONAS CARIGALI PTW

SYSTEM

PETRONAS CARIGALI
PTW STANDARDISATION REV 2.
SEPT 2011

8/3/15

PETRONAS CARIGALI PTW

SYSTEM

Selamat Datang

Permit To Work System Training

Please sign the attendance sheet
Write your name on the folded paper
Switch off your hand phone or silent mode
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No Smoking within this Building

Safety Briefing

f you hear an Alarm,

The fire exit door

One near the Toilet on you right and

One near the toilet on your left

Both will be unlocked and you can exit.

Assemble at the Visitors Car Park area.

You are
here

Wait for further instruction from the Fire Warden

4

About the Trainer

My Name : William Kong
Married 4 Children 2 boys & 2 girls
- independent
Asal Miri, Sarawak
1975
1994
1997
1999
2001
2011
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1994 Sarawak Shell Berhad

1996 Fochi-EP-JV Bintulu
1998 PCSB Turkmenistan
2000 SMDS Reconstruction Bintulu
2010 PCSB, SKO, Lutong, Miri
Present - Freelance
5

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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8

INTRODUCTION
Why the need for a PTW system in PETRONAS
Many fatalities have occurred. Inadequate
precautions for working in hazardous area and
confined spaces.

June 2001 Malaysia - 9 died in a ship. + Other

incidents worldwide. Most cases- Flammable
atmosphere, Toxic gases or oxygen deficiency

Lack of coordination and control activities.

Executing more than one task at the same time.

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INTRODUCTION

Sub contracting of work to contractors. No

experience working in confined space

No proper work procedures and equipment for

working in confined space

Failure in PTW key management system

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10

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11

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12

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13

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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14

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

15

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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Be Trained and competent

Identify risk associated with any work
activity and how these are to be avoided.
Take all the precautions.
Ensure their work does not interfere or
affect with that of others.
16

PURPOSE OF THE PTW

SYSTEM
BASIC UNDERSTANDING OF THE PERMIT TO
WORK SYSTEM
Four ( 4 ) Important things that we must
protect

1. Personnels Safety
2. Environment Prevent polluting the sea,

land & atmosphere

3. Asset Facilities or Equipment for
producing Oil & Gas
4. Reputation of our Company ( PETRONASs
and yours)
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17

PURPOSE OF THE PTW

SYSTEM
To protect PERSONNEL

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18

PURPOSE OF THE PTW

SYSTEM

To protect Environment

KOREAS WORST OIL

SPILL
HEBEI SPIRIT
DEEPWATER HORIZON.
BURNING AND GOING DOWN

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19

PURPOSE OF THE PTW

SYSTEM
To Protect Asset

DULANG B PROPERTY
DAMAGE, 1 APR 2009 CRANE
BOOM FALL ONTO MAIN DECK

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FIRE INCIDENT AT BEKOK C

PLATFORM
20
TH
ON 14 DECEMBER 2010

PURPOSE OF THE PTW

SYSTEM

To protect the company reputation

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21

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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23

DEFINITIONS

Certificat
e

Written and signed statement

indicating that the specified checks
or tests that have been carried out
by an authorized person and the
conditions are acceptable.
Certificates do not replace the PTW
but are complementary.

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24

Hot Work

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DEFINITIONS

Hot work is any work where HEAT is

used and generated.
Examples of hot work are :
* Welding,
* Flame cutting,
* Grinding,
* Grit blasting,
(positive
ignition sources)
Any
work which may generate
incentive sparks or other sources of
ignition e.g. taking of photograph
using camera with flash, use
of
non-intrinsically safe equipment,
including opening
of junction
boxes, Local Control Panel (LCP)
25
(potential ignition sources).

DEFINITIONS
Cold Work

Any work other than hot work as

defined in the previous slide.
Example of cold work;
erect / dismantle of scaffolding ,
Housekeeping etc.

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26

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

An area where all work require

to be controlled by a PTW
System

Work
Description

Work as specified in the PTW

form

Display Board Which displays all active work

permits at an installation /
facility. It is normally located in
the main operation control
room
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28

DEFINITIONS
Gas
testing

Gas testing is done to check a

workplace,
prior
to
the
commencement and during work
activities for the level of oxygen,
flammable and toxic gases. This is
to
alert
personnel involved
should the environment become
dangerous.

Hazard
Assessme
nt

An evaluation of the potential

hazards, their severity and
likelihood associated with any
work activity.

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29

DEFINITIONS
Isolation
source of

A physical barrier between a

energy and a place of work

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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30

DEFINITIONS

Override/Bypa The temporary bypass of a

ss
safety device, to allow bypass
certain work to proceed without
causing an unnecessary process
shutdown or fire alarm (e.g.) fire
detectors
overridden during
welding operations

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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

The period of time (as defined)

during which an
approved
document such as the PTW,
Certificate and other documents
in this PTW system is valid for its
intended
purposes
Test
The period
of time during which a
Equipment test equipment is valid for its
Validity
intended use.

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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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PTW SIGNATORY MATRIX

Signatories

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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37
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
8/3/15,the exact equipment or location
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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39

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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40

RESPONSIBILTY

Authority to Delegate
When on a remote facility, the Approving
Authority
may
delegate
his
roles
and
responsibilities
to
an
Authorised
Supervisor/AAR.

The Permit Applicant and the Approving

Authority/Approving Authority Representative
SHALL NOT BE the same person.
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41

RESPONSIBILTY
Therefore AA has a big responsibility. Simply
said:

If anything goes wrong with a work activity

or an incident takes place, this person takes
the full responsibility and answerable to
Management and other authorities.

This person must therefore ensure the workers

:

trained in the PTW system

trained and competent in their own
work
42
activity

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RESPONSIBILTY
Authorized Supervisor (AS)
(Operations Supervisor/Maintenance
Supervisor/ Production Supervisor or any
person
authorized by AA)

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The person is responsible for ENDORSING

the PTW.
Ensures all precautions are specified.
Controls and recovery measures in place
Work is performed in a safe and efficient
manner
Issue the PTW to the applicant after final
approval
43

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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44

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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45

RESPONSIBILTY
Approving Authority Representative (AAR)
A competent person delegated by the AA

Shall implement all the precautions as

specified in the PTW.

When on a remote facility, AAR may be

delegated as an AA & AS.
Note: AAR may request for Authorised Gas
Tester or carry out the gas test himself if he is
a competent AGT.
When on

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a remote
facility, I
can be a
3 in 1

46

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

The work crew stays within the limitations as

defined in the PTW; and
On completion or suspension of the work, the
site is left in a safe condition and the AS
and/or AA informed.

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RESPONSIBILTY
Work Leader (WL)
(The WL may also be the Permit Applicant and/or RA ).

The WL who is responsible for planning and

supervising the safe execution of the work
shall:
Confirm the site conditions as required by the
PTW and agree by signing;
Brief the work crew on JHA and PTW
conditions;
Supervise the work and remain at the work
site at all times;
Ensure there is no deviation from any
condition as defined in the PTW; and
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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,

synchronizing, etc.) and has sufficient technical

knowledge and experience to enable him to avoid
danger. For him to execute the Works he MUST be
under written Instructions and Appointment from
PETRONAS Carigali Resident Electrical Engineer as
provision in Electricity Regulations 1994 or the
Host
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52

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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53

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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54

RESPONSIBILTY
Dual Skilled Personnel
A person trained and competent in two work
skills
In the application of this PTW System this
person shall;

Assume only one role in this Permit

This person can be either RA or AAR

Note : Dual Skilled person cannot apply and

approve for the
same PTW.
I am a 2 in 1 Prod.
Tech &
Inst Tech.
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55

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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56

PERMIT
1. A Cold Work Permit (an A4
document).

The Cold Work Permit (A4 document) has a

solid green border.
For work in non-hazardous AREA, the Cold
Work Permit may
require the support of
Certificates.
In case of doubt as to whether a work
activity require a PTW, it may be subjected
to PTW requirement if deemed necessary
by the Approving Authority.

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COL
D
PTW

57

PERMIT
2.

The Cold/Hot Work permit (an

document) comprises of the following:

Cold Work Permit

Hot Work Permit

Confined Space Certificate

A3

It is required when any work activity is

considered capable of producing a source of
ignition or using/ generating heat.
Note !! It is mandatory that a gas test be
conducted before any hot work permit and
A3
confined space certificate is issued.

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PTW58

A4 COLD WORK PERMIT

SECTION 1
Details of permit applicantAS writes Y or N.
All boxes must be filled
Work description
And allocates work permit no.
Permit number and Zone classification

RA
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A4 COLD WORK PERMIT

SECTION 2
Identify with a cross ( X ) all possible
HAZARDS related to the work activity

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60

A4 COLD WORK PERMIT

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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61

A4 COLD WORK PERMIT

SECTION 4

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RA / AS to indicate with a cross ( X ) the

relevant and additional personal
protective equipment (PPE) required for
the job.

62

A4 COLD WORK PERMIT

SECTION 5

AS specify supporting certificate required .

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63

A4 COLD WORK PERMIT

SECTION 6
RA designates a technician /worker to be the
Work Leader.
AS nominates an Approving Authority
Representative (AAR)
AAR confirms by signing that precautions
have been implemented
WL confirms acceptance of responsibility for
work as described in Section 1 after
witnessing AAR implementing the
precautions.

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64

A4 COLD WORK PERMIT

SECTION 7
Endorse of the work by the AS
RA to sign acceptance of all conditions as
specified in the permit
Acknowledgement by other personnel as
identified by AA
Approved of the work permit by the AA

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65

A4 COLD WORK PERMIT

SECTION 8
Revalidation for a shift extension of a cold work
permit for the particular work shift of the same
crew .
Approving Authority signature required for any
cold work extension
AAR signature required to ensure AAR is aware
of the extension
WL signature required as this is the person
requesting for the extension
Extension time shall be specified

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66

A4 COLD WORK PERMIT

SECTION 9 - HANDBACK

WL signs off when work is completed ( 1 )

AAR confirms and signs off when work

completed ( 3)

AS Shall sign all copies of the work permit

thus acknowledging the work has been
1
3
completed. ( 4 )

5
4 the work permit is
AAs signature
to certifies
2
now closed . ( 5 )

RA confirms by signing when work has been

completed ( 2 )

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67

A3 COLD / HOT WORK

PERMIT
SECTION 1
Details of permit applicant
Work description
Special Instruction
Permit number and Area
classification

AS writes Y or N.
All boxes must be filled

RA
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68

A3 COLD / HOT WORK

PERMIT
SECTION 2
(Hazards / Hazardous
activities )
Identify with a cross ( X ) all possible
HAZARDS related to the work activity

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A3 COLD / HOT WORK

PERMIT
SECTION 3- WORKSITE PREPARATION /
PRECAUTION

Identify with a Y or N all the worksite

preparation / precautions.
AAR to implement as required and initial.

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A3 COLD / HOT WORK

PERMIT
SECTION 4 - PERSONAL PROTECTIVE
EQUIPMENT

Indicate with a cross the relevant and

additional personal protective equipment
(PPE) required for the job.

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71

A3 COLD / HOT WORK

PERMIT
SECTION 5- SUPPORTING CERTIFICATE
As Identifies with a cross ( X ) and number of
the specific certificate/s.

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72

A3 COLD / HOT WORK

PERMIT
SECTION 6 - JOINT SITE VISIT

RA designates a technician /worker to be

the Work Leader.
AS Nominates an Approving Authority
Representative (AAR) .
AAR confirms by signing that precautions
have been implemented
WL confirms acceptance of responsibility
for work as described in Section 1 after
witnessing AAR implement the
precautions.

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73

A3 COLD / HOT WORK

PERMIT
SECTION 7 - ACKNOWLEDGEMENT

Endorsement of the work by the AS

RA to sign acceptance of all conditions as
specified in the permit
Acknowledgement by other personnel as
identified by AA
Approval of the work permit by the AA

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74

A3 COLD / HOT WORK

PERMIT
IN THE HOT WORK PERMIT
SECTION ,

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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
75

A3 COLD / HOT WORK

PERMIT

CONFINED SPACE ENTRY CERTIFICATE

RA writes name of the
Standby person ( 1 )
and BA Coordinator
(2)
AS indicates with a
cross all the
precautions/conditions
that must be
implemented before the
permit is approved.
AS signs the CSE after
the precautions have
been implemented.
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AGT carry out a Gas Test

76

A3 COLD / HOT WORK

PERMIT
SECTION 8 - GAS TEST RESULTS

AGT to carry out a Gas Test and record

< 10% LEL OUTSIDE
the results
<1% LEL INSIDE
AGTs name and Signature

GAS TEST FOR ANY HOT WORK AND

CONFINED SPACE ENTRY

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77

A3 COLD / HOT WORK

PERMIT
SECTION 9 WIRELINE DAILY ENDORSEMENT

Revalidation for wireline works for up to

seven (7) days. As long as the wireline work
is performed by the same crew on the same
well.

Endorsement by AS and approve by AA for

extension of wireline work

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78

A3 COLD / HOT WORK

PERMIT
SECTION 10 ( SAME AS SECTION 8 IN CWP )
Work Completion Section.
WL signs off when work is completed ( 1)
RA confirms by signing when work has
been completed ( 2 )
AAR confirms and signs off when work
completed ( 3)
AS Shall sign all copies of the work permit
thus acknowledging the work has been
completed. ( 4 )
1
AA signature to certify the work permit 3is
now closed. ( 5 )
2

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79

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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80

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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81

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

Safety System Bypass/Override Certificate (SSBOC)

Electrical Isolation Certificate (EIC)

Purple

Physical Isolation Certificate (PIC)

Maroon

Excavation Certificate

Lifting Certificate

Radiation Certificate

Road Obstruction/Closure Certificate

Dark Blue

Vehicle Entry Certificate

Royal Blue

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10

Limit of Electrical Access Certificate (LoEA)

Red

Dark Green
Orange
Yellow

83

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
8/3/15 with the Confined Space Entry Certificate.
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
8/3/15
85
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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86

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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87

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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88
A
permanent
solution/mitigation
shall
be

SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE

VALIDITY AND EXTENSION

Table 1: Level of Approving Authority by Safety

Integrity Level (SIL)

For bypass of SCE due to maintenance activities with MOS, the AA

shall follow PTW AA.
For bypass of SCE due to faulty and/or maintenance without MOS,
SSBOC SL
the AA shall be based on the SIL.
8/3/15
89
IDES

SAFETY SYSTEM
BYPASS/OVERRIDE
CERTIFICATE

VALIDITY AND EXTENSION

Table 2: Level of Approving Authority by Risk Level

For bypass of SCE due to maintenance activities

with MOS, the AA shall follow PTW AA.
For bypass of SCE due to faulty and/or
maintenance without MOS, the AA shall be based
on the SIL.
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90

BSCE Training Slide

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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91

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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92

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:

Where work has commenced but is, or is

likely to be, suspended due to faulty e.g.
awaiting spares for a repair;

Mothballed

equipment,

which

required in the future;

8/3/15
Where an item of equipment
93

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.

For isolation of radiation source, it is

limited to isolation of equipment containing
radiation source and does not cover
transportation, storage and handling of
radiation source.
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94

ELECTRICAL ISOLATION
CERTIFICATES
The
Electrical Isolation Certificate shall
be
used for work on electrical equipment, and
confirms that an authorized and competent
person has:

Electrically isolated the equipment to be

worked on
Taken suitable precautions to prevent
accidental reconnection.

Note: the detail requirements of the electrical isolation

certificate are defined in the WW ALL S 04 018
PETRONAS carigali energy isolation procedure.

8/3/15

EI PROCEDU
RE

95

PHYSICAL ISOLATION
CERTIFICATES
The Physical Isolation Certificate shall
used for work on process lines
equipment, and confirms that :-

be
and

Process lines and equipment have been

drained of liquid, depressurized of gas.
Isolated from other equipment in the
operating facility
Suitable precautions taken to ensure
they remain isolated.

Note: the detail requirements of the physical

isolation certificate are defined in the WW ALL S 04
PROC isolation procedure.
018 PETRONAS carigali PIC
energy
8/3/15
96
EDURE

RADIATION

CERTIFICATES

The Radiation Certificate shall be used for

handling of Ionizing Radiation / Radioactive
Sources. This certificate confirms that :-

A Radiation Protection Officer (RPO) has

granted permission to use a radio-active
source; and

Related extra precautions have been taken.

8/3/15

RC
PROCEDU
97
RE

EXCAVATION CERTIFICATES
The
Excavation Certificate shall
be
used
whenever excavation deeper than 150mm is
planned. This certificate confirms that a
competent person:

Has checked the work site of a planned

excavation; and

Studied layout drawings to ensure that the

proposed excavation can be made without
damage to existing buried facilities such as
pipelines, drains and electric cables.

8/3/15

EC PROCE
DURE
98

LIFTING

CERTIFICATES

The Lifting Certificate is required for the

following lifts but not
limited to:-

1. Lifting over unprotected process equipment

or wellheads.
2. Lifting dangerous goods
3. Lift exceeding 8 tons
4. Lift inside confined space
5. Lift with slings not made of wire rope ( web
LFC PROC
sling)
EDURE
6. Lift with more than four legs
7. Multiple crane lift
8. Failure to fully illuminate load
9. Failure to fully illuminate path of load
8/3/15
99
10.
When removing or installing wellhead

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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100

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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101

LIMIT of ELECTRICAL ACCESS

CERTIFICATE
The Limit of Electrical Access Certificate is a
certificate of declaration signed and given
by a duly Authorized Competent Person
( ACP ) to person who is performing the
electrical works on site to cover works in
close
proximity
to
Live
conductors/equipment/apparatus, or Testing
of Live Voltage conductors.

LOEAC PR
OCEDURE

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102

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.

8/3/15

103

DIVING CERTIFICATE
The Diving Certificate is used for control of
diving activities during inspection and
maintenance of subsurface structures and
facilities.

8/3/15

104

DISPLAY BOARD
PTW Display Board

Usually located in the main operations control

room or designated by the plant management.
On a remote area can be at a Central Location.
All permits for the day are displayed on the
board so that:
Any interested party can view all the
work in progress.
Is another means of communication.

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105

SITE LOG BOOK

Each installation must maintain a current and

complete record of all PTW and certificates in
force at any one time.
This record serves as an information source
when issuing additional documents.
The log book must be maintained by the
permit issuer (AS) for each installation and
facility.
PTW
Log
Book

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106

SITE LOG BOOK

The following details shall be logged:

Type of permits / certificate issued

Reference numbers of all permits /
certificates
Work Location
Date and time of issue of all
permits/certificates
Date and time of closure of all
permits/certificates
Permits Valid and suspended
Equipment with extended isolation

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107

HOW ARE PTW / CERTFICATE

DISTRIBUTED
(Both Permit and Certificate)
The Top Copy or First Copy
Which has all the required signatures, to be
displayed at the work site when work is in
progress.
The Second copy (Tracking Copy)
to be held by the Authorized Supervisor at the
permit issue point whenever work is in progress.
The Third copy
to be held by the Receiving Authority (Applicant).
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108

TOOL BOX MEETING

Briefings by either the RA or the WL to the
work crew where:

Plan for the work activity is explained

Individual responsibilities are identified
Procedures reviewed
Hazards discussed
Refresher meeting if necessary
Conduct final identification of hazard of
worksite
conditions
and
verify
the
requirement stated in P.A.U.S.E card prior to
work execution
8/3/15

109

8/3/15

110

PTW PREPARATION
CO-ORDINATION

Usually the AA/AS who shall:

Retain overall responsibility for all work

activity

Ensure each work is carried out efficiently

Ensure one work activity does not interfere

with another work.

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111

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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112

PTW PREPARATION
HAZARD ASSESSMENT
The following shall apply in the assessment of
Hazards

WL shall provide details of work activity

Consideration given for safer alternatives,
hazards in process equipment and handling of
hazardous materials
Careful assessment of the surrounding area so
that hazards in that environment does not
affect the safe execution of the work

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113

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
114
8/3/15
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
8/3/15
115
current and valid

PTW PREPARATION
Ensure

All energy sources (mechanical and electrical)

are identified in isolation procedures
Padlocks/key numbered and recorded
Isolations are applied and removed on
instruction from AS.
If more than one task is to be carried out on
same equipment, de-isolation is done ONLY
when all work is completed.
WL, RA, AAR & AS check worksite if work is
not completed within the shift.

8/3/15

116

8/3/15

117

PTW PREPARATION

Isolations continue
Isolations must be secured and shall be:

Highly visible

Impossible to de-isolate

Provided with a tag label that identifies the

securing device

Simple to apply

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118

Preparation
of the Permit
PTW PREPARATION
Isolations continue
Padlocks

Each discipline shall have a known quantity of

SINGLE key padlocks

Padlock shall be stamped with number

Colour coded for each discipline

WL shall record issue and return of the

padlock

8/3/15

119

PTW PREPARATION

8/3/15

120

PTW PREPARATION
ISOLATIONS Lockout Tags

peration permanent plastic tag Chargeman permanent plastic ta

8/3/15

121

PTW PREPARATION
ISOLATIONS Lockout Tags

Disposable Tag for

use
with Lockout Box
(Paper / Tyvec or
similar material )
8/3/15

Disposable Tag with serial

number,
Duplicated
on
perforated section. Used to
Identify
Spade
/
Blind
location
(Paper / Tyvec or similar
122
material )

PTW PREPARATION

ISOLATIONS Lockout Tags

8/3/15

123

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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124

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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125

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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126

PTW PREPARATION
ISOLATIONS CONTINUE
Never assume..

That when an equipment / machinery is

isolated it will not be functioning
That when a job is too small it does not need a
lockout and tag out.

Note : Non compliance to lockout and tag out

can cause loss of lives
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127

PTW PREPARATION
ISOLATIONS FOR MAJOR S/D ACTIVITIES AND
SIMULTANEOUS OPERATIONS

Major Shutdown/ Simultaneous Operations

activities are complex in nature and are
normally well secured by:

PETRONAS Carigali Site Specific Procedures /

Specific Instruction for Simultaneous
Operations (SISO)

Procedures from Original Equipment

Manufacturers ( OEM)

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128

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

8/3/15

PTW PREPARATION

8/3/15

130

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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131

TRAINING AND
PTW SIGNATORY MATRIX
COMPETENCE
The minimum training requirements for
different parties in PTW system are:

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132

PTW INSPECTION & AUDIT

/MONITORING
THE TIERED STRUCTURE FOR SYSTEM AUDIT
ANNUAL
AUDIT
REGIONAL HSE

LEVEL 1

LEVEL 2

LEVEL 3

MONTHLY PTW
AUDIT BY
DEPARTMENT/ASSET

WEEKLY PTW AUDIT

BY APPROVING AUTHORITY

DAILY MONITORING OF PTW SYSTEM BY

LEVEL 4
AUTHORISED SUPERVISOR
& RECEIVING AUTHORITY
8/3/15

133

PTW INSPECTION & AUDIT

/MONITORING
E TIERED STRUCTURE FOR SYSTEM AUDIT
LEVEL 4 AUDIT DAILY
AS and RA shall carryout daily monitoring, as
a minimum the following:
Display of permit at site
Completeness of the PTW and PTW site
log book
All precautions in place, adequate and
implemented
Work party briefed on conditions in the
permit and work scope

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134

PTW INSPECTION & AUDIT

/MONITORING
E TIERED STRUCTURE FOR SYSTEM AUDIT
LEVEL 3 AUDIT WEEKLY
The AA and/or AS shall carryout weekly Audit
as detailed out in Appendix II and
documented.

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135

PTW INSPECTION & AUDIT

/MONITORING
E TIERED STRUCTURE FOR SYSTEM AUDIT
LEVEL 2 AUDIT- MONTHLY
The Country/Region Production Department or
Division Project Head shall carry out monthly
audit as detailed in Appendix II and
documented.

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136

PTW INSPECTION & AUDIT

/MONITORING

LEVEL 1 AUDIT ANNUALLY

The Regional HSE Department shall carry out
annual review of the PTW system. This shall
include the Permits, associated Certificates, Job
Hazard Analysis, P.A.U.S.E and follow up on
previous audit findings.

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137

PTW INSPECTION & AUDIT

/MONITORING

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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138

PTW SYSTEM REVIEW

SYSTEM REVIEW
Changes and improvements shall be an ongoing
effort for continuous improvement. Custodian
shall take the following into account when
reviewing this system

Feedback from PTW Users

Audit findings

Gaps in PTW system as identified in incidents

reports

Recommendations from National and

8/3/15
139
International Regulations, Industry Guidelines

PTW SYSTEM REVIEW

Figure shows the structure of PTW
System Review

LEGISLATION
CHANGES

FEEDBACK FROM
OPERATION OF
SYSTEM

PERMIT TO WORK
SYSTEM
AUDIT
FINDINGS

8/3/15

REVIEW OF
INCIDENT REPORTS

INDUSTRY
GUIDELINES

COMPANY
POLICY
140

PTW SYSTEM REVIEW

Figure shows the structure of PTW
System Review

8/3/15

141

Thank
You
8/3/15

142

8/3/15

143

Process
Hazard

Job
Hazard

Behavioral
Hazard

HEMP PTW

HEMP - JHA

BBS

8/3/15

144