GM 11 031 51

Work Permit System
This is a Controlled Document that complies with Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards. Please check that this is the latest available version before use. Title: Number: Version Number: Date Revised: Owner: Authoriser: Reasons for Creating or Amending Document
WORK PERMIT SYSTEM GM-11-031-51

10.0 02 July 2013 Nikola Maksimovic Melanie Jensen New Owner New or Amended Process Full Review of Document
Actual Change Details:
Reformatted Header & Footer, Detail added to refresher training in Section 3, Error corrected in regards to Out of Service Tags.
TABLE OF CONTENTS
1. 2. INTRODUCTION ................................................................................................................................. 3 DEFINITIONS & RESPONSIBILITIES ............................................................................................ 3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3. 4. 4.1 4.2 4.3 AREA OR BUSINESS UNIT MANAGER ...................................................................................... 3 PERMIT AUTHORISER .................................................................................................................. 4 ISOLATING PERSON ..................................................................................................................... 5 ISOLATION REVIEWER ................................................................................................................ 6 PERMIT HOLDER ........................................................................................................................... 6 TEAM MEMBER ............................................................................................................................. 8 WORK PERMIT REGISTER ........................................................................................................... 9 THE WORK PERMIT BOARD ........................................................................................................ 9 TASK HAZARDS ............................................................................................................................. 9 WORK AREA HAZARDS ............................................................................................................... 9 INCOMPLETE WORK ................................................................................................................... 10
TRAINING AND COMPETENCY ................................................................................................... 10 PLANT OR AREA BOUNDARIES AND CONTROL RESPONSIBILITIES.............................. 10 TRANSFER OF PRODUCTS ......................................................................................................... 10 KWINANA AREAS AND PRODUCTS ........................................................................................ 11 DAMPIER TO BUNBURY NATURAL GAS PIPELINE ............................................................. 11
GM-11-031-51 Version No. 10.0 Document last modified: 02 July 2013.
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5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6. 7. 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 8. 8.1 8.2 8.3 8.4 8.5 8.6 9. 10. PROCEDURE ..................................................................................................................................... 12 WORK PERMIT PREPARATION ................................................................................................. 12 WORKPLACE PREPARATION .................................................................................................... 12 WORK PERMIT ISSUE AND ACCEPTANCE............................................................................. 12 COMMON ISOLATION ................................................................................................................ 13 WORKING UNDER A PERMIT .................................................................................................... 15 INCOMPLETE WORK ................................................................................................................... 17 WORK COMPLETED .................................................................................................................... 17 COMMISSIONING URGENTLY REQUIRED EQUIPMENT ..................................................... 18 SCAFFOLDING .................................................................................................................................. 18 ISOLATION TAGGING AND LOCKOUT ..................................................................................... 18 PERFORMING AND PROVING AN ISOLATION ...................................................................... 19 REMOVING AN ISOLATION ....................................................................................................... 20 ISOLATION FOR WORK NOT REQUIRING A PERMIT WORK ............................................. 21 ISOLATION CHECKLIST ............................................................................................................. 22 ELECTRICAL ISOLATION .......................................................................................................... 23 TESTING AND JOGGING............................................................................................................. 23 PERMIT HOLDER ISOLATIONS ................................................................................................. 23 TAGS AND LOCKS IN THE WORK PERMIT SYSTEM ............................................................ 24 CERTIFICATES USED WITH WORK PERMITS ........................................................................ 27 HOT WORK CERTIFICATE ......................................................................................................... 27 CONFINED SPACE ENTRY CERTIFICATE ............................................................................... 27 HIGH VOLTAGE (HV) ACCESS AND TESTING CERTIFICATE ............................................ 27 EXCAVATION / PENETRATION CERTIFICATE ...................................................................... 28 RADIATION CERTIFICATE ........................................................................................................ 28 ASBESTOS / FIBRO CEMENT SHEETING CERTIFICATE ...................................................... 28 DISCIPLINE AND CONSEQUENCES ............................................................................................ 29 MONITORING AND REVIEW ........................................................................................................ 29 SPOT CHECKS............................................................................................................................... 29 AUDITS .......................................................................................................................................... 30 PERIODIC COMPLIANCE REVIEW ........................................................................................... 30
10.1 10.2 10.3 11. 12.
ASSOCIATED DOCUMENTS AND FORMS ................................................................................. 30 RECORD KEEPING .......................................................................................................................... 32
FIGURES
Figure 1 Work Permit System Flow Chart ................................................................................................... 33 Figure 2 Common Isolation System Flow Chart .......................................................................................... 34
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1.
INTRODUCTION
This document defines the Work Permit System at CSBP Kwinana Operations, where the Work Permit System is to: a. b. c. d. e. f. Authorise and control work other than work defined as work not requiring a permit. Ensure that hazards are identified and that appropriate controls are in place prior to work commencing and that they remain in place during the work. Provide a formal hand-over process to demonstrate that all hazards have been controlled to as low as reasonably practicable. Ensure that personnel carrying out the work are aware of the exact scope of work and the hazard controls specified. Ensure impact of all work on other activities and the operations is understood. Provide a formal hand-back process to ensure the work area is safe to return to normal duties when the work is completed.
This document applies to all employees, all contractors and all visitors to CSBP Kwinana. All work at CSBP Kwinana requires a Work Permit, other than work nominated by the Area Manager as work not requiring a permit. The work not requiring a permit is defined for each area and shall be displayed in the area where permits are issued and be signed by the Area Manager. This document describes the minimum particular safe work precautions and other requirements when establishing work controls under our Work Permit System. The Work Permit system involves the introduction of locks for isolation points, and for use by individuals to lock and tag onto the lock box for the permit of the job they are working on.
2.
2.1
DEFINITIONS & RESPONSIBILITIES

AREA OR BUSINESS UNIT MANAGER
The Area / Business Unit Manager is responsible for defining what work is work not requiring a permit and ensuring that this is displayed in areas where Work Permits are issued. They are responsible to ensure that all their personnel have been trained to the correct level of competence in the Work Permit System. Additionally they are responsible for the compliance of their personnel with the Work Permit System and holding their personnel accountable for any breaches. They authorise in writing: all of the Permit Authorisers and Isolating Persons for their area noting any limitations as to plant and equipment that these authorisations. Extensions to permit durations that might be required for extended shutdowns.
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2.2 PERMIT AUTHORISER
The Permit Authoriser is a person who has been authorised in writing by the Area/Business Unit Manager to authorise and issue Work Permits for a specific building, area, plant or section of plant for which they have been trained and assessed as competent. Competency must be able to be verified by training records: a. b. c. A detailed knowledge of the work environment and the process and area related hazards. Knowledge of the isolation requirements for specific plant or equipment i.e. also competent as an Isolating Person. Deemed competent to authorise permits as described in this document.
The Permit Authoriser is responsible for: d. e. f. g. h. i. j. k. l. m. n. Clarifying the exact scope of work with the Permit Holder (view Work Order if practical). Accepting requests for Work Permits from Permit Holders and agreeing the final set of hazard controls for the area to be made safe for a specific scope of work. Ensuring that a Job Safety Analysis (JSA) or Team Based Risk Assessment (TBRA) has been completed by the Permit Holder / Work Team. Implementing the Work Permit hazard controls defined in the Work Permit and Certificates. Authorising the Isolation Checklist for the specific scope of work and issues isolation locks to the Isolating Person. Confirming that all agreed hazard controls have been implemented and all necessary documentation has been signed off by authorised personnel. Confirming that the work site is safe for work and that any operational activities do not compromise safety in the work area. Briefing the Permit Holder on the hazard controls in place (vital for contractors). Authorising issue of the Work Permit and if required, Isolation Checklist and Certificates e.g. Confined Space, Hot Work etc. Revalidating the Work Permit at recommencement of work (on all 3 copies of the Permit). Managing the Permit Authorisers locks and keys including cross checking of the isolation key number against the key referred to on the Isolation Checklist when locking the Permit Board lock box. Managing the issue and storage of Isolation locks and keys.
o.
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p. q. r. Being aware of the work being carried out in the plant and any interactions from adjacent work activities or hazards. Ensure all certificates are correctly cross referenced to the Work Permit. Ensuring copies of all Work Permits are maintained on the Permit Board (yellow copy), the Permit Register is updated and the pink and blue copies of the Permit and associated documentation, is held secure by the Permit Authoriser. Providing briefing and handing-over the control of active Work Permits to new shift Permit Authorisers. Initiating removal of hazard controls following hand back of a Work Permit. Authorising closure of the Work Permit by signing off all copies of the Work Permit and the Work Permit Register. Filing Work Permit documentation in compliance with Section 13. Record Keeping.
s. t. u. v.
2.3
ISOLATING PERSON
The Isolating Person is a person authorised in writing by the Area/Business Unit Manager to isolate and remove isolations from plant, equipment or systems for which they have been trained and assessed as competent. Competency must be able to be verified by training records: a. b. c. To be able to perform and prove isolations. Knowledge of the isolation requirements for specific plant or equipment. Deemed as competent to isolate as described in this document.
The Isolating Person is responsible for: d. Developing the Isolation Checklist or assisting the Permit Authoriser to do so. Note: The person who develops the Isolation Checklist cannot be the person who validates that the checklist is appropriate for the Scope of Work. This is the role of the Isolation Reviewer.
e.
Establishing isolations of plant or equipment according to the Isolation Checklist to prevent inadvertent re-energisation which may cause injury to others or damage to plant or equipment. Confirming the isolations by conducting a Try Step or a Test step to verify that a zero energy state exists (in conjunction with Control Room operators where DCS input is required).
f.
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g. Tagging all isolation points using either Work Permit Isolation Tag or Common Isolation and reference on the tag: 1. 2. 3. 4. h. Work Permit number applicable, The date of the isolation The name of the Isolating Person, and The system being isolated, when using a Common Isolation Tag.
Isolating with a lock and tag and placing the key in the relevant Permit lock box and informing the Permit Authoriser who then immediately locks the lock box. Until the lock box is locked by the Permit Authoriser the Isolating Person is responsible for the key. De-isolating equipment according to Permit Authoriser requirements.
i.
2.4
ISOLATION REVIEWER
Competency required: a. Same as an Authorised Isolating Person.
The Isolating Reviewer is responsible for: b. c. Verifying that isolation of energies according to the requirements of the Isolation Checklist will generate a safe situation for the scope of work nominated. Signing on the Isolation Checklist that the isolation is appropriate.
Note: For Standard Isolation Checklists an Isolation Reviewer will already have completed this task. This is likely to be the Document Authoriser of the Standard Isolation Checklist.
2.5
PERMIT HOLDER
The Permit Holder will normally be a worker under a Work Permit. The exception will be in the case of major shutdowns where a Permit Holder is a full time supervisor of a large range of Work Permits. In this case they cannot be working on equipment under a Work Permit they are purely a supervisor. Working on equipment is defined as any hands on activity that may or may not involve tools and may alter the state of the equipment being worked on. Note: The exception noted above for shutdown Permit Holders does not apply to Confined Spaces, where the Permit Holder shall always be a worker on the task.
The Permit Holder is responsible for the work being done at all times during the life of the Work Permit. The Permit Holder role can be transferred to another qualified Permit Holder during the works. Competency required:
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a. b. c. d. e. f. Knowledge of the work to be completed as per the scope of work. Knowledge of the Work Permit System as described in this document. Passed the competency assessment for Permit Holder. Area specific induction in which work is to be conducted. Specific skills related to the work being performed (e.g. High Voltage, Radiation, Hot Work, Confined Space Entry etc.). Knowledge of hazard control requirements for the Certificates that will apply to the work.
The Permit Holder is responsible for: g. Presenting to the Permit Authoriser a scope of work that describes at least: 1. 2. 3. Note: What is going to be done Where it will be done (equipment number if applicable) How long it will take.
The scope of work maybe a JDE work order or scope of work under a contract, but must contain the items listed above. Inspecting the work site, understanding the scope of work before commencing the task. Participating in and understanding the JSA or TBRA risk assessments. Signing Permit acceptance on the Work Permit once they understand the extent of hazard controls that have been established and need to be maintained. Retaining the original (white copy) of the Work Permit and associated documentation. Documents shall be available to work team members at all times. Briefing the work site team on the hazard controls in place and the JSA or TBRA. The JSA or TBRA shall be kept at the job site with the original copy of the Work Permit and any certificates that might be required Ensuring that the Permit Authoriser Lock secures the isolation lock key before placing own Personal Danger Lock with Tag on the lock box. Ensuring each work team member signs onto the Work Permit (blue copy) and attaches their Personal Danger Lock with Tag to the correct Permit Board lock box in line with this procedure. Ensuring that work performed remains within the defined scope of work.
h. i. j. k. l. m. n. o.
p.
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q. r. s. t. Ceasing work and informing the Permit Authoriser when any hazard controls have been breached. Where necessary, handing over the work activity and Work Permit to a new Permit Holder at shift change or during work progress. Inspecting the work site before commencing / recommencing work and at the end of shift or completion of work. Confirming that the work site is left in a safe state when work is completed or work has stopped for the day by: 1. 2. 3. 4. that the area is clear Checking that all work team members remove their Personal Danger locks with tags signs off the blue copy of the Work Permit and briefs the Permit Authorisor. signing off the all copies of the Work Permit and any certificates associated with the job (if the work is completed).
2.6
TEAM MEMBER
A Team Member(s) is the person doing the work supervised by the Permit Holder. Competency required: a. b. c. An understanding of the site Work Permit System Area Specific Inductions in which the work is being conducted. Technical skills to perform the work (e.g. Hot Work, Confined Space Entry training etc.).
The Team Member is responsible for: a. b. c. d. Understanding the job scope of work and the hazard controls that have been implemented for the defined work. Participating in the review or development of the job JSA. Signing onto the blue copy of the Work Permit, (this is only necessary when the team member first starts on the job). Attaching their Personal Danger Lock with Tag to the Permit lock box on commencement and removing at the end of their shift. The information on the tag will include the name of the team member, date and Permit Number of the job being worked on. Ensuring that they follow the hazard controls defined in the Work Permit and Certificates. Leaving a clean and safe work site.
e. f.
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2.7 WORK PERMIT REGISTER
The Work Permit Register is used to track Work Permits that have been issued and yet to be signed off. For common isolation i.e. a set of isolations that are part of the hazard controls for more than one Work Permit, the Common Isolation Work Permit Register is used to record all the subordinate Work Permits. Note: During shutdowns electronic work permit registers can be used in place of paper copies.
2.8
THE WORK PERMIT BOARD
This board is located in the permit control area and is used for displaying the yellow copy of the Work Permit and associated Permit documentation, the lock boxes that secure the isolation key(s), for attachment of Permit Authorisers Lock and Personal Danger Locks with Tags. Note: Each area should consider numbering the individual lock boxes for easy reference when multiple jobs are in progress.
Following the locking of the isolations; isolation keys shall be placed in the lock box associated with the Work Permit and secured with a Permit Authorisers lock Any person authorised to work under a Work Permit shall lock their Personal Danger Lock with tag attached on to the lock box for the Work Permit they are working on regardless of whether there is an isolation lock key in the box. The key to the Permit Authorisers lock shall remain with the Permit Authoriser at all times. Each Permit Authoriser shall have a key to the common keyed Permit Authorisers locks. The Permit Authorisers Lock shall only be removed from the Lock Box after: a. b. c. d. the white, yellow, pink and blue copies of the Work Permit have been signed off as completed by the Permit Holder, all Personal Danger Locks with Tags have been removed from the Permit lock box, the area has been left safe and the equipment is safe to be returned to service or when managing changes to a Common Isolation.
2.9
TASK HAZARDS
Task hazards are those directly associated with the completion of the task and may be assessed by using a JSA or a TBRA.
2.10
WORK AREA HAZARDS
The right hand side of the Work Permit form is a risk assessment of hazards related to the work environment where the task is to be completed. .
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2.11 INCOMPLETE WORK
This is work that has been either completed but can not be commissioned or because work on the job has stopped for some other reason.
3.
TRAINING AND COMPETENCY
Structured training based on National Competency Standards shall be given to all users of the Work Permit System, including contractors to CSBP. Standardised training modules shall be established for the following: a. b. c. d. Permit Authoriser Isolating Person Permit Holder and Working under a Work Permit
Permit Authorisers and Isolating Persons require detailed knowledge of the area in which they are authorising permits or carrying out isolations. Such knowledge shall be achieved as a prerequisite to gaining a competency in the Work Permit System. Competency records for all personnel shall be maintained on database. There is an expectation that people will meet the required critical safety refresher training. This should be conducted prior to or as soon as practical after the refresher period of two years.
4.
PLANT OR AREA BOUNDARIES AND CONTROL RESPONSIBILITIES
Each Area is responsible for the issue of Work Permits for work within their plant or area boundary. The issue of Work Permits shall be managed from the designated permit issuing area. The Work Permit System main physical areas of responsibility are shown on a site plan called Work Permit System Kwinana Works - Main Areas of Responsibility (IF2494). Areas of work that do not fall into obvious plant or area boundaries are described below. Assuming that all training and competencies can be verified all combinations of roles within the Work Permit System are allowed except that the Isolating Person cannot be the same person as the Isolation Reviewer.
4.1
TRANSFER OF PRODUCTS
Where fluids (ammonia, acid, steam or condensate etc) are transferred between areas, the lines and associated equipment are the responsibility of the sender up to the building boundary or the receiving plant boundary. Where lines and associated equipment can be fed from two or more
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plants, a Work Permit for the appropriate isolations is required from each plant. The plant/area in which the work is to be conducted shall issue the Work Permit for the work in which the Permit Holder and Team Members shall work from. Where solid material (ammonium nitrate prill or fertiliser etc) is transferred between areas, the solids handling equipment (conveyors or transfer chute) and materials are the responsibility of the sender until the material falls from the last conveyor or belt into the receiving area.
4.2
KWINANA AREAS AND PRODUCTS
Fluorosilicic acid and sulphuric acid despatch, sulphuric acid and liquid import systems are the responsibility of the Fertiliser Manufacture Process Team. Ammonia storage tanks, ammonia transfer lines, ammonia filling and associated equipment are the responsibility of Ammonia Teams (AP2 and ALF). Ammonia import and export is the responsibility of the Ammonia Team. Solids materials activities on the Kwinana Bulk Jetty are the responsibility of the receiving or sending Business Unit. The Bore Water System is the responsibility of the Ammonia Plant. The liquid fertiliser tank farm is the responsibility of the Fertiliser Production Liquid Fertilisers. Works services, such as roads, scheme water, gas, transfer pipelines (e.g. ammonia to BHP) and electrical services outside of plant boundaries are the responsibility of Field Engineering.
4.3
DAMPIER TO BUNBURY NATURAL GAS PIPELINE
CSBP draws gas from the Dampier to Bunbury Natural Gas supply pipe (DBNGP) as a feed for Ammonia production. This pipe supplies high pressure gas from the Northeast corner of the property to the Southwest corner of the Ammonia and Ammonium Nitrate Central Control Room. A 2.5 metre safety zone is in place either side of this pipeline. This is known as the DBNGP corridor. The management of this pipe and corridor is covered by the Dampier to Bunbury Pipeline Act 1997 and the following restrictions apply; 1. 2. No work is allowed within the 5 metre wide (2.5m either side) corridor without written approval from and supervision by DBNGP field officers. Earth works that involve heavy machinery and vibrating rollers or plate compactors is not allowed within 20 metres of the DBNGP.
Any personnel required to carry out such activities within the in the above areas are to seek permission from Field Engineering. Approval for work will be sought from the Department of Regional Development and Lands by Field Engineering.
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5.
PROCEDURE
Refer to Figure 1 Work Permit System Flow Chart for a summarised overview of the Work Permit
5.1
WORK PERMIT PREPARATION
The Work Permit (form PF2462) is the key document associated with the permit system. The Permit Authoriser is responsible for the management of the Work Permit; however other personnel also have responsibilities. When a Work Permit is requested, the Permit Authoriser shall prepare the Work Permit documents (including arranging for any certificates that might be required) agreeing with the Holder the final set of hazard controls based on the Work Area Hazard Identification/Precautions section of Work Permit form and JSA or TBRA presented by the Permit Holder. The Permit Authoriser can include additional controls considered necessary to cover the defined scope of work. Note: In the event that a Work Permit is completed or partly completed and a decision is made that the Work Permit is not required; Cancelled is to be written diagonally across the page.
5.2
a. b.
WORKPLACE PREPARATION
The Permit Authoriser shall initiate implementation of workplace hazard controls as identified in the Work Permit documents. Hazard controls defined in any Certificates shall be implemented according to their respective procedures. The Permit Authoriser shall confirm that the workplace is safe to commence work. This will involve a physical check of the work environment by the Permit Authoriser or confirmation via a competent person. The Permit Authoriser shall authorise the Isolation Checklist once it has been determined that the Isolation Checklist is appropriate for the scope of work i.e. Isolation Review. The Permit Authoriser can be the Isolation Reviewer as long as they did not create the Isolation Checklist. Isolating Persons then commence isolations as per the Isolation Checklist.
c.
d.
5.3
5.3.1 a.
WORK PERMIT ISSUE AND ACCEPTANCE

Work Permit Issue The Permit Authoriser shall sign the Work Permit Authorisation section of the Work Permit after confirming
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1. 2. 3. b. completed Isolation Checklists have been signed off the work place has been checked to confirm it is safe and signed off any certificate requirements have been met
The Permit Authoriser will then nominate which lock box is to be used by: 1. filling in a Work Permit Isolation Tag with description of the job, the date and the Work Permit number. This tag is to be attached to the lock box with a Permit Authorisers Lock; or noting the equipment description and the Work Permit number on the front panel of the lock box.
2. c. d.
The Permit Authoriser shall brief the Permit Holder on the hazard controls in place and how they shall be maintained. The Permit Holder signs the Permit Holder section of the form, accepting the conditions of the Permit and associated documents as correct and that they will strictly observe the hazard controls and brief all the workers in the Permit requirements. All Work Permits are produced in triplicate, with an additional signature page and have a unique Work Permit reference number. The Work Permit copies are located as follows: 1. 2. 3. Permit Holder page (white) and any originals of Certificates, risk assessments etc. remains with the Permit Holder at the worksite while work is in progress. Work Permit Board copy (yellow) remains on the Work Permit Board with copies of any Certificates and Isolation Checklists. Permit Authoriser copy (pink) and Signature Page (blue) remain in the permit issuing area. The Permit Holder signs on and off the blue page copy at the commencement and end of each shift in the presence of the Permit Authoriser. The Permit Holder ensures that all team members sign on the the blue page before commencing work.
e.
f.
The Permit Authoriser shall update the Work Permit Register on a continuous basis. The Permit Authoriser is responsible for checking the register against the status of permits on the Permit Board at every shift.
5.4
COMMON ISOLATION
When a number of different tasks are being completed under separate Work Permits with all tasks sharing the same Isolation Checklist, the isolation is called a Common Isolation. Consideration needs to be given to dividing the plant up into logical, manageable sections, which will allow work in other areas to continue while ensuring the safety of those working in areas that are isolated under the Common Isolation Process.
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Once the need to use the Common Isolation System is decided the following steps shall be taken. Note: The process for establishing the Common Isolation and interaction between the Work Permits is illustrated in Figure 2 Common Isolation System Flowchart. Work Permit is to be raised to carry out Common Isolation of the plant or sections of it. The permit is made out for the expected period of the shutdown or the maximum 30 days. If the shutdown exceeds the 30 day period of the permit the area manager is to authorise the extension period. b. Where process isolations require removal of spools or swinging of blanks, this work shall be undertaken under a Work Permit separate to and prior to the initiation of the common isolation system. The isolation points that this activity creates shall then be referenced on the common isolations Standard Isolation Checklist. c. An Approved Isolations Person shall perform the isolations, fitting locks to isolations and hang green Common Isolations tags on each point of isolation. The Common Isolation Tag shall reference: 1. 2. 3. 4. d. the permit number raised to initiate the Common Isolation System the name of the system being isolated the date and the name of the Isolating Person.
a.
Once all the points of isolation have been isolated, locked and tagged. The isolations key shall be locked in the lock box by the Permit Authoriser for the system that has been isolated. A copy of the Work Permit for the Common Isolation and the supporting Isolation Checklists shall be stored above the lock box in the documentation sleeve.
Work Permits can now be issued under the common isolation system for the areas established. Each Work Permit that is issued shall have its own lock box and documentation sleeve. An Isolation lock (blue) will be attached to the Common Isolation System lock box. This isolation is to be referenced in the Isolation Checklist for the job. The key for those Isolations is locked in the Work Permit Lock Box for that job with an Authorisers lock (yellow). All workers under Work Permit supported by the Common Isolation will place their Personal Danger Lock with Tag on the lock box attached to the lock box for the permit they are working under.
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All Work Permits associated with a Common Isolation shall be recorded on the Common Isolation Work Permit Register not the Work Permit Register. Removal of any isolation points within the Common Isolation shall not start until all Work Permits have been signed off on the Common Isolation Work Permit Register by the Permit Authoriser. The only exception is when a change to a Common Isolation is required as described in Section 6.4.2 where the Work Permits are suspended while changes are authorised and implemented. 5.4.2 Change of Isolations under a Common Isolation System
If it is necessary to alter the isolations and hence energy status of the safe system of work established under a common isolation because of testing activities or the creation of an additional work activity that is required to be undertaken. Form Common Isolation Record of Change (SF2485) shall be used to authorise changes. Only a Supervisor or Process Engineer or above is able to authorise a change to a common isolation. This form is to be stored in the documentation sleeve with the other documentation for the Common Isolation System. The following process shall be followed: a. b. c. d. e. Obtain approval to change the isolations Suspend all Work Permits to stop work in the area to be affected, Have all personnel remove their Personal Danger Locks with Tags (to ensure the safety of personnel during the change). The altered isolations / de-isolations are completed and the isolation removals, changes or additions are noted on the original Isolation Checklist for the common isolation. Any isolation that existed under the original common isolation and has been altered shall have a single line drawn through it and any replacement isolation clearly noted immediately below it. Once the changes have been made all Work Permits shall be revalidated, workers replace their personal danger locks with tags back onto the permit board lock box and work can recommence.
f.
5.5
WORKING UNDER A PERMIT
To commence work under a Work Permit the following shall occur in order: a. The Permit Holder shall brief the work team about the hazard controls already in place and any additional controls required for the job using the Work Permit and Certificates and JSA as a basis for this briefing. Any issues that team members raise will be clarified and they shall sign onto the blue copy of the Work Permit to acknowledge they have been briefed; they understand the hazard controls in place and will comply with the requirements. Team Members attach their Personal Danger Lock with Tag to the relevant Permit lock box.
b.
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c. The Permit Holder ensures the work performed is as defined in the Work Permit scope of work and risk assessed on the Permit and if any conditions are breached, all work shall cease and the Permit Holder shall refer the matter to the Permit Authoriser. When all of the sign on entries on the Blue page of the Permit are used, a photocopy can be attached to the Work Permit for additional entries. Validity of Permits
Note:
5.5.1
Work Permits are issued for the period of work that the work team will be working for that shift. This includes shifts that continue into the next calendar day All Work Permits remain valid for a maximum one calendar month from the date of issue unless the Permit Authoriser specifies a shorter period. If after this period the Work Permit is required to be continued the Permit Authoriser shall: a. b. Close the Work Permit. Raise a new Work Permit and any associated Certificates and direct the Isolation Person to attach new Work Permit Isolation Tags and locks (as required) on the isolation points referencing the new Work Permit number. Update the Work Permit Register.
c.
The Business Unit or Area Manager may authorise the extension of the Work Permit validation period beyond the one calendar month duration during extended plant shutdowns. 5.5.2 Permit Revalidation
Revalidation of all copies of the Work Permit by the Permit Authoriser is required: a. b. c. at the beginning of each shift after all clear is given after the continuous siren has sounded (except after siren testing) Upon change of Permit Holder
Revalidation involves all of the copies of the Work Permit to come together. All personnel new to the job must sign on at the beginning of the day on the blue copy of the Work Permit held by the Permit Authoriser. 5.5.3 Change of Permit Holder
If the Permit Holder needs to be changed after issuing the Work Permit, the current Permit Holder must make the Permit Authoriser aware of the change, sign off of the blue copy of the Work Permit and hand over to a new Permit Holder. The Authoriser ensures the new Permit Holder is fully briefed on the hazard controls in place. All copies of the Work Permit shall come together for revalidation. The original copy of the Work Permit is given to the new Permit Holder who must sign onto the blue copy of the Work Permit as Permit Holder.
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5.5.4 Original or Duplicate Copy of Work Permit Lost
In the event that the original or yellow copy of the Work Permit is lost, a copy of the Work Permit can be made by photocopying the Permit Authorisers pink copy. 5.5.5 Suspension of Work Permits
All Work Permits become suspended after sounding of the evacuation siren. Once the all clear has been declared Work Permits shall be revalidated by the Permit Authoriser before returning to work. Work Permits may be suspended by the Permit Authoriser if conditions change such that the persons working under the Work Permit are put at risk. 5.5.6 Work to be completed by un-inducted person.
When work is required in a plant area that must be completed by a person with specific skills or where critical repair work needs to be carried out; this work can be done by a visitor provided they are always under the direct supervision of the Permit Holder, a risk assessment has been completed and the activity has been authorised in writing by the manager or delegate of the area. Signing on and off the Work Permit is the responsibility of the Permit Holder.
5.6
INCOMPLETE WORK
If work is incomplete and the Work Permit is to remain open then, the following shall occur in order: a. b. c. d. The Permit Holder ensures the work site is left in a clean and safe state. All work team members shall remove their Personal Danger Locks with Tags from the Permit Board lock box. The Permit Holder is shall investigate any remaining locks or tags. The Permit Holder shall return the Work Permit and documentation to the Permit Lock box. The Permit Holder will explain to the Permit Authoriser the state of the job. The Permit Holder or Authoriser may attach an Information Tag to the Lock Box explaining the condition of the job.
5.7
WORK COMPLETED
When work defined in the scope of work is complete or there is a requirement to close the Work Permit, the following shall occur in order: a. b. The Permit Holder ensures the work site is left in a clean and safe state. All work team members shall remove their Personal Danger Locks with Tags from the Permit Board lock box. The Permit Holder is responsible for ensuring that this occurs and shall investigate any remaining locks or tags. The Permit Holder shall return the Work Permit and documentation to the Permit Authoriser and sign off all copies of the Work Permit that the work is complete and the equipment is fit to be returned to work.
c.
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d. The Permit Authoriser shall initiate removal of hazard controls originally installed for the work to take place. This process is started by removing the Permit Authorisers Lock and Tag from the lock box for that job. When isolations are involved authorisation to remove isolations is given by signing De-isolation Authorised section on the Isolation or Standard Isolation Checklist. In the case of work done in a confined space the Permit Authoriser (who may designate to an Isolating Person) shall inspect the confined space to ensure that removal of isolations and closure can proceed. The white copy, yellow copy and associated certificate white copy are to be removed from the lock box and reference to the permit removed from the lock box. Once work environment status has been returned to a state of readiness for return to normal duties, Permit Authoriser shall: 1. 2. h. Sign any certificates as cancelled or ensure certificates are signed as cancelled and Sign the Work Permit Closed section on all copies of the Work Permit.
e.
f. g.
The Permit Authoriser shall file the pink and blue copy of the Work Permit, its Isolation Checklist and associated Certificates in compliance with Section 11.
5.8
COMMISSIONING URGENTLY REQUIRED EQUIPMENT
There may be a need to commission urgently required equipment or process when the Work Permit Holder has failed to sign the Work Completed By section of the Work Permit. The Permit Authoriser will try to locate the Permit Holder named on the Permit. If the person cannot be located then procedure Authorisation Procedure for Signing off Work Permits (SF1777) will be followed.
IF COMPLETION OF THE TASK CANNOT BE CONFIRMED THE EQUIPMENT/PROCESS IS NOT TO BE COMMISSIONED.
6.
SCAFFOLDING
The wording on Work Permits for scaffolding shall be complete and descriptive. The format shall be as follows: Erect and remove scaffold for equipment XXXX to enable access for task YYYY.
7.
ISOLATION TAGGING AND LOCKOUT
The objective of isolation is to create a zero energy state. Isolation is the physical removal of energy sources (including both potential and kinetic energy sources) and substances, which are potentially hazardous to any person performing work on the equipment or being in the vicinity of work performed. It will involve the physical disconnection of
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electrical supply, closure of valves, draining, flushing, venting and purging of lines, placement of blanks / spades or removal of spool pieces and connection of appropriate locks and tags. When isolations are performed as part of the hazard controls for work conducted under a Work Permit, an Isolation Checklist is completed and forms part of the Work Permit documentation. All equipment requiring isolation and all isolation points (including locations for insertion of blanks, removal of spool pieces) shall be uniquely and clearly identified and provide an attachment point (immediately upstream of the isolation point in the case of spool or blank isolations) for locks and isolation tags. The aim of each plant area shall be to uniquely label each isolation point in the field and on drawings. Until all labelling is in place, the isolations points shall be uniquely labelled on the Isolation Checklist and on the tags in the field. For isolation points requiring the insertion of a blank, removal of a spool, or any other item that does not have an attachment point, the lock and tag shall be connected in an acceptably robust way that does not easily allow the removal of the lock without use of the isolation lock key. (eg using a hasp, lock and tag fitted onto the bolt that is used to hold a blank onto a flange face). The intent is to ensure field isolation is clearly labelled, and therefore these isolation points are not unintentionally removed. All isolations are performed by an Isolating Person. Isolation Checklists are reviewed by a person different to the person who created the Isolation Checklist. This review determines if the isolation listing is adequate for the scope of works. This Isolating Reviewer is a qualified Isolating Person. Standardised Isolation Checklists have their isolation points verified during their development. Isolation shall always be applied to the energy source and is not permitted to rely on control circuitry or control valves. Push buttons, stop switches, interlocks, emergency stops, pilot circuitry lanyards, etc. shall not be used as a means of isolation. When isolating there is a requirement to confirm that a zero energy state has been created by either trying to start the system or testing the energy in some way. If zero energy state cannot be reached a separate risk assessment will be carried out to determine how the energies is reduced to As Low As Reasonably Practicable (ALARP) in each situation and the residual risks will be managed. Assuming that all training and competencies can be verified all combinations of roles within the Work Permit System are allowed except that the Isolating Person cannot be the same person as the Isolation Reviewer.
7.1
PERFORMING AND PROVING AN ISOLATION
Following advice from a Permit Authoriser that the Work Permit hazard controls include isolation of energies and proof of zero energy, the following shall occur in order: a. b. An Isolating Person shall carry out isolation of energies they are authorised to perform. Zero Energy = Proving + Try Step.
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1. Proving an electrical isolation requires evidence of a physical break in the electrical supply. If the use of a de-contactor, removal of fuses, visible break contactor or phase lights is not possible, continuity testing by an electrician is required to establish proof of isolation. A Try to Start or Try Step shall be used to fully confirm the isolation. Proving process isolation shall involve closure of valves, flushing, venting, purging, placement of blinds/spades, removal of spool pieces, checking relief valves, pressure indicators etc. to ascertain that energies have been removed.A Try to Start or Try Step shall be used to fully confirm the isolation.
2.
c.
All isolation points will be padlocked with a blue isolation lock and have Work Permit Isolation Tags or Common Isolation Tags attached that reference the Work Permit number, date and the name of the Isolating Person. Drain valves should be locked open whenever practicable and must always be included on Isolation Checklists Note: Electrical Isolations will have a multi lock device fitted when first isolated to allow additional isolation to the same drive, if required.
d.
An Isolating Person shall return the completed Isolation Checklist to the Permit Authoriser and place any isolation lock key(s) in the correctly labelled permit board lock box. The isolation person is to verify with an initial that isolations are tagged and locked, tick the appropriate boxes referring to purging, flushing, try test, zero energy and sign the checklist confirming this is complete. A Permit Authoriser shall ensure that all isolation key(s) are locked by placing a Permit Authorisers lock on the lockbox, locking the isolation key(s) inside. The Permit Authoriser key shall be held at all times by the Permit Authoriser.
e. f.
7.2
REMOVING AN ISOLATION
When work is complete and the actions detailed in section 7.7 are complete, the Permit Authoriser initiates the requirement to remove the isolation. The following shall occur in order: a. All Personal Danger Locks and tags shall be removed by the individual workers from the Permit Board lock box and the Permit Holder signs off the job on the Work Permit (blue copy) and signs off the job as complete on the white, yellow and pink copies. The Permit Authoriser removes the Permit Authoriser lock from the Permit Board lock box. For Permits with isolations, the Permit Authoriser directs the Isolating Person to commence de-isolation and if locked isolation is involved, provides the isolation key(s) to the Isolating Person. The Isolating Person commences removal of the isolation lock / tag(s). When all isolation locks / tags have been removed and the Isolation Checklist signed by the Isolating Person, the Isolation Checklist shall be returned to the Permit Authoriser.
b. c.
d. e.
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Note: The removal of isolation does not mean re-energising / re-commissioning the equipment. The re-commissioning process is a separate function and is controlled by the equipment owner.
7.3
ISOLATION FOR WORK NOT REQUIRING A PERMIT WORK
Work on the work not requiring a permit list does not require a Work Permit, however, verbal authorisation is required and the following shall occur in order: a. b. c. The employee undertaking the work shall be a competent Isolating Person for that equipment / area. The employee seeks verbal permission to perform their own isolation from the relevant Control Room Operator (or equivalent in the case of Field Engineering). If work is safe to proceed, permission will be provided by the Control Room Operator (or equivalent). Consider using the Isolation Checklist and / or a Standard Operating Procedure to document the isolations and methods of isolation required. The employee shall carry out isolation of energies they are authorised to perform. Positive isolation of each isolation point must be confirmed by that Isolating Person. Confirmation = Proving + Try Step. 1. Proving the isolation (to ensure the isolation is effective). Proving an electrical isolation requires evidence of a physical break in the electrical supply. If the use of a de-contactor, removal of fuses, visible break contactor or phase lights is not possible, continuity testing by an electrician is required to establish proof of isolation. Proving process isolation shall involve checking relief valves, pressure indicators etc. to ascertain that energies have been removed. A Try to Start or Try Step shall be used to fully confirm the isolation.
Note:
d.
2. 3. e. f.
The employee attaches their Personal Danger Lock with Personal Danger Tag to each isolation point. The key(s) shall be retained on the person of the employee at all times. If the task is incomplete or unsafe to continue and the employee leaves the work site, they shall remove their Personal Danger Lock and Tag and attaches a completed Out of Service Tag. When returning to the work site, they shall confirm the isolation (refer Step 4. above) and attach their Personal Danger Lock and Personal Danger Tag. If the Control Room Operator gives permission, the employee shall re-energise equipment following removal of their Personal Danger Locks and Tags. Otherwise the equipment can remain isolated with an Out-of-Service tag in place.
g.
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7.3.1 Fault Finding
Where maintenance personnel carry out inspection, fault finding or replacement of pressure and temperature transmitters and analysers, Equipment Testing Jogging and Fault Finding Procedure DP-11-031-17 shall be followed.
7.4
ISOLATION CHECKLIST
The Isolation Checklist (PF2463) shall be used when a Work Permit is issued for all work that requires either process or electrical isolation. Equipment tag number, description of isolation point and isolation method MUST be completed. Where process isolation involve purging, installing blanks, swinging spectacles or removing spool pieces, this work shall be carried out under a Work Permit separate to and prior to the initiation of process isolation. Note: Where equipment tag numbers are not available, sequentially number each process/electrical isolation point in the equipment tag number cell. Each number is to be referenced on the Work Permit Isolation Tags in the field. Standard Isolation Checklist
7.4.1
Standard Isolation Checklists shall be created as a permanent record of isolations required to safely isolate a specific piece of equipment. Each business area should aim to have the majority of its regular or complex isolations established on such a permanent record. These are document controlled versions of the Isolation Checklist PF2463. This standardised Isolation Checklist shall be produced following a risk assessment, authorised by a Process Engineer / Supervisor and controlled within the CSBP Document Control System. They shall not be altered without authorisation by an Isolation Reviewer. The Standard Isolation Checklist shall include isolation activities such as: decontamination, venting of stored energy, securing of rotor / fan blades, electrical isolation, disconnecting, blocking or bleeding of equipment or lines. Using a Standard Isolation Checklists includes checking that the isolation is appropriate to the scope of work. All Standard Isolation Checklists shall include reference to drawings that were used to develop the checklist e.g. Schematics or P&IDs. Note: Note: Any Authorised Isolation Person for the area can review a Standard Isolation Checklist, even if they developed it. If a Standard Isolation Checklist needs to be altered, a second Isolation Person must review the changes.
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7.5 ELECTRICAL ISOLATION
Only personnel who hold a current and appropriate Office of Energy Electrical Workers Licence are authorised to remove or change fuses. All electrical drives must be isolated at their primary isolation point. Generally this is in the Motor Control Centre (MCC) but some equipment has 3 phase isolators installed in the field. Once isolated, the Local Control Panels start button should be engaged in the start position to prove that the electric drive does not energise. Where electric drives are controlled from the Distributed Control System (DCS), the DCS Stop / Start function should be engaged to prove that the electrical drive does not energise. These activities form the Isolation Proved that the Isolating Person signs for on the Isolation Checklist. Trained and competent personnel without an electricians license that have been authorised as Isolating Persons may perform electrical isolation where there is no direct access to live parts. This includes three phase isolators located in either the MCC or the field and switches that are located in the MCC.
7.6
TESTING AND JOGGING
If work on equipment requires de- isolation to test or move the equipment or the equipment needs to be jogged as a part of the scope of work the requirements defined in procedure Equipment Testing and Jogging (DP-11-031-17) shall be followed.
7.7
PERMIT HOLDER ISOLATIONS
This section describes the procedure to be followed to allow for small tasks that are best suited to have the isolations controlled by the Permit Holder. This work is typically carried out by instrument fitters that are carrying out calibration checks and tuning on equipment in the plant, i.e. level or pressure transmitters.
When Isolations are under Permit Holders control. No other work shall be permitted on that equipment or adjacent to it. The Permit Authoriser consults with the Permit Holder to answer the following questions, which must all be yes for the work to proceed under Permit Holder Isolations. Is this a single trade work group? i.e. not mechanical and electrical. Is the Permit holder also an authorised Isolations Person?
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Are process isolations within line of site of the work? Do the isolations valves only isolate flow to the instrument? i.e. they will not affect the plant process.
If these conditions are all confirmed, the permit can be issued marked in the scope of work section Permit Holder Isolations The Permit Authoriser issues the Permit holder with a set of Isolation Locks to complete the isolations. The key for the Isolation set is to be kept by the Permit Holder in a lock box. All others working on the task are to lock onto this lock box.
7.8
TAGS AND LOCKS IN THE WORK PERMIT SYSTEM
There are six different safety tags that apply within the Work Permit System: Work Permit Isolation Tag Common Isolation Tag Personal Danger Tag Testing and Jogging Tag Out of Service Tag Break-in Location Tag The Information Tag is not a Safety Tag and should not be used as such. The use of the Information Tag is detailed in the procedure Information Tag (GM-11-031-41). There are three different safety locks in the Work Permit System: Personal Danger Locks (red) Isolation Locks (blue) Permit Authorisers Locks (yellow) Additional locks and keys can be purchased, but only after approval of the Safety Manager. This process is started by completing the Authorisation to Supply keys to locks for Safety Lockout Padlocks. Once authorised the form and purchase order are to be forwarded to Coastal Lock Service. 7.8.1 Lost keys to Isolation Sets
If the key to an isolation set is lost, all work on the job shall be stopped until the key for the isolation set can be found. If the key cannot be found the spare key is to be used to remove all the locks and another lockset is used for the isolations. Authorisation Procedure and Record for Obtaining a Spare Key to an Isolation Lock Set SF2607 shall be followed.
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7.8.2 Work Permit Isolation Tag and Isolation Lock
A Work Permit Isolation Tag is used when isolating equipment or a section of the plant for maintenance and repair under a Work Permit. An Isolation Lock and Work Permit Isolation Tag are always placed on the isolation point, by an authorised Isolating Person. This lock and tag is a warning to all personnel that the equipment or process to which it is attached is isolated. The equipment or process must not be operated until an authorised person has removed the lock and tag. The Work Permit Isolation Tag is neon red in colour and isolation locks are blue. 7.8.3 Common Isolation Tag and Isolation Locks
The Common Isolation Tag is normally used when a section of a plant to be isolated under a Common Isolation Work Permit, during time of major activity such as day and annual shutdowns. An Isolation Lock and Common Isolation Tag are always placed on the isolation point, by an authorised Isolating Person. This lock and tag is a warning to all personnel that the equipment or process to which it is attached is isolated. The equipment or process must not be operated until an authorised person has removed the tag. The Common Isolation Tag is fluorescent green in colour and isolation locks are blue. 7.8.4 Personal Danger Tag and Personal Danger Locks
The Personal Danger Tag and Lock is used to protect the person named on the tag. Personal Danger Tags are used to indicate which person/s is working on equipment and who could be put at risk if the equipment starts. It is a warning to all personnel that the equipment shall not be operated until the Personal Danger Lock with Tag has been removed from the Work Permit Board by the person named on the tag. The Personal Danger Locks are red and issued to all employees on successful completion of Working under Permit to Work training. Contractors will be provided with locks as a part of being issued with a Work Permit. A Contract Personnel Personal Dangers Locks Issue Register (SF2594) will be kept in Work Permit issuing area of the locks provided to Contractors. Once the Work Permit is completed the Contractors are to hand back the locks to the Permit Authoriser of the area. A person working under a Work Permit (Permit Holder and Team Members) shall attach their Personal Danger Lock (with the Tag attached to the Lock) and place the Personal Danger Lock on the correct Permit Board lock box prior to commencing work. Where operating procedures require isolation for immediate work, for example, clearing of a blockage in the process, each person shall attach their Personal Danger Tags and locks to the relevant isolation points in the field before work commences. In this instance Work Permit Isolation Tags would not normally be attached (Refer Isolation for Work not requiring a permit Work Section 7.3).
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After the work described on the Work Order and Work Permit is completed, Permit Holders check that the plant and equipment is left in a safe condition and the area is clean and tidy. All workers under the Permit then remove their Personal Danger Locks with Tags from the Work Permit Board at the end of each working shift and on completion of work. Where the person named on a Personal Danger Tag has not removed the lock and tag at the time a Permit Holder wishes to sign off a Work Permit, the Permit Holder is responsible for locating the owner of the Personal Danger Lock. To leave a Personal Danger Lock with Tag on the Permit Board and leave the site is a breach of the Work Permit System and is a disciplinary offence at CSBP. If the Permit Holder cannot locate or contact the owner of the Personal Danger Lock and Tag the procedure in Authorisation Procedure and Record for the Removal of Personal Danger Locks and Tags (SF2495) shall be followed.
TO REMOVE SOMEONE ELSES PERSONAL DANGER LOCK OR TAG IS AN EXTREMELY SERIOUS DISCIPLINARY OFFENCE, REFER SECTION 11. The Personal Danger Tag is red, black and white in colour and states Do Not Operate and is always attached to a Personal Danger Lock. 7.8.5 Testing Jogging Tag
Equipment Testing and Jogging Tags are used when an isolation has been de-isolated, for the purpose of testing or jogging that equipment. The Equipment Testing and Jogging Tag are white, with a green border. Refer to procedure Equipment Testing and Jogging (DP-11-031-17) 7.8.6 Out of Service Tag
The Out of Service Tag is used in the following circumstances: Identifying and reporting equipment that could cause injury or damage if operated. Identifying and reporting unsafe portable equipment (e.g. ladders and hand tools). Any person can attach an Out-of-Service Tag. While the Out-of-Service Tag remains in place the equipment is to remain Out-of-Service and shall not be operated. An Out-of-Service Tag may be removed when the equipment has been repaired and inspected by a suitably qualified person and found to be safe for use. The Out-of-Service Tag is yellow with a black diagonal stripe colour.
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8.
8.1
CERTIFICATES USED WITH WORK PERMITS

HOT WORK CERTIFICATE
Hot work is defined as any work which involves the use of tools or equipment that could generate sufficient heat to ignite flammable or combustible gases, liquids, dusts or materials within a confined space, a hazardous zone or restricted area. All hot work undertaken within any of our Major Hazardous Facilities shall require a Hot Work Certificate and hence Work Permit. A Hot Work Certificate exists in triplicate (white, yellow, pink) and has a red edge. It shall be kept with its associated Work Permit at all times i.e. white with white copy, yellow with yellow copy and pink copy with the Permit Authoriser. All hot work conducted outside specified workshop areas but that is not in a Major Hazardous Facility shall as a minimum require permission from a Supervisor or above to be undertaken. In this case a 15m exclusion zone for any flammable materials shall be established. Where there are designated ignition hazards or potential for flammable gases to be present or it is not possible to establish a 15m exclusion zone for any flammable materials a Hot Work Certificate and a Work Permit are required.
8.2
CONFINED SPACE ENTRY CERTIFICATE
All CSBPs Confined Spaces are identified and listed within the Confined Space procedure. The list for each Area shall be displayed in the Control room. Prior to any work in a confined space being authorised, the Confined Space Entry Certificate must be correctly completed and have all required supporting documentation. This includes a Job Safety Analysis produced by or in conjunction with the Permit Holder. The Confined Space Entry Certificate exists in triplicate (white, yellow, pink) and has a green edge. It shall be kept with its associated Work Permit at all times i.e. white with white copy, yellow with yellow copy and pink copy with the Permit Authoriser.
8.3
HIGH VOLTAGE (HV) ACCESS AND TESTING CERTIFICATE
High Voltage (HV) electrical work, including the following, shall always be accompanied by either a HV Access Certificate or a HV Test Certificate: Isolation of HV equipment Work in HV switchyard Work on transformers Access to 132-kV yard.
HV Certificates are not required for electrical isolation of high voltage motors where the Isolating Person has received high-voltage training and has been assessed as competent by Field Engineering electrical staff. These can be administered under the normal Work Permit and Isolation Checklist system. HV Certificates, which are administered by the electrical section of Field Engineering, are in triplicate (white, yellow, pink). The HV Access Certificate has a purple edge and the HV Test Certificate has an orange edge.
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8.4 EXCAVATION / PENETRATION CERTIFICATE
Excavation is defined as work by hand or mechanical means that disturbs the soil or other surface to a depth greater than 150 mm. The work includes: Digging holes or trenches, Cutting concrete Driving piles, posts or spikes Driving of earthing electrodes.
Penetration is defined as work including demolishing, removing, drilling, cutting or otherwise penetrating any floor slab, wall, ceiling, roof, partition or surface where the opposite side is not visible and which may contain electrical cables. This work is always accompanied by a Work Permit and Excavation/Penetration Certificate if it occurs in any of the Plants and shall be required at the discretion of Field Engineering at all other times. Excavation / Penetration Certificates are administered by Field Engineering and exist in triplicate (white, yellow, pink) and have a brown edge. It shall be kept with its associated Work Permit at all times i.e. white with white copy, yellow with yellow copy on the Permit Board and pink copy with the Permit Authoriser. Note: Care shall be taken in the planning of work within excavations and penetrations as if they are more than 1.5m in depth they automatically become confined spaces and shall need to be managed with a Work Permit and a Confined Space Entry Certificate.
8.5
RADIATION CERTIFICATE
Radiation Certificates are required for any work involving the use, calibration and maintenance of devices that emit ionising radiation. This includes radiation gauges, associated pipe work, flanges, density meters and radioactive isotopes used for radiography. Radiation Certificates are issued from the relevant permit issuing area and must be signed by a licensed Radiographer or licensed radiation specialist. The Radiation Safety Officer may also issue and endorse Radiation Certificates. Permit Authorisers are not required to sign Radiation Certificates. The Certificates exist in triplicate (white, yellow, pink) and have a yellow edge. It shall be kept with its associated Work Permit at all times i.e. white with white copy, yellow with yellow copy on the Permit Board and pink copy with the Permit Authoriser. Radiation Certificates are not required for remote calibration.
8.6
ASBESTOS / FIBRO CEMENT SHEETING CERTIFICATE
Asbestos / Fibro Cement Sheeting Certificates are required for any work associated with handling, surface treatment or removal of asbestos cement building products. Asbestos / Fibro Cement Sheeting Certificates are administered by Field Engineering and exist in triplicate (white, yellow, pink) and have a blue edge. It shall be kept with its associated Work Permit at all times i.e. white with white copy, yellow with yellow copy on the Permit Board and pink copy with the Permit Authoriser.
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9. DISCIPLINE AND CONSEQUENCES
The Work Permit System protects all personnel working in operational areas of CSBP. Compliance with this Work Permit Guide Manual is a condition of working at CSBP. Deviation from this procedure, without due process (such as TBRA) and written authority from Production (or Business unit) Manager or their designate, in any way, will be viewed as very serious and shall initiate a thorough investigation. This investigation will be reviewed by the Production (or Business Unit) Manager. Where it is determined by this investigation that persons working under the Work Permit System did deviate from the requirements, consequences will follow including disciplinary action in accordance with CSBP Employee Discipline and Appeals Process GM-01-070-03. Additionally if the competence of a person in breach of the procedure is in question they may be required to have their authorizations within the Permit system downgraded. This may generate an automatic downgrading in employment level. The disciplinary action taken shall match the level of the breach of the Work Permit System. Disciplinary action can be a summary dismissal (in the case of a gross breach of the fundamental safety requirements), a verbal warning, a written warning or a final written warning.
10.
MONITORING AND REVIEW
The Work Permit System is a live system of documentation and procedures. To facilitate the ongoing improvement of the system a User Review Committee will be established and chaired by the Manager - Safety. The make up of the team will include representation from operational employees, management and safety advisors. The User Review Committee is responsible for: Supporting the business by answering specific advice and interpretations of the procedure. Provide support to those investigating Work Permit System breaches Every twelve months review: o o o Trend information from Work Permit System breaches. Work Permit System audits and follow up actions The Work Permit System procedure and related documents to ensure it remains aligned to legislation, best practice, and the requirements of CSBP and ensure any changes are integrated into Work Permit System training.
10.1
SPOT CHECKS
Permit Authorisers or their delegate perform regular inspections of active work sites. The inspection shall be at every shift change when Work Permits are active and will include: a. b. Review of the Work Permit documentation in the Control Room and Permit Board. Confirmation that the work being performed is consistent with the written scope of work and that the hazard controls defined in the Work Permit remain in place.
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10.2 AUDITS
Each Area Superintendent or Manager shall ensure that each Permit Authoriser with in their area of responsibility is audited on a live Work Permit, using an established Work Permit Audit Checklist, at least every six months.
10.3
PERIODIC COMPLIANCE REVIEW
In addition to the above regular inspections and audits, a more formal in-depth review is to be conducted annually as designated by the Document Owner. This review shall be based on all the criteria set out in the Work Permit documents and specifically covers items listed in the audit protocol. The purpose of this audit is to establish the effectiveness of the system and: a. b. c. d. understanding of, compliance with and recorded competency in Work Permit procedures; effectiveness of work planning processes in defining a clear scope of work and hazard controls; communication issues - field briefings and shift hand over, and document close-out and archiving.
11.
ASSOCIATED DOCUMENTS AND FORMS
The Work Permit Certificate is the controlling document in the Permit to Work System. Other procedures and forms listed below define preparations or special precautions required for particular significant risk work and do not, by themselves, authorise work to proceed. They cannot be standalone and shall always be accompanied by a covering Work Permit Key documents and forms associated with the Work Permit include: STOP and Job Safety Analysis Risk Assessment (GM-11-031-23) Breaking into Hazardous Pipelines (GM-11-036-02) Work Permit (PF2462.) Work Permit Register (PF2224.) Isolation Checklist (PF2463) Common Isolation Work Permit Register (PF2464) Common Isolation Record of Change(s) (SF2485) Equipment Testing and Jogging (DP-11-031-17) Authorisation Procedure and Record for Removal of Personal Danger Locks and Tags (SF2495) Confined Spaces (GM-11-031-52) procedure and form Confined Space Entry (PF2465) Confined Space Register (RM-11-031-52) Hot Work (GM-11-036-06) procedure and form Hot Work (PF2466) Radiation Safety (GM-11-031-40) procedure and form Radiation (PF2467) Excavations (GM-11-036-04) procedure and form Excavation / Penetration (PF2470)
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Operation and Testing of High Voltage Equipment (GM-11-032-03) and HV Breaker Maintenance (GM-KS-101-03) procedures and forms High Voltage Access (PF2468) or High Voltage Test (PF2469) Safe Working in a Hot Environment (GM-11-036-03) Gas Testing (GM-11-031-33) Electrical Appliance Testing and Tagging (GM-11-038-06) Access to Switch Rooms (GM-11-032-02) and Isolation of 132kV Switchboard (GM-KS-10101) Asbestos Product Removal (GM-11-031-20) and Asbestos / Fibro Cement Sheeting (PF2492) Surface Treatment of Asbestos Cement Sheeting (ES-14-302-09)
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12.
RECORD KEEPING
Pink and Blue copies of the Work Permit and the Pink copies of other documentation are to be retained as below.
RECORD IDENTIFICATION Form No. PF2462 PF2224 PF2464 PF2465 PF2466 PF2470 PF2468 PF2469 PF2467 SF2495 SF1777 SF2485 PF2492 PF2463 Document Title Pink / Blue Copy of Work Permit Work Permit Register Common Isolation Work Permit Register Pink copy of Confined Space Entry Certificate. Pink Copy of Hot Work Certificate Pink copy of Excavation/ Penetration Certificate Pink copy of HV Access Certificate Pink copy of HV Test Certificate Pink copy of Radiation Certificate Authorisation for Removal of Tag & Locks Authorisation for sign off of Work Permit Common Isolation-Record of Changes Pink copy of Asbestos / Fibro Cement Certificate Pink copy of Isolation Checklist or Standardised version
STORAGE MEDIA Paper
STORAGE LOCATION At location
INDEXING METHOD Date
RETENTION PERIOD 12 months after Work Permit closed
AUTHORISED DISPOSER Area Supervisor
DISPOSAL METHOD Bin or archive
Paper
At location
Date
12 months after Permit closed
Area Supervisor
Bin or archive Std version retained
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WORK PERMIT SYSTEM
Figure 1 Work Permit System Flow Chart GM-11-031-51 Version No.10.0 Document last modified: 02 July 2013. Page 33 of 34
WORK PERMIT SYSTEM

Operations Department
Blanks and spool piece locations are referenced on Isolation Checklist Creates Isolation Checklist 1 to isolate plant / system for installation of blanks or removal of spool pieces Isolates plant / system in accordance with Isolation Checklist 1 and attaches RED Work Permit Isolation Tags to isolation points Installs blanks or removes spool pieces in accordance with Scope of Works No
Permit Authoriser
Isolating Person
Permit Holder
Supervisor / Process Engineer
Permit Holder
Permit Authoriser
Isolating Person
START
1
Raises Work Permit 1 for installation of blanks or removal of spool pieces Work continues
Does the CI require installation of blanks or removal of spool pieces? No Confirms Standard Isolation Checklist(s) for creating Common Isolation System to isolate plant / system
Yes
Has all the work been completed?
Yes
Suspends Work Permit 1 until all Common Isolation work is complete Isolates plant / system in accordance with Standard Isolation Checklist and attaches GREEN Common Isolation Tags
Returns Work Permit 1 to Permit Authoriser
Closes each Work Permit associated with the relevant CI System on handover from Permit Holder (refer to Work Permit Flow Chart)
Raises Work Permit to Common Isolate
Authorises de-isolation of relevant CI System
De-isolates relevant CI System in accordance with Isolation Checklist and removes GREEN Common Isolation Tags
Locks keys for Isolation Locks in Lock Box with Permit Authoriser lock and files Common Isolation Work Permit and Standard Isolation Checklist in folder
Removes blanks or installs spool pieces in accordance with Scope of Works
Revalidates Work Permit 1 for the removal of blanks or installation of spool pieces
Secures an isolation lock to the Common Isolation Lock Box for each Work Permit raised against Common Isolation Work Permit.
Closes Work Permit Key secured with Permit for the job. Commences work in accordance with each Scope of Work Authorises de-isolation of Isolation Checklist 1 created for the installation of blanks or removal of spool pieces De-isolates in accordance with Isolation Checklist 1 and removes RED Work Permit Isolation Tags
1
No Does the Common Isolation System need to be changed?
References the Common Isolation Work Permit number on all Work Permits issued and records in the Common Isolation Work Permit Register
END
Yes Suspends all Work Permits and removes all Personal Locks / Danger Tags from the Lock Box Amends Standard CI System Isolation Checklist to identify new isolation requirements Completes CI - Record of Changes form SF2485 Reviews and authorises the amended Standard CI System Isolation Checklist
Attaches CI - Record of Changes form SF2485 to the Standard CI System Isolation Checklist
Carries out new isolation in accordance with amended Standard CI System Isolation Checklist and attaches or removes GREEN Common Isolation Tags
1
Revalidates Work Permits and ensures Personal Danger Lock / Tags are attached to Lock Box Signs CI - Record of Changes form SF2485, confirming changes are complete
Figure 2 Common Isolation System Flow Chart GM-11-031-51 Version No.10.0 Document last modified: 02 July 2013. Page 34 of 34

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Work Permit System

WORK PERMIT SYSTEM GM-11-031-51

Actual Change Details:

GM-11-031-51 Version No. 10.0 Document last modified: 02 July 2013.

Work Permit System

10.1 10.2 10.3 11. 12.

ASSOCIATED DOCUMENTS AND FORMS ................................................................................. 30 RECORD KEEPING .......................................................................................................................... 32

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Work Permit System

DEFINITIONS & RESPONSIBILITIES

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Work Permit System

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Work Permit System

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Work Permit System

Competency required: a. Same as an Authorised Isolating Person.

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Work Permit System

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Work Permit System

GM-11-031-51 Version No. 10.0 Document last modified: 02 July 2013.

Work Permit System

THE WORK PERMIT BOARD

WORK AREA HAZARDS

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Work Permit System

TRAINING AND COMPETENCY

PLANT OR AREA BOUNDARIES AND CONTROL RESPONSIBILITIES

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Work Permit System

KWINANA AREAS AND PRODUCTS

DAMPIER TO BUNBURY NATURAL GAS PIPELINE

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Work Permit System

WORK PERMIT PREPARATION

WORK PERMIT ISSUE AND ACCEPTANCE

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Work Permit System

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Work Permit System

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Work Permit System

WORKING UNDER A PERMIT

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Work Permit System

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Work Permit System

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Work Permit System

COMMISSIONING URGENTLY REQUIRED EQUIPMENT

IF COMPLETION OF THE TASK CANNOT BE CONFIRMED THE EQUIPMENT/PROCESS IS NOT TO BE COMMISSIONED.

ISOLATION TAGGING AND LOCKOUT

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Work Permit System

PERFORMING AND PROVING AN ISOLATION

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Work Permit System

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Work Permit System

ISOLATION FOR WORK NOT REQUIRING A PERMIT WORK

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Work Permit System