New PTW PDB 2016 - 4

PERMIT TO WORK SYSTEM (NEW)
HSE Department / OEAD

PETRONAS Dagangan Berhad
Date: 8 – 9th June 2016
Venue : Meting Room, Senai Aviation Fuel Terminal
1
Agenda Day 1
0900 - 0915 Opening Remarks
0915 – 0930 Safety Briefing
0930 – 1015 Pre-test
1015 – 1030 Morning Break
1030 – 1230 (1) Goal and Objectives, (2) Introduction, (3) Roles
& Responsibilities, (4) PTW Applicability, (5) Training
& Competency, (6) Monitoring and audit
1230 – 1300 Group work (R&R)
1300 – 1400 Lunch
1400 - 1600 (7) Certificate, (8) Certificate validity (9) Hot Work, (10)
CSE
1600 – 1700 LOTO
2
Agenda Day 2
0900 - 0915 Warm-up
0915 - 1000 (11) JHA, (12) Multiple PTW, (13) Work Leader (14)
PTW Process Flow
1000 - 1030 Morning Break
1030 – 1130 Workgroup (JHA)
1130 – 1245 SIA Common mistakes
1245 – 1300 Question and Answer
1300 - 1400 Lunch
1400 – 1500 Workgroup (PTW process flow)
1500 - 1530 PTW Exam
1530 – 1600 Result and discussion
1600 – 1700 Question and Answer
3
20 minutes
4
15 minutes
5
10 minutes
6
1 minute
7
1. GOALS & OBJECTIVES
8
Goals & Objectives
At the end of this session you will be able to:
a) Identify and assess workplace hazards

b) Coordinate, control and record work activities
using PTW
c) Demonstrate competency on PTW
requirements compliance
9
2. INTRODUCTION
10
Introduction
11
LAWS & REGULATIONS
Occupational Safety and Health Act 1994 (OSHA 1994)
General duties of employers to their employees
– 15 (2) (a) – provision and maintenance of plant and systems of work that are,
so far as is practicable, safe & without risks to health
– Example of safe system of work:
I. Permit To Work System
II. Confine Space Entry
III. Log Out Tag Out
IV. Safe Working At Height
V. Lifting
General duties of employees at work

– 24 (1) (d) - to comply with any instruction or measure on occupational safety &
health
– Penalty for non compliance
A fine not exceeding RM1,000 or Imprisonment not exceeding 3 months Or both
12
LAWS & REGULATIONS
Code of Practices For Safe Working in Confine Space 2010
• Permit System
• Permit to Work
• Duties of Permit Issuer
13
LAWS & REGULATIONS
ZeTo = Zero Tolerance
PETRONAS ZeTo Rules (rule #1)
Individual performing work without an

approved PTW (when required) could
receive warning/ be suspended / be
dismissed
14
Training, Assessment & Appointment
Training is mandatory for all PDB and contractor personnel

who issue, receive and work under a PTW system as well as
designated PTW trainers.
Written examination and other suitable assessment shall be

carried out after the training with the exception of awareness
training. Records of PTW and related training shall be kept
and updated.
Official appointment shall be made by respective Division.

Record shall be kept and updated.
15
Why Use PTW ?
Facility (Terminal, PS, LPG bulk customer sites) handles

hydrocarbons and toxic materials - poses special risks.
Control Non area owners who work in other people’s
area – e.g. maintenance personnel are not familiar with
process conditions.
Area Owners must authorize others who perform work in
their area – e.g. operation will determine that it is safe to
perform a job in a process area.
Basic purpose of permit system is to prevent injuries to
personnel.
16
Why Use PTW ?
Perform Risk Assessment & Implement Control
measures to:
To Protect People, Environment, Asset &

Reputation (PEAR)
Avoid Incidents & Prevent Injury
Ensure that all work is carried out in safest
possible manner
Specify the conditions and procedure for safe
execution
17
PTW is NOT
A Permission to carry out a dangerous job.
A confirmation that hazards and risks have been eliminated.
A security that if you have a Permit, it makes a job safe.
Those carrying out a work must:

i. Be trained and competent
ii. Identify risk associated with any work activity and how these
are to be avoided.
iii. Take all the precautions.
iv. Ensure their work does not interfere or affect with that of
others.
18
Permit To Work
COLD WORK PERMIT - For all general work (no

ignition source)
HOT WORK PERMIT - For use of or generates

local source of ignition, vehicle & engine operated
equipment entry to hazardous areas
19
Where PTW is required?
Hot Work near
Confined Space
Flammable
Entries
Sources
Excavation 150
Lifting
mm
Work on Fixed /
Radiography Temporary
Work Electrical
Installation
20
Where PTW is required?
High Pressure
water jetting
Pressure Testing
outside
designated area
In Situ Grid
Scaffolding Work
Blasting
Work at Height Handling

with no safe Hazardous
platform Chemicals
21
Who can Sign PTW?
Personnel who are authorized to sign on the Work
Permit shall have thorough knowledge of the work to be
performed and the conditions under which the work will
be performed
An authorization list shall be circulated to inform the

Area, HSE, contractors, etc.
22
3. ROLES & RESPONSIBILITIES
23
Roles and Responsibilities
24
Roles and Responsibilities
•Area owner •Job owner

•Approves & •Receives &
signs permit •Assess risks signs permit
•Identify hazards
& control
measures
•Signs permit
•Assist AA for •Assist RA for site •Receives permit
site inspection inspection & from RA to start
& preparation preparation work
•Signs permit •Signs permit
25
Area Owner
i. Ensure appropriate PTW system implementation, with
contractor PTW system is at par with PDB PTW
Procedure/ System
ii. Establish and maintain training programs and competence
standards.
iii. Establish and maintain PTW system monitor / assurance /
audit review.
iv. Ensure contractors are informed of and understand the
broad principles of PDB PTW system for the locations
where their employees work.
26
Approving Authority (AA)
This person has authority and responsibility for the overall
implementation of safe management of work activities for which AA
issues the permit.
Before signing the PTW form to authorise work, AA should verify and
satisfy himself that:
i. Understand work nature, hazards identified and risk reduced to ALARP.

ii. No conflict with the other PTW he issued / works with ongoing
operations
iii. Assign AAR to prepare all the necessary precautions required, and
verify.
iv. Monitor work progress and PTW compliance.
v. Attach and communicate supporting certificates / documents.
vi. Protective equipments and PPE are adequate.
vii. All effected people are informed.
viii. Effective organization exists for work site examination.
27
Approving Authority Representative
(AAR)
The person authorised by the Approving Authority
(AA) to carry out safety precautions prescribed in the
permits/certificates prior to commencement of work.
i. Authorized by the Approving Authority

ii. Ensures all precautions are implemented at site before
permit approval
iii. Assists the Approving Authority
iv. Completes worksite checks
v. Ensures the work leader is suitably informed
vi. May or may not required.
28
Receiving Authority (RA)
Receiving Authority (RA) shall ensure that:
Ensure that:
i. Trained, assessed and authorized as RA.
ii. Related people being trained in PTW system.
iii. Work fully discussed with AA.
iv. PTW /certificate displayed site.
v. Work party is briefed on the details of the
permit/certificate .
vi. Precautions are maintained throughout the work
activity;
vii. Work group follow PTW limitations.
viii. Inform AA on work suspension / completion.
ix. Hand over to another RA if leaving the plant.
29
Receiving Authority Representative
(RAR)
The person authorised by the Receiving Authority (RA) to
ensure all the safety precautions prescribed in the
permits/certificates are carried out prior to commencement of
work.
i. Authorized to assist the Receiving Authority

ii. May be the work leader
iii. Ensures that only the specified work on the work permit is
completed
iv. May or may not required.
30
Permit Applicant (PA)
Ensure that:
i. Clear scope of work is developed.
ii. Hazard controls required for work is determined ,
and initiate the PTW documentation.
31
Work Leader (WL)
The person who leads or carries out the work:
i. Confirms conditions of permit and agreement by signing

ii. Explains Job Safety Analysis (JSA) content and PTW
conditions to workers
iii. Supervises and is at site at all times
Responsible for supervising the work group and the
specified work
iv. Ensures no deviation to permit conditions
Ensures that the work group work in accordance to the
description specified on the work permit
Ensures the worksite is left clean and tidy after work
completed
v. Returns permit to Receiving Authority (RA)
vi. Must be trained on PTW system & passed the exam
vii. Delivers toolbox talk before work commences
32
Individual Working Under the PTW /
Certificate (Permit User)
i. Have received PTW training/instruction and have a
good understanding of the PTW system
ii. Do not start any work requiring a permit/certificate
until it has been properly authorized and issued.
iii. Receive a briefing from the WL on the particular task,
understand the hazards and the precautions taken or
to be taken.
iv. Follow the instructions/conditions specified in the
permit/certificate.
v. Leave work site / equipments in safe condition when
work stop / completed.
vi. Stop work and consult WL if in doubt, or if
circumstances change.
33
Approving Authority For Certificates
A person authorized by the PDB to approve and
issue specific certificates, such as Electrical
isolation, excavation certificates, etc.
i. Authorized competent person from the relevant

trade e.g. electrical
ii. Does NOT approve work permits but is able to
approve certificates
34
Competent Electrical Person (CEP)
i. Adequately trained with sufficient technical
knowledge & experience
ii. Safely isolates and work on low voltage

electrical equipment within the limits of the
Electrical Authorization certificate
iii. This is the only person allowed to:

Carry out electrical isolation and issue Electrical
Isolation Certificate.
Designate a competent Chargeman carry out
Electrical work.
Approved Portable Electrical Temporary Installation
(PETI) certificate
35
Radiation Protection Officer (RPO)
i. Responsible for advising the Approving Authority

on the precautions required for work involving
radioactive sources
ii. Initiates all radiography work
iii. Responsible for approving Radiation Certificates
iv. Responsible for the safe handling of all radioactive
materials on site
36
Gas Tester
Authorised Gas Tester (AGT) – Confine space only
Competent Gas Tester (CGT) – Other gas test
i. Responsible for carrying out testing of toxic, flammable and

oxygen content in the work area, in support of work permit
activities
ii. Appointed by the management team following gas tester training
iii. To check & confirm that the gas testing instrument is working in
perfect condition before proceeding for the area/equipment
iv. To carry out gas test at all critical locations
v. To advise on safe method to work inside/at the location, i.e. gas
freeing, use of PPE, etc.
vi. For work in confine space (Malaysia operation) the gas tester
must undergo training as below and must register with DOSH:
(AGT/ ES training L2 – NIOSH)
(AE/ SP training L1 – NIOSH)
37
Gas Test Results
i. Gas tests are required for all hot work/vehicle entry &
Confined Space Entry
ii. Approving Authority shall determine the requirement of
gas test & frequency of rechecking
iii. Only Competent Gas Tester (CGT) shall carry out the
gas test
iv. Results must be recorded in PTW
Zone 0 – continuous monitoring

Zone 1 – once in every two (2) hours
Zone 2 – as determined by AA
38
Standby Person
Individual who has attended a training course on working
in confined space for authorize entrant and stand by
person and passed the test or examination
Stationed outside one or more confined spaces who

monitors the authorised entrants and who performs all
stand-by person’s duties assigned in the employer’s
confined space programme
Have the knowledge of the hazards that may be faced

during entry
Monitors the worksite during certain activities
Remains alert
Contacts the control room in the event of an emergency
39
Fire watch
Monitor the worksite during a hot work permit
activity
Appointed from a pool of trained firewatchers, by
the Approving Authority
Has basic fire fighting knowledge
Competent in fire monitors/hoses as well as
portable gas detectors
Understands what to do in an alarm situation and
how to raise the alarm
40
PTW Signatory Matrix
Supply and Distribution Division (SDD)
Maintenance Op/Shift Maintenance Technician/
PERMIT TO WORK TM/ Supt Contractor
Engineer Supervisor Supervisor Foreman
PTW – Cold Work AA AA AA AA RA WL

PTW – Hot Work AA RA RA RA RA WL
CERTIFICATE
Gas Test AUTHORISED GAS TESTER (AGT)
Confine Space Entry AA RA RA RA RA/WL WL/RA
Safety System Bypass /
Override AA RA RA RA RA WL/RA
Electrical Isolation
Section 4 Isolation AA - AUTHORIZED COMPETENT PERSON (ACP/CP)
(ACP/AP)
Physical Isolation AA AA RA RA RA/WL WL/RA
Excavation AA - RA RA RA/WL WL/RA
Radiation AA - APPROVED RADIATION PROTECTION OFFICER (RPO)
Lifting AA - APPROVED RIGGER
Vehicle Entry AA - AA RA RA WL/RA
Road Obstruction / Closure AA - AA RA RA WL/RA
41
4. PTW APPLICABALITY
42
PTW Applicability
Non-routine activities.
• Construction.
• All work on ionizing radiation sources within 1 meter of radiation
source.
• Scaffolding erection and dismantling.
• Confined Space Entry.
• Performing Hot Work activities;
• Mechanical lifting using pedestal, mobile and gantry crane.
• Work at the immediate vicinity of overhead power lines.
• Isolating safety control systems / devices - of pipe work, valves and
its associated vessels.
• Excavation works.
• Pilling works.
• Painting works.
• Vehicle entry - except road tanker , LPG cylinder lorry and PDB
operated forklift.
• Temporary removal of isolations.
• Maintenance work.
43
When is PTW NOT required???
Works carried out by Operation Department as part of routine
operation/job which is adhered by Operating Procedure (OP).
Example :
Product Receiving
Refueling Operations
Quality checks
Effluent Management
44
PTW Validity
The Permit shall be valid when the following conditions comply:
i. Work is conducted during the period for which it is issued or a maximum of

seven (7) days with re-validation at each day / shift;
a) Equipment remain the same;
b) Work activity remains the same;
c) Work site conditions remain the same; and
d) Required signatures are in place.
ii. Emergency occurs – stop all works shall stop & PTW is suspended. All PTW
and associated Certificates - cancelled and re-applied before work is
resumed.
iii. False alarm or emergency drills - the work may resume after PTW
revalidation, with condition remains the same.
iv. Equipment test run, PTW closed and re-applied to resume work.
v. Special requirement for Confine Space Entry – only 12 hours. 45

5. TRAINING AND COMPETENCY
46
PTW Training and Competency
Competency requirement or mandatory training for other designated
persons associated with PTW:
PTW
PTW
Certification JSA Refresher
Designated Person (PDB Awareness
Training/ Training Training
and Contractor/others) Training
Competency (1 day) (1 day)
(0.5 day)
(2 days)
Permit Applicant (PA) x x
Approving Authority (AA) for x x x
Permits
Approving Authority (AA) for x x x
Certificates
Approving Authority x x x
Representative (AAR)
Receiving Authority (RA) x x x
Receiving Authority x x x
Representative (RAR)
Work Leader (WL) x x x
47
PTW Records
i. Permit, certificate and other relevant documents

should be kept for a minimum of 1 year.
ii. However for Permits, Certificates and all relevant

documents related to PDB incidents - be kept
throughout the duration of the life of the Plant /
installation / facility.
48
6. MONITORING AND AUDIT
49
PTW Monitoring and Audits
• Frequency of Permit to Work Inspection / Assurance
Inspection / Assurance Frequency Action Party
Approving Authority /
Daily
PTW Sampling Receiving Authority
Quarterly HSE Department
Terminal and PETRONAS
Monthly Area Owner
Station check
Operational /
Formal PTW Compliance
Yearly Corporate Tier 1
Assurance
Assurance Team
50
PTW Inspection / Assurance
Checklists relevant for SDD
Daily Inspection Check List
Monthly Inspection Check List
51
PTW Daily Inspection Checklist
52
LUNCH
53
WORKGROUP
54
7. CERTIFICATES
55
PTW & Certificates Validation requirements
• PDB Has 10 Certificates
Certificates Type Validity
Confined Space Entry Certificate
Radiation Certificate
Normal Certificates is limited to
Lifting Certificate
seven (7) days
Road Obstruction / Closure Normal and does not require
Certificate Certificate revalidation
Vehicle Entry Certificate
Portable Electrical Temporary

Installation Certificate PTW & Confine Space Entry
certificate is limited to 12 hours
Excavation Certificate only without extension or
revalidation
Electrical Isolation Certificate
Physical Isolation Certificate Special Three (3) month, with re-

Certificate validation at every seven (7)
Safety System Bypass / Override
days
(SSB/O) Certificate
56
S1 – Requisition.
Fill by RA or RAR or AA or AAR
S2 – Permission to isolate.
Fill by AA
S3 – PTW dependent on this electrical isolation.

Fill by AA.
S4 – Isolation.
Fill by ACP or AP
S5 – Confirmation & Acceptance.

Fill by all relevant parties
S6 – Weekly revalidation.
Fill by ACP or AP
S7 – Temporary normalisation for testing.

Fill by all relevant parties.
S8 – Permission to normalise.
Fill by AA
S9 – Normalisation.
Fill by ACP or AP
57
Isolation of electrical equipment and allows safe work to be
undertaken on equipment
An authorized and competent person has electrically
isolated the equipment to be worked on and has taken
suitable precautions to prevent inadvertent reconnection
Issuing, Executing authorities and Electrical Maintenance
shall jointly decide the extent of isolation required
58
Physical Isolation Certificate (PIC)
For isolation of all vessels, equipment
and piping.
states that:
1. liquid has been drained
2. gas depressurized
3. isolated from other equipment in the
operating facility
4. suitable precautions taken to ensure they
remain isolated
59
1. One PIC for one equipment/vessel
2. One PIC can be for many jobs/PTW
3. Isolation covers – valves, motors,
pipes, radioactive sources
Filling up the PIC:

i. Section 1 Work request – fill by
equipment owner, with reference to
PTW number, work description, RA lock
number, number of locks & tags
ii. Section 2 Work completion – fill by RA,
AFTER job completed
iii. Section 3 Work continuation – weekly
revalidation by AA
iv. Section 4 Normalization – Close out the
PIC by AA, ACP/AP, RPO
60
Continued…
i. Page 2 of PIC
ii. List of all isolation locations
for a particular equipment
iii. List of all isolation positions
for a particular equipment
(open/close)
61
Safety System Bypass /
Override Certificate
S1 General information (fill by RA) –
location, area, equipment & tag number,
duration, drawing given
S2 Work description (fill by RA) – reason

for bypass & effect on system
S3 Precautions (fill by RA) – risk

assessment control measures
S4 Approval (fill by AA designated by

OPU)
S5 Weekly Revalidation (by AA)
S6 Work completion (by RA and AA)
62
Excavation Certificate
i. Excavation /ground disturbance - Work involving digging or pilling of the ground
within an area.
ii. Certificate required for excavation (digging) deeper than 150 mm
iii. Certificate will confirm that a competent person has checked the work site of a
planned excavation and has studied layout drawings to ensure that the excavation
can be made without damage to existing buried facilities such as: Pipelines,
Drains, Electric cables
iv. Excavation permits applicants must first submit the WORK ORDER to
ENGINEERING to know whether there is underground services in the area.
v. A check on the drawing shall be done by ENGINEERING DEPARTMENT to
ensure any buried services present. Detail drawings of the underground facilities
shall be attached in the PTW.
vi. For excavations more than 1.5 meter deep confined space entry permit is
required. Gas tests shall be done as per entry permit requirements.
63
Excavation Certificate
S1
applicant’s name, work location (fill by RA)
S2
work description (fill by work leader)
S3
Approval by relevant bodies (civil, mechanical,
electrical, area owner)
S4
Safety precautions (fill by AA)
S5
Final Approval (fill by AA & RA), excavation
begins
S6
Excavation completion (fill by work leader)
S6
Acknowledge work completed (by AA)
64
Lifting Certificate
Lifting Certificate for handling of
heavy lifting work at site.
In addition, when any Critical lift is

being conducted, the Critical Lift
Checklist must be completed.
S1 – Crane information
S2 – Activity details
S3 - Approval
65
Lifting Checklist
Critical Lift:
1. Lifting over live or critical/sensitive process equipment
or facility
2. Lifting > 50 % of crane load
3. Lifting load of weight more than 80% of rated capacity of
the lifting equipment at the specified working radius and
boom angle as per crane load chart 66
Certificate covers:
i. Radioactive source and dosage

ii. Duration of radioactive work
iii. Location
iv. Purpose
v. Approval by RO/RPO, together with
AA / RA
67
i. Work involving the use of radioisotopes for radiography work
ii. Risk assessment through JSA
iii. Barricade the area and provide adequate warning signs
iv. Film badges and Dosimeters shall be worn by personnel handling
radiography equipment
v. Job preferably during night time or with least or no person around
vi. Continuous monitoring of cordoned area
vii. Precaution relating to Radiation in this section is to be documented by the
Licensed Radiation Officer (RO)
viii. Handling of Ionizing Radiation Source - Radiation Protection Officer
(RPO) has granted permission to use a radio-active source and that any
related extra precautions have been taken before radiography begins
68
Road Obstruction Certificate
For closure of roads that may affect
the passage of emergency response
vehicles.
• Reasons for blockage?
• Alternative passage?
• FIT / ERT / CEFS to be informed?
69
Vehicle Entry Certificate is used for
control of entry of vehicles into the
process areas.
Optional certificates that can be

used by OPU to manage specific
activity or hazard:
70
CSE Checklist
Required for any CSE activities
Requirements listed for CSE entry

– section 3 ‘Conditions to be
checked by AA
Entry log
Gas test log / record A3
71
8. CERTIFICATE VALIDITY
72
Certificate Validity
i. The maximum validity period for Normal Certificates -

7 days. No revalidation required.
ii. Exception for CSE Permit to Work validity –12 hours.
iii. Special Certificates – may be extended to maximum 3
month, with re-validation at every 7 days.
Safety System Bypass / Override Certificate.
Physical Isolation Certificate.
Electrical Isolation Certificate.
73
9. HOT WORK PERMIT
74
Objective
To clearly outline the requirements and conditions

necessary to safely perform Hot Work activity
75
Types Hot Work
Any work which involves the use of tools, equipment or techniques that could
generate heat of sufficient intensity to ignite flammable or flammable gases,
liquids, dusts or materials. Followings are some of the Hot Work activities:
i. Welding;
ii. Thermal and oxygen cutting;
iii. Heating;
iv. Fire-producing and spark-producing operations;
v. Grinding;
vi. Abrasive blasting;
vii. Concrete chipping and drilling;
viii.Metal drilling;
ix. Heat treatment or stress relieving of pipe work and equipment;
x. Use of hot tapping equipment (subject to appropriate dispensation);
xi. Use of electrically or battery powered cameras, pagers, mobile phones, or instruments;
xii. The opening of any live electrical enclosure;
xiii.Use of internal combustion engines unless they are specifically manufactured and
certified for use in explosive gas atmospheres; and
xiv. Vehicle access into the terminal and jetty.
76
Gas Monitoring Conditions
• To provide a guide, following are the Gas Monitoring
Conditions:-
• Zone 0 / Confine Space
– Hot Work,
• Test conducted outside confine space followed by the Pre-Entry
testing inside confine space.
• Continuous Gas Test to be done. Considered necessary because of
the probable gradual release of the hazardous gas due to deliberate or
accidental disturbance of the sludge or other objects, which have
trapped or absorbed the contaminants. This includes when there is
forced ventilation.
• Authorized Entrant to wear a Personal Gas Detector
• Fire Watcher required including fire extinguishers (2 units)
– Gas Free Condition
• Test conducted outside confine space followed by the Pre-Entry testing
inside confine space.
• Recommended to conduct every one (1) hour as a precaution
77
• Zone 1
– Hot Work,
• Initial Gas Test to be done followed by Gas Test done once in every
two (2) hours,
• Fire Watcher required including fire extinguishers (2 units)
– Cold Work,
• Gas Test done once in every two (2) hours,
• Zone 2 / Safe Zone
– Hot Work, Initial Gas Test to be done, Following Gas Test determined by
AA, Fire Watcher required
– Cold Work, no gas testing required
* Fire watcher required to attend basic fire fighting training
78
• If you have any doubts, you may upgrade the PTW to Hot Work
& take the necessary steps required.
• If you have any doubts, you may increase the frequency of Gas
Monitoring
• Fire watch person duties shall be maintained for at least 30
minutes after hot work ceases.
• Last Gas Test To be Done After Work Is Done
79
Equipment Listing
• All equipment brought into the terminal should be inspected by
terminal staff prior to approving any PTW. Contractors should be
reminded not to bring any equipment into terminal without approval.
• All equipment brought into the terminal should be listed down and
attached to the PTW.
• Welding generators and air compressors, located within Zone 0, 1 or
2, they should be subject to control using Hot Work Permit.
80
• Vehicle Entry Certificate is not required for routine vehicles
below
– Road Tanker
– LPG Cylinder Lorry
– PDB Operated Forklift
• Gas Testing For routine vehicles are not required
• Any other vehicles entering PDB Premise is subjected to vehicle
entry certificate. If AA wish to deviate, SOP should be
established to manage the risk.
• Any movement of vehicles within Zone 0, 1 and 2 area must be
as directed by the Permit Authoriser.
• Company Vehicle only allowed in safe area
81
Hot Work For Vehicle Entry
1. The gas tester to walk the route for the vehicle while the vehicle
stands by in a safe area.
2. Once the area is proven gas free, the vehicle then immediately
drives to its location
3. The engine must be shut off if the vehicle is to remain at the
location for a period of time.
4. An additional gas check shall then be performed when the
vehicle exits the restricted area.
82
10. CONFINED SPACE ENTRY
83
Examples Of Confined Spaces
Process vessels, boilers, water

storage tanks, other tanks including
pontoons on floating roof tanks, tank
cars and trucks, drain pits, sewage
pits and associated tunnels, ducts,
trenches, wells, shafts, cellars,
vaults, cargo ballast or void spaces
onboard ships, etc
84
Examples Of Confined Spaces
EXAMPLES
EXAMPLESOF
OF
CONFINED SPACES
CONFINED SPACES
85
Confined Space Entry
Confined Space Hazards
Failure to identify confined space
Failure to isolate the vessel
Exposure to explosive, toxic or asphyxiating atmosphere
Exposure to hazardous materials
Risks associated with work in a confined space eg. fumes
Inability to exit quickly in emergency
Risk from activities outside the vessel
Radiation
86
CSE - Hazards
TOP 10 HAZARDS IN A CONFINED SPACE (OSHA)
Injury from
Oxygen
Toxic gases Flammable gases misused of tools
deficiency
and equipment
Bodily injury due Physical hazards

to direct contact such as slip, trip & Drowning Noise
with chemicals falling objects
Electric shock,
Excavation
burns and
collapse
scalding
87
PTW
88
CSE Permit Requirements
No Entry Will Be Allowed Into A
Confined Space Without the Issuance
of a Confined Space Entry Permit
Gas Test Results Required for a CSE are:
Oxygen 20% to 20.9%

Combustible <1% LEL
Toxicity < 50% PEL
89
Confine Space Training Requirements
Parties Involved Competency Registration With

DOSH
PTW Approving Authority Authorized Gas Tester & Entry Supervisor (AGTES) No
(AA) Authorized Entrant & Standby Person (AESP)
Authorized Gas Tester Authorized Gas Tester & Entry Supervisor (AGTES) Yes
(AGT) Authorized Entrant & Standby Person (AESP)
Entry Supervisor (ES) Authorized Gas Tester & Entry Supervisor (AGTES) Yes
Authorized Entrant & Standby Person (AESP)
Authorized Entrant (AE) Authorized Entrant & Standby Person (AESP) No
Standby Person (SP) Authorized Entrant & Standby Person (AESP) No
Fire Watch (FW) Authorized Entrant & Standby Person (AESP) No

Basic Fire Fighting
Rescue Personnel Authorized Entrant & Standby Person (AESP) No
Basic Fire Fighting
BOMBA Rescue & Emergency Services Training
Basic First Aid
90
END OF DAY ONE
91
11. JOB HAZARD ANALYSIS
92
Formerly known as Job Safety Analysis
Tool to identify and control hazard
An incident prevention tool that work to identifying
hazards and eliminating / minimizing hazards before the
job is performed and before hazards could cause
incident
Process where the hazards associated with each job
steps are identified, and control measures are put in
place to minimize the risk to client, worker, equipment,
property and the environment
93
WHEN TO PERFORM JHA? -
PTS PTS 60.2005
JHA shall be performed /initiated for the work that requires a Permit to Work (PTW)
and have the potential injury to personnel or damage to property or negative impact
to environment.
JHA shall be performed but not limited to the following activities

• routine tasks that have the potential for serious incidents/ accident.
• routine tasks having history of incidents, including near misses.
• routine tasks being carried out in unusual circumstances.
• routine tasks with change in procedure or standards
• new task or tasks introducing new work methods/procedure
• non-routine or once-off tasks.
• new task or tasks without procedure /work instructions.
8 June 2016 94
JHA Requirements
JHA shall be performed /initiated for the work that requires a Permit to Work (PTW)
and have the potential injury to personnel or damage to property or negative impact
to environment.
95
JHA Preparations
a) JHA leader
b) Front line supervisors responsible (owner and/or

contractor) for the work.
c) Expert or Specialist (Owners and/or Contractor) for

high risk and highly specialized jobs example Confined
Space Entry, Bypassing Safety Critical Equipment,
Critical Lifting, online leak sealing, hot tapping etc.
96
JHA Review
JHA shall be reviewed, agreed and signed by all
members before carrying out the job at site, after an
incident or when there are changes in work methods or
work environment. All JHA documents are controlled
documents at the job locations.
a) Representatives (Owners and/or Contractor) from

relevant discipline (e.g. operations, mechanical,
instrument, electrical, civil etc.) affected by the activities
or individual work steps or tasks.
b) HSE "personnel" (HSED and/or contractor's HSE

personnel (e.g. SHO, Safety Executive) responsible for
HSE) 97
Job Hazard Analysis Steps
1. Define the job / task for JSA
2. Breakdown the job/task into logical/smaller steps
3. Identify all hazards associated with each step thru:-
a) Observations
b) Operation manuals
c) Accident records
d) Experienced workers
e) Discussion with operators
4. Identify method of control for each hazards
a) What controls exists and are they adequate
b) Do the required controls pose an additional risk
c) Are controls reasonable and feasible
Note : Apply bow-tie concept in identifying the threats,
barriers, control or recovery measures (Engineering Control)
98
Example
99
100
101
Benefit of JHA
Allow combination of two or more processes or
procedures into a streamlined core
Establishes good communication
Provides education and training
Increase productivity due to safer workplace
Performance measurement tool
Standardization work procedures
Identify problem before execution rather than after
102
12. MULTIPLE PTW
103
Applying Multiple PTW
Multiple Permits shall be raised for multi-disciplined crews conducting

different work on the same equipment in the same geographical area, in
certain circumstances.
Terminal has the following conditions:-

i. Safe Area (Office1Area still within terminal fence).
Each terminal needs to have HAC diagram and demarcation of
safe area.
ii. Operation Area
Zone 0, Zone 1 & Zone 2 which is defined through HAC
To be organized, filing of PTW may be defined by Safe Area & Operation

Area
3
104
Applying Multiple PTW
• From procedure the PTW approach shall include the following steps:
i. Specifying the work to be undertaken, the exact location and the
equipment to be used, when applying for the PTW;
Examples of suitable statements:- To blow equipment using air
compressor
i. Specifying the precautions to be taken, by completing the relevant
sections of the Permit;
ii. Completing preparatory work, including Certificates, checking that
the worksite is safe and prescribed personal safety precautions
have been taken;
iii. Giving permission for work to start by signing the Permit;
iv. Frequent checking the safety of work in progress, the validity of
Permit and Certificate, and the adherence to specified precautions;
and
v. Checking that the worksite has been left in a satisfactory condition
upon completion of the work prior to closure of the Permit and
Certificates
105
How do determine If Multiple PTW Needed
Yes
Is it multidiscipline?
(Mechanical, Civil or Electrical)
No
Does it have multiple certificates? Yes
(Except for Special Certificate)
No
Apply Single Is the contractor working in the same Yes Apply Individual
Permit area & using the different crew? Permit
No
Is there multiple unrelated tasks in the Yes
same area?
No
No Is the hazard & required Personal Yes
Protective Equipment (PPE) set
different for each task?
106
Yes
No
No
No
same area?
No
107
multidiscipline?
(Mechanical,
Before Now
1 PTW For Multidiscipline Individual PTW for Multidiscipline
Examples:- Examples:-
PTW A PTW A
Excavation Excavation
Lifting
Vehicle Inspection PTW B
Physical Isolation Lifting
PTW C
Vehicle Inspection
108
Yes
No
No
No
same area?
No
109
Does it have multiple certificates?
Before Now
Multiple Certificate in 1 PTW Individual PTW for Individual
Certificate
PTW A PTW A
Excavation Certificate With Excavation Certificate
Lifting Certificate
Vehicle Entry Certificate PTW B
With Lifting Certificate
PTW C
With Vehicle Entry Certificate
110
Yes
No
No
No
same area?
No
111
Is the contractor working in the same area &
using the different crew?
Before Now
Multiple Crew Working In Same Individual PTW for Individual
Area Certificate
PTW A PTW A
Crew 1 Excavation Crew1 Excavation
Crew 2 Lifting
PTW B
Crew 2 Lifting
112
Yes
No
No
No
same area?
No
113
Is there multiple unrelated tasks in the same area?
Before Now
Multiple unrelated tasks in the same Individual PTW for unrelated tasks
area in the same area
PTW A PTW A
Lifting
Welding PTW B
Lifting
PTW C
Welding
114
Yes
No
No
No
same area?
No
115
Protective Equipment (PPE) set different for each task
Before Now
Multiple PPE requirements for Individual PTW for any PPE
multiple job in same PTW requirements for multiple job
PTW A PTW A
PPE: Safety Helmet, Safety Glasses, PPE: Safety Helmet, Safety Glasses,
Jacket/Coverall & Safety Shoes Jacket/Coverall & Safety Shoes
Welding PTW C
Welding
PPE: Welding Mas, Safety Glasses,
Jacket/Coverall, Apron, Welding PPE: Welding Mas, Safety Glasses,
Gloves & Safety Shoes Jacket/Coverall, Apron, Welding
Gloves & Safety Shoes
116
13. WORK LEADER CRITERIA
117
Work Leader Criteria
SAME AREA
Company A
Work Leader 1
PTW No 1 PTW No 2
Group 1 Group 2
Task: Welding Task: Air compressor
Note :
The air compressor is being use for welding activities
1 Work Leader is allowed when visibility of WL for both tasks are clear.
Work Leader MUST always be on site. If he/she isn’t work should be stopped
118
SAME AREA
Company A
Work Leader 1 Work Leader 2

PTW No 1 PTW No 2
Group 1 Group 2
Task: Excavating Task: Scaffolding
2 Work Leader are required although it is in the same area. (reasons : different task , both
are high risk activities & required supervision at all time)
Another example for same area and need to have 2 AWL are: Welding and tank cleaning, erect scaffolding and painting,
heavy lifting and installation of insulation & etc) 119
AREA 1 Company A AREA 2
Work Leader 1 O Work Leader 2

B
PTW No 1 S PTW No 2
T
Group 1 U Group 2
R
Task: Excavating C Task: Scaffolding
T
I
O
N
2 Work Leader is needed when visibility of WL for both tasks are not clear
120
14. PTW PROCESS FLOW
121
Detailed Permit to Work Procedure
SECTION 4 SECTION 5
SECTION 1 SECTION 2 SECTION 3
Work Preparation
Permit Discussion between Approving Authority Approving Authority for Authorized Gas
Need for
applicants fill in Permit Applicant, details the controls and certificates issues the Tester carries out
other
relevant section Receiving Authority, precautions required relevant certificates the necessary gas
certificates?
of permit Work Leader & before and during the stating the required gas test
Approving Authority work test frequency during
the work
SECTION 6
Responsible Receiving Joint site inspection

Responsible Approving by Approving
ApprovingAuthority Authority & Work
Authority ensure that Authority, Receiving
signs the Work Leader confirms
the equipment is in safe Authority & Work
Permit and the work by signing the
condition to be work on Leader
can be started permit
Original copy of the

SECTION 7 Work Permit and any
attached certificate are
Work Execution
Hand over from one displayed at work site

operational shift to the
next should include a Work is
review of all outstanding stopped while Control room holds the
Permit certificates incomplete? second copy of the work
permit and certificates
Permit should be signed off by SECTION 8 SECTION 1 – Requisition

the Receiving Authority and SECTION 2 – Hazards/ Hazardous
returned to the Responsible Receiving Authority signs First and second copy of Activities
Approving Authority off the Work permit and the Permit is field by SECTION 3 – Worksite
hand back to Responsible Approving Authority in a Precautions
Approving Authority “Complete Work” file SECTION 4 – PPE
1. Authorised Gas Tester carries SECTION 5 – Supporting
out the necessary gas test. Certificates
2. Revalidation of Permit The Receiving Authority SECTION 6 – Join Site Visit /
Certificates by responsible Is work files the third copy Approval
Approving Authority, Receiving complete? SECTION 7 – Revalidation
Authority, Approving Authority SECTION 8 – Hand Back
Representative, and Work
Leaders before commencement
of work
122
PTW Process Flow
• How/When to do the job
Planning
• Resources required
• Permit submission with detail description and other

Application supporting documents
Sec 1
Risk
• Hazards identified
assessment • Control measures identified
Sec 2, 3 & 4
• Additional Hazards/Control measures identified

Site visit • Verify area/equipment preparation status
Sec 5 & 6
• Area owner approves for work to proceed

Permit • Permit applicant signs to accept joint responsibility,
approval job begins
Sec 6
• Revalidation when is required

Revalidation & • Housekeeping done, permit returned and signed off
Hand back
• Area owner normalizes area/equipment
Sec 7 & 8
123
PTW Process Flow - Planning
i. How will we do the job? Status of equipment to be worked on?

ii. Do we know the job hazards?
iii. Do we have a procedure for the job?
iv. Do we have the tools and parts for the job?
v. Do we have competent people to do the job?
vi. Do we need contractors for the job?
vii. When should we do it? How much time do we need?
viii. Permit requirements?
ix. Simultaneous work within vicinity?
x. PPE?
124
PTW Process Flow - Application
i. Detailed work description provided?

ii. Correct equipment number from correct area?
iii. Work order raised for the job?
125
PTW Overview
STEP 1
Details of permit applicant
Work description – detailed description, no ‘multiple’ jobs. Example
cleaning machinery using air compressor
Permit number and Zone classification
It is VERY important to ensure date & time are completed
126
Definitions Area Classifications
Hazardous Areas
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.
127
* Classification
area is subject
to Area Owner
128
Sample HAC
TTLR TOP LOADING INTERCEPTORS
Zone 2
Zone 1 Zone 0
Zone 1
129
PTW Overview
STEP 2
Identify certificate to confirm specific additional precautions required and

taken
Is JHA required?
130
PTW Overview
STEP 3
Identify (cross) all possible HAZARDS related to the work activity

Area hazards – Hazards
Job hazards – Hazardous Activities
Kindly refer to JHA to have a better idea on the hazards
*TENORM = Technologically Enhance Naturally Occurring Radioactive Material

131
PTW Overview
STEP 4
Identify all the personal protective equipment (PPE)

PPE for protection against the hazards identified
If the set of PPE are different for the job, there might be multiple activities
taking place.
132
PTW Overview
STEP 5
Identify the control measures - worksite preparation / precautions.

Inspection of site prior to approval can be done with reference to the
selection made below.
133
PTW Process Flow – Site Visit
Joint Site Visit by both AA and RA
Note: AA can nominate AAR
i. Is area/equipment preparation satisfactory?

ii. Energy isolation, Lockout and Tag out completed?
iii. Equipment to be worked on has been identified in
the field?
iv. Any new hazards identified while inspection?
v. Do we need to conduct risk assessment again?
vi. Equipment Inspection Done
vii. Equipment List Available
viii. Are EX Equipment Certification Available?
ix. Do we need to cancel the job?
x. Do we need to re-check on HOT WORK?
xi. Is toolbox ready to be conducted?
xii. If its hot work & gas test is required, the calibration
certificate must be attached to the PTW 134
PTW Overview
STEP 6
Joint site visit by AA & RA or AA & RAR or AAR & RA or AAR & RAR
Confirms by signing that area/equipment has been prepared
RA/RAR confirms acceptance of responsibility for work as described in
Section 1 after witnessing AA/AAR implementing the precautions &
equipment confirmation
1 2
3 4 5
135
PTW Process Flow – Permit Approval
i. AA & RA signs off the permit (person approving permit is

different than person permit applicant)
ii. Permit applicant briefs the work team on permit requirements
iii. Permit is displayed at the work site
iv. Work begins
v. Work monitoring by area owner’s team
136
PTW Overview
STEP 7 (If Needed)
4 5 2 1 3
137
• The Permit shall be valid when the following conditions comply:

i. Work is conducted during the period for which it is issued or a
maximum of seven (7) days with re-validation at each day /
shift;
ii. Equipment remain the same;
iii. Work activity remains the same;
iv. Work site conditions remain the same; and
v. Required signatures are in place.
138
• Should an emergency occurs, all works shall stop immediately and

the Permit shall be suspended.
• All Permit to Work and associated Certificates shall be cancelled
and reapplied prior to resume work.
• In the case of false alarm or emergency drill, the work may resume
after revalidation of Permit and the condition remains the same.
139
PTW Process Flow – Hand Back
i. Job completed
ii. Housekeeping completed
iii. Permit returned and signed off
iv. Provide feedback if any, for future improvements
140
PTW Overview
STEP 8
When the job is complete the Receiving Authority (RA) signs off the Work
Permit and returns it to the Approving Authority (AA) who inspects the job site,
and if satisfied that work, including cleanup, is completed, he signs off on the
original and both copies to show that the permit is now terminated.
1 2
Is it the last AA which close?

141
Distribution of Permits and Certificates
The Permit to Work form and accompanying certificates must be distributed as follows:
Original Copy: To be displayed at the Worksite.
1st Copy: Held at the Control Room
2nd Copy: To be retained by the Receiving Authority
3rd copy: Security
142
TEA BREAK
143
15. CASE STUDY
144
PTW CASE STUDY
• Class member to form into groups of XX
• Group members to each take the roll of AA, RA, AAR, RAR,
WL. AGT as necessary
• Prepare the permit and certificates required for the job.
• Select a team leader to make a presentation to the class
145
Case Study 1
Based on the
picture, kindly
identify the
PTW that
required for
the job.
• Erect scaffold
• Painting work
• Dismantle
scaffolding
146
Case Study 2
Based on the
picture:
i.
identify the PTW
that required for
the job.
ii.
Identify the
competent persons
that involve for the
job
147
Case Study 3
AAYY Sdn. Bhd. is being appointed as a contractor to build a structure
column at Terminal near storage tank.
Additional info:
1. Excavation depth 2 meter using backhoe
2. Piling depth 30 meter
You are required to use PTW to carried out the job. How many PTW will
be issues and what kind of certificate should applied
148
Thank you
149
20 minutes
150
15 minutes
151
10 minutes
152
1 minute
153

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PERMIT TO WORK SYSTEM (NEW)

HSE Department / OEAD

Date: 8 – 9th June 2016

Venue : Meting Room, Senai Aviation Fuel Terminal

At the end of this session you will be able to:

a) Identify and assess workplace hazards

General duties of employees at work

PETRONAS ZeTo Rules (rule #1)

Individual performing work without an

Training is mandatory for all PDB and contractor personnel

Written examination and other suitable assessment shall be

Official appointment shall be made by respective Division.

Facility (Terminal, PS, LPG bulk customer sites) handles

To Protect People, Environment, Asset &

Those carrying out a work must:

COLD WORK PERMIT - For all general work (no

HOT WORK PERMIT - For use of or generates

Work at Height Handling

An authorization list shall be circulated to inform the

•Area owner •Job owner

i. Understand work nature, hazards identified and risk reduced to ALARP.

i. Authorized by the Approving Authority

i. Authorized to assist the Receiving Authority

i. Confirms conditions of permit and agreement by signing

i. Authorized competent person from the relevant

ii. Safely isolates and work on low voltage

iii. This is the only person allowed to:

i. Responsible for advising the Approving Authority

i. Responsible for carrying out testing of toxic, flammable and

Zone 0 – continuous monitoring

Stationed outside one or more confined spaces who

Have the knowledge of the hazards that may be faced

PTW – Cold Work AA AA AA AA RA WL

i. Work is conducted during the period for which it is issued or a maximum of

v. Special requirement for Confine Space Entry – only 12 hours. 45

i. Permit, certificate and other relevant documents

ii. However for Permits, Certificates and all relevant

Daily Inspection Check List

Monthly Inspection Check List

Portable Electrical Temporary

Physical Isolation Certificate Special Three (3) month, with re-

S3 – PTW dependent on this electrical isolation.

S5 – Confirmation & Acceptance.

S7 – Temporary normalisation for testing.

Filling up the PIC:

S2 Work description (fill by RA) – reason

S3 Precautions (fill by RA) – risk

S4 Approval (fill by AA designated by

S5 Weekly Revalidation (by AA)

S6 Work completion (by RA and AA)

In addition, when any Critical lift is

i. Radioactive source and dosage

Optional certificates that can be

Requirements listed for CSE entry

Gas test log / record A3

i. The maximum validity period for Normal Certificates -

To clearly outline the requirements and conditions

* Fire watcher required to attend basic fire fighting training

Process vessels, boilers, water

Bodily injury due Physical hazards

Oxygen 20% to 20.9%

Parties Involved Competency Registration With

Standby Person (SP) Authorized Entrant & Standby Person (AESP) No