WELCOME

TO

PTW SYSTEM
TRAINING WORKSHOP
 Aim:

To familiarize the participants with the

purpose and applications of the PDOC
PTW System
 Objectives:
Upon completion of the session, the participants
should be able to:
• Know the duties as employer under the OSHA Act
• Understand the applications of Permits and
Certificates
• Know the responsibilities of various signatories
under the PTW system.
• Understand equipment isolations , system override,
atmosphere testing and so on as safe work conditions
• Complete the various Permits and Certificates for the
relevant jobs
 Module 1

Legal Requirement for PTW

 OSHA

• It shall be the duty of every employer to

– Provide and maintain the plant and a
systems of work that are as far as practical,
safe and without risk to health.
 Who Is Employer ?

• Employer means the principal employer

or the immediate employer or both.
 Principal Employer

• Principal Employer
– Owner of business or process
– Not directly dealing with employees but their
decision has impact on the employees.
 Immediate Employer
• A person representing the principal
employer in discharging his management
duties.
• The lowest level of management is the
supervisor
• Supervisors, superintendent, heads of
dept, managers, senior managers and
above are all immediate employers.
 Supervisor As Employer
• A supervisor is an immediate employer
as he is directly responsible for the safety
and health of those who work under his
supervision.
• As far as is practical, the supervisor
makes sure that the plant and the system
of work are safe and without risks of
health to all his workers as well as others.
 Safe Plant

• Equipment used for work

• Equipment where work is performed
• Area of a plant
• Unit of a plant
• Electrical equipment
 Safe System of Work
• A system to ensure people work safely
– JSA
– PTW
– SOP
– LOTO
– Lift plan
– Check list and certificates
– Tool box talk etc etc
• Safety and health for the people, the plant and
the environment are taken into consideration.
 Safe Work Documents
• SOP
– This Safe Operating Procedure is established under the
company procedure for a specific activity that is carried
out on a regular basis. Requirements are clearly stated
for safe work.
• JSA
– This document is prepared and approved as a pre-
requisite to obtain a permit to work. It contains details
of job steps, their associated hazards as well as
corresponding control measures for each hazard, in
order to perform the work without any accident.
 Company Procedure
• Company procedures should be an instruction
to meet regulations and legislations
• Standards should be at least the same as the
Regulations
• More stringent conditions or controls are
recommended
• Training must be provided to all workers as
well as contractors
• Compliance is mandatory
 More Employer Duties

• Provide information
• Provide training
• Give instruction
• Provide supervision
• Provide PPE
• Medical surveillance of workers health
 As Far As Is Practicable
• The equipment and the work methods are so
prepared that they are safe
• If any thing could be made safer, it was already
done as far as practicable.
• If any further preventive actions could be
taken, they were already taken as far as
practicable.
• As far as is practicable means that all had been
done to the best of our knowledge, experience,
and within our available resources and cost.
 Penalty
• When an offender is prosecuted
– The offender is guilty until proven innocent
– The offender needs to establish that he had
actually done as far as is practicable and he
could not have done any further due to
certain valid reasons ( which he has to prove )
• If offender convinced the jury, he would
be free or otherwise be penalized.
 General Penalty

• Penalty for employer who offended

- A fine not exceeding RM 50K or jail term
not exceeding two years or both.
• Penalty for employee who offended
- A fine not exceeding RM 1k or jail term
not exceeding 3 months or both
 Module 2

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

• Permit when validated, can proceed with

work activity.
– it may stand alone or it may be
accompanied by certificates.
• Certificate when completed, need to be
attached to a permit. It contains details
of isolations, tests results etc.It does not
authorize work to proceed.
 What PTW Contains ?
• A work request statement and information
• Specification of requirements for safe work
• Equipment or area status is made safe and
ready for work
– Certificates are normally attached
• Names and signatures of those who are
responsible.
• Permit issue, revalidating and closing out
documentation.
 What Are Certificates?
• A documentation of precautions taken to create
a safe plant or equipment for maintenance
work to be performed.
• Designated Person or competent person
perform isolation and precautions and sign for
actions done on the certificates.
• It is a supporting document to permit.
• Certificate by it self is not a permit to work.
• Certificates are closed out after permits are
closed out.
 Module 3

Permits and Certificates

 Permit Areas

• The permit is required for work activities

carried out in the following areas.
– Processing areas
– Storage areas
– Loading areas
 Area Classification

• Zone 0
– Gas is constantly present
• Zone 1
– Gas is present intermittently
• Zone 2
– Gas is not expected under normal operation
 Permits & Certificates

• There are FOUR different work permits

(each has a solid colored border)

• There are SEVEN different certificates

(each has a colored border of diagonal
strips)
 Permits
• Hot work permit
– For all works that may become source of ignition
– Only PDOC Person In-Charge may validate the
permit
• Cold work permit
– Non routine activity that has no potential for
ignition
– Only PDOC Person In-Charge may validate the
permit
 Permits (cont.)
• Radioactive work permit (Blue)
– Work involving x-rays, gamma ray and other radioactive
source
– Person In-Charge validates the permit

• Electrical work permit/ isolation certificate

– Work on electrical equipment or electrical driven equipment
– Person In-Charge /SEAP validate the permit/certificate
 Certificates
• Safety bypass (purple/white)
– Override , forced signals, bypass
• Ground disturbance (brown/white)
– Mechanical excavation deeper than 0.5M
• Scaffold (orange/white)
– Construct, dismantle or modify temporary
platform for work
 Certificates (cont.)
• Mechanical isolation (green/white)
– For process and mechanical isolation
– Lock and tags are to be used
• Electrical isolation (yellow)
– For work on electrical equipment and electrical
driven equipment.
• Lock out Devices and procedure
– Application of locks and tags on isolation points.
 Certificates (cont.)
• Confined space (blue/white)
– Preparations for entry of personnel to do
work
• Gas tests (red/white)
– Check for safe atmosphere by trained gas
testers
• Lift certificate ( /white)
– For lifting activities
 Record keeping

• Permits and certificates are to be kept for

a period of 2 years
• Document is maintained for any would
be lesson learnt or investigation.
• During the period if nothing is to be
traced, they are destroyed
 Module 4

Permits Responsibilities
 Responsibilities
• PTW Validation Authority
– Remove or reduce hazards of the plant and
equipment for worker’s safety
– Protects the plant from risk brought by the work for
plant safety.
• PTW Receiving Authority
– Protects his workers and others from hazards of the
work
– Protects the plant and environment in which work is
performed
 Parties of Responsibilities
• Person In-Charge
– Managers or Superintendents in charge of the
facility.
– He validates the Permit
• Safe Work Permit Certified Supervisor
– Supervisor who has been certified under the PTW
system
– He appoints designated person and has overall
responsibilities for the job and safety
– He specifies requirements
Parties of Responsibilities (cont.)
• Permit Applicant
– Supervisor , staff or contractor trained under the
PTW system
– He applies for permit to work and coordinate work
activities
• Designated Person
– Technician or foreman who carries out the
precautionary works
– He takes precautionary and preventive measures
before and during work.
 Parties of Responsibilities (cont.)

• Authorized Gas Tester (AGT)

– Person trained in use of gas test equipment
and the gas testing techniques
– He certify acceptable tests results
• Workers/Work Crew
– Persons either staff or contractors
performing the tasks.
Parties of Responsibilities (cont.)

• Senior Authorized Electrical Person

(SAEP)
– Electrical engineer or superintendent
authorized by the company as competent
person for high voltage electrical work
– He is the only person who may perform
electrical isolation for HV equipment
 Parties of Responsibilities (cont.)
• Authorized Electrical Person ( AEP)
– Authorized person is competent person who
may perform electrical isolation on LV
electrical equipment.
– Operator may be competent person and
perform isolation and de-isolation as an AEP.
– AEP performs work or takes charge of work on
electrical equipment.
 Module 5

PTW Process
Copies of Permits/Certificates

• Original to be displayed at worksite

• First copy to be kept at Control Centre
• Last copy to be kept by Permit
Applicant
 Requestor of PTW
• Prepare necessary document
– Method statement
– JSA
– Plans (if required)
– Drawing (if required)
• Initiate the permit
• Designate a competent person (if
deem necessary)
 Specifying Requirement
• Person In-Charge and SWP CS specify
– Operations requirement
– Work requirement
– PPE requirement
– Special precautions needed
• They need to know the requirements of
regulations or company procedures as
well as best industrial practices.
 Performing Requirement

• Designated Person appointed to carry out

the necessary requirements.
– A certificate or check sheet is used to
complete the requirement
– Designated Person signed for completion
– Details are recorded on the certificates
– Certificates are attached to the permit.
 Permit Validation

• SWP Certified Supervisor verify &

confirm completion of precautionary
works

• Person In-Charge validates

 Work In Progress

The supervisor in charge is responsible for

what the workers do or fail to do.
– Pre-work meeting is organized
– Workers are given information and training
– Clear instructions and full supervision
– Work must comply to procedures
– Work must comply to PTW conditions
– Safe work practices must be followed.
 Re-validation of Permit

• All copies required

• Applicant, SWP Certified Supervisor
request for revalidation
• Person In-Charge revalidate permit and
certificate.
• Reason for revalidation
 Permit Re-validation
Permits are valid for a period specified
– Permit and certificate need revalidation in
order to extend the period of work
– Revalidation to confirm conditions or
precautions taken are still in tact
– Worker and work supervisor are the same
crew
– If work supervisor is changed, a formal
handover is required
 Reason for Re-validation

1. Operational conditions caused work to stop

2. Construction conditions caused work to stop
3. Unacceptable conditions had occurred
4. End of work day/shift (normal expire time)
5. Emergency alarm initiated.
 Work Completion

• Work site is reinstated back to normal

• Permit Applicant initiate work completion
• SWP CS inspect and confirm completion
• Person In-Charge endorse completion and
authorize reinstatement of any isolations .
Module 6

Isolation
 Isolation of equipment
• Prepare for shutdown
• Shut down
• Isolation ( valves and switches )
• Drain and depressurize
• Cleaning
• Testing
• Positive isolation ( mech.and elect.)
• Isolation certificates completed.
– For confined space entry work
– Ventilation and atmosphere testing
– Atmosphere test document completed.
• PTW authorized
 Prepare for shutdown
• Planning
– Buildup stock
– Reduce inventory in the equipment
– Inform affected parties
• Shutdown
– Stop process flow, close control valves
– Stop operating equipment, push stop button
– Initiate a shut down sequence button ( gas turbine )
 Isolate equipment
• Close manual valves
• Close and chain lock valves
• Hand jack control valves
• Remove valve handles or hand wheels
• Switch off field switches
 Drain and Depressurize

• Depressurize equipment until a few bars

left. ( 2 or 3 bar for low pressure flare )
• Drain the liquid till equipment is empty
• Fully depressurize the equipment to zero
pressure
 Removing Process Hazards

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

• Sample
– pH , lab test, litmus paper
• Atmosphere testing
– O2
– Flammable gas
 Mechanical isolation

• Remove spools and install blinds

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

Confirm zero energies before starting work

 Electrical Isolation
• Lock and tag open circuit
• Disconnect from power supply source
• Removal of fuses
• Discharging capacitors
• Disconnect battery terminals
• Testing to confirm circuit dead
Confined Space Work

• Ventilation
– Natural or mechanical
• Atmosphere tests
– O2 – 19.5 - 23.5 %
– Flammable gas < 10% LEL
– Toxic gas < TLV ppm
 Module 7

Permits Details
 Section 1
• Facility
– The name of the part of the facility in which
work is to be carried out
• Equipment No.
– Name of equipment, unit number or area
specific name
• Date
– Date of application
 Section 2
• Work description
– Direct sentence or phrase
– Breakdown into points if possible
– Clear and simple description
• Special work instruction
– Instruction if not mentioned is not likely to
be carried out. Non routine or non standard
practice or specific site conditions to look out
for.
 Section 3
• Applicant’s name and signature
• Nominate a designated person to be in
charge of the work
• Designated Person sign after being
briefed about precautions to be carried
out.
• Specify work area classification by
checking the appropriate box
 Section 4
• Specifying requirement/precautions
• To be completed by Person In-Charge and
SWP Certified Supervisor.
– All columns to be filled up (yes/no/NA)
– Items not available on the list to be specified (4.3)
– Specify PPE to be used during work (4.2)

Initial column to be completed after the actions are

taken by Designated Person.
# certificate number to be filled up
 Section 5
• Declaration by SWP CS signs the section
to authorize the Designated Person to
proceed with the precautions/actions
required at section 4
• Actions performed by Designated
Person
– Initial section 4 (column with “yes” only)
– Sign declaration at section 5
 Section 6 & 7
• Permit Validation
– Person In-Charge signs section 6
• Permit Revalidation
– If work is not completed within the first validity
period, revalidation becomes necessary
– If work is interrupted by some reasons, revalidation
is required before work may resume
– Applicant, SWP Certified Supervisor and Person
In-Charge sign section 7 stating the reason for re-
validation
 Section 8
• Permit close out
• Applicant complete the tasks, house-keeping and
sign close out section
• SWP Certified Supervisor verify worksite ready
to return to normal and sign close out section
• Person In-Charge signs and authorizes isolations
to be reinstated
End of Training

Thank You