ptw policy_npl (2)

7/31/2019 Ptw Policy_npl (2)

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TECHNICAL PROCEDUREPERMIT TO WORK POLICY

REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 1 of13

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Title : PERMIT TO WORK(PTW) POLICY

No. pages: 13 Filing: Attachment(s) 1 2 3 4 5 6 7 8

Original : Number of pages

Table of Contents :

1) PTW Objective.2) Authority.

3) PTW Rules.

4) Safety Permit5) Protection By passing.

Key Words :

Associated Documents :

4

3

2

1

0 04/11/11 Jitendra Prelim.

Rev. Date Written by Checked by Approved by Revised pages Status


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REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13

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Filing locations

Locations

CEProject Director

O&M Head

Control room X

Maintenance Head

Operation Head

Technical Support

HSE X

HR Head

Admin Head

Finance & accountsContract , Commercial & Stores

Circulation

Management X Executives

Opration Number Technical Support Number

Head of Dpartement X Head of Departement (TS) X

Shift in Charge Engineer X Engineering in charge X

Dy. Shift in Charge Engineer X

Operation Support sectionJr. Assistant Controller

Chemist

Maintenance Number HR, Administration & Finance Number

Head of Department X

Mech. Maint. in Charge X HRD in Charge

Mechanical section X Administration Incharge

Elec. Maint. in Charge X F &A Incharge

Electrical section X

I & C Maint. in Charge XI & C section X

Civil section X

HSE Number Construction management

Project Director

Head of Department (HSE) X External Organisations

Safety in charge X


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1.0 Objective:

To safeguard people working within the premises of Nabha Power Plant, Rajpura from

the dangers inherent in equipment, machines, controls, processes, structural and civil

works, to prevent unsafe acts during such working and to ensure safety of the plant.

2.0 Authority:

Function wise authority provided by this policy to NPL staff is as follows to work within

the premises of NPL.

2.1 For raising work request All employees in Operation, Maintenance, TechnicalServices and Safety

2.2 For forwarding work request Shift Charge Engineer (SCE).

2.3 For canceling work request SCE

2.4 For rejecting work request Section in charge - TS.

2.5 For approval of work request Section in charges of Maintenance & TS

departments

2.6 For creation of work order All maintenance & TS staff

2.7 For scheduling of work order Maintenance & TS staff

2.8 For authorization of isolation SCE

2.9 For isolation from the system SCE with the help of field operators ormaintenance personnel, as required.

2.10 For preparation of PTW SCE

2.11 For issue of PTW SCE

2.12 For receiving PTW All operation, maintenance and TS and Safety staff


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2.13 For returning PTW PTW holder or the person authorized by him

2.14 For closing PTW SCE

2.15 For normalization SCE with the help of field operators or maintenancepersonnel, as required

2.16 For closing work request SCE

2.17 For closing work order In charge of the section which raised the work order orthe engineer authorized by him

2.18 For issuing safety instructions Safety in-charge or his assistant


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3.0 PTW Rules

3.1 Work within premises of the plant shall be carried out, only after receiving a Permit ToWork (PTW) in hard copy form, duly signed by SCE and the PTW holder. For the

purpose of clarity, PTW triggered in the computer is not valid until signed and issued in

hard copy by SCE. Only with signed hard copy the work can be performed.

3.2 Brief description of work to be carried out shall be spelt out in the Work Order. Work

scheduler shall specify any specific safety / isolation requirements known and needed

by him, in the work order. He shall also specify the approximate time duration for

completing the job.

3.3 Any tests to be carried out at the end or beginning of work should be mentioned in the

WO.

3.4 SCE shall verify the Work Order, before confirming the PTW.

3.5 Additional precautions to be taken by the working crew have to be stated in writing by

SCE. Eg. Nearby live lines or environment.

3.6 Even if plant is not in operation, isolations shall be the same as if plant is running or

available for service.

3.7 Each PTW requested shall be issued separately. However PTW for a group of

equipment can be clubbed and issued by SCE after discussion with concerned section

in charge during periods other than annual overhaul. During annual overhaul the

clubbing is listed in advance by the OSE/SCE and in agreement with the maintenance,

TS and Safety sections, the PTW for a group of equipment shall be issued by the SCE.

3.8 If any section (Mechanical, Electrical, I&C etc) has to work on an

equipment/machine/system, which is already under permit to work for another section,

the former section shall take a separate permit.

3.9 All isolations shall be confirmed by SCE before issuing the PTW.

3.10 Validity of PTW

All the PTWs are valid only up to the 'Valid up to' time written in the PTW hard copy.

SCE can issue PTWs for period of 24 hours or the time duration sought by the permit


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requester whichever is lower in case of permits involving isolations. Incase permit is

required for more than 24 hours the same shall be put up in the daily O&M meeting by

the requester section in charge for approval by plant in charge for extension beyond 24

hours. For works, which do not call for isolation, SCE can issue it for a period of 72hours or the time sought by the requester whichever is lower. For prolonged works

involving isolations SCE shall lock the MCC etc where such provisions are available.

3.11 Re-Validation of PTWs. :

After completion of validity period, if the work is not completed, the PTW holder shall

submit the permit to the SCE for revalidation.

SCE shall once again check the isolations and do more isolation if the prevailing

system condition calls for it or if found necessary, the PTW can be changed to "safety

permit" and ask for the clearance from Safety In charge. SCE can re-validate the PTW

for another 24 hours in case isolations are involved for the permit and for another 72

hours, if no isolations are involved. However, SCE shall not normalize the isolation or

take the system in service till the permit holder returns the permit.

3.12 PTW shall be issued only to NPL employee. The safety of the entire working team

including that of out-sourced workers and the safety of the equipment on which work is

taken up, is with the permit holder till returning of the PTW. However, safety clearance

and assistance of Safety personnel can be availed wherever considered necessary bythe PTW holder.

3.13 To avoid the possibility of working on the wrong equipment / location, PTW holder/crew

shall crosscheck the PTW with nameplate of the equipment and also confirm with SCE,

before starting the work. However, the PTW holder is permitted and advised to cross

check the isolations before starting the work.

3.14 Any change or additional isolation or additional protective measures required for the job

shall be intimated to SCE by the permit holder and the same should be normalized and

written in the PTW hard copy when surrendering / closing the PTW. Eg. Gagging of

safety valve, grounding of electrical circuits, opening of vents drains etc.

3.15 If the PTW holder is unable to carryout / complete the job, due to other work exigencies

or shift change over, in such cases he can authorize another engineer of his section for

completing the job and returning the PTW. Both the engineers (original PTW holder


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and the authorized person) shall sign on the original hard copy form of the PTW, while

passing on the permit under such circumstances.

3.16 If the PTW hard copy is lost a duplicate has to be obtained by the PTW holder from

SCE and all contents written on the original permit shall be copied on duplicate by the

applicant and SCE. For this purpose yellow copy available with the SCE shall be

referred. The permit has to be returned as per the procedure on completion of the job.

The lost copy loses it's validity once a duplicate copy of the PTW is issued.

3.17 If the permit holder has to leave the job on which PTW is taken due to any reason

without returning the PTW and without authorizing any staff from his section to return it

and not intimated his section in charge, the concerned section in charge is authorized

to delegate the work to another employee of NPL for completion of the job and return

the PTW. Before such authorization the concerned section in charge shall try to

contact the original PTW holder and retrieve the PTW. Under such circumstances the

original PTW holder is not authorized to resume work on the job using the PTW in his

possession without the consent of his section in charge.

3.18 In case the job is performed by more than one employee of a section, under one PTW,

the permit holder or section in charge shall mention the names of all the NPL engineers

who carry out the job under the same PTW. Also, all the members of the group should

sign- in and sign-out on the original PTW, when working as a group on a same

equipment or system.. If another engineer of the same section wants to work on the

same equipment, who is not a member of the group possessing the PTW, he has to

take a separate PTW.

3.19 Work carried out on the equipment under the PTW, other than specified in the work

order and not under the purview of the work mentioned in the work order or PTW, has

to be stated in writing by the permit holder on the hard copy form of PTW, while

returning the permit.

3.20 PTW shall be returned as early as possible, on work completion.

3.21 Requirement of taking trial run / checking of the equipment has to be analyzed and

indicated in the hard copy form of PTW, by the permit holder, while returning the PTW.

The SCE, based on the recommendation of the permit holder, shall decide for taking

trial run of the equipment. The trial run / checking of the equipment, if decided to be


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performed, shall be done as early as possible, after surrendering / returning of the

PTW. Where ever it is not possible to conduct the trial run after PTW returning, the

same shall be informed to section in charge -TS, by the SCE, for recording in the

pending works and during the next available opportunity such trial run shall be takenjointly by operation & the section who had performed the job.

3.22 When work cannot be completed by one section because of the need of another

sections skills, the first party shall surrender the permit with intimation to the second

party to carry out the job and having written so in the PTW. The second party shall

have to take a separate permit. The first permit shall be returned, only after the second

party takes the PTW. In certain cases the first party can retain the permit and return the

permit along with the second party where certain combined works are involved.

3.23 PTW shall be obtained for software loading on EWS by I&C engineers, during normal

operation of the plant. However, during unit trip conditions, loading can be taken up by

I&C engineers after obtaining acknowledgement of SCE on written intimation. For this

purpose a register is to be maintained in EWS room by I&C - section.

3.24 If testing alone is to be performed, PTW shall be taken for that limited purpose

separately (Eg. Hydro test, safety valve floating, IR checks etc.).

3.25 Feed backs, which are minor in nature but are essential for equipment starting/ running

may have to be forced sometimes. These shall be done only with the concurrence ofSCE and to be registered in the logbook provided in the control room. Eg. Manual

suction isolation valve open feedback for pump starting has gone bad due to failure of

limit switch. In such case SCE will ensure that suction valve is open locked (wherever

such provisions are available) and allow changing of limit switch.

3.26 Once the permit is returned by the permit holder the shift in charge shall close

the permit only after ensuring that all the tags placed on the isolation for the permit are

removed. In case the permit is surrendered for trial run, then the tags of all the

isolations, which are normalized, should be removed and kept with the permit copy.

After trial run if the permit has to be re-issued the same tags are to be placed once

again after isolation before re issue of permit.

3.27 PTW checklist attached at Annexure - 1 shall be referred by SCE & PTW receiver and

filled-up, before issue of PTW. If the PTW is qualified as safety permit, the checks by


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safety department has to be carried out by safety in charge / assistant before starting

the work. The permit holder shall explain the potential hazards of the work to all the

working crew and the applicants instructions to the working group shall be filled

before starting the work.

3.28 In absence of section in charge maintenance, the NPL employee authorized by section

in charge or authorized by plant in charge is authorized to approve work requests.

4.0 Safety Permits

4.1 For working in/on confined space, vessel, storage tanks, oils pits, gas & oil pipelines

PTW clearance by safety section shall be obtained before issue. Also, for gas cutting,

welding, and heating in the vicinity of inflammable material storage tanks & pipeline

PTW clearance by safety section shall be obtained. Similarly, for working on fragile

roofs, works at heights where permanent platform does not exist and SCE feels

necessary, the PTW clearance by safety section shall be obtained before issue of the

permit. SCE shall inform to the safety in charge for permits requiring safety clearance

and type of safety permit required, viz.

a) Hot permit

b) Confined space work permit,

c) Excavation work permit,

d) Hazardous Material work permit.e) Working at Elevations (Heights),

f) Openings in working floor and fragile roofs.

Depending upon the nature of work involved, safety section will issue the safety

clearance form in duplicate to the applicant after doing relevant checks at site (place

of work). The clearance form shall be attached to the permit copies in the control

room.

Safety in charge is authorized to recommend for carrying out the health check up of

workers before clearing the safety permits, if found necessary.

4.2 The permits, which are declared as 'safety permit' will have to be submitted to the

safety in charge every day morning, before starting the work. Safety In charge shall

sign for re-ensuring all the required safety checks after thorough checking.


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4.3 Safety department shall carry out regular checks/field inspections of the PTW for

validity, location, equipment, work procedures, tools and plants used for work and other

safety aspects. If any violation is observed with respect to this PTW policy by any NPL

employee the same shall be intimated to SCE or Section in charge of Safety or, TS or,Mechanical or, Electrical or I&C who has the authority to stop the work immediately and

inform HOD for further actions.

5.0 Protection Bypass

5.1 No protection bypasses are permitted, other than the protections listed below, without

the concurrence of head (O&M). The concurrence shall be obtained by SCE and

recorded in the protection by-pass register.

5.2 Protections bypassing permitted with SCEs approval

SL Protection description I. Reason for bypass II. Precautions / Approving Authority

1 Mill trip on PA flowWhile purging flowtransmitters during PMschedule

Possibility of running mill without airflow and flamfailure. Mill DP to be watched during such bypasMay be bypassed with the approval of SCE.

2 Secondary air flowWhile purging flowtransmitters during PMschedule

Reduce the trip setting to half and do t

maintenance work one side at a time. This wthe protection is available even durimaintenance work. CMC to be taken off befostarting maintenance work. May be bypassed wthe approval of SCE.

3When only one windingtemp reads erratically

To avoid trip on falsereading

The defective RTD may be substituted / bypassewith the approval of SCE.

4Mill trip on seal air tobowl DP

While purging DPtransmitters during PMschedule

Possibility of seal failure. May be bypassed wthe approval of SCE.

5Generator trip on levelhigh of LLD of generator

casing

During maintenance jobon LLD or gas leak

arresting

Danger of liquid level builds up. May be by passwith the approval of SCE

6Winding temperaturehigh trip of 6.6kvequipment

During maintenance workon thermocouple / RTD

May be by passed with the approval of SCE

7Bearing temperaturehigh trip of6.6KVequipment

During maintenance workon thermocouple

Local temperature to be watched. May be passed with the approval of SCE

8 CW pump level low tripDuring level transmittercalibration

Local watch required. With the approval of SCE


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SL Protection description I. Reason for bypass II. Precautions / Approving Authority

9PRDS CV positionfeedback

During maintenance forgetting permissive forspray valves to operate

Danger of water admission without steam awater hammer. With the approval of SCE

10 Mill hot air gateWhen gate feedback istoggling

To avoid opening of cold air damper to 100% aconsequent puffing of coal. May be bypassed wthe approval of SCE by the C/R engineer.

11 PA fan runningFor starting of first feederwith one fan running.

May be bypassed with the approval of SCE C/R engineer.

12All 6.6 KV motorconsecutive start

For keeping PA fanavailability aftersubstituting for runningfeedback.

May be reset with the approval of SCE, if tactual starts are not more than 2, in an hour.

13CW sump level controllerset point

To maintain low sumplevel during working onCWP sump.

May be done with the approval of SCE.

14 Atomising steam MIVOpen feedback foravailability of corner

May be done with the approval of SCE.

15SADC dampersoperation

During SADC checkingLocking of corners may be done with approval ofSCE

16BFP lube oil / working oiltemp

Bad quality / coolerchangeover

Danger of high oil temperature. May be done wthe approval of SCE for short duration, and loctemp. to be monitored. Change over the BFPreduce the load and stop the BFP having thproblem.

Note:1 The above protection may be revised and updated after actual experience with the unit operation.Note:2 The engineer whoever carries out the bypassing shall take the approval of SCE in the simulation registe

and as soon as the requirements are met, the same has to be normalized.


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ANNEXURE-1

SAFETY CHECK LIST FOR CLEARANCE PERMITS

SCE's CHECKS BEFORE ISSUING YES NAYES

NA

1. All required isolations completed 2. Purging as per procedure completed

3. Required de-pressurisation completed 4. Isolators earthed

5. Locks & tags fixed as per the procedure 6. Further checks & clearance by safety section required.

This is a (for type motioned below final clearance by SCE will be given only after receiving check list cleared by Safety

Hot permit Confined spacework permit

Excavation workpermit

Hazardous materialwork permit

Working at Elevation Openings in worfloor

Additional information

Sign SCE Date&Time

APPLICANTS CHECKS BEFORE STARTING JOB YES NAYES

NA

1 Equipment / pipelines washed with water. 2Hazards pertaining to the job are identified andpreventive measures taken

3Other equipment, in the area / below have beencovered / protected

4 Welding machine properly earthed

5 Surroundings checked for inflammables / leakage 6 Earthing done.

7 Road / passage barricaded 8 Potential hazards explained to the work group

9 24V AC lighting arranged 10 Number of persons on the job.

Additional measures taken:

III.IV. Sign. of applicant:

Date&Time

General instructions to the permit holder:

This PTW is governed by the rules stipulated in the latest PTW policy of NPL. Seek advise from Safety Dept, ifnecessary. Additional person shall be given to hold the ladder, whenever ladder cannot be secured. Dont carry 24V transformerin a confined space.

Follow all specific safety procedures while working in Hydrogen/ Chlorine hazardous area. Ensure all safety gadgetsare in good condition Ensure Slings, Chain pulley blocks etc. are of adequate capacity and are tested. Ensure lighting / machinery cables areinsulated.

1. Surrendered Permit Status:-

IV.1. Permit Surrendered For :

IV.2.

IV.3. Serial No. of Isolations Normalised

Applicant's Sign Date&Time Issuer Sign Date&Time

Clearance Permit Re-Issue / Re-Validation

IV.4. Permit Re-issued / Re-validated until:

IV.5. All the relevant isolations/ checks re-ensured

IV.6. All relevant safety checks re-ensured by safety charge

IV.7. Serial No. of Isolations not repeated for re-issue purpose :

Additional Isolations


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IV.8. Precautionary measures to be taken:

Issuer sign Date Time Applicant's Sign Date Time

2. Surrendered Permit Status:-

IV.9. Permit Surrendered For :

IV.10.

IV.11. Serial No. of Isolations Normalised

Applicant's Sign Date&Time Issuer Sign Date&Time

Clearance Permit Re-Issue / Re-Validation

IV.12. Permit Re-issued / Re-validated until:

IV.13. All the relevant isolations/ checks re-ensured

IV.14. All relevant safety checks re-ensured by safety charge

IV.15. Serial No. of Isolations not repeated for re-issue purpose :

Additional Isolations

IV.16. Precautionary measures to be taken:

Issuer sign Date Time Applicant's Sign Date Time