Safe Work Permits A Safety Advantage AMI Safety Conference March 20, 2013 J. Dan McCausland Senior Director, Worker Safety & HR
Safe Work Permits Everyone knows what a Hot Work Permit is -- right? Where do we use HWP s? Where don t we use HWP s? Why do we use? Provides extra focus on fire prevention. Do you use Work Permits at your facility? What permits do you require? Each type focuses on specific hazards outside normal work. Permits should be a key part of any plant safety program/process. Makes us stop and assess the hazards within an entire unit of work before exposures occur. Minimizes risk in non-standard situations.
Safe Work Permits Typically, we focus on production work. Also, on routine Sanitation and Maintenance work We know this work, and its hazards, well. Routinely prepare as needed for safety. Non-standard work are things outside our normal frame of reference. Often things done quarterly, or as part of other projects. Or, certain kinds of maintenance work. Ammonia system work Specialty sanitation (e.g. fumigation) Each type has intrinsic hazards that must be dealt with. Each type presents hazards that intrude on production work Permits for such work are task/hazard specific.
Today s Agenda: Safe Work Permits What is this about? What is the big picture with regard to Safety Permits? Why are permits necessary and/or appropriate? When are permits most useful? Where should permits be applied? How do you implement a Safety Permit process? Examples of permit applications
Safe Work Permits What is this all about? Most of our work is standard and repetitive in nature. Has a variety of risks, but usually those are well known and with safe job practices in place. We are de-sensitized work is normal in a normal area. Non-standard work also occurs from time to time. Need to prepare for those occasions, because they are out of the ordinary frame of reference for standard work. Such work may pose particularly serious hazards and require more than normal attention. These situations are perfect applications for the use of taskspecific safety permits.
Safe Work Permits Why bother? One word, Safety. Makes us evaluate the work that will be performed in our otherwise normal work area for possible hazards. Makes us define what Safe Work practices are, and how to follow same for this case. When Every time non-standard work will be done Permit(s) should at least be considered up front. Where Throughout the facility, and grounds.
Safe Work Permits How do we set up a Safe Work Permit Process? Identify each type of non-standard work. Key is to do this up front, with time to plan. Evaluate risk/hazard potential. Involve local SME s (subject matter experts). Use the What If analysis approach. Define the safe work process (to be followed). Develop in sufficient detail. Practice the doctrine of no surprises. Define who will be involved, who needs to approve, etc. Plan work well in advance. Cross check for complications of other work being done at same place and time. Resolve any territorial issues.
Safe Work Permits How do we set up a Safe Work Permit Process (continued)? Notify all who may be in the work area doing other tasks; may have to clear the work area. Work site security is essential. No non-essential personnel in area during permit work. Follow through with work according to permit plan. Close the permit: follow-up session to learn for next occurrence. Maintain a file on each class of permits will ultimately be very helpful for repeated occurrences of such work.
Safe Work Permits What kind of work may warrant a Safe Work Permit? Ammonia system line breaking/opening, device work, etc. Confined Space Entry as required for permit spaces. Energized (live) Electrical Work all occasions Natural Gas work venting, blowing, purging, etc. Hot work outside the welding shop, etc. Sprinkler system impairments, maintenance Extraordinary Hazardous Chemical work Trenching Crane/derrick rigging and lifting Critical Safety Bypass/Device Override situations Let s consider potential permits for each of these work types.
Ammonia Line Breaking Permit Valves, Relief valves, Flanges, Piping, Insulation, etc. Pre-work Safety review/plan Subject matter experts involved in review/plan of work. Procedures for opening a pressurized system Lines pumped down and confirmed empty Pipes plugged or capped as appropriate PPE including SCBA, eye wash/shower in place LO/TO for all related valves, vessels Nearest shut-off valves pre-identified Other permits needed Hot work, etc. Return to service protocol to assure safe restart Leak tests completed Formal sign-off on completion of work, permit.
Confined Space Entry Permit Follow OSHA rules @ 29CFR1910.146 these things can be deadly; no 2 nd Chance to get it right. Plan the work Characterize the space as Permit or non-permit Plan the entry based on the hazard(s) present Atmospheric checks initial, ongoing Isolation, ventilation Lockout as appropriate to condition PPE body harness, tripod, SCBA, etc. Communication and Rescue procedures planned Permit closing review
Energized Electrical Work Permit Require justification why do we have to work hot? Assess Hazard(s) devices, max. voltage/current, etc. Plan the work Job brief by (at least 2) qualified employees Establish Arc Flash boundaries PPE Helmet, V-rated gloves, FRC, etc. Clear the area Complete work under direct supervision Return to service protocol to assure safe restart System returned to Safe status Exposed electrical devices/wiring closed. Formal sign-off on completion of work, permit.
Natural Gas Line/Use Permit Incidents where NG permits were not used. Slim Jim plant (NC) explosion and fire Kleen Energy utility plant (CT) explosion Gas-fired hot water heater installation Plan the work and permit conditions Purging, Blowing, or Venting applications Line breaking or new equipment installation Secure ignition sources; clear area Lockout valves Ventilate Return to service protocol to assure safe restart Formal check for leaks Sign-off on completion of work, permit.
Hot Work Permit Welding, cutting, plasma arc all types of hot work Use FM Global HWP process very comprehensive Plan the work Precautions specific to area flammables, gases, liquids, etc. Explosive atmospheres must be neutralized Pressurized vessels must be purged, vented and neutralized Pre-work cleanup (e.g. dust) and LO/TO as appropriate. Sprinklers, extinguishers in place and working Protect materials on other side of walls, ceilings, etc. Fire watch during and 1-2 hours after work Return to service protocol to assure safe restart Formal check-off 4 hours post work Sign-off on completion of work, permit.
Sprinkler System impairment Permit Whenever a FP water supply valve is closed or water shut-off to the system; sprinklers are out of service. Notify property insurer, fire department, etc. Post fire watch during maintenance work. Provide extra fire safety support. No Hot Work allowed during impairment. Restore system to service and check pressure at inspectors test valve to assure safe restart. Formal check for leaks, other issues. All valves verified as open (in fire water supply loop). Sign-off on completion of work, permit.
Hazardous Chemical Permits Use for non-routine chemical applications where chemicals present toxic/deadly properties. Specialty cleanup work, Pesticide/fumigate applications, etc. Plan the work Pre-work meeting; who s required, timeframe, preparations, etc. Review nature of chemicals to be used, OSHA safety data sheets; application criteria and hazard analysis. PPE as appropriate to hazards Secure the area to be treated; no non-essential employees. Perform work. Return to service protocol to assure safe restart Formal check for residual chemical properties Sign-off on completion of work, permit.
Other Potential Permits Trenching Treat as a Permit-required Confined Space Follow OSHA rules on shoring, use trench boxes, etc. Monitor from outside trench. Critical Safety Device Override Similar to hot electrical work Lockout to extent possible Active monitoring in place while bypass is in effect. Cranes and Derricks Lifting Permits Clear the area below the lift; maintain security. Review crane and rigging documentation, certificates, etc. Follow OSHA rules rigging, supervision, load control, etc.
Conclusion What is unique to each of these work situations? They are outside the normal conduct of production work. Not on our typical radar screen. Hazards associated with each are deadly; injury potential is severe. Bad planning (or no planning) can result in fatalities. Permit processes create safe work conditions, and that is essential.
Conclusion Questions and discussion Sample permits are available for those who would like a copy. We will be happy to discuss later as well, and appreciate your time today.
Thank you!