Ptw Policy_npl (2)
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7/31/2019 Ptw Policy_npl (2)
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RAJPURA POWER
STATION
TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 1 of13
|
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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STATION
TECHNICAL PROCEDUREPERMIT TO WORK POLICY
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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
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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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STATION
TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
REFERENCE :TG/OPER/001_________________________Revision : 0 | PAGE 2of13
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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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TECHNICAL PROCEDUREPERMIT TO WORK POLICY
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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