Safe Working Practice

Zirku-HRT Revision: 7.
1
Instrumentation Training Course Page: 1
Module 1 Safe Working Practice of: 42
Module 1 Contents
FOREWORD: ZADCO EMERGENCY PROCEDURES................................................ 2
PERSONAL SAFETY:
M1.0 SAFE WORKING PRACTICE ........................................................................... 4
M1.1 ELECTRICAL SAFETY ..................................................................................... 4
M1.2 EARTHING (GROUNDING) .............................................................................. 5
M1.3 WORK PERMITS .............................................................................................. 6
M1.4 NON-SPARKING TOOLS ............................................................................... 18
M1.5 CONFINED SPACES ...................................................................................... 18
M1.6 INERT GAS ..................................................................................................... 18
M1.7 OTHER HEALTH HAZARDS ON SITE ........................................................... 18
M1.8 PRESSURISED LINE & COMPRESSED AIR PRECAUTIONS ..................... 19
PLANT SAFETY:
M1.9 FLAMMABLE FACTS ...................................................................................... 20
M1.10 HAZARDOUS AREA CLASSIFICATION ........................................................ 21
M1.11 ELECTRICAL EQUIPMENT FOR USE IN HAZARDOUS AREAS ................. 23
M1.12 SUITABILITY OF METHODS OF PROTECTION FOR ZONE 0, 1, 2 ............ 24
M1.13 TEMPERATURE CLASSIFICATION OF EQUIPMENT .................................. 25
M1.14 GAS GROUPS ................................................................................................. 25
M1.15 INTRINSIC SAFETY ........................................................................................ 26
M1.16 ZENER BARRIERS ......................................................................................... 28
M1.17 MAINTENANCE WORK IN HAZARDOUS AREAS ........................................ 31
M1.18 PRESSURE RELIEF & SAFETY VALVES ..................................................... 31
M1.19 RUPTURE DISCS ........................................................................................... 35
M1.20 HYDROGEN SULPHIDE .................................................................................. 36
M1.21 INGRESS PROTECTION ................................................................................ 36
M1.22 PRACTICAL .................................................................................................... 37
M1.23 QUESTIONS ................................................................................................... 38
ZADCO COLD WORK PERMIT .................................................................................. 39
ZADCO HOT WORK PERMIT .................................................................................... 40
APPENDIX REFERENCE ........................................................................................... 41
Revisions:
v1 1989 First version
v6.1 Sept 2001 Foreword and Pilot Operated PSV added. Electrical safety revised
April 2002 1.5b page 6 'Health Hazards' added
v6.2 Aug 2002 Reference Section Added, On site exercise added
Nov 2002 PSV terminology added 1.18.1
v7.0 Jan 2003 Zadco work permit procedures updated
v7.1 June 2003
1_safety.p65 (W. Phillips)

Zirku-HRT Revision: 7.1
Objectives of Module 1
This section aims to make trainees aware of the potential hazards of:
1. Electricity
2. Confined Spaces
3. Compressed Air
4. Fire and Explosion
5. Hydrogen Sulphide
and to explain how safe working practices and procedures and a permit to work system
allow us to work on a petrochemical plant without risk to ourselves, to other people, to the
plant or to our environment.
FOREWORD
Before starting your instrument training, you should have received;
1. Fire Fighting Training
2. First Aid Training
3. H2S Training
4. Gas Test Training
and you must know the following:
ZADCO EMERGENCY PROCEDURES
1_safety.p65 (W.Phillips)
ZADCO EMERGENCY PROCEDURES continued

M1.0 SAFE WORKING PRACTICE - PERSONAL SAFETY
ALL PERSONS EMPLOYED IN INDUSTRY HAVE A RESPONSIBILITY TO ENSURE THEIR

OWN PERSONAL SAFETY AND THAT OF OTHERS WHOM THEIR ACTIONS MAY AFFECT.
M1.1 ELECTRICAL SAFETY RULES

If you are careful and follow the company's safety rules, work on electrical circuits and equipment
can be done safely. Listed below are some electrical safety rules which should always be followed.
The list is not complete. For a complete list of the regulations you should refer to the company
electrical rules and procedures or Electricity at Work Regulations 1989, U.K.
Whenever possible, avoid working on or near energised circuits or equipment. This does
not forbid working live but doing so requires justification. (This means you must have a good
reason for working live.)
Never work on electrical equipment unless you are competent.

Do not work on electrical circuits with wet hands or when standing on wet ground.
Always check for yourself that a circuit is de-energised.
Avoid shortcuts
Accidents often happen when routines become familiar, so consider the result of each action you
take.
Replace a fuse only with one of the same value.
Examine all flexible leads before using them.
Treat batteries with respect: do not assume that low voltage is not dangerous.
Do not use damaged electrical tools or equipment.
Do not distract someone who is working with electrical tools or equipment.
Do not fool around in the workplace.
Report all dangerous conditions and equipment to your supervisor.
Report all accidents to your supervisor.
Always use the correct safety tools, equipment and clothing for the work you are doing.
Keep your work area clean and tidy.
Put tools and equipment away in the correct place.
Do not switch on any circuit or equipment without permission from the proper authority.
Precautions are put in place to prevent accidents
NOTES:
1. Circuits with capacitors (for example, uninterruptable power supplies) may give severe shock
even after being disconnected from the supply. They can be discharged by shorting with a 5 kohm
resistor. They should not be directly shorted as this can cause damage to the plates of the capacitor
and the device shorting them.
2. Before connecting any instrument to the electrical supply be sure to check that it is of correct
voltage and frequency.
3. When connecting or disconnecting an instrument to its power supply make sure that all switches
are in the OFF position. This prevents arcing when connecting up. After connecting replace all
covers on terminals.
M1.2 EARTHING (GROUNDING) (See also Zadco HSE Guide 1.6)

By holding any exposed conducting parts of an instrument, e.g. case or chassis, at the same voltage
as the earth and as the person operating or repairing the instrument, a factor of safety against
electric shock can be built into any device with electrical power.
The safety earth conductor (bonding) from the instrument to the earthing plate should be as low a
resistance as practical. (Zadco specify a maximum resistance to earth of 4 ohms.) It will often be
found in a three core cable that the earth core is thicker than the other two. The need for low
resistance in the earth conductor is that resistance, however slight, causes build up of voltage and
raises the faulty equipment above earth voltage.
Earth connections should be direct to earth and not via another instrument. This prevents any fault
on one instrument being transmitted to another.
The neutral in an ac circuit should be at earth potential.
REMEMBER - ELECTRICITY IS INVISIBLE AND CAN BE LETHAL
TAKE NOTHING FOR GRANTED. Personal caution is your greatest safeguard.

1) Use a meter to check for voltage to earth
2) Do not point at anything inside a live panel
3) Keep hands out until you are sure what you are going to touch and why.
There is never a good reason to take chances.
4) Do not ground yourself (e.g. by resting one hand on a panel while working live with the other
hand.)
5) Do not energise equipment if there is any evidence of water leakage.
You should know how to give artificial respiration BUT DO NOT TOUCH ANYONE SUFFERING
FROM ELECTRIC SHOCK UNTIL YOU ARE SURE THAT THEY ARE DISCONNECTED FROM
THE SUPPLY. Drag someone clear of a live supply by touching only their clothing.
Exercise 1.1
The international colour code for single phase ac mains cable is;
LIVE.........................., NEUTRAL..........................., EARTH.........................
How is live different from neutral?
Note:
If the mains cable supplied with an instrument is not to the standard colour code, then
1. EARTH is the core that is connected to the metal case or chassis
2. LIVE is the core that goes to the fuse
Working with electricity - Suggested rules for instrument technicians

An instrument technician may work on live circuits if:
1. the supply voltage is not above 48 vdc,
2. there is a good reason for not isolating the supply,
3. he has the correct type of work permit in a hazardous area,
4. he is competent to work with that equipment.
Fault finding on live, mains powered equipment must only be done by technicians who have been
assessed as competent to do so.

M1.3 WORK PERMITS

The work permit system:
Specifies the job to be done
Specifies the place where it is to be done
Specifies the personal protective equipment to be used
Specifies safety requirements
Confirms that it is safe to do the job
EVERYONE MUST COMPLY WITH THE WORK PERMIT SYSTEM.
The Permit to Work System in force on Zirku is described in a Zadco Safety Guide and this
document should be studied and understood.
M1.3.1 EXTRACT FROM ZADCO WORK PERMIT PROCEDURES

See Zadco HSE Guide (available on the intranet)
SECTION 1. GENERAL
1.1 Definitions
Approved. Accepted by, and endorsed by the authority having jurisdiction.
Area Authority. A Company employee, at a supervisory level or his officially assigned
delegate, who is directly accountable and responsible for the operation of a Company
process plant, site, field or installation.
Authority Having Jurisdiction. The Company Management, Department Manager, Site
Management, or individual responsible for approving equipment, installation or procedures.
Company. When mentioned, it means ZADCO.
Competent. A person, who is Approved by the Company as having the required
qualifications and experience to be accountable and responsible in carrying out pre-defined
tasks.
Contractor. An independent organization or person, hired by the Company, to provide
a service, to act on behalf of the Company in carrying out a pre-defined scope / service, or
for temporary / long term filling of any of the Companys established posts.
Designated. Is the nominated competent person approved by his hierarchy to act in the
capacity of Senior Operator or Senior Technician.
Emergency. Undesirable event which could result in fire, explosion, or hazardous
condition that poses an immediate threat to the safety of life, damage to property, or to the
environment.
Jurisdiction. Any Company location, site or installation that adopted this system of work
and procedures.
Performing Authority. A Company employee, or Contractor acting on behalf of the
Company. He shall be at a Supervisory level or above, of the section which is directly in charge
of performing the work or supervising the work performance of a Contractor.
Performer.A Company employee or a Contracted person, who is required by the Company,
either by himself, or leading a group of persons to carry out specific tasks (e.g. maintenance,
construction, demolishing, checking, etc.), on a specific Company facility.
Shall. Indicates a mandatory requirement.
Should. Indicate a recommendation or that which is advised, but not mandatory.
M1.3.1 EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued
1.2 Introduction
The Permit To Work (PTW) System is a formal written procedure used to control all types of work
that are potentially hazardous. Essential features of a Permit To Work (PTW) System are:
Clear definitions stating who may authorize particular jobs, who is responsible for specifying the
necessary precautions and who may accept the precautions to be undertaken during the work.
Training and instruction in the issue and use of permits.
Effective monitoring to ensure that the system works as intended.
A permit to work is not permission to carry out a dangerous job, but is an essential part of a
procedure that provides instructions on how a job can be carried out safely. The issue of a permit
does not, by itself, make a job safe. This can only be achieved by those preparing and those
carrying out the work. The permit to work is a written document that authorizes certain people to
carry out specific work at a certain time with measures needed to complete the job safely.
1.3. Legislation
The United Arab Emirates Law No. 8 for year 1980 on Conservation of Petroleum Resources
Chapter V, Articles-91 and the Ministerial Order No. 32 for year 1982 Protection of Employees
Against Occupational Hazards Article-1, both state that:
Every employer shall provide adequate protection methods to protect the employees from the
danger of injuries and vocational disease that may occur during work as well as from danger of fire
and from hazards that may occur because of employment of machines and other tools. Moreover,
it shall apply any other preventive methods as approved by the Ministry of Labour & Social Affairs.
A recognized means of complying with the above is the use of a written Permit to Work System.
1.4 Objectives
The objectives of this system is to establish means for the safe control of work which will:
a) Prescribe the nature and extent of the work.
b) Prescribe the conditions (Isolations, Gas tests, etc.) that have to be observed.
c) Provide for maximum safety of both personnel and plant and for good co-ordination between
Operations and maintenance work.
1.5 Hot Work in Hazardous Areas
Hot work is to be avoided in live hazardous areas whenever practicable. Site Management together
with Engineering Department to minimize the need for hot work and provide cost effective
alternatives by careful consideration during the design/modification and construction phases.

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

SECTION 2. RESPONSIBILITIES
2.1. Site Management
Shall be responsible for:-
Operation of the PTW System.
Nomination and maintaining registers of suitably competent personnel in order to implement/
operate this system.
Investigation of any accidents/incidents which may be attributable to any mis-operation of the
system.
Identifying training needs for operation and maintenance personnel involved in the permit to work
system.
The Site Manager/Head of Field who grants permission for work to be undertaken by delegating
his authority for the issue of permits to the competent supervisory level personnel or above, referred
to as Area Authority. A list of the approved competent persons is held by Site Manager/Head of Field
and regularly updated.
2.2 Health, Safety & Environment (HSE)
HSE (Abu Dhabi):
Shall be responsible for:
Custodianship of the PTW System on behalf of Management.
Initiating periodic reviews of the system with the objective of further improvement.
Conducting independent annual audits.
Site HSE:
Shall be responsible for:
Upon request, advising on procedures and precautions or any additional safety measures on tasks,
to be carried out safely.
Initiating regular audits / inspections to ensure that a safe system of work is being implemented.
Endorsing/countersigning the Connection to Equipment in Service (Hot Tapping) and vessel entry
complementary permits.
Providing an advisory and training service to all concerned site personnel.
2.3 Area Authority
The Area Authority is the Sr. Supervisor/Supervisor or above in charge of a particular area or his
official delegate approved by Site Manager/Head of field.
The Area Authority shall be responsible for:-
Identifying the hazards and specifying the precautions to be taken before, during and after all tasks
covered by the main and complementary permits, as applicable. As a guideline, reference can be
made to Annex 1 (Task Based Risk Assessment).
Cross-referencing between the main and the complementary permits, as applicable.
Checking that the correct type of permit (Hot / Cold) to be issued, fill all the required details in the
permit and issue any additional complementary permit, procedures, instructions and drawings.
Ensuring that inspection of work sites is undertaken before, during and after the performance of
each task.
The issue of main and complementary permits to the Performing Authority.
Carrying out combustible, toxic gas and oxygen deficiency tests and entering the results on the
permit.
Seeking the expertise of other disciplines for advice where necessary.
Ensuring that adequate handovers take place at shift change.
Ensuring that the signatory authorities are still available or the relievers have countersigned the
Transfer of Responsibilities Handover Form (Appendix-13)
Seeking the expertise of other disciplines for advise where necessary.
Ensuring that the signatory authorities are available or the relievers have countersigned the
Transfer of Responsibility Form (Appendix-13).
2.4 Performing Authority
The Performing Authority shall be a Company employee, or Contractor acting on behalf of the
Company. He shall be at a Supervisory level or above, of the section which is directly in charge of
performing the work or supervising the work performance of a Contractor.
The Performing Authority shall be fully aware and understand all relevant regulations and
procedures prior to being designated as Performing Authority Representative. It will be his
responsibility to ensure that the Performer (Company or Contractor), who is involved in the work
covered by the permit, is aware of and comply with the permit conditions.
The Performing Authority shall be responsible for:-

Compliance with the conditions and precautions specified on the permit.
Briefing his team on the conditions and precautions.
Ensuring that the only activity performed is as specified on the permit.
Ensuring that adequate handovers take place at shift change.
Ensuring that on completion or supervision of the work, the work team have been withdrawn and
the worksite left in a safe and clean condition and properly protect the parts/equipment from
corrosion.
Seeking the expertise of other disciplines for advise where necessary.
Ensuring that the signatory authorities are available or the relievers have countersigned the
Transfer of Responsibility Form (Appendix-13).
2.5 Performer
Performer is the person carrying out the job, or in charge of a number of workers jointly
carrying out the job. The Performer initiates the Work Permit by filling the necessary details
in the INITIATOR Section as referred to in the maintenance work request or planned
maintenance / inspection. The Company Performing Authority shall countersign on this part
as an approval for the application of a Work Permit. The Performer shall state the following:
The nature and description of the work and tools / equipment to be used.
The requested date and time to start the work and the expected duration.
The exact location with any necessary details, drawing or sketches and procedures to be
attached.
The Performer shall be responsible for:-

Compliance with the conditions and precautions specified on the permit.
Briefing his team on the conditions and precautions.
Ensuring that the only activity performed is as specified on the permit.
On completion of the work, the Performer shall leave the worksite in a safe and clean
condition.

SECTION 3. TYPES OF PERMITS
3.1 Main Permit:

The Main Permit, which is valid by itself for a certain hot or cold work, is also the supporting
document for complementary permits. Without a Main Permit, the others cannot exist.
The Main Permit will specify:

Nature of Work (Hot or Cold).
The Complementary permit required.
Date and expected duration of the work.
Exact location of the work site, with sketch if necessary.
The condition of the equipment on which work is to be carried out.
The specific safety measures recommended by the Area Authority.
3.1.1 Cold Work Permit

A cold work permit, colored green, is required for any non-operational cold work, other than the jobs
listed under 3.3, which does not involve the use of a local source of ignition or produce / expose
an electrical ignition source.
3.1.2 Hot Work Permit

A Hot Work Permit, colored red, valid for one day shift only, is mandatory for any work which
involves the use of a local source of ignition or work which could produce or expose an electrical
or auto-ignition source. Issuance of Hot permit for night shift is subject to the Site Manager / Head
of Field approval. Examples of local ignition sources:
All naked flames, fires or smoldering material.

Portable equipment, machinery or tools operated electrically or by internal combustion engines.
All electrical equipment which is not of flameproof construction or intrinsically safe, or approved for
use.
Caterpillar cranes and other such pieces of equipment which may be specified for certain work.
Grit blasting (wet / dry).
Any equipment or operation which can produce mechanical or electrical sparking or sufficient heat
to cause a fire or induce an explosion.
Any hand tool liable to cause sparking when used in areas where flammable gases may be present
3.2 Complementary Permits

Complementary Permits, as the description implies, become attached to, and become a permanent
part of the Main Hot / Cold Permit where their use has been prescribed.
3.2.1 Confined Place Entry Permit

A confined Entry Permit, colored blue, is necessary each time a person has to enter any confined
space. This permit is issued only after a close check of the atmosphere by Site HSE, the stipulated
precautions to maintain a safe working environment have been met and endorsed by the Site HSE
Engineer. This permit is valid for only one working day shift considering continuous gas monitoring.
3.3 No Permit Required
Under certain circumstances, an Area Authority may allow certain works to be carried out in his area
of control without the issue of a Permit, but based on a specific formal procedure. The discretion
to use this facility lies entirely with the Area Authority.
This in no way relieves the Area Authority of the responsibility to control work effectively.
The work must not be hazardous to either the person who carries it out or to anyone else including
equipment & environment, and the Area Authority must be satisfied that all reasonable practicable
steps have been taken to ensure the safety of those involved, and anyone else that the work might
affect.
A list of such jobs shall be produced by the Area Authority for approval by the Site Manager / Head
of Field. Examples of such jobs are listed here under for guidance:
Routine production operations (covered by Operating Manuals).
Production / flow testing operation.
Routine Materials handling.
Routine work in offices.
Routine domestic activities (Catering, Cleaning etc.)
Routine helideck operations (including refueling).
General cold work inside workshops.
Watchkeeping.
Visual inspection of areas (not including confined spaces).
Operating or demonstrating portable fire fighting, safety / lifesaving equipment during drills,
training or testing.
Construction site of new facilities until hydrocarbons are first introduced, except where work comes
within 50m of an operating facility.
Well services operations at locations where only well services personnel are working.
Visual inspection.
Simple lubrication of machinery.
Simple cleaning tasks.
Regular and routine check of instruments.
Changing light bulbs in unclassified areas such as offices and buildings.
Sampling of fluids.
Refueling of helicopters.
For each of the Site approved list of jobs, a specific safety standing instructions should be
developed by the Area Authority in consultation with Site HSE and approved by Site Manager / Head
of Field.

SECTION 4. INITIATING A WORK PERMIT AND PERMIT DISTRIBUTION
4.1 Initiation
4.1.1 The Performing Authority shall initiate the Work Permit by filling the necessary details in the
INITIATOR Section as referred to in the maintenance work request or planned maintenance /
inspection. The Company Performing Authority to sign on this part as an approval for the application
of a Work Permit. The Permit should state:
(i) The nature and description of the work and tools/equipment to be used.
(ii) The date and time to start the work and the expected duration.
(iii) The exact location with any necessary details, drawing or sketches and procedures to be
attached.
4.1.2 An application for a Work Permit is normally made at least a day in advance of the start of
the work. This is to give adequate time for the correct arrangements to be made.
Exceptions will be made at the discretion of Area Authority in order to deal with urgent / emergency
works, but the full Permit to Work System must be applied.
4.1.3 Under no circumstances shall a Contractor be authorized to issue a work permit.
4.1.4 In no case will the same person be allowed to sign the permit as both Area and Performing
Authorities.
4.1.5 In certain cases where the Area Authority is the work Performer, then the Senior Supervisor
/ Supervisor will issue the permit as Area Authority and his subordinate Supervisor/Sr. Operator will
sign as Performing Authority. (see 4.1.4 above).
The Area Authority Supervisor may at his discretion delegate the most competent and trained Snr.
Operator or designated Operator to authorize a work to start after checking that all listed conditions/
precautionary measures are met and the intended work will be carried out safely.
A designated operator will sign on the work permit in the capacity of Snr. Operator.
The performing Authority Supervisor may at his discretion delegate the most competent and
trained Snr. Technician or designated Technician (ZADCO or Contractor) to receive the work
permit at location as Performer after checking that all conditions and precautionary measures are
met.
A formal list of all competent and trained Operators and Technicians designated as work permit
signatories will be kept and updated as required by site.
The designated competent operators and technicians are proposed by their direct Supervisors,
trained in the PTW by site HSE and approved by the Site Manager/Site Team Leader who will be
responsible and accountable for the delegation under items 4.1.6 and 4.1.7 above.
4.2 Permit Distribution
4.2.1 Original Copy (white):
Will be issued to the Performer and will be retained and clearly displayed on site by the person
responsible for the work and will be kept on the job site until the work is complete.
4.2.2 Yellow Copy:
Will remain in the possession of the Area Authority until completion of work.
4.2.3 Pink Copy:
Should be collected by HSE Engineer for random daily auditing of work permits.
4.2.4 Green Copy:
Will be posted in a permanent place in the control room at a convenient location.
SECTION 5. GAS TEST
5.1 Only trained persons, approved by the Area Authority and Site Senior HSE Engineer, will
carry out and certify gas tests. A list of such approved persons, will be held and updated by the
respective Site Manager / Head of Field and copied to all site concerned Authorities.
5.2 A person authorized to carry out gas tests will be responsible for ensuring that the gas
detector is tested and functioning properly.
5.3 In case of hot work the gas test must be carried out prior to immediate commencement of
work.
5.4 Gas Test must show the absence of hydrocarbon vapor / gas.
5.5 Should repetitive gas tests be required then the Authorized Gas Tester may indicate the
result on the Performers copy of work permit. If the risk of gas release may exist at any time
then a continuous gas monitor should be considered.
5.6 In certain Cold/Hot works the Area Authority Supervisor may indicate in the GAS TEST
Section that the area is safe from gases i.e. gas test is not required and sign accordingly.
5.7 Whenever work stops for any reason (e.g. tea, lunch, etc.) then prior to resumption of work,
further gas tests shall be taken. Should the gas test readings section become full, the gas
tester shall continue to record the readings and sign on the reverse side of the permit.
5.8 Training of Site Personnel, to be Approved Gas Testers, shall be conducted by Site HSE.


SECTION 6. VALIDITY OF PERMIT AND WORK COMPLETION
6.1 Validity:
6.1.1 A permit will be valid only when all the required signatures are on the permit.
6.1.2 Normally a work permit is valid for one day shift only.
6.1.3 A permit may be extended to cover the hours of darkness, subject to the endorsement of the
Site Manager / Head of Field, or his delegate, provided that the work conditions and requirements
remain unchanged.
6.1.4 Only cold work permits can be extended, up to one week duration, provided that the work is
continued daily with no change in the nature, conditions and location of the job.
The signatures of the duty Area and Performing Authorities along with the date and time are
necessary to close the permit daily as shown on the reverse side of the cold work permit form.
By the end of the working day, and if the work has not been completed, then an extension for the
following day may be submitted. The extension should be endorsed on the reverse side by the
concerned authorities.
All other permits (HOT, Complementary) are not allowed to be extended, except the excavation
complementary permit which could be extended for a period up to one month. Electrical
complementary permit remain valid as long as the main permit is valid.
6.1.5 In situations where the Performers copy of the work permit is in possession of the Performer
on a WHPT, or in Transit on a boat or helicopter, it is permissible for the Performing Authority
Supervisor to provide, for record, a photocopy of the original permit, or a faxed copy with formal
request in writing on the reverse side to one day extension.
To be valid as an extended permit it must be signed and dated by the recognized Area Authority
as well as the Performing Authority.
A new permit may be initiated whenever there is any disagreement amongst the Authorized
Signatories.
6.1.6 When a long term electrical lock out is required, as in the case of unavailability of spare parts,
both Main and Complementary Electrical permits will be retained with the respective working trade
together with the keys of the isolation locks until the spare parts are available for installation. Then
the retained permits will be cancelled and new permits (Main & Electrical) should be issued.
If the Performer is required to carry out an unplanned urgent cold job at a remote location, without
first returning to base, the following shall apply:
i)The Area Authority, Performing Authority, on the base, shall fill/issue the required cold work
permit.
The work permit number and the required work conditions/precautions, shall then be transmitted
over a recorded radio message (where applicable) from the base to the delegated operator and
Performer on the remote location.
The Performer and the operator shall then record these requirements on a blank work permit form,
acknowledge it through the recorded radio transmission, sign on their work permit (Performers
acknowledgement and operators authorization for work) and record the work permit number as a
cross reference.
Work completion acknowledgement shall be done as per 6.2 below.
Upon returning to base, Area Authority shall attach the work permit, filled by the Performer and the
operator, to the original permit issued at base for the purpose of record keeping.
6.2. Work Completion:
On completion of the work, the Performing Authority Supervisor will return the original copy of the
permit to the Area Authority Supervisor for his acknowledgement signature and filing.
In case of work carried out at remote areas (satellites, WHPTS), where Area Authority and/or
Performing Authority are not available at the work location, the Performer and the Sr. Operator may
confirm the completion and acknowledgement respectively of work.
Area Authority shall retain both the white and yellow copies, HSE shall also retain the pink copy for
a period of three months.
SECTION 7: WITHDRAWAL AND CANCELLATION
7.1 Withdrawal:
7.1.1 If the site or working conditions change, or are likely to change, after the issuance of the
permit, the Area Authority Supervisor must inform the Performing Authority Supervisor to stop the
work. Similarly if the Performing Authority feels that conditions have changed then he must
withdraw the permit and consult with the Area Authority Supervisor.
7.1.2 All work permits shall be considered withdrawn when the emergency alarm is
sounded. The Performing Authority is not required to hand over the work permit copy to the Area
Authority under emergency condition. The permit may later be re-issued when the Area Authority
is satisfied that the original conditions, under which the permit was issued remain or restored as
originally approved. Re-endorsement to this effect must be indicated by the Area Authority.
7.2 Cancellation:
7.2.1 A work permit is immediately cancelled as soon as the stipulated conditions are not
maintained.
7.2.2 When a work permit has been cancelled work cannot be resumed unless a new permit has
been raised.
SECTION 8: CONDITIONS APPLICABLE TO COLD AND HOT WORK

8.1 The Area Authority will be responsible for ensuring that the site and equipment subject to
permit control are properly prepared so that work may be carried out safely.
Work on Wellhead Platforms Involving the Opening of Cabinets Enclosing Wellhead Safety
Control Systems
Prior to such work commencing on a wellhead platform, a hydrocarbon gas test has to be carried
out by an Authorized Gas Tester. The procedure to be adhered to is as follows:
On arrival at the site, an Authorized Gas Tester is required to conduct a general survey of the area.
Positive readings on gas detection equipment at this stage must be reported by radio to the Area
Authority.
Wellhead control systems cabinets shall be opened and time to be allowed for any accumulated
gas to disperse. All personnel involved to stay up wind of open cabinets.
Test the cabinet enclosure for hydrocarbon gases.
On completion of work all electrical enclosures and other control cabinets to be closed.


9.2.3 Safety Lock and Tag Out:
Each discipline performing any work on electrical equipment or conductors will be provided with an
individual safety padlock and key as per Site Electrical Procedure. The padlocks should be either
color coded or tagged to signify that they are part of a safety system.
When more than one discipline is assigned to work on any equipment that needs to be isolated then
there must be provision for all disciplines involved to have their own locks.
All locks, keys and tags, will be returned to the responsible supervisor after completion of work. In
the event of a worker leaving his lock and being re-assigned to another job, or not reporting to work,
the responsibility will immediately be transferred to his supervisor.
Whenever a lock has been installed, a prominent tag will be placed and must remain until the lock
has been removed. The tag will say DO NOT OPERATE WORK IN PROGRESS.
In case of a key lost both OPS & MTN Supt. Should obtain dispensation from Site Manager to
remove the lock.
A list of the assigned locks, and the installed locks, with their discrete numbers, will be drawn up
by the supervisor.
When a long term electrical lock out is required, as in the case of unavailability of spare parts, the
Complementary Electrical Permit along with the Main Permit should be retained with the respective
working trade together with the keys of the isolation locks until the spare parts are available for
installation. Then the retained permits will be cancelled and new permits (Main and Electrical)
should be issued.
9.2.4 Work and Operations not subject to Electrical Isolation Procedures:
9.2.4.1 Normal Operations:
The normal handling of installations, machinery or circuits provided these operations correspond
to the normal use for which the unit is designed.
9.2.4.2 Very Low Voltage Equipment up to 50V AC/DC

Checks, tests, etc. of very low voltage equipment provided they are carried out with the
appropriate apparatus.
10.2.2 Precautionary Measures

a) When opening man holes or breaking lines on any tank or vessel, the possibility of internal
pyrophoric scale being present must be considered. Water hoses must be immediately available
to damp down any pyrophoric material. Great care should be taken in the case of tanks and vessels
which have contained crude oil, raw gas or unrefined distillates, since the corrosive sulphur
compounds present in these materials may form an easily oxidizable scale which is often
pyrophoric.
b) In opening manholes or breaking lines where there is a possibility of the evolution of H2S rich
gas, a suitable breathing apparatus must be worn.
c) The operation of breaking into lines to swing blanks or to remove distance pieces is one which
can be hazardous and before permission is granted to do this by a work permit, the Operating
Authority must be satisfied that all possible means have been taken to remove pressure from the
lines. Any possibility of liquid being trapped in the butt end of lines or valves must be pointed out
to the Safety Supervisor and referred to on the work permit, which must also specify which blanks
are to be swung, bearing in mind that drain lines may require to be left open.
SECTION 12: EQUIPMENT USED IN HAZARDOUS AREAS

12.1 Introduction:
In order that maximum protection be afforded to persons, plant and equipment within ZADCOs
jurisdiction, effective control must be exercised over equipment used, particularly in restricted
areas. Preventive measures are aimed at the elimination of the coincidental occurrence of a
dangerous atmosphere and a source of ignition. Since by definition a hazardous area is one in
which a dangerous atmosphere might be present, it is necessary to apply certain minimum
standards to equipment, used in these areas. Use of such non-classified equipment in these areas
is always controlled by Hot Work Permit.
12.2 Specifications of Electrical Equipment used in Classified Areas:

12.2.1 Zone 0 Areas:
In these areas, any ignition could lead to an explosion or fire since a dangerous atmosphere is
always present. All electrical equipment or any source of ignition should be avoided.
If electrical equipment has to be installed, then intrinsically safe (Exia) apparatus and circuits must
be used.
12.2.2 Zones 1 & 2 Areas:
Only equipment certified / Approved for use in these areas shall be allowed (e.g. Flame Proof,
Explosion Proof or Intrinsically Safe).
12.2.3 Unclassified Areas:
Approved industrial / marine type equipment are commonly used.
12.4.4 Plugs and Sockets:
Plugs and sockets shall be weatherproof and certified if located in hazardous areas. Domestic type
are not permitted.
Socket outlets and their associated plugs operating at different voltage levels must not be
interchangeable.

M1.4 NON-SPARKING TOOLS

For work in zone 1 or zone 0, when the use of steel tools risks causing ignition by spark, then special
tools made from bronze called non-sparking tools should be used.
M1.5 CONFINED SPACES

A confined space may be defined as any enclosed space or compartment without open ventilation
such as tanks, vessels, pits, the roof of a floating tank etc.
A compartment or space containing machinery used for handling dangerous substances may also
be regarded as a confined space.
Before allowing personnel to enter a confined space without wearing breathing apparatus the
atmosphere must be free of flammable or toxic vapours and the oxygen level must be checked and
maintained within the approved range of 20% - 23% by volume of air.
Oxygen concentration in an atmosphere can be determined with the aid of an oxygen meter.
N.B. Under no circumstances is it permissible to rely on valve closure only as a means of

isolation where men have to enter a tank or vessel.
A confined space may be dangerous because H2S or inert gas can build-up if we have not ensured
adequate ventillation.
M1.6 INERT GAS

Inert gas is used to purge (= drive out) air/oxygen from vessels, equipment and pipework before
hydrocarbons are brought in. In this way we can be sure that we never have an explosive mixture
inside process plant.
Inert gas is made by burning a hydrocarbon fuel with air and collecting the exhaust gases. The
oxygen that was in the air will be converted into carbon dioxide and carbon monoxide (and water
vapour).
CARBON MONOXIDE IS POISONOUS.
Note that the same combustion process happens in a motor car engine and if you stay in a closed
garage with a car engine running, then you may die from carbon monoxide poisoning.
M1.7 OTHER HEALTH HAZARDS ON SITE

M1.7.1 NOISE
If you are working in an environment that is so noisy that ordinary conversation is difficult, you
should be wearing hearing protection. High pitched noise e.g. turbines and control valve noise is
particularly damaging to hearing.
M1.7.2 HEAT
If you are working in a high ambient temperature or in direct sun, then at the first sign of dizziness
stop work and go immediately to a cool place, take a drink and cool down before sarting to work
again. Protect yourself from the direct rays of the sun whenever possible.
M1.7.3 SPRAY CLEANING FLUIDS AND LUBRICANTS
Do not spray in confined spaces and take care not to breathe the spray.
M1.7.4 MINERAL OILS
Protect your hands with BARRIER CREAM before starting work. Use rubber gloves when cleaning
equipment with diesel. Repeated exposure of the skin to crude oil, diesel oil (and mineral oils in
general) can lead to dermatitis and skin cancer.
M1.8 PRESSURISED LINE & COMPRESSED AIR PRECAUTIONS

M1.8.1 PRESSURISED LINES may need to be uncoupled for instrument maintenance or
calibration. The line may contain process fluid which could be a liquid or a gas and may be hot,
corrosive, poisonous, inflammable or irritant. Any of these poses a hazard.
BEFORE UNCOUPLING
1. Obtain a work permit.
2. Find out contents of pipe and get necessary protective clothing and equipment.
3. Inform process operator, he may need to change from automatic control to manual.
4. Ensure process isolator is closed.
UNCOUPLING
1. Open drain/vent valve to depressurise instrument system, ensure process fluid is correctly
disposed of.
2. Close instrument isolators.
3. Remove instrument and fit blanking plugs to the open ends of impulse lines.
4. Close drain/vent valves.
5. On refitting the instrument, again ensure that the system is depressurised before removing
blanking plugs.
NOTE: On process lines which have only a gauge isolator;

1. Close valve off tightly.
2. Depressurise system by cracking open connection to gauge.
3. When completely depressurised (as shown by gauge reading) remove gauge.
4. Fit blank plug in the open end.
5. Again ensure system is completely depressurised before removing plug in order to refit gauge.
M1.8.2 COMPRESSED AIR

On all occasions when compressed air is being used the greatest care must be taken to ensure
its proper use.
The danger caused by wrongful use of compressed air should be thoroughly understood by all
persons employed where it is used. For instance a pressure as low as 13 psi has been known, when
improperly used, to penetrate the skin introducing air into the blood stream, resulting in death.
Compressed air must not be used to clean benches or equipment as there is danger of dust being
blown into the eyes and causing severe damage to eyesight.

PLANT SAFETY
M1.9 FLAMMABLE FACTS
THE EXPLOSION PROCESS
OXYGEN (usually in AIR)

+
FUEL (infammable gas)
+
"SPECIFIC CONDITIONS"
+
ENERGY (spark or heat)
= FIRE OR EXPLOSION
Inflammable (or combustible) gases or vapours mixed with air will form an explosive atmosphere
if the mixture is between certain limits. These limits are expressed as a percentage of the gas by
volume in air. Below the Lower Explosive Limit (LEL) the mixture of gas in air does not contain
enough gas to ignite and cause an explosion. Above the Upper Explosive Limit (UEL) the mixture
does not contain enough air to ignite.
Examples of explosive limits;
GAS + AIR LEL% UEL%

HYDROGEN 4.1 74.2
ACETYLENE 5.3 82.0
PROPANE 2.3 9.5
CRUDE OIL 1.0 10.0
HYDROGEN SULPHIDE 4.3 46.0
A Combustible Gas Monitor (Explosimeter) is used to measure the concentration of gas in the
air and to give an alarm if the concentration of gas goes above 25% of the LEL.
These monitors are installed all over the plant to give an alarm in case of leaks or spillages.
Hand-held versions are used during HOT WORK to make sure that when the work invloves a source
of ignition, then there is no explosive mixture present.
NOTE: Certain mixtures are particularly hazardous since they will ignite without a spark
(spontaneously) e.g.
1) grease or oil plus oxygen - gauges for oxygen cylinders must not get oil inside when calibrated
2) pyrophoric scale (formed inside pipes and vessels that have contained oil or gas mixed with H2S)
ignites when pipes (and instruments) used for "sour service" are opened to the air.
M1.10 HAZARDOUS AREA CLASSIFICATION

A hazardous area is a part of the plant where there may be the risk of a fire or an explosion.
In some places the risk is greater than others and so these areas - called ZONES - are divided
into high risk areas called ZONES 0 and ZONE 1, and areas where the risk is less, called
ZONE 2.
The International Electrotechnical Commission (IEC) - the recognised international body for
electrotechnical standards - defines hazardous areas as follows:
Zone 0: An area in which an explosive gas/air mixture is constantly present or is present

for long periods (typically more than 1000 hours per year).
Zone 1: An area in which an explosive gas/air mixture is likely to occur under normal oper
ating conditions (10 to 1000 hours per year).
Zone 2: An area in which an explosive gas/air mixture is unlikely to occur in normal

operation, but if it occurs, will be of short duration (typically less than 10 hours per year).
TABLE 1.10.1
EUROPE ZONE 0 ZONE 1 ZONE 2
USA DIVISION 1 DIVISION 2
DEFINITION Explosive Explosive Explosive

OF atmosphere atmosphere atmosphere
AREA ALWAYS sometimes not normally
present present present
SUITABLE Ex ia Ex Increased
INSTRUMENTS only certified safety 'e' if
See Table 1.3 capable of
sparking or
good industrial
standard if
incapable of
sparking.
Ex marked on an instrument means that it has been tested and approved for use in a
HAZARDOUS AREA
EEx means that the equipment has been tested at a European (CENELEC) approved testing
laboratory.
FM Ex or CSA Ex are N. American equivalents

FIGURE 1.10.1 PART OF A HAZARDOUS AREA CLASSIFICATION DRAWING
M1.11 METHODS OF PROTECTING ELECTRICAL EQUIPMENT FOR USE IN HAZARDOUS

AREAS (so that the equipment can not cause a fire or explosion)
A conformity certificate proves that the equipment meets (or conforms to) the requirements of
the standard for electrical equipment used in hazardous areas. In Europe the equipment must now
be marked EEx followed by one or more of the following letters indicating the method of protection
which has been used.
'd' Flame (or explosion) proof enclosure

'i' Intrinsic safety, 'ia' or 'ib'
'p' Pressurised or purged apparatus
'e' Increased safety
'q' Powder filling
'o' Oil immersion - mainly used for transformers
FLAMEPROOF ENCLOSURE "d" - protection is based on non-propagation of ignition. If there is

an explosion inside the enclosure then the enclosure will prevent the ignition of the surrounding
atmosphere. The method most commonly used for zone 1 instrumentation.
NOTE: Flameproof enclosures (like junction boxes) are not necessarily weatherproof. Flange gaps
may be sealed with non-setting grease. Correct cable glands must be used.
INTRINSIC SAFETY "i" - protection is based on non-ignition of the gas. Energy is limited to a level
too low to ignite an explosive atmosphere by spark or hot spot even if the equipment fails. Since
this equipment is part of a circuit, it is necessary to be sure that the whole circuit (certified apparatus
and wiring) maintains a level of safety suitable for the explosive atmosphere in which it is to be used.
Design and calculations are included in a "system document". Increasingly this is the method
preferred for zone 1. Intrinsic safety is the only method approved for zone 0.
PRESSURISED or PURGED EQUIPMENT "p" - protection is based on exclusion of the explosive

gas. The equipment is inside an enclosure which is pressurised with inert gas or air to prevent
ingress of external atmosphere. Often used for local instrument panels e.g. see gas detection
control panel on unit 401.
INCREASED SAFETY "e" - protection is based on the non-ignition of the gas. The equipment is
so designed as to produce neither arc, spark nor hot point. Often specified for lighting.
NON-SPARKING "n" - as for "e", protection is based on special design
SPECIAL METHODS "s" as for "e", protection is based on special design
POWDER FILLING "q" - protection is based on the non-propagation of flame. The equipment is
inside an enclosure filled with inert powder or beads. Ignition inside the enclosure by spark or hot
point cannot ignite the surrounding atmosphere. Not much used at present.
OIL IMMERSION "o" - protection is based on the exclusion of the explosive atmosphere.
The electrical equipment is immersed in oil and the hazardous atmosphere cannot be in contact
with the equipment. Mainly used for heavy duty electrical equipment.
A Zadco list of which methods of protection are acceptable in each zone is shown in table 1.11.1

M1.12 SUITABILITY OF METHOD OF PROTECTION FOR USE IN ZONE 0, 1, 2
TABLE 1.12.1 ZADCO DOCUMENT
M1.13 TEMPERATURE CLASSIFICATION OF EQUIPMENT FOR HAZARDOUS AREAS

To ensure that equipment cannot ignite an explosive mixture by high surface temperature, (auto-
ignition), the approval certificate specifies the maximum temperature that the equipment can attain
under fault conditions (above an ambient temperature of 40 deg. C usually). This temperature
classification is into bands denoted by T1 to T6, T1 being the highest temperature band. When
specifying equipment we must ensure that the temperature class of the equipment is below the
auto-ignition temperature of our particular gases. See table below;
TABLE 1.13.1 Temperature Classification
T1 FOR TEMPERATURE < 450 deg. C

T2 300
T3 200
T4 135
T5 100
T6 85
M1.14 GAS GROUPS PRESENT IN HAZARDOUS AREAS (Ignition by spark)

Gases are grouped on the basis of the minimum level of energy required to ignite by spark the most
explosive mixture of the gas with air. The Code of Practice (e.g. BS 5345 part 1) gives the gas group
classification of common industrial gases. The instrument we use must be suitable for our gas
group
TABLE 1.13.2
GAS GROUP REPRESENTATIVE GAS

EUROPE N. AMERICA
Increasing 11A D Propane
risk IIB C CLASS 1 Ethylene
11+ B Hydrogen
11+ ) Acetylene
EXAMPLE OF INSTRUMENT CERTIFICATION
E Ex d IIc T4
European approved for method(s) safe for max temp.
hazardous used for these of this equipment
test centre area protection gases with fault
Exercise
You should copy the hazardous area certification from the following instruments and explain what
the symbols mean and whether we can use the instrument on Zirku in Zone 1.
1. Honywell I to P
2. Camflex Electropneumatic Positioner
3. Hydrocarbon Gas sensor.

M1.15 INTRINSIC SAFETY

The principle of protection by the method of "intrinsic safety" is to limit the energy passing
into the hazardous area to an amount too small to ignite an explosive mixture.
Intrinsic Safety is the most dependable of the recognised techniques for use in hazardous
environments and this is confirmed by the fact that it is the only system permitted for Zone 0 and
no known recorded failure is attributable to its use. Currently there are two standards of intrinsic
safety - ia and ib ;
ia - Incapable of causing ignition in normal operation with a single fault and with any combination
of two faults, with the following safety factors:
1.5 in normal operation and with 1 fault
1.0 with 2 faults.
ib - Incapable of causing ignition in normal operation and with a single fault applied, with the
following safety factors:
1.5 in normal operation and with 1 fault
1.0 with 1 fault if the apparatus contains no unprotected switch contacts in parts likely to be exposed
to a potentially explosive atmosphere and the fault is self revealing.
Equipment which is certified to ib standards is suitable for all applications in all zones with the
exception of Zone 0. ia equipment is suitable for installation in all zones.
An INTRINSICALLY SAFE SYSTEM consists of a certified field instrument connected to a safe

area power supply and other loop elements by a barrier between safe and hazardous areas. The
loop must be certified as a whole by an authorised laboratory which issues a certificate of the form:
EEx SYST ia IIC T6 or each of the hazardous area elements must be certified and calculations by
the designer must justify the system and connecting cable. For the cable it is sufficient to have
results of dielectric tests and values of inductance and capacitance from the manufacturer. Every
system must have its own system document.
This page is for reference and is not required as part of the basic training course
M1.15.1 INTRINSIC SAFETY AND ENERGY STORAGE
When energy storing devices are included in an intrinsically safe circuit, a spark caused by a short
circuit or a circuit breaking condition will be enhanced by the discharge of the stored energy. Hence,
circuits containing capacitance and/or inductance are subject to additional limitations.
Ignition curves for both capacitive and inductive circuits are published in the European Standard
EN50 020. The energy E stored in a capacitance C charged to a voltage V is calculated from the
expression:
E = CV2 Joules
For a given safe level of energy, the maximum permissible capacitance is therefore dependent
upon the open circuit voltage available to charge the capacitance. When determining the value of
capacitance from the ignition curves, a factor of 1.5 is applied to the maximum working voltage of
the circuit and the value of capacitance is then read off from the curve.
In circuits containing inductance it is the circuit breaking condition which is critical and therefore the
maximum permissible inductance depends on the maximum possible short circuit current. The
energy E stored in an inductance L carrying a current I is given by the expression:
E = LI2 Joules
When using the ignition curves to determine the maximum permissible inductance, a factor of 1.5
is applied to the maximum short circuit current and the permissible inductance value is then read
off from the ignition curve.
M1.15.2 CABLING FOR INTRINSICALLY SAFE CIRCUITS

Cables, since they are capacitive and inductive by nature, can be regarded as a means of energy
storage. Generally:
at low voltages, cable inductance will be predominant
at higher voltages (i.e. a 28 v barrier), cable capacitance will be predominant.
Cable capacitance and inductance will generally not require consideration with hazardous area
cable runs of less than a 1000 metres.
Cable parameters for gas group IIA and IIB are 8 and 3 times those for IIC.
The parameters for normal instrument cables where the circuit is in twisted or adjacent cores, rarely
exceed the following values:
Capacitance (C) 110 pF/metre
Inductance (L) 1 mH/metre
Inductance to resistance L/R 30 mH/W

M1.15.3 INSTALLATION OF INTRINSICALLY SAFE CIRCUITS

In all cases good, standard electrical practice, as applicable to low voltage circuitry, should be
followed and the installation must conform to the appropriate Code of Practice - BS 5345 in the UK.
In essence the installation must be such that the intrinsic safety is not compromised by:
Exposure to risk of mechanical damage
Unauthorised modification or interference
Exposure to moisture, dust and foreign bodies
Exceeding the maximum ambient temperature
Invasion of intrinsically safe circuitry by other electrical equipment or circuitry.
In panels containing both intrinsically and non-intrinsically safe circuits, both must be clearly
labelled and separated by at least 8 mm.
There must be at least 20 cm between I.S and non-I.S. cables.
I.S. and non-I.S. must not run in the same multicore.
The earth connection must never be disconnected from a zener barrier while the circuit is live.
Supply voltage must not exceed 250 v.
M1.16 ZENER BARRIERS

The commonest type of barrier uses;
1. A zener diode to limit voltage to the hazardous area
2. A resistance to limit the maximum current entering the hazardous area
3. A fuse to limit the maximum current that can flow through the diodes.
The maximum value of Vz and the minimum value of R (see figure 1.16.1) are used for the
description of the barrier. e.g. 28 v, 300 ohms.
The voltage Vz should not be taken as the working voltage of the device. A 28 v barrier cannot be
used with a 28 v power supply. For a 28 v barrier the maximum working voltage would be 26 v and
below this voltage the zeners would not be conducting and the device acts like a resistance in series
with the signal line (see figure 1.16.2).
FIGURE 1.16.1 BASIC BARRIER CIRCUIT
FIGURE 1.16.2 EQUIVALENT CIRCUIT OF BARRIER DURING NORMAL OPERATION

Details on this page are for reference. They are not required as part of the basic training
course.
M1.16.1 DETERMINING SUITABILITY OF BARRIER FOR AN APPLICATION
FIGURE 1.16.3
When connecting a barrier to intrinsically safe equipment it is necessary to ensure that the
maximum voltage and current delivered by the barrier are smaller or equal to the voltage and current
levels which can be safely received by the apparatus.
In addition, the maximum unprotected capacitance and inductance of the load are subtracted from
the maximum values allowed by the barrier. The remaining inductance and capacitance define the
maximum cable parameters.
The apparatus in figure 1.16.3 may be connected to the barrier providing that:
Vb does not exceed Va
Ib does not exceed Ia
Ca does not exceed Cb
La does not exceed Lb
Cable capacitance does not exceed Cb - Ca
Cable inductance does not exceed Lb -La
where;
Va = maximum voltage the apparatus can receive and remain intrinsically safe
Vb = maximum open circuit voltage of the barrier
Ia = maximum current the apparatus can receive and remain intrinsically safe
Ib = maximum short circuit current of barrier
Ca = maximum unprotected capacitance of apparatus
Cb = maximum capacitance permitted to be connected to barrier
La = maximum unprotected inductance of apparatus
Lb = maximum inductance permitted to be connected to barrier
For more information, see "Intrinsically Safe Instrumentation: A Guide" by Robin Garside, 2nd
edition 1988,Hexagon Technology, ISBN 0 9508 188 0 1
M1.16.2 USE OF SIMPLE EQUIPMENT WITH A ZENER BARRIER

Simple equipment has only electrical resistance (no capacitance or inductance). It cannot store
energy and requires no certification. It is sufficient to provide the correct barrier between simple
equipment and safe area apparatus.
Examples of simple equipment;
Thermocouples
Resistance thermometers
Switches (level, pressure, temperature etc.)
M1.16.3 CHOICE OF INTRINSICALLY SAFE SYSTEMS

Zone 0 "ia" certified systems only
Zone 1 "ia" or "ib" certified systems
Zone 2 "ia" or "ib" certified systems
M1.17 MAINTENANCE WORK IN HAZARDOUS AREAS

Zone 1: Calibration and fault finding can be performed on live intrinsically safe circuits in zone
1, if the multimeter or test equipment is Ex certified for zone 1.
If any other method of protection is used for the equipment, circuits must be isolated before
the equipment can be opened or, a hot work permit must be obtained.
If using tools may cause a spark e.g. hammering, then non-sparking tools must be used.
Zone 0: Only electrical equipment certified intrinsically safe "ia" can be taken into zone 0
M1.18 PRESSURE RELIEF & SAFETY VALVES

Typical PSVs are illustrated over the page in Figure 1.18.1.
The following is taken from Zadco operating procedure:
i) All tanks and vessels must be protected by atmospheric vents or pressure/vacuum relieving
devices, according to duty, and maintained in good working condition by regular inspection.
ii) The fitting of an intervening stop valve, for maintenance purposes, either between a pressure
vessel and its relief valve, or on the downstream side should only be resorted to after careful
consideration of the possibilities of malfunction of the stop valve. It will need the written agreement
of the Operating Authority and may require the further permission of statutory or insurance bodies.
iii) Stop valves in ii) above must be locked either in the open or shut position, as appropriate.
iv) During the exceptional period when a tank or vessel is operated without a relief valve an
Authorized Person must remain at the control point to observe that the internal pressure does not
exceed the vessels set working pressure.
v) If the operating conditions on a vessel or system protected by a relief valve are changed then
the Operating Authority must be notified in order that the relieving capacity of the valve may be
recalculated.
vi) Where vents are fitted, filter screens must be regularly inspected to ensure that they are in good
condition and free from blockage.
Note:
The name Pressure Relief Valve usually means that the valve is for use on liquids and opens
progressively with over pressure.
The name Pressure Safety Valve usually means that the valve is for use on gases or steam and
is designed to provide a wide opening immediately and to close below the set (or 'popping')
pressure.

FIGURE 1.18.1 A PRESSURE SAFETY VALVE and its P & ID SYMBOL
M1.18.1 PRESSURE SAFETY VALVE TERMINOLOGY

(extracts from NFE.29410 standard).
1 -SET PRESSURE
The effective pressure at which the disc of a safety relief valve starts to open under working
conditions. It is this effective pressure which, under these conditions, exerts the force under
the disc which balances out the pressure keeping the disc on its seat
2 - COLD DIFFERENTIAL TEST PRESSURE
The effective pressure at which a safety relief valve starts to open on a test bench.
The cold differential set pressure can be different from the set pressure because of the
corrections which have to be made in order to compensate for certain conditions such as
temperature and the possible effect of back pressure.
3 - OVERPRESSURE
The increase in pressure over set pressure, generally expressed as a percentage of the set
pressure.
4 - CLOSING PRESSURE
The value of the effective pressure measured in the installation protected by the safety relief
valve once the disc re-establishes contact with the seat.
5 - BLOWDOWN
The difference between the set pressure and the closing pressure. This is generally expressed
as a percentage of the set pressure.
6 - LEAK TEST PRESSURE
The pressure at which a safety relief valve is leak-free. This is generally different from the
closing pressure. It is at this pressure that tightness is checked. Leak test pressure is equal to
90% of cold differential test pressure.
7 - INITIAL BACKPRESSURE
The pressure existing downstream from the safety relief valve at the moment it starts to
function.

FIGURE 1.18.2 A PILOT OPERATED RELIEF VALVE (Fisher Type 414-6305)
PRINCIPLE OF OPERATION
The key to relief valve operation is the pilot ball (figure 1.18.2) which is anchored between the ball
adjuster and ball seat. Inlet pressure registers on the main valve disc and enters the pilot through
the control line. As long as inlet pressure remains below set pressure, the pilot control spring holds
the pilot exhaust ball seat ring against the pilot ball. Inlet pressure loads the piston through the pilot
restriction and keeps the main valve closed. An inlet pressure rise above the set pressure
overcomes the pilot control spring and strokes the pilot exhaust ball seat ring away from the ball.
Piston loading pressure bleeds downstream through the pilot exhaust ball seat ring faster than it
can build up through the pilot restriction. This permits inlet pressure to unbalance the main valve
disc and open the main valve. As inlet pressure drops back to set pressure, the pilot control spring
pushes the pilot diaphragms and pilot exhaust ball seat ring back against the ball. Inlet pressure
again loads the piston and closes the main valve.
M1.19 BURSTING (RUPTURE) DISCS

Bursting discs, also called rupture discs or safety discs, are thin sheets of metal which will fail at
a predetermined pressure or vacuum and will then allow excess process pressure to escape.
ADVANTAGES OF RUPTURE DISCS
1. Fast relief of over pressure when set pressure is reached.
2. Up to set pressure they provide a complete seal for the process against leakage.
3. Mechanical damage or corrosion can only decrease the bursting pressure, never increase it.
4. No moving parts, simple, low weight and reliable
5. Easy to install
DISADVANTAGES OF RUPTURE DISCS
1. Complete shut down is required to replace a bursting disc.
2. Requires replacement at regular intervals (approx. every 12 months)
M1.19.1 CONDITIONS AFFECTING WORKING LIFE OF BURSTING DISCS
The advantage of a bursting disc, that it will always fail safe, is the reason that its use is limited. All
the metals from which bursting discs can be manufactured are affected by physical changes that
tend to weaken the disc until it fails under normal working pressure. No disc should be subjected
to a steady working pressure that is greater than 75% of its rated bursting pressure. It is good
practice to replace discs during the annual maintenance shutdown.
Exposure of the disc to temperatures above the rated temperature will reduce its bursting pressure.
The bursting pressure will increase at temperatures lower than the rated temperature.
Early failure of the disc can occur if it is subjected to pulsating pressure. In this case a vacuum
support should be fitted to prevent excessive flexing of the disc dome with reversal of pressure.
Most discs are made of thin metal foil and even mildly corrosive conditions can cause a weakening
effect. Discs can be coated with P.T.F.E. to protect against corrosion.
M1.19.2 USE and LOCATION of BURSTING DISCS (See 440 PSV 001)
A bursting disc may be the only protection for a system but often it is used in addition to a pressure
safety valve, especially when the contents of the protected system could prevent effective operation
of the valve. Sometimes a rupture disc is fitted upstream of a PSV in order to protect the PSV from
corrosive conditions, see figure 1.19.1. In this example a high pressure switch is installed between
the rupture disc and the PSV. Can you explain why?
Considerable energy can be released when a large disc bursts, so the discharge pipe should be
of sufficient diameter and as short as possible to avoid dangerous or damaging conditions during
discharge. The risk of causing ignition of inflammable vapour or liquid by shock-wave in the
discharge pipe should be taken into account.
FIGURE 1.19.1 INSTALLATION OF RUPTURE DISC
P & ID SYMBOL

M1.20 HYDROGEN SULPHIDE

This section is to be completed by the trainee after he has received H2S training from the safety
department. Before entering the Satah Plant I should;
1.
.......................................................................................................................
2.
.......................................................................................................................
3.
.......................................................................................................................
4.
.......................................................................................................................
5.
.......................................................................................................................
6. At what Hydrogen Sulphide concentration in PPM (Parts Per Million) is the first alarm stage
indication by the DRAGER H2S Personnel Gas Detector to evacuate the area)
Note: In the future, crude oil and gas from Zakum will also be sour and these rules will apply to the
whole plant.
M1.21 INGRESS PROTECTION
Complete the following table of to explain the meaning of INGRESS PROTECTION (IP) CODES.
CODE PROTECTION AGAINST SOLIDS CODE PROTECTION AGAINST WATER
M1.22 On Site practical exercise

SITE INSPECTION OF METHODS USED TO MAKE EQUIPMENT SAFE FOR ZONE 1
TAG
TYPE OF EQUIPMENT MANUFACTURER CERTIFICATION NOTES
NUMBER
Junction Box
Tra ns m i tte r o ld e r
Rosemount
model
Tra ns m i tte r ' S m a rt'

Rosemount
model
Tra ns m i tte r Foxboro
I to P ABB
Gas Detector Panel
Position Switch
Other
By inspection on site, you should fill-in the blanks in the table above.

1.21 QUESTIONS
1. What do we call a mixture containing the least amount of an inflammable substance in air which
will ignite (or explode)?
2. What principle of protection is used for an intrinsically safe loop?
3.What does the IP specification of an instrument tell you?
4. Is an instrument marked EEx ib IIA T2 suitable for use on an ethylene plant in zone 1?
5. What is the difference between a pressure relief valve for liquids and a pressure safety valve for
gasses?
6. What I.P. specification is usually required for a field instrument?
7. For what purpose is an earth connection provided on the metal case of a mains powered
instrument?
8. What precautions must be taken before using a multimeter in zone 1?
9. What is the temperature classification and gas group of crude oil?
10. How do you report an emergency?
11. What voltage is safe to use in zone 1 without special precautions?
12. When can you work on a live circuit in zone 1?
13. What are non-sparking tools?
14. Why do we need a permit to work system?
15. What is hot work?
16. What is a confined space?
17. What is meant by an area of plant classified as zone 1?
18. What is an explosion proof enclosure?
19. What is a rupture disc?
20. Where on unit 401 will you find a pressurized/purged enclosure?
21. How would you know that that there was a leak of H2S on the plant?
22. Why do we need 434-PSV-006 in the drawing below?

ZADCO WORK PERMIT PROCEDURES

1.30 REFERENCE MATERIALS

1.31 SAFETY SYSTEM CONSIDERATIONS
1.31.0
1.31.1

1.31.2
1.31.3

1.31.4

Safe Working Practice

Uploaded by

Copyright:

Available Formats

You might also like

Safe Working Practice

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Safe Working Practice

Uploaded by

Copyright:

Available Formats

Zirku-HRT Revision: 7.

1_safety.p65 (W. Phillips)

ZADCO EMERGENCY PROCEDURES

ZADCO EMERGENCY PROCEDURES continued

1_safety.p65 (W. Phillips)

M1.0 SAFE WORKING PRACTICE - PERSONAL SAFETY

ALL PERSONS EMPLOYED IN INDUSTRY HAVE A RESPONSIBILITY TO ENSURE THEIR

M1.1 ELECTRICAL SAFETY RULES

Never work on electrical equipment unless you are competent.

Precautions are put in place to prevent accidents

M1.2 EARTHING (GROUNDING) (See also Zadco HSE Guide 1.6)

The neutral in an ac circuit should be at earth potential.

REMEMBER - ELECTRICITY IS INVISIBLE AND CAN BE LETHAL

TAKE NOTHING FOR GRANTED. Personal caution is your greatest safeguard.

LIVE.........................., NEUTRAL..........................., EARTH.........................

How is live different from neutral?

Working with electricity - Suggested rules for instrument technicians

1_safety.p65 (W. Phillips)

M1.3 WORK PERMITS

M1.3.1 EXTRACT FROM ZADCO WORK PERMIT PROCEDURES

M1.3.1 EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

1_safety.p65 (W. Phillips)

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

2.4 Performing Authority

The Performing Authority shall be responsible for:-

The Performer shall be responsible for:-

1_safety.p65 (W. Phillips)

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

SECTION 3. TYPES OF PERMITS

3.1 Main Permit:

The Main Permit will specify:

3.1.1 Cold Work Permit

3.1.2 Hot Work Permit

All naked flames, fires or smoldering material.

3.2 Complementary Permits

3.2.1 Confined Place Entry Permit

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

3.3 No Permit Required

1_safety.p65 (W. Phillips)

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

SECTION 4. INITIATING A WORK PERMIT AND PERMIT DISTRIBUTION

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

SECTION 5. GAS TEST

1_safety.p65 (W. Phillips)

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

SECTION 7: WITHDRAWAL AND CANCELLATION

SECTION 8: CONDITIONS APPLICABLE TO COLD AND HOT WORK

Test the cabinet enclosure for hydrocarbon gases.

1_safety.p65 (W. Phillips)

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

9.2.4.2 Very Low Voltage Equipment  up to 50V AC/DC

10.2.2 Precautionary Measures

EXTRACT FROM ZADCO WORK PERMIT PROCEDURES continued

SECTION 12: EQUIPMENT USED IN HAZARDOUS AREAS

12.2 Specifications of Electrical Equipment used in Classified Areas:

1_safety.p65 (W. Phillips)

9.2.4.2 Very Low Voltage Equipment up to 50V AC/DC