-- INTRODUCTION --

SIMULTANEOUS OPERATIONS AND

PERMIT TO WORK SYSTEMS

January,
Date 2010
 Plant Operations Safety Agenda

• Introduction
• Key Points
• Interim Production System or Facility
• Simultaneous Operations Control (SIMOPS) Areas
• Additional Hazards Associated with Production Operations
• SIMOPS Planning
• New Features of the SIMOPS Plan to mitigate hazards associated with
Production Operations
• Permit To Work System
• Permit To Work System Examples
• Questions and Answers

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 Plant Operations Safety Topic

• Current Simultaneous Operations (SIMOPS) Planning addresses

activities associated with Construction Activities ONLY

• The New Simultaneous Operations (SIMOPS) Plan addresses

activities associated with Construction and Production

• Additional precautions must be taken to mitigate the hazards

associated with Production Operations

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 Plant Operations Safety Topic

• With the introduction of hydrocarbons, the potential

hazards and risk factors were altered and in some
instances, increased.

• After introduction of hydrocarbons, additional control

measures were required and the SK Permit To Work System
(PTWS) came into effect to ensure consistency as other
areas and systems became energized.

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 Plant Operations Safety Topic

• With the introduction of hydrocarbons and production

chemicals, personnel shall be aware that these products
exhibit unique aromatic odors, which in themselves, are not
inherently dangerous.

• It will be a normal occurrence to smell aromatic odors from

the production chemicals; however, any unusual odors
should be reported to the SK authority immediately.

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 Key Points

• Key Reminders

– Non-Intrinsically Safe cell phones Are Not allowed in the operating plant areas
– No smoking materials (e.g. lighters, matches) are to be carried into plant areas
– Jewelry prohibited (e.g. rings, necklaces, bracelets)
– PPE usage is obligatory, it is not an option
– A high standard of Housekeeping must be maintained, particularly combustibles

• New Key Items

– Flame Retardant Clothing required in operating plant areas

– Non-Sparking (brass) tools required in plant areas

– Only intrinsically safe electrical equipment is allowed in plant areas (e.g. radios,
torches/flashlights)

– Safety footwear shall not have any exposed metal

– Fire blanket/containment is required for hot work in plant areas

– Battery powered cameras are not allowed without permission from SK. A Hot Work Permit is
required for their use.

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Key Points

No Metal Ladders Allowed.

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Key Points

Dedicated plant area firefighting equipment shall not be used for hot work firewatch.

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Key Points

Be aware of location of eyewash stations prior to commencing work.

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Key Points

Utility System (Air, Water, Nitrogen)

Permission required from each SK plant prior to the use of utility stations (e.g.
air, nitrogen, instrument air, water).

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Key Points

React to Plant Alarms by reporting to your assembly area.

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Plant Operations Safety Topic

FEATURES OF SIMOPS

– More Control Exercised Over Work in Plant Areas

– Additional Communication Requirements across

Construction/Operations Activities

– Multiple Approvals for High Risk Work

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 Plant Operations Safety Topic Agenda

• In order to allow on-going Transition Operations, SK utilizes a Permit To Work

(PTW) System

• This is designed to enable the following:

– Control the work activities on the SK facilities in order to prevent incidents

resulting from uncontrolled work faces.

– Communicate information clearly to avoid an inadequate understanding of

work task hazards.

– Ensure the management and control of:

• Procedures relating to the safety of individuals and facilities
• Risks relating to individual operations and work tasks.

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 Plant Operations Safety Topic

The Permit To Work System is based on the principle of Internal

Control.
There are 3 independent parties involved.

Management Team

SK Operations Work Group, e.g.

Interface
(PTWS) Maintenance

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 Plant Operations Safety Topic

Supervisors and Management Team

• Plan and Co-ordinate
• Review proposed work activity/scope
• Review and create effective JSA and Permits
• Review and endorse Permits
• Audit the effectiveness of the Permit To Work System

SK Responsibilities:
Work Group responsibilities:
•Overview of operable systems and area
• Have expertise and skills for the specific work
•Maintain control & status of systems to be performed.
•Manage all required energy isolations • Perform required safeguards related to the
•Perform safety preparations prior to starting work work activity.
• Preparation of tools & equipment.
•Reinstate systems & isolations after completion of work
• Ensure work site is safe.
•Maintain control of interfacing activities
• Ensure that work is executed according to the
PTWS.

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 Plant Operations Safety Topic

SK Operations has developed a Permit To Work System consistent with SHEMS.

The purpose of the Permit To Work System is:

 Control work activities at all Plants

• HDPE
• EO/EG
• Olefins
• Utilities
• Phenolics
• Polypropylene
• Polycarbonates

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 SIMOPS CONTROL AREAS

• Photo of Plants (Complex) if authorized by SK, Security, RC etc.

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Plant Operations Safety Topic

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 Saudi Kayan
Complex Layout
SK Project

Olefins

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 Plant Operations Safety Topic

• Production of Petrochemicals Introduces additional hazards:

– Flammable Liquids
– Production Chemicals
– Flowing High Pressure Liquid
– Flowing High Pressure Instrument Air Lines
– Flowing High Pressure Gas (Significant Quantities)

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 Plant Operations Safety Topic

• Flammable Liquids NEEDS PHOTO CHANGE

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 Plant Operations Safety Topic

•Production of Petrochemicals Introduces additional hazards:

 Electrical  Thermal
 Generated  Machines or Equipment
 Static  Potential Chemical
Reaction

 Mechanical  Pressure
 Transitional  Hydraulic
 Rotational  Pneumatic
 Vacuum
 Gravity
 Springs

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 Plant Operations Safety Topic

• Flowing High Pressure Injury

– 50-100 PSI - Skin Puncture

– 3000-10000 PSI
• <2000 PSI - 40% amputation
• >2000 PSI - 50% amputation
• <7000 PSI - non prognostic
• >7000 PSI - 100% amputation

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 Plant Operations Safety Topic

• Flowing High Pressures

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 Plant Operations Safety Topic

• Flammable Liquids

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 Plant Operations Safety Topic

• Production Chemicals, Hot Liquids, and Vapors

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 Plant Operations Safety Topic

• Additional hazards associated with working in “Live”

Production Areas that can cause Production Shutdown
– Striking level transmitters

– Striking instrument airlines

– Start / Stop switches or equipment

– Standing on valves and handles

– Standing / walking on cable trays

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 Plant Operations Safety Topic

SK Permit to Work System (PTWS)

• A permit-to-work is a document that

will set out the way in which the risk is
to be controlled by specifying :

- The scope of work to be carried out

- The location of the work
- Who is responsible
- Who is to doing the work
- What precautions need to be taken
- Gas Test Required
- Hazards identified
- Hazard mitigation
- PPE Appropriate to the assigned task
- Permit Co-signing
- Authorization to commence work
- What checks will need to be carried out
- The emergency arrangements
- What to do in unusual circumstances
- The time limit of the permit
- Permit Close-out / Return
- Permit Cancellation

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 Plant Operations Safety Topic

PERMIT COMPARISON

SKAre
There PTWS
( 9 ) Different Safe Work Permits Used on the Project

Each Permit is Color Coded

• Hot Work
• Cold Work
• Confined Space Entry
• Electrically Hazardous Task Plan
• Radiography
• Line Break
• Excavations
• Hot Tap
• Hazardous Energy Control
Surveillance Permit

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 Plant Operations Safety Topic

Permit to Work (PTW)

• A pre-task inspection of the work scope must be conducted by SK

Operations, or the assigned Lead Worker.

• Other workers and entities, depending on the location and scope

of work.

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 Plant Operations Safety Topic

Job Site JSA

• Will accompany all Work Permits

• Is not a permit to start work
• Shall be written for each shift.
• Breaks down work activity into:

– Individual steps
– Potential hazards associated with
each step
– Controls implemented to reduce
potential hazard
– Every worker needs to review and Insert Sample Here
sign
– Close Out at end of shift, or task is
completed.

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 Plant Operations Safety Topic

Do I need a Permit?
Certain routine tasks may be performed at our facilities without a
Permit
These are:

• First line maintenance performed by an operator in accordance with

appropriate procedures (Operations)
• Inspection that is carried out without physical interference with the
inspected equipment
• Situations requiring immediate action to maintain safety and / or plant
integrity

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 Plant Operations Safety Topic

Permit to Work (PTW)

Most PTW violations occur because:

• The workers do not understand the PTW.

• The responsible person does not control the PTW.
• The conditions of the PTW are not complied with.
• The PTW is no longer relevant (expired).
• A new hazard is introduced, or the environment changes.

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 Plant Operations Safety Topic

Permit to Work (PTW)

One Must Never:

1. Leave employees without having signed the PTW over to a responsible person.
2. Change the PTW without having it counter signed by the Permit Authority
3. Violate the conditions of the PTW
4. Fail to conduct pre-start briefings with workers regarding the PTW.

Proper attention to permit requirements and the execution of

the work, reduces the potential of incidents

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Plant Operations Safety Topic

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 Plant Operations Safety Topic

Hot Work Permit

• Task involves process or equipment that may ignite hydrocarbons if present.

HOT WORK PERMIT SAMPLE

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 Plant Operations Safety Topic

Critical/Hazardous Work – Other

Used to capture other critical work activities not defined adequately

in other work certificates.

Examples include:

• Critical and heavy lifts

• Excavation work

• Activities involving radioactivity

or radioactive substances

• Tasks with identified interface

issues or formal communications
requirements

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 Plant Operations Safety Topic

Temporary Defeat
Examples: Emergency Shutdown (ESD) System - Fire and Gas System - Fire Water System

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 Plant Operations Safety Topic

Confined Space Entry

Work place has restricted access and /

or is enclosed.
SAMPLE OF
CONTINU-
ATION
SHEET

SAMPLE OF PERMIT Continuation Sheet

• Provides a means to record additional gas
checks

• Requirement to record oxygen, LEL

hydrocarbon, and toxic on a regular
basis /

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 Plant Operations Safety Topic

Confined Space Entry Misconceptions

• I don’t smell or see anything funny. It’s alright to enter.

• I’ll just stick my head in and take a look. I’m not really entering the space.

• Everything checks out. We can go to work, and put the testing equipment away.

• I’ll be able to hold my breath and get out if anything does happen

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 Plant Operations Safety Topic

Two additional forms attached to each Permit

Gas Re-test
• Initial gas test is completed on the front of the Permit.
• Approved Gas Testers record the presence (if any) of toxic or flammable gases
• Required for all Permit activities.

Declaration
• Must be read and signed by all personnel
‘using’ this Permit.

•
Provide Form if System is Records that the attendees at the ‘tool box’
talk:
- Discussed the job
Being Used - Understood the risks
- Are aware of the controls implemented
to mitigate the risk

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 Plant Operations Safety Topic

Work Permit Register

• Register used
to record all
permits

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 Plant Operations Safety Topic

The Isolation Control Certificate (ICC)

• Integral part of the Permit to Work System
• The Energy Isolation process addresses electrical energy, hydrocarbon energy,
pressurized energy, mechanical, and spring energy sources.
• Control is maintained by the use of numbered Isolation Permits generated through,
and monitored by, the Permit To Work System

• Certificates are uniquely numbered

and linked to a Work Permit
• A Certificate, by itself, does not
permit you to start work
Include Sample if
system is being used

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 Plant Operations Safety Topic
Isolation Confirmation

Operations
Tag/Lock

Contractor Work Permit

Requester Tag/Lock

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 Plant Operations Safety Topic

The Isolation Control Certificate (ICC)

• Isolation points are recorded on this form.
• Isolations must only be applied or
removed by authorized personnel .
• Isolations may be:
– Electrical
– Mechanical
– Process
• When there is a requirement for a large
number of isolations, the ICC continuation Samples if system is in use
sheet is available for use.

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Plant Operations Safety Topic

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 Plant Operations Safety Topic

Permit - Suspension or Withdrawal of Permit

 A Work Permit can be withdrawn or suspended at any time.

 A Work Permit must be suspended if:

• Urgent conflicting work develops
• Unsafe situation develops
• Emergency occurs or an emergency alarm sounds.
• The work scope changes.
• Prescribed safety precautions are not followed.
• Work is not being conducted in a safe manner.

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 Plant Operations Safety Topic

1. What is the most commonly used Permit ?

(a) General/Cold
(b) Temporary Defeat
(c) Hazardous or Critical Work (Other)
(d) Hot Work

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 Plant Operations Safety Topic

2. What Work Permit would you use when working on

ESD Systems or Fire and Gas Systems?

(a) Temporary Defeat

(b) Critical Work – Spark Potential
(c) Critical Work – High Risk Electrical
(d) Job Safety Analysis

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 Plant Operations Safety Topic

3. What Work Permit would you use for opening live

electrical boxes in hazardous zones?

(a) General
(b) Hot Work
(c) Isolation Control Certificate
(d) Confined Space Entry

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 Plant Operations Safety Topic

4. What document would you use to record potential

hazards associated with each step of a Work Permit?

(a) The Job Site JSA

(b) They are not recorded
(c) The Continuation Sheet
(d) The Declaration form

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 Plant Operations Safety Topic

Module 2 Assessment Test Answers

(correct answers in Red)

1. (a) General
(b) Temporary Defeat
(c) Critical Work - Other
(d) Hot Work

2. (a) Temporary Defeat

(b) Critical Work – Spark Potential
(c) Critical Work – High Risk Electrical
(d) Job Safety Analysis

3. (a) General
(b) Hot Work
(c) Isolation Control Certificate
(d) Confined Space Entry

4. (a) The Job Site JSA

(b) They are not recorded
(c) The WCC Continuation Sheet
(d) The WCC Declaration form

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 Plant Operations Safety Topic

Question and Answer Session

Are there any questions you have

concerning the events leading up
to the introduction of hydrocarbons
or the SK PTWS?

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