Control of Work

GUPCO HSE Training

Agenda
Location Emergency Procedures Trainer Introduction Training course ground rules GUPCOs Commitment to Personnels HSE Competence Roles and Responsibilities Competency/Training Requirements Types of Work Activities Categories of Permits Task Risk Assessment Key Operational Requirements Work Flow ( Routine and Non-Routine Work) Completing the Permit Exam

Training Course Ground Rules

Start/end on time Effective participation is important Focus on topic Avoid side talks Switch mobile phone off or put in silence mode

GUPCOs Commitment to Personnels HSE Competence

GUPCO HSE Training Practice states: Peoples behaviour is critical to GUPCOs success; therefore, our workforce will be carefully selected and trained, and their skills and competencies regularly assessed.

CoW
Purpose of training Business need & associated risk For more information, please refer to GUPCO-HSEMS-S-100

Control of Work

Module 1 Intro + Roles & Responsibilities + Training

Safe Systems of Work (SSOW)

Why Control of Work?

The need for CoW is compelling
CoW is a major factor in GUPCO accidents

CoW focuses on safe execution of workplace activities CoW is underpinned by 8 GRs, which detail the minimum safety standards to be followed

Introductionthe Problem..
Analysis of 38 Fatalities 2000 2003 by frequency of causes
8.4 Inadequate ID of Worksite Job Hazards 14.1 Lack of Job Safety Awareness 11.1 Inadequate Work Planning

5% 2% 8% 7% 9% 29% 9% 31%

PTW TRA Personal Factors Training Knowledge transfer Contractor Selection and Oversight Engineering Design Purchasing Material Handling and Material Control Tools and Equipment Communications

2010 Egypt CoW GOS CoW Incident in Violations Incidents

CoW Incidnt
25 20 15 15 10 10 5 0 2007 2008 2009 2010 20 19

CoW

Control of Work
Permit to work System Safe Isolation & Reinstatement of Plant

Risk Assessment

Control of work underpins the safety of every job that you do. All accidents are preventable. Without adequate control of our work, accidents will occur it is only a matter of time...

The CoW Standard 12 Elements

1. 2. 3. 4. 5. 6. 7. 8. A written policy Roles with clear accountabilities People are trained & competent Planning of work will identify individual tasks and their interaction Tasks must have a risk assessment A permit will be obtained before conducting work Risk will be controlled and communicated and signed off Work requiring a permit will be managed by a responsible person (AA/PA). 9. The work site shall be left in a safe condition. 10. The CoW process will be regularly audited. 11. Lessons learned will be captured, incorporated, and shared. 12. Every one has the obligation to stop work if unsafe.

Roles and Responsibilities

Roles and responsibilities must be clear The following positions have key roles in CoW what is your role??

1. 2. 3. 4.

District Manager Area Authority Performing Authority Isolating Authority

5. 6. 7. 8.

Authorized Gas Tester Responsible Electrical Person Firewatcher Safety Supervisor

HSE Competency Assurance Passport

GUPCO HSE COMPETENCY ASSURANCE PASSPORT

Back

Front

Control of Work
Module 2 Risk Assessment & Safe Work Permitting

When work is out of Control??

SIMOPS (Simultaneous Operations)

SIMOPS is any two or more discreet activities carried out simultaneously within an Operation (but not necessarily in a single location). This work is seen to have the potential to add risk or impact the safety of one or more of the ongoing activity sets. Common Activities where particular SIMOPS attention is required :
Installation approach or docking by another vessel. Cessation of platform activities e.g. lifting, drilling and ops and wells and shut-ins, Survey or seismic activities Aviation activities in and around live installations or over associated support vessels Impact to aviation regarding operational changes (cold venting/ helideck selection) Hydrocarbon intervention work in relation to other activities (Hot work NF, SP) Lifting operations in and around live installations

If Rig, Barge, or Platform Heli-deck is used, the control should be at the Radio Room of either depending on where the helicopter is landing.

For more information, please refer to Simultaneous Operations (SIMOPS) Practice GUPCO-HSEMS-S-109

Types of Work Activities

(1) Non-Permitted Activities (2) Permitted activities

Non-permitted Activities
Operations carried out in accordance with site procedures covering the following:
Production plant day-to-day operations Drilling operations Helideck operations. Battery-operated cameras and intrinsically safe instruments Naked flame work in mechanical workshops located well away from a live process. Visual inspection of areas (except confined space, rope access or over-side work). Operation of equipment for approved training purposes handling and use of non-hazardous materials. Emergency response activities

Permit to Work
All other activities require a Permit to Work
Define the scope of work, location and its duration. Identify hazards and reference risk assessments. Identify isolation of energy sources required to carry out the job. Establish control measures to eliminate or mitigate risks. Link the work to other associated work permits or simultaneous operations. Ensure that where there are isolations common to more than one permit, the isolations are not removed before all permits have been signed off. Specify those carrying out the work and verify that the risks and control measures have been communicated to them. Be authorised, monitored and re-validated by the responsible person. Ensures adequate control over the return to normal operations.

Mandatory Permitted Activities

Hot Work Cold Work (including Breaking of Containment) Confined Space Entry Energy System Isolation (ICC) Ground Disturbance Vehicle Entry into a Process Area and, Any other potentially hazardous work activities which require a similar degree of control
for example working at heights, critical lifts, construction and demolition

Task Based Risk Assessment

EVERY JOB must have a Risk Assessment!!!

Risks can be described as:

Task Related (Caused by the action of people in the work place) Inherent (associated with the design of the work place, its equipment and location) Process Related (arising from the process being carried out, the properties of the substance and materials involved and the process conditions that may exist at the time)

Task Risk Assessment Process

Method for systematically examining an individual task to identify the hazards, evaluate the risks and specify appropriate controls.

Risk assessment levels are: Level 1: Typically carried out by PA and AA. Level 2: Semi-quantitative overview carried out by a team led by the AA.

Level 2 Risk Assessment are mandatory for Some Jobs like HW-NF. Safe Systems of Work (SSOW)

Pre-Job Tool Box Talk

Allows personnel involved to be fully aware of the details of the TRA and its associated documentation Allows personnel to fully understand all hazards and control measures Provides an opportunity for those involved in the work to raise any concern If anyone at this stage identifies some additional hazards or they think that the control measures are inadequate, then the job should not proceed until the TRA has been re-evaluated

Control of Work
Module 3 Operational Guidelines

Hot Work In Hazardous Areas

It is GUPCO Policy that Naked Flame should NOT be carried out in Hazardous Areas. Alternative engineering solutions should be sought for such work. Such work should be carried out when the plant can be depressurised, drained and made hydrocarbon free. In exceptional circumstances, approval can be sought for this type of work, according to GUPCO guidelines.

Key Operational Guidelines

Hot Work Challenge

For any Hot Work- Naked Flame work, on a process unit a Hot Work Challenge must be completed.

Approval of Naked Flame Hot Work

In circumstances where the Site Controller (OIM) considers that Naked Flame Hot Work can be carried out safely:
Request Division Manager, HSE GM & The Deputy District Manager approval

Key Operational Guidelines

Safe Work Permitting

and Unplanned Shut Down

In the event of an Unplanned Shutdown, the following actions should be taken:

All activities are to cease All permits are to be returned The AA suspends all permits until such time as the AA deems it safe to re-issue permits.

Key Operational Guidelines

Safe Work Permitting

and Emergency Actions

In the event of an emergency, the following actions must be followed:

On activation of the Emergency Alarm all permits are automatically suspended Work is to cease and the work site made safe as practicable Proceed to your Muster Point, or follow instructions given over the Public Address system

Key Operational Guidelines

Safe Systems of Work

Work Control Flow Chart
Issue Work Order Job Description

Routine work Yes AA/ PA Review Generic Procedure/ Risk Assessment Yes Changes? No Concerned Division Issue (updated) Generic Procedure

No

Note: - Hot work Challenge - Lifting Plan - Risk Assessments etc are used to design if/ how job will be done and then procedure is written

PA raises Work Pack; Procedure and L2 risk assessment etc

Approval from Dept/ HSE/ Dist. Mgr. or D. D. (Oper.'s)

Approval from Dept/ HSE/ Dist. Mgr. or D. D. (Oper.s)

Permit to Work Process

Work Flow: Plan the Work 1

Performing Authority
 Describes task/ scope of work  Establish Job Procedures

Permit Request

Area Authority
      

Permit Definition

Reviews work request Defines type of permit Defines Controls Face to face discussion with PA Visits worksite Identifies isolations Identifies fire and gas overrides

Work Flow: Plan the Work 2

Per it Meetin
 Team review all permit requests  Review RA + Isolations  Review ongoing jobs  Review SIMOPS  Site coordinator authorises high risk permits

Permit Authorized

Area Authority
    

Preparation of work site

Prepares work site Isolations put in place Controls put in place Undertake gas test Confirm all other certificates

Work Flow: Assess and Manage the Risks

Area Authority
    

Permit Issued

Face to face discussion with PA Inspects work site with PA For SIMOPs, FtF discussion with AAA Verifies controls in place Issues permit/ approves work to proceed

Performing Authority
     

PA accepts permit

Visits worksite with Safety Supervisor Accepts permit Ensures precautions are understood Assembles team at worksite Toolbox talk/ Signatures on permit Work commences

Work Flow: Control the Work

Area Authority, Performing Authority and Safety

 Monitors compliance

End of Job

Performing Authority
 Cleans up worksite

Area Authority Job Complete

 AA instructs all controls and isolations reinstated  Confirms through signature that site is restored to

normal and that all isolations have been listed

 Inspects worksite and closes out permit

Shift Change / Revalidation

Shift Change /Revalidation

 At end of shift, if work is continuing, PA will halt work and suspend permit  Permit to be re-issued by on coming AA
Permit Suspended & Re-issued

Shift Changes
Effective handovers are essential for continuity of work and safe operating practices. PA duties are:
Sufficient time must be set aside to discuss the work status from both a safety and technical point of view. The oncoming PA must fully understand all precautions and procedures identified on the permit The off-going PA will suspend the permit and state that he is leaving the work site in a safe and tidy condition and the oncoming PA will then accept the permit to confirm that he is taking over the task and work site. The oncoming PA must countersign the relevant certificates to signify that he will be taking responsibility for them from the off going PA.

PA Duties

Shift Changes
The AA should follow the same process as the PAs, but furthermore ensure that the oncoming AA understands the status and the scope of the ongoing jobs Once the oncoming AA is satisfied that a certificate can be re-issued he will issue the permit. The oncoming AA must countersign all of the permits for his area

AA Duties

Working at Night
As a minimum, for night work to be approved by Concerned Division Manager, HSE & DDGM the following requirements must be implemented. Request written permission for night work to be attached to the original work package and permit. Pre-job meeting for all crews to understand the work and precautions Emergency plans available and discussed. Maximum working hours for the crews to not exceed 14 consecutive hours. Where possible, use the buddy system. The work activities and crews to be managed by the Gupco AA/PA Gupco AA/PA is physically at the work site during the duration of the work.

Working at Night
All employees wear proper PPE. Lifting gear and slings properly color coded and certified Good lighting available to cover the working area and placed in proper position to prevent shadows. Housekeeping maintained to prevent fall and trip hazards. Follow reporting criteria for incidents and potential hazards. No over side work.

Control of Work Module 4 Completing the Permit

Types of Permits

Colour

Permit Categories
Hot Work (Naked Flame) Cold Work Confined Space Entry Vehicle Entry into a Process Area Ground Disturbance Hot Work (Spark Potential) Cold Work (Breaking Containment)

Distribution of Permits

Permit
Original

Distribution
Retained by AA and displayed in a prominent location (e.g. Control Room) at a designated location / permit board. Retained by Safety

Copy 1

Copy 2

Issued to third parties, e.g. Affected Area Authority or other interested parties.

Copy 3

Hard copy - retained by PA and displayed at the worksite.

4 Part Permits

Permit Sections
Each permit is divided into sections:
Top Registry No., Permit Validation period and Work Location Section 1 Task description Section 2 Level 1 RA. Assessment & whether a Level 2 RA is required. Section 3 Cross referenced Certificates Section 4 Permit Authorization Section 5 Site Gas Test (where required) Section 6 Permit Issue Section 7 Permit Re-issue (for transfer from one shift to the next) Section 8 Work Completion / Cancellation Section 9 Registry of Work Completion

Completing the Permit Section 1

This section of the permit is completed by the Department carrying out/requesting the work.

Section 2 Section 2
This section is the Risk Assessment. Each box must be checked either yes or no. For each identified hazard there must be a safeguard. For most permitted work,

Section 3

The AA lists all supplementary permits and Isolation Confirmation Certificates (ICCs) raised in connection with the permit. Actions by the AA: Raises supplementary certificates and permits, e.g. ICC & CSE Approves all isolations Authorises Isolating Authority (IA) to apply required isolations prior to permit issue

Section 4

This section authorizes the permit. The following persons must sign: 1. AA 2. Where required by local procedure, District Manager 3. For any SIMOPs, the Affected Area Authority (AAA) 4. Safety Dept. (Safety AGM / Supervisor)

Section 5 Section 5

This section is for recording Gas test results. Allowable limits are indicated for each atmosphere hazard. Initial gas testing is required prior to any hot work or confined space entry and may be required for other permits, such as cold work.

Section 6 Section 6

This section authorizes start of work.

Section 7 Section 7

This section is used to re-issue the permit when handing over the job from one shift to the next. The requirements in Section 6 (and other areas of the permit) are in full force.

Section 8

This section of the permit must be completed when the work was completed or in-completed (the job must be interrupted) or cancelled. This section also assures that the work area has been inspected (by both the AA and PA) and is in a safe clean condition.

Section 9

This section closes out the permit. This section is completed by a member of the safety department.

Safe Systems of Work

Auditing

Auditing of the safe work permit system must occur at least annually. Purpose of auditing is to ensure that there is understanding and rigor around safe systems of work process. Audit Forms for auditing permits and ICCS are based on a list of standard question that are answered Yes, No OR Not Applicable The results are then scored to give an assessment of the overall conformity of the Permit or ICC Actions to close any gaps must be assigned and completed.

Thanks