273372884-Permit-To-Work.pptx

Petronas Permit to work briefing

1. Selamat Datang Permit To Work System Training 1 8/6/2012 Welcome REV 2 SEPT 2011

2. PETRONAS CARIGALI “PTW STANDARDISATION REV 2. SEPT 2011” 2 PETRONAS CARIGALI PTW SYSTEM 8/6/2012

3. 8/6/2012 3 Selamat Datang Permit To Work System Training 3 Please sign the attendance sheet Write your name on the folded paper Switch off your hand phone or silent mode No Smoking within this Building PETRONAS CARIGALI PTW SYSTEM

4. 4 Safety Briefing If you hear an Alarm, The fire exit door One near the Toilet on you right and One near the toilet on your left Both will be unlocked and you can exit. Assemble at the Visitors Car Park area. Wait for further instruction from the Fire Warden You are here 4

5. 8/6/2012 5 About the Trainer My Name : William Kong Married – 4 Children – 2 boys & 2 girls - independent Asal – Miri , Sarawak 1975 – 1994 – Sarawak Shell Berhad 1994 – 1996 – Fochi -EP-JV Bintulu 1997 – 1998 – PCSB – Turkmenistan 1999 – 2000 – SMDS Reconstruction – Bintulu 2001 – 2010 – PCSB, SKO, Lutong , Miri 2011 – Present - Freelance

6. 8/6/2012 6 About You! Your Name : Your Position: Your Company:

7. 8/6/2012 7 Behavioral Hazard Job Hazard Process Hazard BBS HEMP - JHA HEMP - PTW

8. 8 Petroleum industries handle large quantities of flammable and toxic materials. Potential for accident is high. When accidents do occur, root cause - often due to: Failure to implement procedures Lack of training and knowledge in the application of the PTW system. The assumption that- “The permit when approved is a confirmation that all hazards and risks have been eliminated from the work area” INTRODUCTION INTRODUCTION 8/6/2012 Why the need for a PTW system in PETRONAS

9. 9 Why the need for a PTW system in PETRONAS Many fatalities have occurred. Inadequate precautions for working in hazardous area and confined spaces. June 2001 Malaysia - 9 died in a ship. + Other incidents worldwide. Most cases- Flammable atmosphere, Toxic gases or oxygen deficiency Lack of coordination and control activities. Executing more than one task at the same time. INTRODUCTION 8/6/2012

10. 10 Sub contracting of work to contractors. No experience working in confined space No proper work procedures and equipment for working in confined space Failure in PTW key management system INTRODUCTION 8/6/2012

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14. 14 PTW system is applicable for all activities carried out at all work locations including office throughout PETRONAS Carigali global operations, including Contractors and Sub-Contractors. Contractors working on their facilities where PETRONAS Carigali have the prevailing influence, may use their own PTW System; however the PTW system shall be subject to detail review and approved by PETRONAS Carigali. SCOPE 8/6/2012

15. 15 An important part of a work system and guides us how a job shall be carried out safely. Is a formal written system and as a means of communication so that: Plant management, supervisors, operators and ALL those carrying out the job are aware of the work being done. Only approved people are so permitted to carry out: A Specific job At a Specific time At a Specific place. WHAT IS A PERMIT 8/6/2012

16. 16 Permission to simply carry out a dangerous job. A confirmation that hazards and risks have been eliminated. Security that if you have a Permit, it makes a job safe. Those carrying out a work must: Be Trained and competent Identify risk associated with any work activity and how these are to be avoided. Take all the precautions. Ensure their work does not interfere or affect with that of others. A PERMIT IS NOT 8/6/2012

17. 17 BASIC UNDERSTANDING OF THE “PERMIT TO WORK SYSTEM” Four ( 4 ) Important things that we must protect P ersonnel’s Safety E nvironment – Prevent polluting the sea, land & atmosphere A sset– Facilities or Equipment for producing Oil & Gas R eputation of our Company ( PETRONAS’s and yours) PURPOSE OF THE PTW SYSTEM 8/6/2012

18. 18 To protect PERSONNEL 8/6/2012 PURPOSE OF THE PTW SYSTEM

19. 19 To protect Environment DEEPWATER HORIZON. BURNING AND GOING DOWN KOREA’S WORST OIL SPILL HEBEI SPIRIT 8/6/2012 PURPOSE OF THE PTW SYSTEM

20. 20 To Protect Asset DULANG B PROPERTY DAMAGE, 1 APR 2009 CRANE BOOM FALL ONTO MAIN DECK FIRE INCIDENT AT BEKOK C PLATFORM ON 14 TH DECEMBER 2010 8/6/2012 PURPOSE OF THE PTW SYSTEM

21. 21 To protect the company reputation 8/6/2012 PURPOSE OF THE PTW SYSTEM

22. 22 AREA CLASSIFICATION Non-Hazardous Area An area in which a flammable atmosphere is not expected to be present. Hazardous Area An area in which a flammable atmosphere is, or may be expected to be present. Therefore, special precautions for any work are necessary. DEFINITIONS 8/6/2012

23. 23 HAZARDOUS AREAS 1 . A4 CWP area classification 2 . A3 Permit-To-Work Form - area classification Zone 0 Flammable gases and vapors are constantly present Zone 1 Flammable gases and vapors are intermittently present Zone 2 Flammable gases and vapors are not expected to be present unless conditions become abnormal. DEFINITIONS 8/6/2012

24. 24 DEFINITIONS Certificate Written and signed statement indicating that the specified checks or tests that have been carried out by an authorized person and the conditions are acceptable. Certificates do not replace the PTW but are complementary. 8/6/2012

25. 25 DEFINITIONS Hot Work Hot work is any work where HEAT is used and generated. Examples of hot work are : * Welding, * Flame cutting, * Grinding, * Grit blasting, (positive ignition sources) Any work which may generate incentive sparks or other sources of ignition e.g. taking of photograph using camera with flash, use of non-intrinsically safe equipment, including opening of junction boxes, Local Control Panel (LCP) (potential ignition sources). 8/6/2012

26. 26 DEFINITIONS Cold Work Any work other than hot work as defined in the previous slide. Example of cold work; erect / dismantle of scaffolding , Housekeeping etc. 8/6/2012

27. 27 DEFINITIONS Confine space An enclosed or partially enclosed space that is at atmospheric pressure during occupancy and is not intended or designed primarily as a place of work, and is liable at any time to have an atmosphere which contains potentially harmful levels of contaminants; have an oxygen deficiency or excess; or cause engulfment; and with restricted means for entry and exit. 8/6/2012

28. 28 DEFINITIONS Specific Worksite An area where all work require to be controlled by a PTW System Work Description Work as specified in the PTW form Display Board Which displays all active work permits at an installation / facility. It is normally located in the main operation control room 8/6/2012

29. 29 DEFINITIONS Gas testing Gas testing is done to check a workplace, prior to the commencement and during work activities for the level of oxygen, flammable and toxic gases. This is to alert personnel involved should the environment become dangerous. Hazard Assessment An evaluation of the potential hazards, their severity and likelihood associated with any work activity . 8/6/2012

30. Isolation A physical barrier between a source of energy and a place of work 30 DEFINITIONS Job Hazard Analysis (JHA) Job Hazard Analysis (JHA) is the application of the hazards and effects management process (HEMP) at the job/task level, identifying and assessing the hazards of each element of the task and defining appropriate controls and recovery measures. 8/6/2012

31. 31 DEFINITIONS Override/Bypass The temporary bypass of a safety device, to allow bypass certain work to proceed without causing an unnecessary process shutdown or fire alarm (e.g.) fire detectors overridden during welding operations 8/6/2012

32. 32 DEFINITIONS Potential Hazards An event, circumstances or condition, if not controlled, have the potential to harm personnel, environment , asset or reputation Potential Precautionary Preventive and contingency steps taken to ensure a safe worksite and to prepare for emergencies 8/6/2012

33. 33 DEFINITIONS   Validity The period of time (as defined) during which an approved document such as the PTW, Certificate and other documents in this PTW system is valid for it’s intended purposes Test Equipment Validity The period of time during which a test equipment is valid for its intended use. 8/6/2012

34. 34 DEFINITIONS Safety Equipment The period of time during which a safety equipment such as PPE and rescue equipment is valid for its Validity intended use. Proof of validity shall be visible by documents as attached or affixed on the equipment 8/6/2012

35. 35 The PTW is a written document authorizing persons to carry out the work concerned, warning them of possible hazards and Spell out precautions needed and taken for the job to be done safely . WHAT IS A PTW 8/6/2012

36. 36 As a general principle, PTW shall be applied for ALL activities which may harmfully affect the p ersonnel, e nvironment, a sset and r eputation carried out on PETRONAS Carigali facilities . WHEN IS PTW APPLICABLE 8/6/2012

37. 37 Signatories Personnel Permit Applicant Competent PCSB/Contractors’ Personnel Approving Authority (AA) Offshore/Onshore Installation Manager (OIM) Authorised Supervisor (AS) Operations Supervisor / Maintenance Supervisor/ Senior Technician / Technician Approving Authority Representative Senior Technician/Technician Receiving Authority Competent PCSB/Contractors ’ Personnel Work Leader Competent PCSB/Contractors’ Personnel PTW SIGNATORY MATRIX 8/6/2012

38. 38 RESPONSIBILITY Permit Applicant The person who applies for the PTW e.g. the foreman / supervisor / RA responsible for planning and execution of the work and may be a Company or Contractor personnel. The Permit Applicant shall be responsible for the following : Describing in detail the work activity to be carried out; Stating the tools and equipment to be used , the number of personnel to do the work ,the exact equipment or location where the work is to be carried out Completing a JHA specifying hazards and precautions to be taken . 8/6/2012

39. The person responsible for approving the work permit, shall ensure all precautions are specified, controls in place, and work is performed in a safe and efficient manner. The person shall verify and ensure the following :-   All hazards associated with the job are identified and risks have been reduced to as low as reasonably practicable; The authorized work does not endanger other ongoing operations in the facility; The AAR is competent and aware of the conditions as stated in the Permit/Certificate and to implement precautions prior to start of work; Other permits/work activities that may interact are cross-referenced; Approving Authority ( AA ) ( Offshore/Onshore Installation Manager ) 39 RESPONSIBILITY 8/6/2012

40. All supporting certificates and documents are attached and made known to all concerned parties; Effective communication to ensure that the work site is inspected before work begins, suspended and on completion; Effective handover for outstanding work after each shift/crew change; and The list of authorised PTW signatories is regularly updated. Note : Without Approving Authority's signature you cannot start a Job 40 RESPONSIBILITY 8/6/2012

41. Authority to Delegate When on a remote facility, the Approving Authority may delegate his roles and responsibilities to an Authorised Supervisor/AAR.   The Permit Applicant and the Approving Authority/Approving Authority Representative SHALL NOT BE the same person. 41 RESPONSIBILTY 8/6/2012

42. Therefore AA has a big responsibility. Simply said: If anything goes wrong with a work activity or an incident takes place, this person takes the full responsibility and answerable to Management and other authorities. This person must therefore ensure the workers : trained in the PTW system trained and competent in their own work activity follow procedures and work safely 42 RESPONSIBILTY 8/6/2012

43. Authorized Supervisor (AS) ( Operations Supervisor/Maintenance Supervisor/ Production Supervisor or any person authorized by AA) The person is responsible for ENDORSING the PTW. Ensures all precautions are specified. Controls and recovery measures in place Work is performed in a safe and efficient manner Issue the PTW to the applicant after final approval All hazards associated with the job are identified and risks have been reduced to as low as reasonably practicable, 43 RESPONSIBILTY 8/6/2012

44. The authorized work does not endanger other ongoing operations in the facility ,    All supporting certificates and documents are attached and made known to all concerned parties,   All the required equipment and PPE are adequate for completion of work safely ,   Effective handover for outstanding work after each shift/crew change .   The list of authorised PTW signatories is regularly updated. 44 RESPONSIBILTY 8/6/2012

45. Authority to delegate When on a remote facility, the Authorised Supervisor may delegate his roles and responsibilities to an AAR.   45 RESPONSIBILTY 8/6/2012

46. Approving Authority Representative (AAR) 46 A competent person delegated by the AA Shall implement all the precautions as specified in the PTW. When on a remote facility, AAR may be delegated as an AA & AS. Note : AAR may request for Authorised Gas Tester or carry out the gas test himself if he is a competent AGT. When on a remote facility, I can be a 3 in 1 RESPONSIBILTY 8/6/2012

47. The RA who is responsible for planning and supervising the safe execution of the work shall ensure that:-   All personnel involved in the work activity shall receive adequate PTW training ;   Job is fully discussed with the AS and AA; The PTW top copy is displayed at the work site and the work party briefed on the PTW The precautions are maintained throughout the work activity ;   The workers understand that if circumstances change, work must stop and advice sought ;     Receiving Authority – RA ( The RA may also be the Permit Applicant and/or Work Leader. ) 47 RESPONSIBILTY 8/6/2012

48. The work crew stays within the limitations as defined in the PTW; and   On completion or suspension of the work, the site is left in a safe condition and the AS and/or AA informed.   48 RESPONSIBILTY 8/6/2012

49. The WL who is responsible for planning and supervising the safe execution of the work shall:-   Confirm the site conditions as required by the PTW and agree by signing ; Brief the work crew on JHA and PTW conditions ; Supervise the work and remain at the work site at all times ; Ensure there is no deviation from any condition as defined in the PTW; and Return the signed PTW to RA upon completion of work. Work Leader (WL) ( The WL may also be the Permit Applicant and/or RA ). 49 RESPONSIBILTY 8/6/2012

50. 50 A team of workers who carryout the job and shall: Not start work unless a permit is approved and issued Use all the required PPE Receive briefing from their WL on the particular task, understand hazards and precautions to be taken. Leave the worksite and equipment in a safe condition upon completion of work. Stop work if in doubt or if circumstances change and inform the WL/RA. Sec 4 -Pg-4 RESPONSIBILTY Work Crew 8/6/2012

51. Authorized Gas Tester - AGT 51 A person who is trained to meet the requirements of DOSH Malaysia Code of Practice or equivalent Host Country’s Authority for safe working in a confined space and industry practices on gas testing, and is authorized by PETRONAS Carigali to carry out gas testing and recording in the PTW. If different tests are used, the authorization may be specific to the type of test. AGT has the authority to withdraw a PTW if condition is unsafe. RESPONSIBILTY 8/6/2012

52. 52 A person, especially trained for certain duties (e.g. isolation/de-isolation of electrical equipment, synchronizing, etc.) and has sufficient technical knowledge and experience to enable him to avoid danger. For him to execute the Works he MUST be under written Instructions and Appointment from PETRONAS Carigali Resident Electrical Engineer as provision in Electricity Regulations 1994 or the Host Country’s Authority. Appointed Person (AP) RESPONSIBILTY 8/6/2012

53. 53 A person also referred to as the Chargeman , who is registered with Energy Commission and authorised by Management. He has sufficient technical knowledge and experience to enable him to avoid danger and who can have authority delegated to him, according to his knowledge and experience to carry out operations in power systems and work on electrical equipment. He has the authority to issue and cancel Electrical Isolation Certificate (EIC) and Limit of Electrical Access ( LoAC ) on Electrical Equipment/System. Authorised Competent Personnel (ACP) RESPONSIBILTY 8/6/2012

54. 54 PTW training is MANDATORY for all contractor personnel who work under a PTW system. Contract Management shall ensure all their employees who work in PETRONAS Carigali facilities are trained and competent in the PTW system. RESPONSIBILTY Contractor Management 8/6/2012

55. I am a 2 in 1 Prod. Tech & Inst Tech. 55 A person trained and competent in two work skills In the application of this PTW System this person shall; Assume only one role in this Permit This person can be either RA or AAR Note : Dual Skilled person cannot apply and approve for the same PTW. Dual Skilled Personnel RESPONSIBILTY 8/6/2012

56. 56 In PETRONAS Carigali there are two different PTW documents : A Cold Work Permit (an A4 document). Cold/Hot Work permit (an A3 document) PERMIT 8/6/2012

57. The Cold Work Permit (A4 document) has a solid green border. For work in non-hazardous AREA , the Cold Work Permit may require the support of Certificates . In case of doubt as to whether a work activity require a PTW, it may be subjected to PTW requirement if deemed necessary by the Approving Authority. 57 A Cold Work Permit (an A4 document). PERMIT COLD PTW 8/6/2012

58. 2. The Cold/Hot Work permit (an A3 document) comprises of the following: Cold Work Permit Hot Work Permit Confined Space Certificate It is required when any work activity is considered capable of producing a source of ignition or using/ generating heat. Note !! It is mandatory that a gas test be conducted before any hot work permit and confined space certificate is issued . 58 PERMIT A3 PTW 8/6/2012

59. 59 SECTION 1 Details of permit applicant Work description Permit number and Zone classification AS writes Y or N. All boxes must be filled And allocates work permit no. RA A4 COLD WORK PERMIT 8/6/2012

60. 60 SECTION 2 Identify with a cross ( X ) all possible HAZARDS related to the work activity A4 COLD WORK PERMIT 8/6/2012

61. 61 SECTION 3 AS to identify with a Y or N all the worksite preparation / Precautions . AAR to implement as required and initial . Write additional precautions A4 COLD WORK PERMIT 8/6/2012

62. 62 SECTION 4 RA / AS to indicate with a cross ( X ) the relevant and additional personal protective equipment (PPE) required for the job. A4 COLD WORK PERMIT 8/6/2012

63. 63 SECTION 5 AS specify supporting certificate required . A4 COLD WORK PERMIT 8/6/2012

64. 64 SECTION 6 RA designates a technician /worker to be the Work Leader. AS nominates an Approving Authority Representative (AAR) AAR confirms by signing that precautions have been implemented WL confirms acceptance of responsibility for work as described in Section 1 after witnessing AAR implementing the precautions. A4 COLD WORK PERMIT 8/6/2012

65. 65 SECTION 7 Endorse of the work by the AS RA to sign acceptance of all conditions as specified in the permit Acknowledgement by other personnel as identified by AA Approved of the work permit by the AA A4 COLD WORK PERMIT 8/6/2012

66. 66 SECTION 8 Revalidation for a shift extension of a cold work permit for the particular work shift of the same crew . Approving Authority signature required for any cold work extension AAR signature required to ensure AAR is aware of the extension WL signature required as this is the person requesting for the extension Extension time shall be specified A4 COLD WORK PERMIT 8/6/2012

67. 67 SECTION 9 - HANDBACK WL signs off when work is completed ( 1 ) RA confirms by signing when work has been completed ( 2 ) AAR confirms and signs off when work completed ( 3) AS Shall sign all copies of the work permit thus acknowledging the work has been completed. ( 4 ) AA‘s signature to certifies the work permit is now closed . ( 5 ) A4 COLD WORK PERMIT 1 2 3 4 5 8/6/2012

68. 68 SECTION 1 Details of permit applicant Work description Special Instruction Permit number and Area classification AS writes Y or N. All boxes must be filled RA A3 COLD / HOT WORK PERMIT 8/6/2012

69. SECTION 2 (Hazards / Hazardous activities ) Identify with a cros s ( X ) all possible HAZARDS related to the work activity 69 A3 COLD / HOT WORK PERMIT 8/6/2012

70. 70 SECTION 3- WORKSITE PREPARATION / PRECAUTION Identify with a Y or N all the worksite preparation / precautions. AAR to implement as required and initial. A3 COLD / HOT WORK PERMIT 8/6/2012

71. 71 SECTION 4 - PERSONAL PROTECTIVE EQUIPMENT Indicate with a cross the relevant and additional personal protective equipment (PPE) required for the job. A3 COLD / HOT WORK PERMIT 8/6/2012

72. 72 SECTION 5- SUPPORTING CERTIFICATE As Identifies with a cross ( X ) and number of the specific certificate/s. A3 COLD / HOT WORK PERMIT 8/6/2012

73. SECTION 6 - JOINT SITE VISIT RA designates a technician /worker to be the Work Leader. AS Nominates an Approving Authority Representative (AAR) . AAR confirms by signing that precautions have been implemented WL confirms acceptance of responsibility for work as described in Section 1 after witnessing AAR implement the precautions. 73 A3 COLD / HOT WORK PERMIT 8/6/2012

74. 74 SECTION 7 - ACKNOWLEDGEMENT Endorsement of the work by the AS RA to sign acceptance of all conditions as specified in the permit Acknowledgement by other personnel as identified by AA Approval of the work permit by the AA A3 COLD / HOT WORK PERMIT 8/6/2012

75. IN THE HOT WORK PERMIT SECTION , Condition compile by RA AS indicate with a cross ( X ) all the precautions/conditions AAR implements all the specified precautions/conditions as identified in the Hot Work permit and signs at the bottom of the Hot Work Permit Endorsed by AS Approve by AA 75 A3 COLD / HOT WORK PERMIT 8/6/2012

76. RA writes name of the Standby person ( 1 ) and BA Coordinator ( 2 ) AS indicates with a cross all the precautions/conditions that must be implemented before the permit is approved. AS signs the CSE after the precautions have been implemented . AGT carry out a Gas Test , the results of which are recorded in Section 8 of the work permit and sign off. CONFINED SPACE ENTRY CERTIFICATE 76 A3 COLD / HOT WORK PERMIT 8/6/2012

77. SECTION 8 - GAS TEST RESULTS AGT to carry out a Gas Test and record the results AGT’s name and Signature 77 A3 COLD / HOT WORK PERMIT < 10% LEL – OUTSIDE <1% LEL – INSIDE GAS TEST FOR ANY HOT WORK AND CONFINED SPACE ENTRY 8/6/2012

78. SECTION 9 – WIRELINE DAILY ENDORSEMENT Revalidation for wireline works for up to seven (7) days. As long as the wireline work is performed by the same crew on the same well. Endorsement by AS and approve by AA for extension of wireline work 78 A3 COLD / HOT WORK PERMIT 8/6/2012

79. 79 SECTION 10 ( SAME AS SECTION 8 IN CWP ) Work Completion Section . WL signs off when work is completed ( 1) RA confirms by signing when work has been completed ( 2 ) AAR confirms and signs off when work completed ( 3) AS Shall sign all copies of the work permit thus acknowledging the work has been completed. ( 4 ) AA signature to certify the work permit is now closed. ( 5 ) A3 COLD / HOT WORK PERMIT 1 2 3 4 5 8/6/2012

80. 1 . Permits are valid for the period it is issued or a maximum of one shift (i.e.) 8 – 12 hours. 2 . Equipment remains the same. 3 . Work activity remains the same. 4 . Crew/workers remain the same. 5 . Work site conditions remain the same. 6 . All the required signatures are in place . Note: A Work Permit may require several certificates before it may be validated . 80 PTW VALIDITY 8/6/2012

81. EXCEPTIONS Revalidation can be given for a shift extension of a cold work permit for a “particular work shift of the same crew”. (Section 7 of the Cold Work Permit ) Note: Extensions granted shall not extend into the next day Revalidation for up to seven days ( 7 ) can be given for wireline work, as long as the work is performed by the same crew on the same well. 81 PTW VALIDITY EXCEPTIONS 8/6/2012

82. If there is an Emergency Shut Down (ESD), General Platform Alarm (GPA) INCLUDING false alarm or an emergency drill, All work must STOP immediately. Work sites must be secured and made safe All personnel proceed to their designated muster stations. Before work activities may resume, All Hot Work permits and associated certificates, within the affected areas of the emergency shall be cancelled and new documents issued . For Cold Work and Wire Line, the PTW shall be revalidated.   82 PTW CANCELLATION 8/6/2012

83. The PTW system has twelve (12) certificates. Each is intended for a specific purpose, as the name implies, and each has a coloured border of diagonal stripes.   83 CERTIFICATES No Certificates Color Indication 1 Confined Space Entry Certificate (part of A3 PTW ) - 2 Safety System Bypass/Override Certificate (SSBOC) Red 3 Electrical Isolation Certificate (EIC ) Purple 4 Physical Isolation Certificate (PIC) Maroon 5 Excavation Certificate Dark Green 6 Lifting Certificate Orange 7 Radiation Certificate Yellow 8 Road Obstruction/Closure Certificate Dark Blue 9 Vehicle Entry Certificate Royal Blue 10 Limit of Electrical Access Certificate (LoEA) - 11 Electrical Temporary Installation Certificate - 12 Diving Certificate. - 8/6/2012

84. 84 CONFINED SPACE CERTIFICATE Forms part of the A3 PTW. Confirms that a competent person has: Checked the work site of a planned confined space entry. Identified the hazards within & the controls to ensure a safe work environment. An important part of the Confined Space Certificate is the Confined Space Checklist : The Confined Space Entry Checklist is a list of work site conditions that must be checked by the AS before a PTW can be issued. This checklist shall be used in conjunction with the Confined Space Entry Certificate. 8/6/2012

85. 85 The Safety System Bypass/Override Certificate (SSBOC ) shall be used for work on process, mechanical and instrument equipment. A safety system bypass/override certificate confirms that:- One or more of the process control and F&G safety system have been bypassed to prevent accidental S/D. You can carry out the work on that equipment process/mechanical/instrument without an accidental S/D. Examples of work requiring SSBOC are such as Hot work in an area with UV/IR detectors Maintenance of FWP Testing ESD etc Note: The detail requirements of the SSBOC are defined in the WW ALL S 04 019 PETRONAS Carigali Bypass of Safety Critical Equipment Guideline. SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE 8/6/2012

86. 86 The bypassing/overriding/isolating/defeating of Safety Critical Equipment (SCE) MAY BE ALLOWED for the following reasons: Maintenance Activities Faulty SCE Other consideration SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE 8/6/2012

87. 87 THE FOLLOWING SCE SHALL NOT BE BYPASSED:-  Pressure relieve devices e.g. Pressure Relief Valve, Pressure Vacuum Relief Valve etc; Thermal relieve devices; and Electrical overload relay Risk assessment shall be conducted, prior to bypass/isolation/defeating of SCE. Note: The detail requirements of the SSBOC are defined in the WW ALL S 04 019 PCSB Bypass of Safety Critical Equipment Guideline. SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE 8/6/2012

88. 88 VALIDITY AND EXTENSION Bypass/override/isolation/defeating of SCE should be allowed for a maximum period of twelve weeks ( 12 ) , subjected to weekly re-validation. In cases more than 12 weeks, e.g. due to faulty SCE, the extension should be allowed with the following conditions: Maximum cumulative bypass shall not exceed 48 weeks; A more detail risk assessment required before the approval beyond 12 weeks; Weekly revalidation; The Approving Authority shall be escalated for each extension as tabulated in Table 1 and Table 2; and A permanent solution/mitigation shall be established to prevent bypass/override/isolation/defeating of SCE beyond 48 weeks. SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE 8/6/2012

89. 89 VALIDITY AND EXTENSION Table 1: Level of Approving Authority by Safety Integrity Level (SIL) For bypass of SCE due to maintenance activities with MOS, the AA shall follow PTW AA. For bypass of SCE due to faulty and/or maintenance without MOS, the AA shall be based on the SIL. SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE SSBOC SLIDES 8/6/2012

90. 90 VALIDITY AND EXTENSION Table 2: Level of Approving Authority by Risk Level For bypass of SCE due to maintenance activities with MOS, the AA shall follow PTW AA. For bypass of SCE due to faulty and/or maintenance without MOS, the AA shall be based on the SIL. BSCE Training Slide SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE 8/6/2012

91. 91 Bypass/override/isolation/defeating of SCE should be allowed for a maximum period of 12 weeks, with weekly revalidation. In cases where bypass/override/isolation/defeating of SCE is more than 12 weeks, e.g. due to faulty SCE, the extension shall be allowed for a maximum period not exceeding 48 weeks. SAFETY SYSTEM BYPASS/OVERRIDE CERTIFICATE Note : 8/6/2012

92. The isolation certificate confirms that the equipment has been drained of liquid, depressurized of gas and isolated from other equipment in the operating facility and from power sources. Isolation Certificates consist of the following :- Electrical Isolation Certificate Physical Isolation Certificate Radiation Certificate 92 ISOLATION CERTIFICATES 8/6/2012

93. Energy isolation shall be required during service, inspection, installation, modification and/or maintenance of live equipment and/or pipeline. Energy isolation may also be required to remain in place although none of the above being carried out due to the following reasons:   Where work has commenced but is, or is likely to be, suspended due to faulty e.g. awaiting spares for a repair; Mothballed equipment, which may be required in the future; Where an item of equipment becomes redundant and is isolated pending removal or decommissioning. 93 ISOLATION CERTIFICATES 8/6/2012

94. All energy isolation shall be approved through the application of Physical Isolation Certificate (PIC), Electrical Isolation Certificate (EIC) and Radiation Certificate (RC). The energy isolation shall only be carried out after the issuance of an approved PIC, EIC or RC.   For isolation of radiation source, it is limited to isolation of equipment containing radiation source and does not cover transportation, storage and handling of radiation source. 94 ISOLATION CERTIFICATES 8/6/2012

95. 95 The Electrical Isolation Certificate shall be used for work on electrical equipment, and confirms that an authorized and competent person has: Electrically isolated the equipment to be worked on Taken suitable precautions to prevent accidental reconnection. Note: the detail requirements of the electrical isolation certificate are defined in the WW ALL S 04 018 PETRONAS carigali energy isolation procedure.   ELECTRICAL ISOLATION CERTIFICATES EI PROCEDURE 8/6/2012

96. The Physical Isolation Certificate shall be used for work on process lines and equipment, and confirms that :- Process lines and equipment have been drained of liquid, depressurized of gas. Isolated from other equipment in the operating facility Suitable precautions taken to ensure they remain isolated. Note: the detail requirements of the physical isolation certificate are defined in the WW ALL S 04 018 PETRONAS carigali energy isolation procedure. 96 PHYSICAL ISOLATION CERTIFICATES PIC PROCEDURE 8/6/2012

97. 97 The Radiation Certificate shall be used for handling of Ionizing Radiation / Radioactive Sources. This certificate confirms that :- A Radiation Protection Officer (RPO) has granted permission to use a radio-active source; and Related extra precautions have been taken.   RADIATION CERTIFICATES RC PROCEDURE 8/6/2012

98. 98 The Excavation Certificate shall be used whenever excavation deeper than 150mm is planned. This certificate confirms that a competent person: Has checked the work site of a planned excavation; and Studied layout drawings to ensure that the proposed excavation can be made without damage to existing buried facilities such as pipelines, drains and electric cables. EXCAVATION CERTIFICATES EC PROCEDURE 8/6/2012

99. 99 The Lifting Certificate is required for the following lifts but not limited to:- Lifting over unprotected process equipment or wellheads. Lifting dangerous goods Lift exceeding 8 tons Lift inside confined space Lift with slings not made of wire rope ( web sling) Lift with more than four legs Multiple crane lift Failure to fully illuminate load Failure to fully illuminate path of load When removing or installing wellhead hatch/grating When a safety device is bypassed ( crane safety device ) LIFTING CERTIFICATES LFC PROCEDURE 8/6/2012

100. 100 The Road Obstruction certificate is used when the closure of any road may affect the passage of vehicles particularly for emergency response vehicles. ROAD OBSTRUCTION / CLOSURE CERTIFICATES ROC PROCEDURE 8/6/2012

101. 101 The Vehicle Entry Certificate is used whenever vehicles are required to enter process areas that are controlled by the Permit to Work system. One PTW is valid for more than one certificate Each certificate is valid for one vehicle Mechanical Technician must check the vehicle. VEHICLE ENTRY CERTIFICATES VEC PROCEDURE 8/6/2012

102. 102 The Limit of Electrical Access Certificate is a certificate of declaration signed and given by a duly Authorized Competent Person ( ACP ) to person who is performing the electrical works on site to cover works in close proximity to Live conductors/equipment/apparatus, or Testing of Live Voltage conductors. LIMIT of ELECTRICAL ACCESS CERTIFICATE LOEAC PROCEDURE 8/6/2012

103. 103 The Electrical Temporary Installation Certificate is used for control of temporary electrical installation set up such as generator set, ELCB and power cable. ELECTRICAL TEMPORARY INSTALLATION CERTIFICATE 8/6/2012

104. 104 The Diving Certificate is used for control of diving activities during inspection and maintenance of subsurface structures and facilities. DIVING CERTIFICATE 8/6/2012

105. 105 Usually located in the main operations control room or designated by the plant management. On a remote area can be at a Central Location. All permits for the day are displayed on the board so that: Any interested party can view all the work in progress. Is another means of communication. PTW Display Board DISPLAY BOARD 8/6/2012

106. 106 Each installation must maintain a current and complete record of all PTW and certificates in force at any one time. This record serves as an information source when issuing additional documents. The log book must be maintained by the permit issuer (AS) for each installation and facility. PTW Log Book SITE LOG BOOK 8/6/2012

107. 107 The following details shall be logged: Type of permits / certificate issued Reference numbers of all permits / certificates Work Location Date and time of issue of all permits/certificates Date and time of closure of all permits/certificates Permits Valid and suspended Equipment with extended isolation SITE LOG BOOK 8/6/2012

108. 108 The Top Copy or First Copy Which has all the required signatures, to be displayed at the work site when work is in progress. The Second copy (Tracking Copy) to be held by the Authorized Supervisor at the permit issue point whenever work is in progress. The Third copy to be held by the Receiving Authority (Applicant). ( Both Permit and Certificate) HOW ARE PTW / CERTFICATE DISTRIBUTED 8/6/2012

109. 109 Briefings by either the RA or the WL to the work crew where: Plan for the work activity is explained Individual responsibilities are identified Procedures reviewed Hazards discussed Refresher meeting if necessary Conduct final identification of hazard of worksite conditions and verify the requirement stated in P.A.U.S.E card prior to work execution TOOL BOX MEETING 8/6/2012

110. 8/6/2012 110

111. 111 CO-ORDINATION Usually the AA/AS who shall: Retain overall responsibility for all work activity Ensure each work is carried out efficiently Ensure one work activity does not interfere with another work. PTW PREPARATION 8/6/2012

112. 112 Proper planning of the work to ensure: Approval is obtained All are aware of the safety precautions All are aware that there shall be no interaction with other work activities Adequate time is available for identification of potential hazards, implementation of precaution and worksite preparation PTW PREPARATION 8/6/2012

113. 113 HAZARD ASSESSMENT The following shall apply in the assessment of Hazards WL shall provide details of work activity Consideration given for safer alternatives, hazards in process equipment and handling of hazardous materials Careful assessment of the surrounding area so that hazards in that environment does not affect the safe execution of the work PTW PREPARATION 8/6/2012

114. 114 TYPES & CATEGORIES OF WORK The following are some of the work activities but not limited to: Maintenance and repair work Any work that may generate sparks or ignition Hook up and commissioning Well services Electrical work Excavation Diving Confined space entry Working at heights Work on equipment which contains or has contained flammable or toxic materials Work that uses dangerous substances such as radioactive and explosives materials. NOTE : Consult the Approving Authority when in doubt PTW PREPARATION 8/6/2012

115. 115 ISOLATIONS An essential component of any safe system of work is the method and integrity of the isolation procedure. The isolation principle to be adopted, prior to carrying out maintenance or repair, shall be determined by a number of factors, such as potential for pressure, dangerous substances, moving machinery and other hazards. Reference shall be made to WW ALL S 04 018 PETRONAS Carigali Energy Isolation Procedure. Plan and record on a working drawing that is current and valid Discuss isolation with all those involved so that all understand and agree Attach copy of marked up P & ID’s with permit at worksite Preparation of the Permit PTW PREPARATION 8/6/2012

116. 116 Ensure All energy sources (mechanical and electrical) are identified in isolation procedures Padlocks/key numbered and recorded Isolations are applied and removed on instruction from AS. If more than one task is to be carried out on same equipment, de-isolation is done ONLY when all work is completed. WL, RA, AAR & AS check worksite if work is not completed within the shift. PTW PREPARATION 8/6/2012

117. 117 8/6/2012

118. 118 Isolations ……continue Isolations must be secured and shall be: Highly visible Impossible to de-isolate Provided with a tag label that identifies the securing device Simple to apply PTW PREPARATION 8/6/2012

119. 119 Isolations …… continue Padlocks Each discipline shall have a known quantity of SINGLE key padlocks Padlock shall be stamped with number Colour coded for each discipline WL shall record issue and return of the padlock Preparation of the Permit PTW PREPARATION 8/6/2012

120. 120 PTW PREPARATION 8/6/2012

121. 121 ISOLATIONS …… Lockout Tags PTW PREPARATION Operation permanent plastic tag Chargeman permanent plastic tag 8/6/2012

122. 122 ISOLATIONS …… Lockout Tags PTW PREPARATION Disposable Tag for use with Lockout Box (Paper / Tyvec or similar material ) Disposable Tag with serial number, Duplicated on perforated section. Used to Identify Spade / Blind location (Paper / Tyvec or similar material ) 8/6/2012

123. 123 ISOLATIONS …… Lockout Tags PTW PREPARATION 8/6/2012

124. 124 ISOLATIONS …… CONTINUE Operation personnel/AAR shall be the first and the last person to place/remove LOTO devices. Exceptions shall be given to electrical isolation and isolation of ionizing radiation source where the ACP/AP or RPS/RPO is the first to install the lockout tags on the isolation device and last to remove when the job is completed For any system with positive isolation, minimum of two (2) Operation personnel shall present to conduct or to witness the isolation (in cases where the isolation is carried out by Contractors ). PTW PREPARATION 8/6/2012

125. 125 ISOLATIONS …… CONTINUE In cases where electrical isolation is required, the Operation personnel shall accompany the ACP/AP to the equipment breaker location. The ACP/AP shall then isolate the breaker and install LOTO devices (red tag). The Operation personnel shall then place LOTO devices on the breaker (blue tag). The breaker number and location including the lock and tag numbers shall be recorded on the EIC. For electrical isolation , after the LOTO devices were placed at the breaker, the Operation personnel shall conduct equipment testing at the field e.g. local mounted START/STOP for the particular equipment with the presence of ACP/AP to confirm energy is isolated. Once the isolation is confirmed, the isolation point is then fitted with LOTO devices by Operation personnel (blue tag). PTW PREPARATION 8/6/2012

126. 126 ISOLATIONS …… CONTINUE For physical isolation , the Operation personnel shall conduct equipment testing to confirm the energy is isolated for mechanical and hydraulic equipment. The AA or his delegates (for remote facilities or satellite platform) shall present to witness the testing and verify energy has been isolated. The AA or his delegates (for remote facilities or satellite platform) shall then sign on the PIC. PTW PREPARATION 8/6/2012

127. 127 ISOLATIONS …… CONTINUE Never assume.. That when an equipment / machinery is isolated it will not be functioning That when a job is too small it does not need a lockout and tag out. Note : Non compliance to lockout and tag out can cause loss of lives PTW PREPARATION 8/6/2012

128. 128 ISOLATIONS FOR MAJOR S/D ACTIVITIES AND SIMULTANEOUS OPERATIONS Major Shutdown/ Simultaneous Operations activities are complex in nature and are normally well secured by: PETRONAS Carigali – Site Specific Procedures / Specific Instruction for Simultaneous Operations (SISO) Procedures from Original Equipment Manufacturers ( OEM) PTW PREPARATION 8/6/2012

129. 129 GAS TESTING As a minimum requirement, the following shall apply for work activity where there may be a hazardous atmosphere: Gas testing is done at the workplace, prior to commencement and during work activities to check the level of oxygen, flammable and toxic gases. This is to alert personnel involved should the environment become dangerous. Gas test result shall be recorded and timed AS shall specify frequency of gas testing. PTW PREPARATION 8/6/2012

130. 130 PTW PREPARATION 8/6/2012

131. 131 TRAINING AND COMPETENCE Training is mandatory for all PETRONAS Carigali and contractor personnel who issue, receive and work under a PTW system. Written examination and other suitable assessment shall be carried out after the training. Records of PTW and related training should be kept by HR Department. Note : The validity of the training shall be three (3) years . 8/6/2012

132. 132 PTW SIGNATORY MATRIX The minimum training requirements for different parties in PTW system are : TRAINING AND COMPETENCE 8/6/2012

133. ANNUAL AUDIT REGIONAL HSE MONTHLY PTW AUDIT BY DEPARTMENT/ASSET WEEKLY PTW AUDIT BY APPROVING AUTHORITY DAILY MONITORING OF PTW SYSTEM BY AUTHORISED SUPERVISOR & RECEIVING AUTHORITY LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 THE TIERED STRUCTURE FOR SYSTEM AUDIT 133 PTW INSPECTION & AUDIT /MONITORING 8/6/2012

134. THE TIERED STRUCTURE FOR SYSTEM AUDIT 134 PTW INSPECTION & AUDIT /MONITORING LEVEL 4 AUDIT – DAILY AS and RA shall carryout daily monitoring, as a minimum the following: Display of permit at site Completeness of the PTW and PTW site log book All precautions in place, adequate and implemented Work party briefed on conditions in the permit and work scope 8/6/2012

135. THE TIERED STRUCTURE FOR SYSTEM AUDIT 135 PTW INSPECTION & AUDIT /MONITORING LEVEL 3 AUDIT – WEEKLY The AA and/or AS shall carryout weekly Audit as detailed out in Appendix II and documented. 8/6/2012

136. THE TIERED STRUCTURE FOR SYSTEM AUDIT 136 PTW INSPECTION & AUDIT /MONITORING LEVEL 2 AUDIT- MONTHLY The Country/Region Production Department or Division Project Head shall carry out monthly audit as detailed in Appendix II and documented. 8/6/2012

137. 137 LEVEL 1 AUDIT –ANNUALLY The Regional HSE Department shall carry out annual review of the PTW system. This shall include the Permits, associated Certificates, Job Hazard Analysis, P.A.U.S.E and follow up on previous audit findings. PTW INSPECTION & AUDIT /MONITORING 8/6/2012

138. 138 RETENTION OF DOCUMENTS Top and Second copy of all completed permits, certificates and other relevant documents must be retained for seven (7) years . The permit, certificate and all relevant documents relating to any incident shall be kept throughout the duration of the life of the plants/facilities PTW INSPECTION & AUDIT /MONITORING 8/6/2012

139. 139 SYSTEM REVIEW Changes and improvements shall be an ongoing effort for continuous improvement. Custodian shall take the following into account when reviewing this system Feedback from PTW Users Gaps in PTW system as identified in incidents reports Audit findings Recommendations from National and International Regulations, Industry Guidelines and other authorities. PTW SYSTEM REVIEW 8/6/2012

140. PERMIT TO WORK SYSTEM FEEDBACK FROM OPERATION OF SYSTEM REVIEW OF INCIDENT REPORTS LEGISLATION CHANGES AUDIT FINDINGS INDUSTRY GUIDELINES COMPANY POLICY Figure shows the structure of PTW System Review 140 PTW SYSTEM REVIEW 8/6/2012

141. Figure shows the structure of PTW System Review 141 PTW SYSTEM REVIEW 8/6/2012

142. 142 Thank You 8/6/2012

143. 8/6/2012 143

144. 8/6/2012 144 Behavioral Hazard Job Hazard Process Hazard BBS HEMP - JHA HEMP - PTW