Permit to Work Major Hazard Standard

Transcription

1 WMC Environment, Health & Safety Management System Major Hazard Standard MHS-07 DocsOpen Ref: , 23/12/2003 Uncontrolled copy check web for latest revision Revision Reviewed Description of Changes Date Approved 2 D Batchler Revised to incorporate Confined Spaces, Hot Work etc 23/12/2003 P Plavina 1 A Barfield Revised Isolations Standard 17/10/2001 P Plavina 0 First Issue of Isolations Standard 12/07/2000 K Thomas WMC Resources Ltd WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no representations as to the applicability of the information for use by any party other than WMC and should not be relied upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application of this document and its requirements by third parties.

2 EHS MS WMC EHS Management System Major Hazard Standard CONTENTS 1 PURPOSE AND SCOPE Purpose Scope GENERAL DOCUMENT STRUCTURE SYSTEM OVERVIEW TRAINING AND COMPETENCY MONITORING AND AUDITS WORK PERMIT PROCESS Scope of Work Hazard Identification and Assessment Work Permit Document Preparation Workplace Preparation Work Permit Issue and Acceptance Work Permits Work Permits with a Block Isolation Work Progression Work Commencement Shift Handover Work Permit Relinquishment Scope of Work Change Work Permit Suspension Testing Work Permit Hand-back RESPONSIBILITIES Permit Issuer Isolator Isolation Checker Service Provider / Permit Requestor Permit Acceptor Work Team Member Site General Manager REFERENCES...13 WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 2 of 59

3 EHS MS WMC EHS Management System Major Hazard Standard 10 TABLE Guide for When a Work Permit is Required APPENDICES...16 A PERMIT TO WORK OVERVIEW FLOWCHART B WORK PERMIT C WORK PERMIT REGISTER D1 ISOLATION PROCEDURE D2 ISOLATION CERTIFICATE E1 SAFE WORKING IN CONFINED SPACE PROCEDURE E2 CONFINED SPACE ENTRY CERTIFICATE E3 REAR OF CONFINED SPACE CERTIFICATE E4 CONFINED SPACE ENTRY/EXIT LOG E5 CONFINED SPACE WORK AUTHORISATION TAG E6 CONFINED SPACE EVALUATION F1 HOT WORK PROCEDURE F2 HOT WORK CERTIFICATE F3 FIRE WATCH SIGN OFF/ON ( rear of Hot work certificate) F4 HOT WORK- WORK AUTHORISATION TAG G1 RADIATION PROCEDURE G2 RADIATION PROCESS - FLOWCHART G3 RADIATION CERTIFICATE H1 EXCAVATION PROCEDURE H2 EXCAVATION CERTIFICATE H3 EXCAVATION FLOWCHART WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 3 of 59

4 1 PURPOSE AND SCOPE 1.1 Purpose This Standard details the requirements of the System for application at all WMC Resources owned and operated sites. The purpose is to: Authorise and control high-risk work designated as requiring a Work Permit Provide a process for competent personnel to authorise progress of highrisk work Ensure that all hazards are identified and that appropriate controls are in place and communicated prior to work commencing Provide a formal hand-over process to acknowledge that all hazards have been addressed Ensure that personnel carrying out the work are aware of the exact scope of work and the hazard controls required Ensure the impact of work on other tasks and the Operations is understood Provide a formal hand-back process to ensure the work area is safe to return to normal duties when the work is completed Provide a process for controlling the safety of specific types of work that, due to circumstances, have been classified as lower risk work (e.g. some Hot Work and Confined Space inspection activities) Provide a record of a safe system of work. 1.2 Scope This Standard defines a comprehensive Permit to Work System. This document includes Appendices that describe particular hazard controls and other requirements that need to be considered when establishing work controls for designated high-risk work activities. This set of high-risk work activities includes: Intrusive work on systems containing energy (Appendix D1) Working in a Confined Space (Appendix E1) Hot Work (Appendix F1) Working with or near Radiation Sources (Appendix G1) Excavation Tasks (Appendix H1). Not all work in these areas will be designated as high-risk and require a Work Permit. The site is required to establish criteria that allows personnel to judge when a Work Permit is required versus alternative work controls. The specific requirements for working at heights is covered in Major Hazard Standard 08 Safe Work at Height. Similarly there may be other activities deriving from risk assessment processes that will need a Work Permit. Typical examples of additional high-risk work are working with mineral fibres and removal of grid mesh/platform walkways in operational areas. 2 GENERAL The System describes a rigorous process for managing designated high-risk work. WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 4 of 59

5 Not all high-risk work requires a Work Permit. For instance risk assessment can lead to a low risk designation for inspection of certain confined spaces and some hot work activities. For such examples, this Standard provides for a simplified process of safe work authorisation through the use of appropriate stand-alone Work Authorisation tags. In all cases the use of a Work Authorisation shall require a formal risk assessment confirming the application of the tag and the availability of a THA or Standard Work Procedure. This simplified process is covered in respective Appendices E1 and F1. Table 1 provides general guidance on when a Work Permit is required. Reference to this table can be made, as a guide for each site to decide and document which types of high-risk work requires a Work Permit. This analysis shall be formal and consider the type of activity as well as different geographical areas of the site in which the activity takes place. The results of this process shall be effectively communicated to provide clarity to those personnel required to decide whether a Work Permit is required to progress work. All work that does not require the higher level of rigour that a Work Permit provides shall be carried out using the Take Time, Take Charge (TTTC) process, a Task Hazard Analysis (THA), Standard Work Procedure (SWP) or the use of a Work Authorisation tag, or combinations of these as appropriate. 3 DOCUMENT STRUCTURE The System encompasses the following core documents: A Work Permit Certificates for designated high-risk work: - Isolation of energy (including reference to High Voltage work under SP 25 Procedures) - Confined Space Entry - Hot Work - Radiation - Excavation. Note: Certificates are documents that define the core preparations required for work to proceed and do not, by themselves, authorise work to proceed. They cannot stand-alone and shall always be accompanied by a covering Work Permit. Work Authorisation tags for inspection of low risk Confined Spaces and performing low risk hot work. These tags can standalone Work Permit Register when using a Block Isolation. 4 SYSTEM OVERVIEW Core functions of the System are summarised in Flow Chart Appendix A. Following the identification of a work need and the definition of a scope of work an assessment of the hazard controls required to ensure safe work should be conducted. If this analysis leads to a decision to initiate the full process, the following core activities shall take place: Initial preparation of the Work Permit (this process is managed by the Service Provider) Final agreement to the required hazard controls and completion of all Work Permit documentation (this process is managed by equipment/plant owner) Implementation of agreed hazard controls by authorised personnel Authorisation and issue of the Work Permit by the Permit Issuer to a representative of the work team (Permit Acceptor). This is the hand-over process. WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 5 of 59

6 The Permit Acceptor ensures the work team understands the extent of hazard controls in place and assumes control of work activities for the duration of work. The Work Permit hazard controls shall remain in place whilst work is in progress. When the agreed work is complete the Permit Acceptor leaves the work site clean and safe and hands back the Work Permit to the Permit Issuer. The Permit Issuer resumes control over the equipment / plant and progresses the removal of any temporary hazard controls established for the task before returning to normal operations. 5 TRAINING AND COMPETENCY Structured competency-based training shall be given to all users of the System. Competency shall be reassessed at a maximum interval of two years. Standardised training modules shall be established for the following: Permit Issuer Isolator (including Isolation Checker) Permit Acceptor Confined Space Entry Confined Space Stand-by Person Hot Work and Fire Safety (including Fire Watch) Work Team Member. Permit Issuers and Isolators require detailed knowledge of the area in which they are issuing permits or carrying out isolations. Such knowledge shall be achieved as a prerequisite to gaining competencies. Competency records for all personnel shall be maintained on a site register and the extent of specific competency for individuals shall be clearly known to users of the System. 6 MONITORING AND AUDITS It is a requirement of the System that Permit Issuers, or a competent delegate, perform regular inspections of active Work Permits in the work site. The frequency and degree of detail included in this inspection should be based on the level of risk and complexity of the task being performed. The inspection shall include: Review of the Work Permit documentation Confirmation that the actual work being performed is consistent with the defined hazard controls in place. This does not require a detailed knowledge of the technical aspects of work being done. Confirmation that the hazard controls defined in the Work Permit remain in place. Each site shall conduct regular (at least quarterly) compliance audits of the Permit to Work System. A person independent of the area in which Work Permits are issued shall carry out a compliance audit of the over-all functioning of the System at least annually. 7 WORK PERMIT PROCESS Effective work planning and risk assessment processes are essential to the smooth and safe execution of the System. 7.1 Scope of Work For any potentially hazardous work activity there shall be a clearly defined Scope of Work (SOW). This SOW shall: Be defined by the Service Provider in consultation as appropriate with a Permit Issuer (or another equipment / plant owner representative) Enable identification of all hazards WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 6 of 59

7 Be used to determine resource requirements (people, materials etc.) and estimated time to complete the task Enable identification of which particular hazard control(s) is most appropriate (i.e. Work Permits / Certificates, Work Authorisation tags, Standard Work Procedures or THA). 7.2 Hazard Identification and Assessment Using the scope of work as a basis, the Service Provider shall make the initial identification of hazards associated with conducting the work and determine necessary controls. Assistance in developing this can be sought from the Permit Issuer or their representative. Tools used to identify necessary hazard controls will vary according to the risk exposure and range from application of TTTC to use of a THA and other risk assessments. Some hazard controls will be defined in a Standard Work Procedure and other work defined to be at the high-risk exposure level will require the increased level of rigour of a Work Permit and associated Certificates. The site criteria established for deciding when a Work Permit is required (see guidance in Table 1) shall be used to help in this process. Work that is determined to be low risk inspection of certain confined spaces or low risk hot work shall proceed with the use of Work Authorisation Tags as described in respective Appendices E1 and F1. Work that is determined as not requiring a Work Permit or a Work Authorisation Tag shall proceed with appropriate use of TTTC / THA / Standard Work Procedure controls and processes. The Service Provider confirms that a THA(s) or Standard Work Procedure(s) is available for the defined scope of work A final assessment of the number of Work Permits/Certificates required for the particular scope of work shall be conducted. Issues to be considered are: - The degree of confidence that the scope of work is complete - Whether multiple crews will work under a common Work Permit (see reference following) - If a Block Isolation is applicable (see section 7.5.2) - If Testing or jogging is applicable (see section 7.6.6). Work Permits shall be specific to the scope of work. Generally they are raised for discrete tasks and do not span several different work crews or unrelated tasks. However, a Work Permit can be raised for multi-disciplined crews conducting different work on the same equipment in the same geographical area, in certain circumstances. For example crews working on a autoclave, a bank of flotation cells or a conveyor system with little potential impact on other work activities can be covered under one Work Permit. Separate THA s or Standard Work Procedures would cover each of the different tasks. (Note that the Permit Acceptor shall accept this Work Permit on behalf of all separate work crews and must fulfil all of the normal accountabilities of the Acceptor). 7.3 Work Permit Document Preparation If a decision is taken that a Work Permit is required to authorise progress of defined work, the following shall occur: WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 7 of 59

8 Using a full knowledge of the scope of work and hazard controls necessary to complete the work, the Service Provider should commence filling out the first two Sections of the Work Permit and submit to the Permit Issuer (see Appendix B Work Permit form). This is best done as a consultative process between the Service Provider and the Permit Issuer (or other equipment/plant owner representative). The Permit Issuer shall review the Work Permit request (including the THA) and agree the final set of hazard controls. The Permit Issuer can include additional controls as appropriate. If the planned work incorporates any change (as defined in the EHS Management System Standard #5 Management of Change) the Permit Issuer shall confirm with the Service Provider that a Change Management Plan has been implemented. The Permit Issuer is not accountable for the management of the change management process, simply confirming that a change implementation plan is in place if required. If the Change has not been signed off, the Permit Issuer shall refer the Work Permit request back to the Service Provider. The Permit Issuer shall complete the necessary Work Permit document preparation (including any Work Permit Certificates) ensuring that all hazards due to workplace interactions or unique aspects are identified and controls indicated. 7.4 Workplace Preparation The Permit Issuer shall initiate implementation of the workplace hazard controls as identified in the Work Permit and Certificates. Hazard controls identified on the Work Permit/Certificates shall be carried out according to the requirements in their respective Appendices D1 to H1. Authorised personnel shall establish these preparations. 7.5 Work Permit Issue and Acceptance Work Permits The Permit Issuer shall confirm that all defined hazard controls have been established and that authorised signatories have completed Certificate requirements. The Permit Issuer shall confirm that the workplace is safe to commence work. This may involve a physical check of the work environment by the Permit Issuer or confirmation via a competent source. The Permit Issuer shall brief the Permit Acceptor (Service provider s representative for the work team) on the hazard controls in place. The Permit Issuer shall sign the Work Permit Authorisation section of the Work Permit (Note: the Permit Issuer shall not act as Permit Acceptor for the same Work Permit). Once the Permit Acceptor understands the hazard controls in place they shall sign the Permit Acceptance section of the Work Permit and take the original copy of all permit documentation (including any Certificates and THA/SWP) to the work site. The Work Permit original and associated documentation shall be clearly displayed in the Permit Control Board (see Section 7 of Appendix D1) at the work site. A duplicate copy of the Work Permit shall be retained in the Permit Office as a record of a live permit Work Permits with a Block Isolation When a number of different tasks are being completed under separate Work Permits with all tasks sharing the same Isolation Certificate, the isolation is called a Block Isolation (see Appendix D1 Section 4). WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 8 of 59

9 All Work Permits associated with a Block Isolation shall be recorded on a Work Permit Register by the Permit Issuer and signed on when issued and off when the Work Permit is closed (see Work Permit Register in Appendix C). No de-isolation of any points within the Block Isolation shall commence until all Work Permits have been signed off on the Work Permit Register by the Permit Issuer. Note: If a Testing Program is in place for any one of the Work Permits under a Block Isolation then all work shall cease and the procedure as defined in Section 9 of Appendix D1 followed. 7.6 Work Progression Work Commencement The Permit Acceptor shall brief the work team about the hazard controls already in place and any additional controls required for the job. The THA and Work Permit shall be used as a basis for this briefing. As part of this process the THA shall be given a final review The Permit Acceptor seeks to clarify any issues team members have about the hazard controls in place and asks them to sign onto the Work Permit to acknowledge the fact that they have been briefed, they understand the hazard controls in place and will comply with the requirements. The Permit Acceptor checks that controls are maintained during work progress. If any conditions are breached, all work shall cease and the Permit Acceptor shall refer the matter to the Permit Issuer. If the Permit Acceptor accepts multiple Work Permits they should not perform tasks as a working team member under any one of the Work Permits. Note: When energies are isolated as part of hazard controls, each work team member shall also attach their Personal Danger Tag with a lock to the Permit Control Board, as per the requirements of Appendix D1 Isolations Shift Handover If work covered by a Work Permit proceeds from one work shift to another, the following shall occur: The off going Permit Acceptor shall check that all work team members remove their Personal Danger Tag if energies are isolated A formal handover occurs between the off going and the new Permit Acceptor with respective signatures being recorded on the Work Permit. During this handover the new Permit Acceptor is briefed on the hazard controls in place and the status of work An informal handover between the off going and new Permit Issuer shall occur The new shift Permit Acceptor seeks to clarify any issues team members have about the hazard controls in place and asks them to sign onto the Work Permit to acknowledge their understanding and acceptance to comply with requirements Work Permit Relinquishment If a face-to-face handover from the off going to the new Permit Acceptor is not possible, then the following shall occur: The off going Permit Acceptor checks that all work team members have removed their Personal Danger Tag if energies are isolated The Permit Acceptor shall return the Permit Control Board to the Permit Issuer and provide a formal brief on work status and sign off in the Change of Permit Acceptor section of Work Permit The receiving Permit Issuer shall sign in the Relinquishment to Permit Issuer section of the Work Permit and indicate the reason WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 9 of 59

10 The off going / new Permit Issuers carry out a face-to-face hand over with a full brief on hazard controls in place and the general work status When the new shift Permit Acceptor is available the new Permit Issuer shall provide a face-to-face briefing on the hazard controls in place and re-issue the Work Permit by signing as the issuing Permit Issuer in the Relinquishment to Permit Issuer section. The Permit Acceptor accepts by signing in the Change of Permit Acceptor section of Work Permit. The new shift Permit Acceptor shall brief the work team members and ask them to sign onto the Work Permit prior to commencing work Scope of Work Change If the scope of work changes during work progress the Permit Acceptor shall consult their line supervisor and the Permit Issuer as necessary and together consider the impact of the proposed changes on the existing hazard controls in place and the potential for additional hazards. The THA shall be reviewed as part of this process. If this analysis indicates a need to change an existing Work Permit condition or the need for additional controls and the newly defined work is ready to commence, all work shall cease. The Permit Acceptor shall return the Work Permit to the Permit Issuer and indicate the scope of work change (the change is highlighted in Scope of Work section of Permit) and request any additional hazard controls. The Permit Issuer shall vet the request for additional controls and initiate implementation as necessary. These are recorded / added to the existing Work Permit and highlighted. When all additional hazard control preparations have been completed the Permit Issuer shall sign and date all changes made on the Work Permit. Authorisation is then provided to the Permit Acceptor for work to proceed. The Permit Acceptor shall take Permit documents to the worksite, brief the work team members on any changed hazard controls and indicate that it is safe to return to work Work Permit Suspension If there is a need to suspend work for a number of shifts due to delays in material or resource availability the following shall occur: Permit Acceptor leaves the worksite in a safe state, returns the Permit Control Board and associated documentation to the Permit Issuer with a briefing on reason for suspension and signs off the Work Permit The Permit Issuer signs in the Relinquishment to Permit Issuer section of Work Permit and records the reason for suspension When the Work Permit is required to be re-instated the, Permit Issuer arranges for an Isolation Checker to revalidate the isolations and sign the original Isolation Certificate The Permit Issuer shall re-issue the Work Permit by signing in the Relinquishment to Permit Issuer section of the Work Permit Testing When energies are isolated and there is a need to carry out testing or re-positioning of equipment during work progress and temporary removal of isolations is required, reference should be made to Appendix D1 Section Work Permit Hand-back When work defined in the scope of work is complete or there is a requirement to close the Work Permit, the following shall occur: The Permit Acceptor ensures the work site is left in a clean and safe state WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 10 of 59

11 If energies have been isolated, all work team members shall remove their Personal Danger Tags The Permit Acceptor shall return the Work Permit/documentation and Permit Control Board to the Permit Issuer and indicate that the work is complete and the equipment is fit to be returned to work or alternately, whether there are any restrictions on its use The Permit Acceptor shall sign the hand back section of the Work Permit The Permit Issuer shall assemble all of the Work Permit documentation and initiate the removal of hazard controls originally installed for the work to take place In the case of work done in a confined space the Permit Issuer shall inspect the confined space to ensure that removal of isolations and closure can proceed Once the work environment status has been returned to a state of readiness for return to normal duties, the Permit Issuer shall sign the permit closure section of the Work Permit on both original and duplicate copy The Permit Issuer shall file the Work Permit original and associated certificates in compliance with WMC Resources document retention policy. 8 RESPONSIBILITIES The following general roles have been identified within the System. Specific other roles have been identified and described in respective Appendices. 8.1 Permit Issuer Competency required: A detailed knowledge of the work environment and the process and area related hazards A competent knowledge of the isolation requirements for specific plant or equipment i.e. competent as an Isolator A competent knowledge of the Permit to Work System. Is responsible for: Reviewing the Work Permit request from the Service Provider and agreeing the final set of hazard controls for the defined scope of work Verifying that a change implementation plan has been implemented for Management of Change initiatives covered by the Work Permit Initiating implementation of the Work Permit hazard controls defined in Certificates. When isolations are involved, develop the Isolation Certificate/Instruction for the specific scope of work Maintaining control over the isolated equipment (through control of isolation padlocks) Confirming that all agreed hazard controls have been implemented and all necessary documentation signed off by authorised personnel Confirming that the work site is safe for work and that any operational activities do not compromise safety in the work area Briefing the Permit Acceptor on the hazard controls that have been put in place Authorising issue of the Work Permit Managing the Permit Issuer s lock and key cabinet (see Appendix D1 for details) Being aware of the work being carried out and any interactions from adjacent work activities or hazards Ensuring routine inspections of the work environment are carried out WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 11 of 59

12 Ensuring copies of all Work Permits are maintained in the Permit Office Handing-over the control of active Work Permits to a new shift Permit Issuer Initiating removal of hazard controls following hand back of the Work Permit Authorising closure of the Work Permit by signing off on both original and duplicate copies of the Work Permit Filing Work Permit documentation originals in compliance with WMC Resources document retention policy. 8.2 Isolator Competency required: Maintaining a technical and / or legislative ability to be able to perform and prove isolations A competent knowledge of the isolation requirements for specific plant or equipment A general knowledge of the Permit to Work System and a competent knowledge of the Isolations Procedure. Is responsible for: Establishing isolations of plant or equipment according to the Isolation Certificate/Instruction to prevent inadvertent re-energisation which may cause injury to others or damage to plant or equipment Note: In the situation in which the Permit Issuer performs the role of the Isolation Checker, the Isolator shall confirm that the Permit Issuer defined Isolation Certificate/Instruction is appropriate for the defined scope of work. De-isolating equipment according to Permit Issuer requirements. 8.3 Isolation Checker Competency required: Achieving the competency of an Isolator. Is responsible for: Confirming that the Permit Issuer defined Isolation Certificate / Isolation Instruction is appropriate for the defined scope of work Validating that isolation of energies has been completed according to the requirements of the Isolation Certificate/Isolation Instruction and the Isolation Procedure. 8.4 Service Provider / Permit Requestor Competency required: A knowledge of the System Understanding the work planning processes. Is responsible for: Developing a clear scope of work Making the initial determination of hazard controls required for work to proceed and initiating Work Permit documentation. 8.5 Permit Acceptor Competency required: A competent knowledge of the work to be completed as per the scope of work A knowledge of the System A competent knowledge of requirements for Certificates that they will accept. Is responsible for: Signing the permit acceptance on the Work Permit once they understand the extent of hazard controls that have been established Retaining the original of Work Permit documentation in the Permit Control Board at the work site WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 12 of 59

13 Briefing the work site team on the hazard controls in place and reviewing the THA Ensuring each work team member signs on to the Work Permit (and attach their Personal Danger Tag if energies isolated) Ensuring that work remains within the defined scope of work Ceasing work and informing the Permit Issuer when any hazard controls have been breached Handing over the work activity and Work Permit to a new Permit Acceptor at shift change or during work progress as necessary Relinquishing and suspending a Work Permit as required Inspecting the work site before commencing/recommencing work at end of shift or completion of work Confirming that the work site is left in a clean and safe state when work is completed Checking that all work team members remove their Personal Danger Tags when work is complete, if isolations have been involved When work is complete, returning the Work Permit documentation and the Permit Control Board to the Permit Issuer, providing a briefing on the status of work and signing off the Work Permit. 8.6 Work Team Member Competency required: Having a general understanding of the site System Completed a successful Area Induction. Is responsible for: Understanding the job scope of work and the hazard controls that have been implemented for the defined work Participating in the review or development of the job THA Signing on to the Work Permit and, if applicable, attaching their Personal Danger Tag to the lock box within the Permit Control Board Ensuring that hazard controls defined in the Work Permit/Certificates are strictly followed Leaving a clean and safe work site If isolations are involved, removing their Personal Danger Tag when work is completed. 8.7 Site General Manager Is responsible for: Authorising the implementation of this Standard across the site Approving the criteria for determining what work requires a Work Permit Approving the necessary competencies for personnel fulfilling roles. 9 REFERENCES AS2865 AS1596 AS1940 AS2430 Safe Working in Confined Space SAA LPG Code SAA Flammable & Combustible Liquids Code Classification of Hazardous Areas AS1674 Safety in Welding & Applied Processes AS6124 Electrical Apparatus for use in the Presence of Combustible Dusts AS2275 Combustible Gas Detection Instruments for use in Explosive Atmospheres Radiation Safety Act Radiation Safety (Transport of WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 13 of 59

14 Radioactive Substances) Regulations 1992 and various conditions imposed by the Radiological Council SP 25 High Voltage and Access Procedures EHS MS Management Standard #5 Management of Change WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 14 of 59

15 10 TABLE 1 Guide for When a Work Permit is Required Note: Each site shall decide and document which types of high-risk work require a Work Permit. This analysis shall be risk based and consider the type of activity as well as different geographical areas of the site in which the activity takes place. Tasks requiring level 2 isolation Work in Confined Spaces Work with High Voltage equipment WORK PERMIT REQUIRED Hot work in Classified Areas (Class 1, Zone 0 and 1) When isolating safety control systems or devices All work on ionising radiation sources and working within 1 metre of radiation source (dosage based assessment. For example, work in areas or with products that emit natural radiation are excluded) Excavation greater than 300mm in vicinity of buried services The following general criteria is provided to assist sites in deciding what other work requires a Work Permit: Work at heights Work in designated areas Work with special hazards Whenever swinging blanks or blinds in hazardous systems Work of high complexity Work involving inexperienced personnel. WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 15 of 59

16 APPENDICES APPENDIX A APPENDIX B APPENDIX C APPENDIX D1 APPENDIX D2 APPENDIX E1 APPENDIX E2 APPENDIX E3 APPENDIX E4 APPENDIX F1 APPENDIX F2 APPENDIX F3 APPENDIX G1 APPENDIX G2 APPENDIX G3 APPENDIX H1 APPENDIX H2 APPENDIX H3 PERMIT TO WORK OVERVIEW FLOWCHART WORK PERMIT FORM WORK PERMIT REGISTER ISOLATION PROCEDURE ISOLATION CERTIFICATE SAFE WORKING IN CONFINED SPACE PROCEDURE CONFINED SPACE ENTRY CERTIFICATE CONFINED SPACE ENTRY WORK AUTHORISATION TAG CONFINED SPACE ENTRY EVALUATION HOT WORK PROCEDURE HOT WORK CERTIFICATE HOT WORK WORK AUTHORISATION TAG RADIATION PROCEDURE RADIATION FLOWCHART RADIATION CERTIFICATE EXCAVATION PROCEDURE EXCAVATION CERTIFICATE EXCAVATION FLOWCHART WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 16 of 59

17 APPENDIX A A PERMIT TO WORK OVERVIEW FLOWCHART Work need identified Scope of Work developed including identification of hazards Area made clean and safe Work complete Permit Acceptor instructs team to remove their PDT / lock (if applicable) Permit Acceptor returns Permit Control Board and briefs Permit Issuer No Is a Work Permit required? Carry out work using TTTC, Work Authorisation Tag or THA / SWP tools Yes Hazard controls remain in place during work progress Permit Acceptor signs off Work Permit Agree safe work precautions and prepare permit documents Work commences Permit Issuer ensures all temporary hazard controls removed Implement workplace hazard controls Workteam signs onto Work Permit Workteam attaches PDT to Lock box (if isolations involved) Permit Issuer closes Work Permit Permit Issuer Briefs Permit Acceptor on hazard controls Permit Acceptor briefs workteam (ie. no briefing, no work) Equipment available for normal duty Work Permit and any associated certificates issued WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 17 of 59

18 APPENDIX B B WORK PERMIT WORK PERMIT No: Plant / Area : Equipment Description: Scope of Work: Equipment No.: Work Permit Register No.: THA / SWP No.: NO WORK OUTSIDE OF THIS SCOPE MAY BE PERFORMED UNDER THIS PERMIT SPECIAL PRECAUTIONS AND CONDITIONS Work Permit certificates Y/N Number Y/N Number Isolation Excavation Confined Space Entry Radiation Hot Work Testing Program Plant Change Applicable Any other conditions Work Permit Authorisation I acknowledge that all preparatory work has been completed and that work is safe to proceed. Permit Issuer: Signature: Date: Time: I fully understand the hazard controls in place for this work to proceed. Permit Acceptor: Signature: Date: Time: Work Permit Closure I confirm that the work is complete and the work environment is in a clean and safe state. Permit Acceptor: Signature: Date: Time: I have confirmed that work is complete and the job site is safe to return to normal duty. Permit Issuer: Signature: Date: Time: AUTHORITY TRANSFER, WORKER SIGN ON REQUIREMENTS ON REAR OF THIS FORM WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 18 of 59

19 WORK PERMIT SIGNATURES (Reverse of Work Permit) CHANGE OF PERMIT ACCEPTOR: I confirm that the hazard controls as stated on this Work Permit and attached documents will be strictly observed and all persons in my work team will be informed of them Dat e SIGN ON SIGN OFF Time Name Initials Date Time Name Initials RELINQUISHMENT TO PERMIT ISSUER All work has ceased and Work Permit returned to Permit Issuer for subsequent re-issue Receiving Permit Issuer Re-Issuing Permit Issuer Date: Name: Initial: Date: Name: Initial: Reason: Reason: Date: Name: Initial: Date: Name: Initial: Reason: Reason: Date: Name: Initial: Date: Name: Initial: Reason: Reason: WORK TEAM MEMBER: I have read, fully understand and will comply with all conditions stated on this Work Permit SIGN ON SIGN ON Date Name Initials Date Name Initials WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 19 of 59

20 APPENDIX C C WORK PERMIT REGISTER WORK PERMIT REGISTER Plant / Area : Overall Scope of Work: No: Isolation Certificate No. (Block Isolation): WORK PERMITS UNDER THIS BLOCK ISOLATION No. Work Permit No. Work Commences Permit Issuer Work Completed Permit Issuer Date Name Initial Date Name Initial Register Closure Permit Issuer: Signature: Date: Time: WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 20 of 59

21 APPENDIX D1 D1 ISOLATION PROCEDURE PURPOSE AND SCOPE The purpose of this Procedure is to minimise risk of injuries from an uncontrolled release of energy. It forms an integral part of the System and shall be read in conjunction with the requirements of the preceding section of this Standard. Isolation is the act of ceasing the flow of energy and installing a hard barrier to maintain integrity of isolation. This procedure covers isolation and removal of the hard barriers when work is completed. It does not cover the process of reinstating energies following work completion. This forms part of a recommissioning process and outside of the scope of this procedure. This Procedure applies to: All work with a risk of a hazardous release of energy Fixed and mobile equipment (including design, construction, commissioning, operation, maintenance, cleaning, modification or demolition of equipment) WMC Resources owned or controlled sites DETAILS 1. Levels of Isolation This Procedure addresses two levels of isolation to cater for the wide variation in complexity of plant and equipment. These are: Level 1 Non-recorded isolation Level 2 Recorded isolation Each level has different requirements and a competent and authorised person shall determine which level is appropriate to the work. 1.1 Level 1 Non Recorded Isolation This level of isolation is intended for routine work covered by a Standard Work Procedure or THA that describes the specific points of isolation as one component of the total task. Each Site shall identify what work is covered under a level 1 process Permission to carry out the task is verbal and a person carrying out the work performs the isolation and proves the integrity of such isolation(s). If more than one work team member is engaged in the work they shall confirm the integrity of all isolations prior to commencing work The isolation is not recorded on an Isolation Certificate. However it is recommended that a log of such work activities is maintained by the work environment owner An isolation tag is not required and instead a Personal Danger Tag shall be attached by a lock to each isolation point by all work team members Note: By itself Level 1 isolation does not require a Work Permit. However, some of the tasks carried out in association with Level 1 isolation may require a Work Permit. 1.2 Level 2 Recorded Isolation WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 21 of 59

22 All isolations are performed by an Isolator and checked by an Isolation Checker. This is a recorded isolation performed under the System. A written record is required on an Isolation Certificate and forms part of the documentation attached to the covering Work Permit. Note: When High Voltage or radiation sources are involved there is a need for specialist help and a need to demonstrate compliance with a legislated requirement then a High Voltage (HV) Permit according to requirements of SP 25 or Radiation Certificate will be required in addition to the Isolation Certificate. 2. Isolation Documents 2.1 Isolation Certificate An Isolation Certificate is a checklist and permanent record showing nominated isolation points and the precautions that have been taken to address special hazards associated with performing Level 2 Isolation (see Appendix D2). These can be manually generated or produced in electronic document controlled form (using the same Isolation Certificate format) for frequently executed isolations. For work on High Voltage equipment an additional SP 25 Permit(s) is required and a Radiation Certificate for work on or near radiation sources (See Appendix G3). These serve as checklists and permanent records indicating safe work precautions have been taken to address special hazards as per legislated requirements. When HV or radiation isolations are conducted the specific points are also recorded on the Isolation Certificate/Instruction. 2.2 Isolation Instruction An additional Isolation Instruction can be used for a complex isolation or an isolation that has to be done in a sequential order to bring the equipment to a state of zero energy for work to commence. It is attached to the Isolation Certificate that records the Instruction reference number. The Instruction shall include: The limits and extent of the isolation Any special conditions to be met (beyond those already specified in Work Permit) Specialist isolations required (eg. HV or Radiation) Isolation point information in the same format as the Isolation Certificate This Instruction shall be produced following a risk assessment, authorised by a senior line person and controlled within the sites document control system. It shall not be altered without proper authorisation by a senior line person. A procedure for authorising alteration shall be developed by the site. 3. Performing an Isolation Following advice from a Permit Issuer that as part of implementing agreed Work Permit hazard controls, isolation of energies is required: An Isolator shall confirm that the Permit Issuer prepared Isolation Certificate (and Isolation Instruction if attached) is appropriate for the defined scope of work (in the situation in which the Permit Issuer performs the role of an Isolation Checker) An Isolator shall carry out isolation of energies they are authorised to perform. Positive isolation of each isolation point must be proved An Isolator shall padlock each isolation point with a uniquely keyed isolation lock(s) and isolation tag cross referenced to the Work Permit number An Isolator shall sign the Isolation Certificate indicating that isolations have been achieved and proved. Isolators who isolate multiple isolation points on one Certificate may sign once only to acknowledge their work WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 22 of 59

23 A Permit Issuer shall arrange for an Isolation Checker to check completed isolations and sign on the Isolation Certificate (checking for correct isolation point as per Certificate/Instruction and that tag / lock are in place). If the Permit Issuer also performed the isolations as Isolator, then the Isolation Checker shall additionally confirm that the Isolation Certificate/Instruction as defined by the Permit Issuer is appropriate for the scope of work. Because the competency of the Checker is equal to the Isolator it is anticipated that the Checker will check isolation integrity as a part of the process The Isolation Checker shall be a different person from the person who performed the isolations (this person can be the Permit Issuer if they did not perform the isolations). An Isolator shall return the completed Isolation Certificate to the Permit Issuer and place the isolation lock key(s) in the Permit Control Board (see Section 7). A Permit Issuer shall ensure that all isolation key(s) are locked in place with an isolation tag (with the Work Permit number recorded) and uniquely keyed Permit Issuers lock. When a Testing Program (see Section 9) forms part of the defined scope of work, the following shall occur: The Isolator performs isolations following the standard method, but uses a different uniquely keyed lock(s) for the nominated testing points. The Permit Issuer places all non-testing point isolation key(s) in a separate lock box, apply an isolation tag and lock in place with a Permit Issuer lock. This lock box is placed inside the Permit Control Board. The remaining testing point isolation key(s) are placed in the Permit Control Board. 4. Performing a Block Isolation When a number of different tasks are being completed under separate Work Permits with all tasks sharing the same Isolation Certificate the isolation is called a Block Isolation. If the need for a Block Isolation has been established by the scope of work/hazard control analysis conducted by the Service Provider, the Permit Issuer initiates the standard isolation process. The Permit Issuer shall draw up a Work Permit Register and the number of this document is recorded on the Isolation Tag for use during isolations. Note: The Permit Control Board resulting from this isolation should be placed centrally as close to the common worksite as possible. When a large number of personnel are involved in work associated with a Block Isolation, additional Permit Control Boards may be used and placed closer to the specific worksite. In this situation the following shall occur: The Permit Issuer shall attach an additional Isolation Tag annotated with the specific Work Permit number and secured in place by a uniquely keyed Isolation lock to the central Permit Control board The key for this lock is placed in an additional Permit Control Board that is taken to the specific work site Following a Permit Acceptor briefing, each work team member shall attach their Personal Danger Tag and lock to the worksite located Permit Control Board prior to commencing work. 5. Cancelling an Isolation When work is complete and the Permit Issuer initiates the requirement to remove the isolation, the following shall occur: The Permit Issuer removes the Permit Issuer lock and Isolation Tag and provides the isolation key(s) to the Isolator WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 23 of 59

24 The Isolator commences removal of the isolations lock/tag(s) When all isolation locks/tags have been removed, the Isolator shall return the Isolation Certificate together with all locks/tags to the Permit Issuer The Permit Issuer shall confirm the number of locks/tags matches the Isolation Certificate requirements 6. Tags Isolation procedures shall use the following four tags: Isolation Tag Personal Danger Tag Testing Tag Out of Service Tag 6.1 Isolation Tag This is an instruction tag that indicates the equipment is in a state that prevents the flow of energy. The tag shall refer the reader to the person(s) or position(s) who are authorised to change the status of the equipment. The tag shall be locked in place at an isolation point with an isolation lock. When used to secure the isolation key(s) in the Permit Control Board, it is locked in place with a Permit Issuers lock. 6.2 Personal Danger Tag (PDT) This is an instruction tag indicating that there shall be no change in equipment status while this tag is in place. The tag shall be locked in place with a uniquely keyed lock All persons working on isolated equipment shall affix their PDT to the Permit Control Board before commencing work. Whilst any PDT remains in place removal of isolations shall not take place. Any person may place their PDT on any or all isolation point(s) affecting their safety. A PDT shall be removed by the owner before they leave the work site e.g. at shift end. Only the tag owner shall remove their PDT. If this is not possible, the site shall have a procedure in place for the removal of a PDT without risk to personnel..this procedure shall be authorised by the General Manager (or equivalent). 6.3 Testing Tag This is an instruction tag indicating to the reader that the isolations associated with the tag have been temporarily removed to allow testing to be carried out. The tag shall be tied onto the Permit Control Board and onto isolation points whilst testing. 6.4 Out of Service Tag This is an informational tag, indicating to the reader the equipment item shall not be used until cleared for safe operation by a competent person. When Out of Service tags are used, they must be secured in place. 7. Permit Control Board A Permit Control Board has the dual function of housing the Work Permit documentation and securing the isolation key(s) in a lock box. WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 24 of 59

25 Following isolations, all isolation keys common to locks used at specific isolation points shall be placed in the lock box section of the Permit Control Board The lock box shall be locked with an Isolation Tag and a Permit Issuer s lock prior to work team members attaching their Personal Danger Tags The key to the Permit Issuer s lock shall remain in a Permit Issuers key cabinet under control of Permit Issuers at all times The Permit Issuer shall not remove the Isolation Tag and Permit Issuer Lock from the Permit Control Board until the Work Permit has been handed back and signed off by the Permit Acceptor Removal of isolations shall not commence before all Personal Danger Tags have been removed from the Permit Control Board 8. Achieving and Securing Positive Isolation All equipment requiring isolation and all isolation points shall be uniquely and clearly identified Isolation shall always be applied to the energy source and not rely on control circuitry. Push buttons, stop switches, interlocks, emergency stops, pilot circuitry lanyards, etc. shall not be used as a means of isolation To achieve positive isolation the following steps shall be followed: Isolate and prove (By Isolator) Tag and lock (By Isolator) Test (By Permit Acceptor/Work team member) Effective mechanical and process isolations shall be achieved to a particular standard for all intrusive work. Energies associated with mechanical, kinetic, pressure and chemical processes shall be isolated to an acceptable standard. The method used shall be based upon risk assessment with the objective being to ensure that the risk of release of energies is reduced to as low as is reasonably practicable (ALARP). All parts of isolation shall be proved during installation to confirm that they do prevent the flow of energy. During the period that the isolation is in place it may be necessary to confirm that the integrity has not been compromised, by monitoring bleeds or vents for isolation breach. Isolation methods range from physical disconnection and insertion of blanks/spades to double block valve and bleed through to single block valve. Each method has advantages/disadvantages and the risk assessment shall be used to determine the most effective method. Proof of electrical isolation requires evidence of a physical break in the electrical supply. If the use of a de-contactor, visible break contactor or phase lights is not possible, electrician continuity testing is required to establish proof of isolation. All isolations shall be secured by use of a locking device and these locking devices shall require the use of a key or special tool to achieve removal. Isolation locks are uniquely keyed or keyed alike in sets. Personal Danger locks shall be uniquely keyed. Permit Issuers locks shall be uniquely keyed (Note: these locks and keys are best secured in a Permit Issuers cabinet with Permit Issuers retaining a common key to cabinet). Coloured padlock systems shall not be used under this procedure. A system of locking device and key management shall be defined by the site. WMC-EHS-MHS-007 DocsOpen Ref : Issued: 23/12/03 Page 25 of 59