Job Plan
CONTRACTOR
All Contractors
HAZARD
Unauthorized entry into the green
tagged area
WORK SCOPE AND AREA
Stub-in Inspection and Repair Works in Green Tagged Areas
CONTROLS
• Green tag notification and signage shall be placed on the
entrance around the fenced area.
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Caustic in the pipe line
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Contact with Caustic
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Fire
Molten metal
Welding/grinding sparks
Flammable or combustible materials
in the work area.
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Inhalation of weld fumes
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Exposed moving parts
Electrical hazard
Entanglement,
Exposure to heat,
Noise,
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ATA operation to drain and flush the line.
Issue the Lock Out Tag Out Verification Certificate after
verifying zero energy and place equipment isolation to ensure
lines are isolated.
Nearest safety shower shall be identified prior to start any
work in the caustic area.
Chemical suits shall be used while working directly on caustic
lines/removing any valve from the line.
No hot work whilst wearing chemical suit
Obtain Hot work permit from ATA Ops.
Provide relaxation to use normal glasses under the welding
hood at the time of hot work only inside the welding booth.
Welders/grinder to keep mono-goggle with them all the time.
Immediately after completing the welding/grinding, monogoggle to be worn instead of normal glasses. Welder/grinder
shall not come outside the booth without mono-goggle.
Removal of nearby combustible materials (such as flammable
liquids, wood, paper and plastics etc.)
Protection of nearby combustible materials that cannot be
moved by using suitable protection such as metal sheeting
and fire blankets.
Keep fire extinguishers at the work proximity.
Use of flame-resistant sheets or fire blankets to prevent hot
particles passing through openings.
Assigning trained fire watch during and after the work finishes.
No hot work whilst wearing chemical suit
When the work commenced in closed area without proper
ventilation, such areas providing with Local Exhaust
Ventilation.
Use of suitable respirator if required.
Trained and authorized operators to operate the grinding
machine
Rotating part guards must be provided and adjusted properly
to protect the employee and guards shall never be removed to
replace with larger disks.
Before use, check the manufacturer’s stated RPM on machine
and wheel. Always ensure the machine’s speed is at or below
the maximum operating speed (RPM) of the wheel.
Machine will not operate without checking the dead-man
switch.
Electrical cords are free from damages and keeping the
power cord away from the grinding wheel.
Use of both hands when operating the grinder.
Not using foot, hand, or any part of body to secure the object
Page 1 of 9
Job Plan
•
Possible Life Critical
while in the process of grinding.
Avoiding loose clothing during the grinder operations
Possible actions to prevent life critical breach
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Permit
LOTO
•
Defeating Safety Devices
Equipment
•
Never conduct a high-risk activity without an approved and
valid permit in place.
Comply with all permit requirements.
Never commence work until all energy sources have been
identified, isolated and tested for dead in accordance with the
LOTO procedure.
Never disable, bypass, modify or remove any safety protection
device without proper authorization (Removing rotating
equipment guards, removing equipment/tool handles etc.)
Never operate mobile plant or vehicles or use equipment
unless trained and authorized to do so (Using a hand-held
grinder without training and authorization from your Employer,
using a 7-inch grinder when you are not a tradesperson or
without training and authorization).
EMERGENCY PREPARATION
• In case of emergency all personnel to assemble at nearest assembly point adjacent to the work area
(remind personnel as part of STARRT Card) and in case of chemical/caustic burn/exposure, follow
emergency protocol stated on page 09.
• All injuries – initial first aid to be provided by first aider, call EGA Emergency number 02 509 2222.
• Report all incidents/injuries to BPJV Superintendent and ES&H Representative.
PEOPLE:
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Welders
Grinders
Frontline Supervisors
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Helpers
Technician / Electrician
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Caustic awareness training
Personal lock training
SPECIALISED TRAINING:
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ATA Green tag induction
Power tools training
Receiving authority training
EQUIPMENT/MATERIALS/TOOLS/HAZARDOUS SUBSTANCES:
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Welding machine
Electric generator
Power tools
Electrical generator
DRAWINGS/PERMITS:
• ATA Ops permits and associated certificates (LOTOV)
• Mark UP P&ID’s
• Approved Method Statement and Task Risk Assessment
CONTRACTOR ESH REVIEW
Name:
Position:
Signature:
Date:
Signature:
Date:
Signature
Date:
CONTRACTOR CONSTRUCTION REVIEW
Name:
Position:
CONTRACTOR SITE APPROVAL
Name:
Position:
Page 2 of 9
Job Plan
Permitting Process for Stub-in Work in Green Tagged Area
Permitting Process for Stub-in Work in Green Tagged Area
BPJV and Contractor
ATA Operation
Permit
Receiving
Authority
identify the task and apply
permit to work for stub-in work.
A marked-up P&ID along with
clear scope of work submitted
to
ATA
Operation
whilst
applying for Permit
ATA Operation identify
the required isolation/
bypass for the requested
stub-in repair work
Permit receiver verify the
isolation, zero energy and other
testing prior to accepting permit
to work from ATA Operation.
Conduct joint walk down and
ensure
that
equipment
identification sticker hanged on
all the isolated equipment
No
Is line contain caustic or
other hazardous
substance?
Permit receiver follow the
secondary LOTO protection flow
chart (refer the sheet 1) and
ensure that all individual places
their personnel lock.
No
Yes
Perform line flushing and
lab testing
Is lab test result for caustic
satisfactory?
Yes
Drain the line and verify
zero energy
The Supervisor along with crew
reconfirm that all the drains/
vents are in open condition and
pipe line contains no liquid
residue.
Complete the final
isolation and Permit to
work and handover it to
BPJV/Contractor
The crew proceed for the line
cutting or removal of valve as
per the condition
Use full chemical suit to dismantle
the valve, or inspection of line.
Is there risk of
trapped caustic?
Yes
No
For hot work to cut the line, keep
your body away from line of fire (use
work platform to keep your body
elevated) with hot work PPE’s. No
chemical suit require
Flush the dismantled valve and/or
pipe spool with water and test the
surface
with
PH
kit.
Upon
satisfactory result, apply a tag stating
that valve/line re-flushed and safe to
commence the welding /other repair
work.
Perform necessary repair work
as per approved MSRA and
Permit to work
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Job Plan
JOB STEPS – Stub-in Inspection and Repair Works in Green Tagged Areas
Task & Key Controls – Documentations and Pre-use Inspection
Method Statement and Risk Assessment
(MSRA)
prepared
by
contractor
and
BPJV/EGA/ATA approval obtained.
Permit Receiving Authority marked-up the P&ID is
prepared and submitted to Permit Issuing authority
for the location of the works and the system that
need to be worked on.
No picture available
Email communication or verbal approval.
ATA Operation performs line flushing (as
applicable) to remove any caustic residue from
the pipe line or other system.
BPJV Superindentent verifies with ATA Operation
that the required line has been flushed inorder to
remove any caustic residue
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Job Plan
Mechanical Isolation performed by ATA
Operation and zero energy verified. All the drains
Electrical Isolation performed by authorized are kept in open condition and drainage confirmed
electrical person of ATA Operation and zero tag (green tag) attached to the drain valve. In
energy verified.
addition, equipment identification tags (yellow tag)
are hung on the valves/equipments where work to
be performed.
ATA Isolation officer verifies and issues final
LOTOV certificate and Issuing Authority complete
the Permit to Work based on the marked-up P&ID
submitted by the Receiving Authority.
Permit Issuing Authority (IA) and Receiving
Authority (RA) conducts joint walkdown on the
system and confirm that all the isolation points
have been identified and locked. Permit
boundaries understand and ensure the
equipment identification tag available for the
equipment being worked
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Job Plan
ATA permit Issuing authority handover the permit
with card safe to Receiving Authority
The Permit Receiver conduct STARRT meeting
with the crew and brief the permit conditions
All involved parties place their personal locks on
the card safe.
All involved parties signed on the personal lock
placement register
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Job Plan
Card safe in placed on the work location.
Full chemical PPE shall be worn when removing
valves from a line where caustic residue may
present.
Task & Key Controls – Commencement of Work
As far as reasonably practicable work from an
elevated position when removing valves so as to
avoid any caustic spill (keep body away from line
of fire from caustic)
Once valve is removed it shall be again flushed
with water to get rid of any caustic residue.
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Job Plan
Receiving Authority and area ES&H shall verify
with a pH kit that the valve/pipeline is free of
caustic residue and it can be worked on with
normal caustic PPE.
If caustic is present, then the pH kit will give the
same reading as the yellow highlighted circle (10
-14). Then water flushing shall continue till the
reading comes down to 7-8
Permit receiver shall place a tag on the valve
(tag shall state that the valves is flushed with
water and safe to commence the hot work).
Then the fabrication crew can start working on
the stub in repair.
Hot work commenced as per aproved MSRA with
adiditnal Hot work PPE’s. Welders/grinder to
keep mono-goggle with them all the time and
perform the hot work inside the welding booth.
Immediately after completing the welding
/grinding, mono-goggle to be worn instead of
normal glasses. Welder/grinder shall not come
outside the booth without mono-goggle.
Page 8 of 9
Job Plan
Emergency Protocol for Chemical/Caustic Exposure
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Move away from danger
Immediately remove any contaminated clothing, remove mud etc. with gloved hand
Leave mono goggles on if eyes not contaminated
Spray the affected area with DAP as quickly as possible. Get from other if additional DAP is
required.
Immediately get to the nearest Safety Shower and activate the shower.
Alert others/activate emergency button at safety shower.
Continue staying under the shower for a minimum of 20 minutes or till emergency services
arrives.
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