5-Star Safety and Health

Management System
MECHANICAL WORK PERMITS
Date: 26/04/2014 (V2) Revision: Pages: 20
1.4, 1.15,
Element: 5.21 Safety Manual: OHSAS:
4.2

Purpose
To ensure employees' safety and to protect property from potential hazards when performing
tasks by maintaining an integrated system to identify responsibilities and accountabilities for
issuing, receiving, transferring and closing mechanical work permits

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1. Objective
To ensure employees' safety and to protect property from potential hazards
when performing tasks by maintaining an integrated system to identify
responsibilities and accountabilities for issuing, receiving, transferring and
closing mechanical work permits.

2. Scope
This Standard should be applied to all SEC and its subsidiaries mechanical
works such as Hot work, cold work, confined space entry and release of
flammable gasses or liquids work

Any instructions or procedure issued through any party and related to work
permit procedures or forms should not conflict with this standard.

This standard supersedes any previously issued General Instruction concerning

work permits.

3. Definitions
3.1. Issuer

An SEC employee who has been trained, qualified and authorized to issue /
close work permits for work which falls under his department / division
responsibilities and he possesses a valid issuer card.

3.2. Receiver

An SEC / Contractor employee who has been trained, qualified and

authorized to receive / transfer / close work permits and he possesses a
valid receiver card)

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3.3. Work permit

An official authorization document issued by (an issuer) to ( a receiver) in

order to perform a specified work in a restricted area.

A work permit is considered an official record that includes the conditions

and requirements that have been agreed to between the issuer and the
issuer.

The work permit prescribes the minimum safety requirements and

precautions for the task.

3.4. Isolation

Documented procedures which are performed in order to secure the site,

equipment and employees’ safety before issuing the work permit for either
mechanical or electrical works.

3.5. Mechanical isolation Program (Mechanical Clearance)

Procedures by which a portion of the facility is isolated and kept safe for
performing a task.

Examples:

 Opining /closing of valves,

 Liquid / gas pressure venting or draining

3.6. Mechanical clearance Number

This number is issued by operation division and must be written on the Work
Permit Form (WPF) when issuing the permit.

3.7. Restricted areas (permit required areas)

Areas, tasks and facilities which require a work permit when work is to be
executed within these areas, it include:

3.7.1. Facilities and equipment for generation, transmission and distribution

of electric power

3.7.2. Areas where flammable liquid / gas or oxidizing agents are handled,
stored, piped, or processed in significant quantities.

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 3.7.3. Any area (or task) that has the potential for hazardous conditions
such as working in or around:

Examples:

power plants, switch yards, fuel pipelines, storage tanks, hydrogen

tanks and pipelines, gasoline service stations, water or sewage
treatment plants, areas where explosive or radioactive materials are
used or stored substations, overhead lines, bulk supply consumer
service equipment, electric poles/towers, transformers, Ring Main
Units "RMU's", underground and overhead cables (above 480 volts),
electrical manholes,

3.7.4. An Electrical Work Permit is Required for any conditions mentioned

above that involves:

3.7.4.1. Any work on energized equipment

3.7.4.2. Any work or maintenance on de-energized equipment

3.7.4.3. Work near electrical lines / equipment

3.7.5. Department managers have to designate all restricted areas within

their departments and maintain a list of these restricted areas.

4. Responsibility and Accountability

4.1. Manager, Supervisor and Contractor

It is the responsibility of the Manager, Supervisor or Contractor to:

4.1.1. Implement this Standard in all restricted areas

4.1.2. To ensure that their employees are trained and qualified to execute
the assigned works

4.1.3. To assign the issuers / receivers of work permits and to ensure they
are in possession of valid issuer's / receiver's cards

4.1.4. To ensure the provision of the needed work permit forms and hold
tags and locks.

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 4.1.5. To apply a request of there needs of Work Permit Forms to industrial
security Department (Occupational Safety & Health) in the operating
areas

4.2. All Managers, Supervisors, Contractors and Employees

4.2.1. Any employee, manager, supervisor, contractor or safety engineer /

inspector has the right to stop the work when this Standard is
violated.

4.2.2. All SEC employees and contractor employees must abide by the
requirements of this standard.

4.2.3. To prepare and organize procedures for training and qualifying the
issuers and receivers. And to prepare the training material for this
Standard's training.

4.2.4. To organize and conduct the required training sessions on work

permit procedures to qualify / re-qualify (certify / recertify) work
permit issuers / receivers.

4.2.5. To issue authorization cards for issuers and receivers who

successfully pass the work permit course test. The card is valid for
(2) years.

4.3. Industrial Security Department (Occupational Safety & Health):

4.3.1. The industrial security Department (Occupational Safety & Health)

will supervise the printing and distributing of the work permits forms
and make them available

4.3.1.1. The Industrial Security Department (Occupational Safety &

Health) in the operating areas will receive the needed
quantities of work permit forms and will distribute the forms
to the proponent.

4.3.1.2. The Industrial Security Department (Occupational Safety &

Health) in HQ will supervise the printing of work permit
forms.

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 4.3.2. Conduct regular inspections to monitor the implementation of this
standard as part of the inspection and audit process.

4.4. Issuers and Receivers

Issuers and Receivers should carry their authorization cards at all times in
which they issue or receive work permits.

They should retain their authorization cards with them during the validity
period of permit, for inspection and audit purposes.

5. Work that Requires a Mechanical Work Permit

Mechanical (non-electrical) work such as inspection, performing tests,
maintenance, repair, storing / handling combustible materials in restricted areas
which could be accompanied by hazards.

5.1. Hot Work

5.1.1. Hot work is any temporary operation being performed outside of the
controlled confines of a workshop area, involving open flames, or
producing heat and / or sparks. This includes, but is not limited to:
Brazing, Cutting, Grinding, Soldering, Torch Work, Welding. Sand
blasting, using tools which produce sparks (drill, electrical engine) or
any operation or equipment which produce heat such as halogen lamp.

5.1.2. Electrical switching in areas that contain flammable environments are

considered as hot work situations.

5.2. Confined Space Entry

Work requiring entry into a confined space for inspection, cleaning,

mechanical or electrical maintenance or repair requires a Confined Space
Entry Permit.

5.2.1. Confined spaces:

5.2.1.1. Not designed for natural / continued worker occupancy.

5.2.1.2. Have limited or restricted means for entry or exit.

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 5.2.1.3. Have poor air ventilation.

5.2.1.4. Are large enough and configured so that an employee can

bodily enter and perform the assigned work

5.2.1.5. May contain a hazardous atmosphere

5.2.2. Confined space hazards:

5.2.2.1. Toxic gases.

5.2.2.2. Flammable gases.

5.2.2.3. Oxygen deficiencies (less than 20%) or over rich (more

than 22.5%).

5.2.2.4. Mechanical or electrical hazards and others

5.2.2.5. Difficult retrieval and rescue situations

Examples:

Tank entry (water / fuel), sumps, sewers, manholes, holes / trenches

of 1.2 m deep or more, turbines combustion chambers, boilers, etc.

5.3. Release of Flammable Gases / Liquids:

Release of flammable gases or liquids from tanks / containers / pipes is

accompanied by the risk of fire, poisoning or suffocation and requires a
Release of Flammable Gases Permit.

Examples:

Releasing fuel from tanks or pipes for repair / maintenance or

repairing a pump on a fuel pipe.

5.4. Cold Work Permit

Cold work includes all work in restricted areas which does not include the
use of heat sources or sources which produce sparks and flames, and are
not classified as electrical, mechanical, hot work, confined space entry or
release of gas permit-required tasks. Cold Work requires a Cold Work
Permit.

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 Examples:

Water pump maintenance, manual excavation, painting, work at height, X-ray or

Gamma tests (considered as a hot work if done in flammable environments).

6. Mechanical Work Permit, (Work Permit Form 5.21.3)

The mechanical work permit form includes the (4) mentioned above mechanical
works that require a work permit, and it is a permit and checklist that, when
completed and issued, ensures that the work area has been inspected and that
all precautions for potential loss have been taken for the following permits:

6.1. Hot Work Permit:

To prevent fire or explosion occurring and to allow open flame work or other
hot works to be done and the issuer and receiver verify that the hot work is
necessary.

6.2. Confined Space Entry Permit:

To allow the confined space safe entry and exit and to protect the entrants
from all confined spaces hazards.

If there is more than one entrant, the Entry – Exit list must be filled
(attachment 5.21.5)

6.3. Release of flammable gases or liquids Permit:

To prevent the risk of fire or explosion occurring and to prevent any hot work
in the work area during the validity period of the permit

6.4. Cold Work Permit:

To allow work safely for the cold work by taking all necessary safety
precautions.

6.5. Diving:

Underwater inspection or repair at outlets / inlets of sea water demands a

diving work permit. Diver must possess a valid diving license from an
approved agency.

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7. Training, Qualification and Authorization Procedures
7.1. Mechanical Clearance

Manager and Supervisor must be ensure that the issuer and receiver of the
mechanical clearance have been trained and qualified and authorized by
their departments. And to ensure issuing the authorization card of switching
program for issuer / receiver. This cards will be issued by their departments.

7.2. Work permit

7.2.1. Managers, Supervisors And Contractors:

7.2.1.1. Ensure that the personnel who are assigned to mechanical

works have the proper technical training and skills to
execute the assigned work.

7.2.1.2. Ensure that their employees understand the safe work

procedures and have the capability to deal with risks that
may arise during the execution of the work.

7.2.1.3. Ensure that issuers / receivers of work permits have the

necessary training and have attended the work permit
course and are in possession of valid cards.

7.2.1.4. To authorize Issuers and Receivers (who successfully pass

the work permit course) to execute work according to the
authorization given to them and documented by their
departments / division. This authorization:

7.2.1.4.1. Will be printed at the issuing / receiving card.

7.2.1.4.2. To maintain and update the records of qualified

issuers and receivers who must be re-qualified every
(2) years, and to keep updated records thereof.

7.2.1.5. To nominate and authorize (as a sponsored department)

the contractors' personnel who receive work permits to
attend the work permit course only as receivers. This
authorization will be printed on the back side of the receiving
card.
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8. Procedural Requirements Before Issuing a Mechanical Permit
These precautions are taken before starting the work and before issuing a
Mechanical Work Permit to ensure that the work to be undertaken will not affect
the safety of personnel or property.

8.1. Mechanical Clearance

The mechanical clearance is performed by:

8.1.1. All energy sources must be Isolated and verified thereof.

8.1.2. Locking, and placing hold / warning tags and safety locks at the
points of isolation in a defined and specific way, to make the
condition safe to perform maintenance / repair / tests or other work

8.1.3. The mechanical clearance is issued only by a trained, qualified and

authorized issuer to a trained, qualified and receiver

8.2. Gases tests

8.2.1. Gas tests are to be conducted where necessary as indicated on the

permit (when needed for confined space entry or work in an area
containing flammable gas or liquid).

8.2.2. Gases tests form must be filled (5.21.4).

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8.3. Lockout – Tag out, Try out Procedures

Lockout – Tag out, Try out, means isolating the sources of energy then
placing locks and tags on the specific control equipment, then testing to
ensure all sources of stored energy are isolated correctly

8.3.1. Lockout devices

8.3.1.1. Approved lock out devices must be placed on electric /

mechanical controls / devices / circuits (disconnects) once
these connects have been switched off to prevent the
accidental operation or release of any energy source such
as electrical, mechanical, pneumatic, hydraulic, steam, etc.

8.3.1.2. Tests must be conducted after isolation to verify that the

correct equipment or circuits have been identified and that
they are in fact locked out.

8.3.1.3. Each person working on the source of energy shall apply

his own lock and affix his own tag to the equipment
isolation points. Safety lockout hasps allow for more than
one padlock in these situations.

Lock Out Hasps for Multiple Locks Mechanical Padlock, Hasp and Hold Tag
Mechanical locks shall always be used in conjunction with a hold tag on all occasions

8.3.2. Hold Tags

A hold tag must contain the following information:

8.3.2.1. Name of person applying the lock.

8.3.2.2. Date of lock out.

8.3.2.3. Reason for lock out.

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 Hold Tag
8.4. Work Permit Issuer's Responsibilities:

For safety purposes, the issuer must verify and ascertain the following
before issuing the work permit:

8.4.1. To execute and verify the mechanical isolation.

8.4.2. To obtain the Mechanical clearance number (CN)

8.4.3. To conduct gas tests where necessary as indicated on the work

permit.

8.4.4. To ensure that Lockout – Tag out, Try out Procedures have been
performed correctly.

8.4.5. To verify that cranes and lifting equipment to be used should have
valid inspection stickers, and the operator must possess a valid
operator's license

8.4.6. The issuing party (issuer) has the right to request a list of workers
who are working with the authorized receiver if the receiver is not
SEC employee.

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9. Work Permit Issuing / Receiving / Transferring / Handling and Closing
procedures.
These are procedures taken before, during and after executing work to ensure
that the work procedure follows all safety precautions required to ensure that
workers or property are not put at risk.

9.1. Issuer's Responsibilities

9.1.1. To ensure that all needed safety equipment such as barriers /

barricades are provided to secure the safety of workers and others.

9.1.2. To stop the work any time if conditions become unsafe and cancel
the permit.

9.1.3. To take the necessary action to correct the status

9.1.4. To allow restarting the work after all safety requirements are met and
issue a new permit.

9.1.5. To ascertain that all personnel / material / tools / equipment that are
not necessary and may create hazards to personnel / equipment are
kept away from the job-site

9.2. Authorized Receivers Responsibilities:

9.2.1. To perform the work safely and maintain his own safety as well as
that of those who work with him

9.2.2. To ensure that all required tools and equipment including personal
protective equipment are provided and in are in a good condition.

9.2.3. To coordinate with the issuer before starting and after completion of
the work.

9.2.4. To stop the work any time he feels it is not safe and to inform the
issuing party / issuer immediately upon stopping the job

9.2.5. To take the necessary action to correct the safety deficiencies.

9.2.6. If the work permit is cancelled due to unsafe conditions he must

obtain a new permit once the conditions are rectified.

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9.3. Before issuing:

9.3.1. Before starting any work in a restricted area, the executing receiving
party (maintenance / repair technician in charge) will request the
proper work permit from the issuer (operation)

9.3.2. For safety purposes and before issuing the work permit, the issuer
must verify and ascertain that the issuer possess:

9.3.2.1. a valid up-to-date receiving card and approved for the type
of work to be executed,

9.3.2.2. a valid up-to date personal SEC-ID card, or a temporary

authorization from the Industrial Security Department

9.3.3. The issuer has the right to ascertain the validity of the issuer's
certificate.

9.4. Issuing

9.4.1. A clearance number must be obtained before the permit can be

issued

9.4.2. The issuer must familiarize himself with the work area or site and
confirm that the work can be done safely.

9.4.3. The issuer must visit the site before the permit can be issued and
issuance by telephone or fax is not acceptable.

9.4.4. The issuer and the receiver will conduct a joint inspection of the site
to determine existing and potential hazards and plan for executing
the work safely.

9.4.5. Any abnormal conditions and required a special precautions must be

noted on the work permit. The issuer will fill in the portion "additional
/ special precautions" where necessary. These special precautions
must be followed by the receiving crew

9.4.6. After ascertaining that the facility and the job site are safe for workers
and that the work can be executed in a safe manner the issuer may

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 issue the work permit to the issuer by completing the issuer sections
of the work permit form

9.4.7. Both the Issuer and the Receiver must have their authorization cards
with them during the issue.

9.5. Receiving

9.5.1. The issuer will receive the work permit at the job site by completing
the receiver's portion of the work permit.

9.5.2. The receiver's signature on the work permit implies his complete
acceptance of the conditions that are mentioned in the work permit
and that all safety precautions have been taken

9.5.3. In case of long term tasks such as (Major changes or construction

Comprehensive maintenance):

9.5.3.1. One work permit that includes all required tasks to be

executed can be issued, on condition that all tasks are
under the supervision of one person.

9.5.3.2. If any new tasks are to be executed and are not listed in the
main work permit, a new work permit must be issued for
those tasks.

9.5.4. The issuer can receive more than one work permit providing that the
work permit is specified for a certain job.

For example:.

 confined space entry needs a work permit to enter the confined

space, and a separate work permit for the assigned task

 for more than one task in adjacent area

9.6. Work permit duration period

9.6.1. The work permit is issued for a period that is agreed upon by the
issuer and the receiver, this period should not exceed the normal
work shift except in the following cases:

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 9.6.2. For more than one shift but not more than (7) days, the issuer and
the issuer can sign the work permit.

9.6.3. For more than (7) days but not more than (30) days, the supervisor of
operations must issue the permit and the supervisor of maintenance /
construction must receive the work permit.

9.6.4. For more than (30) days but not more than (120) days, the operation
division manager / section head must issue the permit and the
division manager / supervisor of maintenance / construction must
receive the work permit.

9.6.5. Both parties must agree on the way of executing the work in a safe
manner and agree to stop the work when it is unsafe until the unsafe
conditions have been made safe.

9.7. Procedures for Transferring Work Permits

In case the receiver is replaced during the validity of the work permit, the
outgoing receiver must inform the a issuer about this change (and the
issuer's approval should be obtained) and transfer his authorization to
another receiver (the incoming receiver) as is detailed below:

9.7.1. The outgoing receiver must discuss the safety aspects of the job
being undertaken with the incoming receiver.

9.7.2. The incoming and outgoing receivers must conduct an inspection to

determine the safety of personnel and facilities

9.7.3. The transfer must be documented by the outgoing receiver and the
incoming i receiver on the specified portion in the work permit.

9.7.4. The outgoing receiver will release his responsibility by completing the
outgoing receiver portion of the work permit.

9.7.5. The incoming receiver will accept the responsibility of continuing the
job safely by completing the incoming receiver portion of the work
permit.

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 9.7.6. The outgoing receiver must inform the issuer of the incoming
receiver's name and the badge number as soon as responsibility is
transferred.

9.7.7. If the incoming receiver is not satisfied with the safety of the worksite,
he can ask the outgoing receiver to close the work permit and
request a new work permit once the site has been made safe.

9.7.8. In case the issuer is replaced during the validity of the work permit,
the outgoing issuer must inform the incoming issuer about all permits
issued and any special instructions issued to receivers. Receivers
should be notified of this change.

9.8. Handling the Work Permit

9.8.1. The receiver must display the correctly filled in permit at the job site
for the entire period of the job so that it is open for safety inspection
and audit. Plastic weather-proof envelopes are ideal for this purpose.

9.8.2. If a valid permit is not displayed at the site, the site will be shut down
immediately and workers will be removed from the site.

9.8.3. The receiver must stay at the job site throughout the entire period of
the work permit. If he leaves the job site for a short period of time
(not more than 2 hours) with the permission of the issuer, and his
absence does not contradict the requirements of the permit, he will
delegate the work permit to another crew member who will be the
receiver until he returns.

9.8.4. If the absence is more than (2) hours, the work permit must be
transferred to a new receiver

9.8.5. If the job is not completed by the end of day, the receiver is
responsible to ensure that there are no safety hazards at the job site
before leaving the site.

9.8.6. During the entire period of the work, it is the duty of the receiver to
conduct frequent inspections to ensure the safety of his personnel
and the facility while the work is in progress.

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 9.9. Emergency Procedures

9.9.1. The issuer has the right to cancel the work permit at any time if
conditions become unsafe to continue work.

9.9.2. When work is stopped for safety reasons, both the issuer and the
receiver must close the work permit.

9.9.3. When conditions are safe again, the issuer must issue a new work
permit.

9.10. Procedures for Closing the Work Permit

9.10.1. Before closing the work permit, both the issuer and the receiver will
conduct a joint inspection to ensure that the work has been
completed and the conditions are safe to close out the work permit.

9.10.2. The work permit will be closed out by the signature of both the
receiver and the issuer after the work has been completed and after
ensuring that all personnel, equipment, tools and waste has been
removed from the job site.

9.10.3. The work permit is closed out by the last receiver who completed
the work permit by filling in the "Closing the Work Permit" portion of
the permit form and by the last issuer who also completes the
"Closing the Work Permit" portion of the permit form.

9.10.4. In case of emergency, or if the receiver is not present, the division

manager / section head or receiver's supervisor will close out the
work permit.

9.10.5. The closed out copy should be returned to the issuer immediately
after completing the job. If the work permit has been transferred to
another issuer, the work permit will be closed by last issuer.

10. Return To Service procedure

The person in charge of the facility must ascertain that all personnel are free of
exposure to dangerous conditions that may result when returning the facility to

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 service, and that isolated mechanical equipment or grounded equipment are
prepared for return to service.

11. Work Permit Filing Procedures

The issuing party / issuer must keep the closed out original copy of the work
permit for a minimum of (3) months.

12. Document Retention

This document needs to be kept in the Safety and Health Management System
(5-Star) files and made available for auditing purposed.

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 EXAMPLE ONLY DO NOT USE

Figure1

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5.21.4

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5.21.5

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