PERMIT SYSTEM Soehatman Ramli
Latar Belakang • Lingkungan industri khususnya yang mengelola bahan berbahayasangat rawan terhadap bahaya kecelakaan. • Pada umumnya kecelakaan terjadi pada pekerjaan pemeliharaan. • Perlu pengawasan dan pencegahan yang baik melalui sistem ijin kerja
Philosophy Ijin Kerja Tujuan sistem Ijin Kerja • mencegah kecelakaan • mencegah kebakaran dan peledakan • mencegah gangguan terhadap proses produksi dan lingkungan sekitarnya. • Melindungi manusia dan peralatan akibat kondisi berbahaya
Manfaat Ijin Kerja • Perlindungan Tenaga Kerja • Mencegah kerugian akibat kecelakaan • Meningkatkan sikap tanggungjawab dan disiplin kerja • Perlindungan hukum (claim) jika terjadi kecelakaan • Sebagai dasar penyelidikan kecelakaan • Sebagai alat kontrol – pengawasan K3 • Meningkatkan kinerja K3 perusahaan
Safe Work Permits Safe Work Permit
Permit #
Type: (hot work, confined space, line break, etc....
location:
Valid __/___/___ ____ From: M D Y time
Issued to:
to
__/___/___ M D Y
____ time
Work Description: ____________________________________________ ____________________________________________ ____________________________________________ Atm Combustible vapors or gases (<10%) Tests
________________________________ Supervisor’s Signature Print name Work Order No.
Oxygen Concentration (>19.5% & <21%)
Toxic Material Concentration
Precautions Always Required:
Tujuan sistem ijin kerja adalah untuk mengidentifikasi semua bahaya yang berkaitan dengan pekerjaan non rutin, dan memberikan pengamanan untuk mencegah potensi bahaya yang timbul
Sasaran Permit System • Melindungi peralatan dari kerusakan • Mencegah bahaya kebakaran • Memastikan pekerjaan dilakukan dengan cara yang aman • Memberikan arahan mengenai cara yang aman dalam melaksanakan pekerjaan
WORK PERMIT REQUIREMENT Permit diperlukan untuk pekerjaan berikut ini : • • • • • • • •
Major & Minor Maint. work. Inspection. Construction. Alteration. Process Equip. cleaning Entry into confined space. Excavation Vehicle entry into hazardous areas etc.
Jenis Ijin Kerja 1. 2. 3. 4. 5. 6. 7. 8.
Ijin Kerja Panas – Hot Work Permit Ijin Kerja Dingin – Cold work Permit Ijin kerja penggalian _ Digging Permit Ijin Kerja Masuk Ruang Tertutup – Entry Permit Ijin Kerja Radioaktif Ijin Kerja Listrik Ijin Kerja di ketinggian Dsb.
Prinsip Permit System THE FIRE TETRAHEDRON
FUEL
TEMPERATURE
Prinsip Ijin Kerja Bahan bakar
Oksigen
Panas
1. Mengendalikan Bahan Bakar 2. Mengendalikan Panas 3. Mengendalikan Oksigen
Prinsip Ijin Kerja Mengendalikan Bahan Bakar Bahan bakar
• Mencegah atau mengendalikan adanya sumber bahan bakar • Boleh menggunakan api
Oksigen
Panas
• Menggunakan Ijin Kerja Panas
Ijin Kerja Panas, menggunakan atau menimbulkan sumber panas, atau nyala seperti pekerjaan pengelasan, api dapur, sant blasting dll. Unsur yang dihindarkan adalah adanya sumber bahan bakar dengan melakukan gas test.
Prinsip Ijin Kerja Mengendalikan Panas Bahan bakar
Oksigen
• Sumber bahan bakar tidak bisa dikendalikan dan dapat timbul sewaktuwaktu Panas
• Kendalikan atau cegah adanya/timbulnya sumber panas atau energi
• Jenis Ijin Kerja Dingin Ijin Kerja Dingin, adalah pekerjaan yang tidak atau tidak boleh menimbulkan adanya sumber panas atau percikan api. Sumber bahan bakar diperkirakan timbul setiap saat Contoh pekerjaan menggunakan palu di tanki minyak
Prinsip Ijin Kerja Mengendalikan Oksigen Bahan bakar
Oksigen
• Kadar Oksigen diperkirakan tidak aman bagi manusia atau untuk kelangsungan proses pembakaran (segi tiga api) Panas
• Ijin Masuk ruang tertutup
Ijin Kerja Ruang tertutup dimana kadar oksigen harus diperhitungkan untuk keselamatan pekerja
Sistem Ijin Kerja Pihak yang terlibat dalam sistem ijin kerja Issuing Authority
Ijin Kerja Safety Advisor
Perrforming Authority
Sistem Ijin Kerja Issuing Authority – Pemberi Ijin – Yaitu pihak operasi atau pengawas daerah/peralatan yang bertindak sebagai pihak yang memberikan ijin melaksanakan suatu pekerjaan yang menyangkut tempat, alat atau lingkungan – Issuing Authority adalah : • • • •
Pengawas Operasi Shift superintendent Kepala pabrik Pengawas instalasi dll
Sistem Ijin Kerja Issuing Authority – Pemberi Ijin – Tugas dan tanggungjawab • Memebebaskan semua perlatan dan proses yang berkaitan dengan pekerjaan dari semua sumber bahaya dan energi sehingga aman untuk dikerjakan. • Mengamankan peralatan, tempat kerja dan proses untuk keamanan pekerjaan, termasuk memasang sorokan, membersihkan alat, menyetop kegiatan sementara waktu, melakukan isolasi sumber energi dsb.
Sistem Ijin Kerja Performing Authority – Penerima ijin – Yaitu pihak yang melaksanakan pekerjaan yang menyangkut suatu alat, tempat kerja atau fasilitas – Pelaksanaa Pekerjaan : • • • •
Bagian pemeliharaan Bagian teknik sipil, listrik atau mekanik Pekerja telekomunikasi Pekerja pembersihan dll
Sistem Ijin Kerja Performing Authority – Penerima ijin Tugas dan tanggung jawab : • Melaksanakan pekerjaan dilakukan dengan cara yang aman menyangkut pekerja, peralatan dan metoda pelaksanaan. • Mematuhi semua rekomendasi yang dikeliuarkan oleh pemberi ijin dan bagian K3 • Mengawasoi secara langsung selama kegiatan kerja berlangsung dan segera mengambil tindakan jika ditemukan kondisi berbahaya
Sistem Ijin Kerja Unsur Pengawas Keselamatan – Yaitu pihak yang bertanggungjawab memberikan saran dan petunjuk serta pengawasan keselamatan selama pekerjaan berlangsung – Unsur pengawasan terdiri atas : • • • • •
Fungsi K3 perusahaan Fungsi Listrik Fungsi Inspeksi Fungsi Telekomunikasi Dll yang diperlukan
Sistem Ijin Kerja Unsur Pengawas Keselamatan – Tugas dan tanggungjawab • Melaksanakan monitoring selama pekerjaan berlangsung • Meneliti dan meyakinkan bahwa semua syarat keselamatan telah dipenuhi • Memberikan rekomendasi cara kerja yang aman • Melaksanakan pengetesan gas berbahaya • Menghentikan pekerjaan jika dinilai kondisi keselamatan tidak terjamin atau terjadi pelanggaran prosedur
Ijin Kerja Panas • Semua pekerjaan yang menggunakan atau menimbulkan energi panas atau bunga api yang memiliki cukup energi untuk proses pembakaran. • Jenis pekerjaan panas : – Pengelasan – merokok, menyalakan api dapur,, korek api – Menghidupkan kendaraan dengan internal combustion engine di daerah berbahaya gas – sand blasting – Penggunaan alat pneumatik – Peralatan listrik – dll
Ijin Kerja Panas Persyaratan Utama • Harus bebas gas (gas free) • Bebas dari sumber bahaya dari lingkungan, minimal dalam radius 25 meter • Dilaksanakan pemeriksaan gas secara berkala
Ijin Kerja Panas Tindakan pengamanan (safety precaution) • Memeriksa kondisi gas berbahaya setiap saat • Mengisolir dan mengamankan semua sumber bahan bakar seperti perpipaan, parit terbuka, venting dsb • Memasang tirai air untuk pengamanan sumber panas
Ijin Kerja Dingin • Semua pekerjaan yang tidak menggunakan sumber panas atau tidak diperkenankan menimbulkan sumber panas. • Jenis pekerjaan Dingin : – Menggunakan martil besi didaerah gas (tindakan anti bunga api) – Mengecat di daerah berbahaya – Perbaikan pompa atau peralatan proses yang sedang beroperasi – Menggali di daerah unit proses – dll
Ijin Kerja Dingin • Persyaratan – Tidak boleh timbul sumber api (percikan, bunga api dsb) – Harus dilakukan tindakan anti bunga api, misalnya dengan membasahkan peralatan dengan air, penggunaan martil tembaga atau kuningan dsb – Diperlukan tindakan waspada karena adanya sumber gas berbahaya tidak dapat dikendalikan misalnya bekerja di lingkungan unit proses yang sedang beroperasi – Semua peralatan kerja harus diamankan dari kemungkinan terjadinya percikan bunga api.
Ijin Kerja Ruang Tertutup • Bekerja di lingkungan dengan kadar oksigen tidak memadai • Contoh : – Masuk dan bekerja dalam tangki bekas berisi bahan cair mudah terbakar – Bekerja dalam ruangan dengan ventiliasi terbatas
Ijin Kerja Penggalian • Diperlukan untuk pekerjaan yang melakukan galian tanah : – Penggalian jalur pipa – Penggalian tanah untuk konstruksi – dll
Safe Work Permits
Excavations may expose hazardous materials, which have leaked and are contaminating the soil. Permits ensure that procedures to protect workers from exposure to toxic substances have been identified.
Ijin Kerja Listrik • Untuk melindungi pekerjaan yang menggunakan peralatan listrik atau bekerja pada lingkungan peralatan atau sarana pembangkit dan penyalur listrik
PREPARATION OF WORKPERMIT
PREPARATION OF THE EQUIPMENT • • • • • • •
Equipment electrically isolated Inspection tested(for cold & hot job) Isolated from steam,air & gas Depressurized Drained Positively isolated/blinded Steamed & water flushed
PREPARATION OF EQUIP. CONTD. • Ventilated & gas freed • Continuous inert gas flow / continuous adequate ventilation arranged. • Vehicle/equipment in good condition with spark arrested • Radiation source removed(Confined space entry)
PREPARATION OF EQUIP. CONTD. • Ventilated & gas freed • Continuous inert gas flow / continuous adequate ventilation arranged. • Vehicle/equipment in good condition with spark arrested • Radiation source removed(Confined space entry)
RESIDUAL HAZARDS • • • • • • •
Lack of oxygen H2S and/or any other toxic gases Combustible gases Corrosive chemicals Steam / Condensate Pyrophoric iron High humidity
RESIDUAL HAZARDS • • • • • • •
Lack of oxygen H2S and/or any other toxic gases Combustible gases Corrosive chemicals Steam / Condensate Pyrophoric iron High humidity
PROTECTION MEASURES • • • • • • •
Protective clothing Hearing protection Safety Harness Eye protection Face protection Respiratory protection Keep fire equipment stand-by
PROTECTIVE MEASURES CONTD. • • • • • • •
Barricade the area Remove flammable and combustible Cover with fire retardant tarpaulin Crane with basket stand-by Attendance with Airline set keep man ways open Allow minimum possible no. of persons inside confined space
PROTECTIVE MEASURES CONTD.
• To ensure positive isolation & maintain it all through • Ensure adequate ventilation all through • Display copy of entry permit near entry manhole
GAS TEST FOR WORK PERMIT Why gas test is required ? • Most of the gases are unwanted Hazards involved -
• Flammability(Fire & Explosion) • Toxicity(health hazard) • Oxygen Deficiency
GAS TEST FOR WORK PERMIT
• • • • •
Common flammable gases/liquids in refinery are All petroleum products,Crude and intermediates Hydrogen LPG Common toxic gases in refinery H2S, CO,NH3,CL2, etc.
GAS TEST FOR WORK PERMIT COMMON TERMINOLOGIES : For flammable substances: • Flash Point : Minimum temp. at which a liquid gives off sufficient vapor to form an ignitable mix. It will give a flash, flame will not continue. Auto Ignition Temp.: The lowest temp. to which a substance will ignite without a spark or flame.
GAS TEST FOR WORK PERMIT • Explosive limit : The concentration range of vapor in air when propagation of flame(ignition) occurs in presence of an ignition source. • LEL (Lower Explosive Limit) : The minimum concentration of vapor to air required to propagate(ignite) flame.
GAS TEST FOR WORK PERMIT • UEL(Upper Explosive Limit) : The maximum vapor to air conc.above which propagation of a flame will not occur(will not ignite).
GAS TEST FOR WORK PERMIT Material Hydrogen Methane Propane Naphtha ATK/ATF Diesel Fuel Oil
LEL 4 5 2 1.1 0.7 0.7 1
UEL 75 15 9.5 5.9 5.0 5.0 5.0
F Pt.(C) AIT(C) Gas 585 Gas 538 - 104 466 - 18 288 35-50 210 32-96 256 66 262-407
GAS TEST CONTD. Toxic substances : TLV (Threshold Limit Value / PEL(Permissible Exposure Limit) : The maximum permissible conc. of a toxic substance to which exposure of a person will have no adverse effect on health for working 8 hrs per day. STEL(Short Term Exposure Limit) : Maximum conc. to which worker can be exposed for a period of 15 mins. without any adverse effect to health.
GAS TEST CONTD. IDLH(Immediate Danger to Life & Health) • A maximum conc. from which one can escape within 30 mins. without irreversible health effect. • HYDROGEN SULPHIDE (H2S) Highly toxic, combustible, colorless. Smells like rotten egg.
GAS TEST - H2S EFFECTS ON HUMAN BODY PHYSICAL EFFECT CONC.(PPM) Can be smelled as rotten egg 0.13 TLV 10 STEL 15 Smelling sense will dry within 150 - 200 2 mins, burning sensation in eye & throat
GAS TEST - H2S CONTD. PHYSICAL EFFECT CONC(PPM) IDLH(Loss of smelling sense, 300 heavy breathing, dizziness, headache,and total collapse within 1 to 4 Hrs) Dizziness,headache,lungs 450 problem and total collapse within 30 to 60 mins.
GAS TEST-H2S CONTD. PHYSICAL EFFECT CONC(PPM) Slow down of heart beats, 700 heavy breathing with coughing, then death, if not rescued Fatal emergency
over 700
Explosive limits : 4.6 to 46%, it gives blue flame when ignited.
GAS TEST-H2S CONTD. FIRST AID : IF INHALED Remove exposed person to fresh air and administer oxygen immediately. PROTECTION: Use fresh air mask in case conc. exceeds 10 PPM
TOXIC GAS - CO TOXIC AS WELL AS FLAMMABLE TLV 50 PPM STEL - 400 PPM IDLH - 1500 PPM LEL - 12.5% UEL - 74 %
GAS TEST - CO HEALTH HAZARDS: CO combines with hemoglobin of blood and make it unable to carry oxygen. Symptoms : Headache, dizziness to unconscious and ultimately death. First Aid : Remove to fresh air and apply oxygen at the earliest.
OTHER TOXIC GASES TOXIC GAS
TLV
NH3 SO2 CL2
25 2 0.5
STEL IDLH 35 5 1
30
GAS TEST CONTD. For hot work the gas test results shall be : • Combustible - Below 1 % LEL ( Preferably NIL) For confined space entry : • Oxygen - 19.5% minimum • Combustible - 10 % LEL Max. • Toxic gases - below TLV
GAS TEST CONTD. Confined space With BA protection : • Combustible - 20% of LEL maximum • H2S - Less than 100 PPM • CO - Less than 500 PPM However, no hot job can be carried out inside the confined space at this condition.
WORKS NEED GAS TEST • Gas tests are required for all hot work/vehicle entry and confined space entry permits & some cold permits also. • Issuing authority shall determine the requirement of gas test & frequency of re-checking. • Trained Gas tester only shall carry out the test.
RESPONSIBILIES OF GAS TESTING AUTHORITY • To check & confirm that the gas testing instrument is working in perfect condition before proceeding for the area/equipment • To carry out gas test at all critical locations/positions • To advise on safe method to work inside/at the location i.e., further gas freeing , use of PPE etc.
ELECTRICAL ISOLATION • Before issuing a Work Permit, it is essential to ensure that the equipment / facility to be worked on is electrically safe and electrical power is isolated to the extent necessary for the safe conduct of the authorized work. • Issuing, Executing authorities and Electrical Maintenance shall jointly decide the extent of isolation required.
SPECIAL REQUIREMENT FOR WORKING WITH RADIOGRAPHY • Risk assessment through checklist • Barricade the area and provide adequate warning signs. • Film badges and Dosimeters shall be worn by personnel handling radiography equip. • job preferably during night time or with least or no person around. • Continuous monitoring of cordoned off area
SPECIAL REQUIREMENTS FOR HOT WORK • The person who authorizes the Hot Work Permit is responsible for ensuring that the site and the equipment are properly prepared to prevent the danger of fire & explosion involving flammable material. • The equipment shall be emptied and cleaned of flammable materials and isolated from sources of hydrocarbons by means of disconnection, blanking or insertion of blinds.
• Equipment and surrounding areas shall be checked to ensure that they are free from any combustible gas.Carry out gas test. • Any heavy oil deposit, dried vegetation or other flammable / combustible materials within 8 m of a hot work site shall be cleared away. • No hot work shall be allowed within a radius of 15 m of any sample point, drain or relief valve outlet unless precautions have been taken to prevent the escape of flammable liquids and vapors.
• The outlet of all units drain seals within 15 m of the hot work shall be plugged. • If welding or grinding is to be done at height, then precautions shall be taken to prevent the spread of sparks and molten metal to the surrounding of the work area with fire-resisting or flame-retarding tarpaulin. • A hose capable of reaching up to the hot work point and connected to fire water main. • Fire Station (333/5989) shall be informed of hot work.
VALIDITY OF PERMIT • Work permit shall be initially issued for a period of 8 hrs. and shall be renewed for one more shift . • On need basis , permit can be given for max. 7 days period. • Clearance to be obtained every shift. • Clearance to be given after physically checking the site.
