Safe work Practice up date.

Title : PERMIT TO WORK SYSTEM


1. INTRODUCTION

In the shipbuilding and ship-repairing industry, there are a number of operations that pose high risk. It is therefore necessary to have a form of control to carry out these operations safely. This control is brought about through a permit to work system. A permit-to-work is essentially a document which sets out work to be done, location, personnel responsible to apply endorse and approve, date and time and precautions to be take. It is a clear record that all foreseeable hazards are considered in advance and that appropriate precautions are defined and taken in the correct sequence. It does not, however, by itself make the job safe. It is the concerted efforts of all those involved in the permit to work system to ensure that the operations are carried out safely.

Under the company in-house regulations, it is mandatory to obtain a permit to work before any hazardous work is carried out in the shipyard.

2. PURPOSE

• To ensure that hazardous work can be carried out with due regard to the safety, health and welfare of workers;

• To prevent any incompatible work from being carried out at the same time in the shipyard or at any location on board the ship; and

• To ensure that the necessary safety precautions are taken and enforced when hazardous work is being carried out.

3. SCOPE

The following work processes are covered under the permit-to-work system.

Hot-Work
Painting in confined space
Chemical cleaning of boilers, coolers, Generators, Motors etc.
Electrical switch board cleaning
Radiography work
Dismantling/Testing of oil pipelines, valves and heating coils.
Work activities in CO2/Halon room
Ballasing/Deballasting
Bunkering/Transferring of oil
Sludge cleaning

The above permits are required to be raised if the work is intended to carry out on board vessel/new building erection area.


4. RESPONSIBILITIES

For jobs carried out by yard personnel, the Trade Foreman/Supervisor is responsible for maintaining the safety requirements throughout the job performance. For jobs tendered out by the yard the responsibility rests jointly with the Trade Foreman/Supervisor and the Sub-contractor Foreman/Supervisor.

For jobs undertaken by the ship staff of their hired contractors, the responsibility of maintaining the safety requirements throughout the job performance rests with the Master/Chief Officer/Chief Engineer. All the jobs shall be performed in accordance with the shipyard’s prevailing rules and regulations.

5. DESCRIPTION

In line with the company rules and regulations, the shipyard generally uses a 4-stage permit. The 4 basic stages are as follows:-

SATGE I Application by the “Trade” Foreman/Supervisor

The Trade Foreman/Supervisor/Ship staff applies for a permit to carry out the work process at a specified location for a specified time period. HE also has to undertake that he will be providing and maintaining appropriate safety measures during the entire work process.

STAGE II Endorsement by Safety Officer/Safety Supervisor

The Safety Officer/Safety Supervisor verifies that the necessary safety requirements have been complied with. If he is satisfied, he will endorse the permit.

STAGE III Approval by Ship Repair Manager/Project Engineer


The ship Repair Manager evaluates the information given by the applicant and the risks and hazards involved in the job.

The Ship Repair Manager/Project Engineer confirms that no incompatible processes will be carried out in the same vicinity as the work and all safety measures and precautions have been implemented and enforced. The SRM/PE will cause a thorough inspection and proper assessment of the work area and its surroundings to be made before he approves Stage III of the application for the permit-to-work. He will then approve the work.

STAGE IV Notification of completion of work by the Trade Foreman/Supervisor

The Trade Foreman/Supervisor notifies the safety personnel on completion of the work by returning the “Display” copy of the permit duly signed.




6. WHO SHOULD RAISE THE PERMIT

It is the duty of the Trade Foreman/Supervisor to apply for the permit-to-work if the work is intended to be carried out by the yard or yard engaged sub-contractors. If the job is undertaken by ship and their sub-contractors then the Master/Chief Officer/Chief Engineer or any other senior member of the ship staff who attends the VSCC meeting should apply for the permit. The person applying for the permit is hereinafter referred to as “applicant”

IMPORTANT NOTE

Permits are controlled documents with serial numbers and it is the duty of the Departmental Mangers to see that the permit forms issued to their Foremen/Supervisors are properly accounted for.

7. GENERAL GUIDELINES FOR FILLING THE PERMIT FORM

Each stage of the permit can be signed by the respective personnel only after the preceding stage has been signed.

The dates of commencement of the work, application, endorsement by Safety Officer/Supervisor and approval by SRM/PE shall all be the same.


The foreman or supervisor may make a cancellation on the permit. However, it must be done neatly and he must initial the cancellation made.

The Safety Officer/SafetySupervisor must initial beside the foreman’s or supervisor’s initials to indicate awareness of the cancellation before he signs Part II of the permit. No amendments must be done to the permit once it has been signed by the Safety Officer/Safety Supervisor except for the commencement date and time. Should there be a need to make any other amendments the Safety Officer/Safety Supervisor must be informed and the Safety Officer/Safety Supervisor must initial against the amendments made. In the same context no additions should also be made in the permit once it has been signed by the Safety Office/Safety Supervisor.

The SRM/PE before approval of the permit must ensure that the commencement date and time has been entered. If not, he must enter the commencement date and time in the permit. If the commencement date and time had been entered by the Trade Foreman/Supervisor and if it is required to be amended, the SRM should amend it. He must however initial against the amendments made. The commencement date and time SHOULD NOT precede the approval date and time on the permit.








8. PROCEDURE FOR OBTAINING PERMIT-TO-WORK

The applicant must highlight in the VSCC meeting the intended work activities for the next 24 hours before raising the permit application. The Ship Repair Manager/Project Engineer must co-ordinate this particular work activity in the VSCC meeting so that incompatible works are not carried out at the same or adjacent locations. In the event that work arises after the VSCC meeting, the SRM/PE must convene another meeting with the trades involved before the application is made.

The applicant must be familiar with the work schedule, the nature of the work to be carried out and the hazards and risks associated with the job. He must take relevant safety measures before submitting the permit-to-work.

He must raise 2 copies of the appropriate permit-to-work. He must fill up the particulars correctly and legibly in the appropriate boxes such as the vessel’s name, location of work, commencement and completion date and time and details of work to be carried out.

He must complete the Stage I “Application by Trade Foreman/Supervisor” and submit the form (2 copies) to the Safety Officer/Safety Supervisor.

Upon receiving the application, the Safety Officer/Safety Supervisor should familiarize himself with the work schedule, the nature of work to be done and the risks and hazards involved. He should then inspect the site of the intended work and its surrounding area together with the applicant to ensure that there are no hazards or danger present. He would then endorse Stage II of the permit after confirming that the stated conditions and any other safety measures recommended have been complied with. If he is not satisfied with the results of the inspection, he can refuse to endorse the permit.

The Safety Officer/Safety Supervisor should then forward all 2 copies to the SRM/PE for his approval. On receipt of the application for the permit, the SRM/PE must evaluate the hazards and risks that the applicant had highlighted. He should instruct the Safety Officer/Safety Supervisor to ensure that the hazards and risks are eliminated/reduced to a practicable standard of acceptance and the necessary safety measures are in place. The SRM/PE would approve the permit by signing the Stage III if he satisfied that a thorough inspection and proper assessment of the work area and its surroundings have been made so that the work can be carried out safely.

The applicant is required to display the copy marked ‘DISPLAY’ at the work area with the sketch (if any) before commencement of the work and the copy marked ‘SAFETY (FILE) in the vessel documentation file maintained in the Safety Department.

Upon completion of the work or invalidation of the permit, the Trade Foreman/Supervisor/Ship Staff (as the case may be) must sign the Stage IV “Notification of completion of work by the Trade Foreman/Supervisor” in the copy marked “Display” and hand over that copy to the Safety Personnel.

If the job is not completed within the stipulated time, a fresh permit will have to be raised. No work can commence until the permit is duly completed and signed by all the relevant personnel.

It is the duty of the ‘Trade Foreman/Supervisor’ to maintain the safety requirements throughout the job performance. If the condition changes, he must stop the job and notify the SRM/PE and the Safety Personnel.

The permit is invalidated if the conditions change or any incompatible work process need to be carried out due to priority. During such conditions, the permit must be returned to safety personnel and a fresh permit must be obtained.

Request from the sub-contractors for the approval of a permit will not be entertained.

9. DISPLAY OF WORK PERMITS

The permit-to-work shall prominently be displayed in the vicinity of the work for which it has been issued.

If the permit is issued for a work to be performed inside a confined space, it must be displayed at the entrance to the confined space.

The permit on display must not be defaced or obliterated. In the event that they become defaced or obliterated, immediate measures must be taken to replace them.

For permits to be displayed in open areas such as the main deck and the weather deck, permit holders must be used. For permits that are to be displayed in sheltered areas e.g. engine rooms, pump rooms, accommodation, plastic covers with strings attached, may be used. The plastic covers with the permits must be hung in the vicinity of the work.



Title : HOT WORK

1. INTRODUCTION

Fires and explosions have been one of the major hazards in the shipbuilding and repairing industry. Uncontrolled welding and cutting operations have been the source of numerous fires on board vessels. Many of the work processes carried out during shipbuilding/ship-repairing such as painting, chemical cleaning etc. are incompatible to hot-work’. It is therefore necessary to have a form of control and this can be achieved by implementing a permit-to-work system for “hot-work”. No “hot-work” shall be allowed to be carried out on board vessels/erection without first obtaining a “hot-work” permit.

2. PURPOSE

This permit is intended to ensure that all necessary precautions are taken during the process.

3. SCOPE

This permit is applicable to any “hot-work” carried out on board vessels/erection area.

4. DEFINITIONS

“Hot-work” means riveting, welding, flame cutting or burning and includes any other work involving the use or generation of heat or production of sparks.

5. SAFETY REQUIREMENTS TO BE PROVIDED BY APPLICANT

The applicant must provide the under mentioned safety requirements prior to commencement of work and maintain them during the ‘hot-work’:

i Presence of fire watch with fire extinguishers/fire hoses.
ii Prominent display of ‘hot-work’ permit with sketch.
iii Supply of sufficient forced ventilation and provision of adequate lights, for work in confined spaces.
iv Prominent display of ‘hot-work’ signboards.
v Any other special measures to contain hazards and risks associated with the job as indicated in the permit application.










5. GENERAL REQUIREMENTS/CONDITIONS

5.1 INCOMPATIBILITY

‘Hot-work’ permit shall be invalidated should combustible materials be introduced in way of the ‘hot-work’ area or any of the following incompatible works be carried out in the same area:-

i Dismantling of valves and pipelines
ii Ballasting and Deballasting
iii Testing of valves/pipes/heating coils
iv Painting
v Chemical cleaning
vi Sludge cleaning

In any of the above cases ‘hot-work’ should be stopped immediately and Safety Department must be informed.

5.2 USE OF ACETYLENE GAS

Only acetylene gas should be used for gas welding/cutting operations in double bottom tanks, pump rooms, void spaces and other deep seated tanks.

5.3 “HOT-WORK” FOR RENEWAL OF HULL ANODES

Number of ‘hot-work permits required for the hull anode renewal shall be as follows :-

Rudder, stern area - one permit
Sea cheasts - one permit
Hull (Port & Stbd) (including bilge keel) - one permit

5.4 DISCONNECTION OF GAS HOSES DURING LUNCH BREAK PERIODS

Gas hoses shall be disconnected from gas manifolds during meal breaks and for deep seated confined spaces, the hoses shall be removed from the spaces. At the end of the day’s work, all gas hoses shall be removed from all confined spaces.








5.5 FLUSHING OF HEATING COILS IN CARGO TANKS WITH MAJOR STEEL WORK

Heating coils in cargo tanks with major steel work should be flushed as there is a risk of heating coils discharging combustibles into “hot-work” area due to some damage occurring during steel renewal. Major steel work refers to:-

i renewal of bulkheads of cargo tanks
ii renewal of shell plate in way of cargo tanks
iii renewal of stringers inside cargo tanks

5.5 REASSESSMENT OF “HOT-WORK” AREA AFTER DOCKING/UNDOCKING

Docking/undocking may introduce combustible material into area hither to free of them. “Hot-work” at the following locations should be reassessed after docking/undocking of vessel for change of condition:-

i Void spaces
ii Double bottom tanks
iii Pump room bilges
iv Engine room bilges

5.6 PROHIBITION OF OTHER WORK ACTIVITIES IN CONFINED SPACES DURING INITIAL “HOT-WORK” IN THE SPACES

During initial ‘hot-work’ in any confined space, all other work activities in the space shall be suspended. This is to ensure that there are no other workmen in the space during this period which is considered the critical period. For example, if a deck access opening has to be cut in way of a confined space, no other activity shall be permitted in the tank until the access has been cut.

In case of extensive ‘hot-work’ like renewal of internals in the space, all other activities in the space shall be suspended over a period of atleast 2 hours during which time the ‘hot-work’ will be monitored. Other activities shall only be allowed to resume after the safety officer is satisfied with the condition in the space.


5.7 PROVISION OF ALTERNATE ESCAPE ROUTE FOR WORK IN CONFINED SPACES

when there is extensive ‘hot-work’ in a confined space or when many people are working in a confined space or when many people are working in a confined space in which ‘hot-work’ is also carried out, an access opening shall be cut at a suitable location in the confined space. This is to facilitate the workmen to escape from the confined space in which they are working, in the event of an emergency.

The criteria for cutting access opening shall be based on the safety considerations. The decision whether access openings are needed or not rest with the safety department.

5.8 “HOT-WORK” BY SHIP STAFF AND OWNER’S CONTRACTORS

All ‘hot-works’ shall be performed in accordance with the prevailing safety rules and regulations pertaining to “hot-work”.






Title : CHEMICAL CLEANING OF GENERATORS AND MOTORS


1. INTRODUCTION

Chemical cleaning of generators/motors involves the use of solvents in atomized form. Solvents are highly toxic and flammable, thus necessitating special safety precautions for the operation. Any chemical cleaning of generators/motors on board a vessel in the yard can be carried out only after obtaining a permit for the same.

2. PURPOSE

This permit is intended to ensure that all necessary precautions are taken during the process.

3. SAFETY REQUIREMENTS TO BE PROVIDED BY THE APPLICANT

The applicant must provide the under mentioned measures prior to commencement of work and maintain them during the entire process:

• Prominently display appropriate signboards at all entrances to the area where chemical cleaning is intended to be carried out.

• Isolate generator/motor breaker and heater circuit in the switchboard

• Supply sufficient exhaust ventilation.

• Ensure no hot-work in the space where chemical cleaning is intended.

• Use appropriate flame proof lights and

• Any other special measures to contain hazards and risks associated with the job as indicated in the permit application.



In addition, the applicant shall ensure that

• The workers involved in chemical cleaning are briefed on the hazards and preventive measures

• Chemical cleaners and their assistants use appropriate PPE such as air fed masks/respirators, body protection and eye protection.


4. GENERAL REQUIREMENTS/CONDITIONS

• Chemicals can be brought on board only after the permit has been approved. Once brought on board it should be kept in an area approved by the Safety Officer/Supervisor.

• Upon completion of chemical cleaning the Trade Foreman/Supervisor/Ship staff (as the case may me) must arrange for the removal of all chemicals from the vessel and clean up any spillage. The Safety Officer/Supervisor should then check and confirm that the area is free from flammable/toxic vapours.

• The applicant when applying for the permit should submit copies of MSDS to safety personnel and SRM/PE.

• The use of flammable liquids/solvents for cleaning engine parts is prohibited.

• A chemical cleaning permit must be obtained if the application of the chemicals/flammable liquids for the purpose of general cleaning/degreasing is done by means of spraying.

5. INCOMPATIBILITY


“Hot-work” and chemical cleaning are incompatible process. No ‘hot-work’ shall be allowed in the area where chemical cleaning is under progress.


Title : ELECTRICAL SWITCH BOARD CLEANING


1. INTRODUCTION

Electricity is extensively used in the shipyard for various purposes such as driving workshop machinery, lifting machines, motors and providing general lighting throughout the yard and also on board vessels. Electricity is not dangerous, if used properly. However, if used unwisely, serious accidents can occur. The severity of the injury depends on the following factors:-

i Nature of current, whether A.C or D.C
ii Path of the current flowing through the human body
iii Duration of contact with the current
iv Physical condition of the human body, i.e. wet or dry
v Magnitude of the current

Hence, it is necessary that personnel involved in carrying out electrical repair/maintenance work, are familiar with the safe work procedures to avoid incidents during such activities.

In the shipyard, the following activities are regularly carried out:-

i Electrical switch board repairs on board vessels
ii Electrical repairs of the facilities within the shipyard premises

The primary hazards due to electrical repairs are as follows:-

• Electric shock
• Fires/explosions
• Inhalation of toxic fumes

2. ELECTRICAL SWITCH BOARD REPAIRS ON BOARD VESSELS

Electrical switchboard repair involves cleaning the switchboard of carbon deposits. Usually cleaning is done with a brush. However, at times solvents are used. The main hazards from such operations are electrical shock, fires and inhalation of toxic gases.


2.1. PURPOSE

This permit is intended to ensure that all necessary precautions are taken during the process.





2.2. RESPONSIBILITIES

• Prior to applying for the permit, the applicant shall notify the Chief engineer/Electrical Engineer of the vessel that shore supply cable to the vessel is going to be disconnected.

• Upon confirmation from trade supervisor concerned, the marine services foreman/supervisor shall

i Isolate the transformer breaker,

ii disconnect the shore supply cable of the vessel from the berthside Link Box and display “DANGER DO NOT CONNECT – MEN AT WORK” signboard and

iii ensure that power supply will not be restored until a request is received from the Trade Foreman/Supervisor.

2.3 SAFETY REQUIREMENTS TO BE PROVIDED BY THE APPLICANT

The applicant must provide the under mentioned measures prior to commencement of work and maintain them throughout the process.

• Ensure that there is no power supply at the bus bar.

• Ensure that the emergency generator start-up system is isolated.

• Earth the switchboard’s bus bar.

• Install adequate lights at work areas, accommodation and access to work place.

• Any other measures to contain special hazards and risks associated with the job as indicated in the permit application.

3. ELECTRICAL REPAIRS OF THE FACILITIES WITHIN THE SHIPYARD PREMISES

3.1 GENERAL SAFETY PRECAUTIONS

• All current carrying parts shall be enclosed

• Insulated tools and rubber protective devices shall be periodically inspected and cleaned by competent persons. When their conditions is in doubt, these shall be subjected to high voltage tests.

• When high structures are moved under electrical lines, proper clearances shall be maintained.

• Hands, shoes and clothing must be kept dry when handling energized electrical equipment.

3.2 SAFETY PRECAUTIONS AGAINST DIRECT CURRENT

• All the live parts of electrical system shall be protected by insulation of adequate rating. It is also advisable to carry out measurement of Insulation Resistance (IT) at regular interval to gauge the effectiveness.

• Certain parts of electrical system like the busbar, motor cable terminals etc., are generally not insulated. These parts must be enclosed. If the enclosure is made of metal, suitable earthing, shall be provided. Alternatively, barriers in the form of wire mesh, perforated sheets etc., shall be used

• Unnecessary approach to high voltage apparatus or “live” parts shall be avoided.

• If ‘live’ conductor/apparatus are exposed in the course of the work, barriers shall be erected to prevent other coming into contact with the system. Barriers shall only be removed upon positive isolation of the system.


3.3 SAFETY PRECAUTIONS TO BE TAKEN AGAINST INDIRECT CURRENT

3.2.1 PROTECTIVE EARTHING

It is a requirement that all current carrying metal parts of electrical driven equipment shall be earthed properly

The objectives of earthing are :-

• to keep the non-current carrying parts of electrical driven equipment at zero potential.

• to discharge electrical energy in case of earth fault in the system

• to allow sufficient current to flow to blow the fuses or operate protective devices and thereby disconnect the faulty apparatus.

3.2.2 PROTECTIVE INSULATION

Protective insulation means insulation in addition to operational insulation of the current carrying parts of the equipment. The internal layer of protective insulation completely isolates the electrical components from the outer housing in case of a fault in the winding or other current carrying parts.

3.2.3 PROTECTIVE CIRCUITS

a) OVERLOAD AND SHORT CIRCUIT PROTECTION

Dangers from excess current due to overload or short circuit shall be prevented by providing :-

i. Fuses
ii. Circuit Breakers
iii. Thermal Protection

Fuses, relays and circuit breakers shall be of sufficient breaking capacity to operate safely at the desired currents. All protective apparatus shall be set at an appropriate current valve, so that it operated effectively only in faulty conditions.



b) THERMAL PROTECTION

The electrical equipment or circuits in which the fault current does not exceed the load current or where small overloads can cause burnout thermal fuses and relay, operation on temperature increases, shall be provided.

c) EARTH LEAKAGE PROTECTION

All portable electrical driven equipment as well as other electrical equipment where protection afforded by the over current and circuit breakers along with the earthed conductor is not adequate, shall be provided with earth leakage protection. Earth Leakage Circuit Breakers (ELCBs) shall be provided for all portable electrical driven equipment.

Earth Leakage Circuit Breakers work on the principle of differential current between phase and neutral/earth circuits. It is designed to isolate the circuit/equipment when an earth fault current of 30mA flows for a duration of more than 30 milli seconds.

d) In AC circuits, 24 Volts is considered to be a “safe” voltage. All AC electrical arc welding sets used in the shipyard shall be provided with “Low Voltage Safety Device” (LVSDs) to reduce the no-load secondary open circuit voltage to below 24 V to prevent electric shock to welders.

3.3.4 PROTECTION AGAINST RADIATION BURNS

All personnel engaged in welding processes shall use face shields fitted with suitable filter lenses of the correct shades to prevent the eyes and face from exposure to ultra violet and infra red rays emitted from the process. Protective screens shall be provided to protect other personnel working in the vicinity from the harmful rays.