Issuing Organization Document No. Revision No. Effective Date Page No

General Instruction Work Permit System
Industrial Security Function

Issuing Organization Safety Department
Document No. Revision No. Effective Date Page No.
PR/IS/SFD/GI-024 4 September 1, 2018 1 of 49
Company General Use Restricted Confidential Government Confidential

Table of Contents
1.0 Purpose ......................................................................................................................................................... 3

2.0 Scope ............................................................................................................................................................. 3
3.0 Acronyms / Definitions ................................................................................................................................... 3
4.0 Responsibilities .............................................................................................................................................. 9
5.0 Process Description ..................................................................................................................................... 16
6.0 Forms & Formats for Records ..................................................................................................................... 28
7.0 Reference .................................................................................................................................................... 29
8.0 Document History ........................................................................................................................................ 29
9.0 Work Permit Flowchart ................................................................................................................................ 33
10.0 Annexure ..................................................................................................................................................... 34
1.0 Purpose
1.1 This General Instruction (GI) establishes minimum responsibilities and requirements for issuing/receiving
work permits, and for certifying those responsible for implementing the system. When issued, permits
serve as official records of conditions and requirements agreed upon by the issuer and receiver to control
the hazards associated with the activity. They list minimum safety precautions to be taken and hazards,
which must be controlled. Additional requirements may be applied by the issuer to control the hazards
associated with performing a job.
1.2 This Instruction provides uniform mechanism to be followed while executing the jobs.
2.0 Scope
2.1 This Instruction is applicable to all restricted areas at PRC, which include but not limited to, facilities
processing, handling, transferring or storing hydrocarbon or toxic substance. All facilities of Petro Rabigh
or facilities located and operated by contractors are considered restricted areas. Activities conducted
within the Community can be handled based on the critical job described in this GI with the exception of
utility facilities within the community, which is considered as restricted area.
2.2 During the construction phase of grassroots projects and before a facility, or portion thereof, is certified
as mechanically complete, the contractor shall implement an approved work permit system in line with
this General Instruction for all hazardous work requiring the appropriate planning, control and authority
that does not meet the criteria defined in Section 2.1. After mechanical completion or during electrical
work on systems that are attached to PR electrical distribution system (e.g., pre-commissioning of
substations), the work permit system described in this instruction shall be implemented.
3.0 Acronyms / Definitions
3.1 CCR: Central Control Room
3.2 Certified Gas Tester: A Person who successfully completed the training from HCM Department and
certified and authorized by their Managers to conduct gas tests.
3.3 CO: Carbon Monoxide
3.4 Cold Work: Activities that may not produce sufficient energy to ignite flammable atmospheres or
combustible materials. This includes but is not limited to bolting and unbolting flanges on pipelines,
manual excavation to a depth of less than 1.2 meter, and scaffold erection.
3.5 Confined Space: Any enclosure having a limited opening for entry and exit; unfavorable natural
ventilation which could contain or produce dangerous air contaminants; presents serious hazards to
occupants; or which is not intended for continuous human occupancy. Confined spaces include, but are
not limited to, storage tanks, process vessels, ventilation and exhaust ducts, fin fan structure, manholes,
pits, excavations more than 1.2 m in depth and the area at the top of floating roof tank of which the top
of the roof is 1.2 m below the rim.
3.6 Confined Space Entry: The act of physically entering a confined space. Entry covers not only complete
body, but also when part of body such as head is inserted for a quick visual inspection.
3.7 Confined Space Entry Supervisor: A work permit receiver or an individual assigned by the receiver,
who is familiar and understand the requirements of this instruction, safety requirements for confined
space entry procedure PR/IS/SFD/GI-033 and PRC Construction Safety Manual (CSM). Confined space
entry supervisor is responsible to direct the activities of the confined space entry.
3.8 CSM: Construction Safety Manual
3.9 Critical Jobs: All works which could result into one or more of the following
 Immediate danger to life or health of personnel involved in work and/or other personnel i.e. lost time
injury, disability or death
 Damage to company assets or property i.e. physical damage, fire/explosion damage, product loss
 Significant impact on the environment by way of toxic release, pollution. etc.
Typical examples of Critical Jobs include, Open flames (Welding, Grinding, Hot cutting) in process area,
all confined space entries, hot tapping, working on elevations over 1.8 meter with fall possibility,
excavations more than 1.2 meters, rotating equipment, utility facilities, radiography, opening flanges and
lines containing hazardous materials and volatile hydrocarbons, blinding flare lines, and any work where
there is a potential of oil spill /leak.
3.10 Critical Lifts: Any Crane lift that requires a Critical Lift Plan.
3.11 Critical Lift Plan: A Critical Lift Plan is a document that identifies a specific load and the operating
restrictions. Pertinent information also includes all weights on hook blocks and attachments.
3.12 DCS: Distributed Control System
3.13 Designated Representatives: Employees designated by his section head or department manager, who
must be experienced, competent and familiar with the requirements of this GI and the work permit system
and be able to perform the duties associated with issuing work permits. Designated representatives shall
successfully complete all required work permit training courses. Designated representatives cannot sign
work permits.
Note: The re-certification requirement for the ‘designated representatives’ will be four (4) years (i.e.,
validity of the Designated Representative Certificate)
3.14 EOHD: Environment & Occupational Health Department
3.15 Equipment Opening/Line Break Permit: A completed document PR/IS/SFD/F-050 authorizing to

perform operations where there is potential for actual or possible release of flammable, combustible, toxic
and other hazardous materials, in levels that can pose a risk of injury to personnel, damage to property
or the environment.
3.16 ESO: Electrical System Operator
3.17 Examples of Critical Lifts: Crane operation around power lines; operating around hydrocarbons and
above-ground pressurized piping areas, and populated/traffic areas; All loads of 40 tons or greater; All
loads exceeding 85% of the rated load capacity of the crane for that specific lift; Tandem, multiple, or
tailing lifts (any lift requiring two or more cranes to lift one load); Crane suspended personnel platforms
(man-baskets); High level and/or long reach crane lifts; Nighttime crane lifts; other lifts as determined by
Petro Rabigh Management.
3.18 Extended Work Permit: A work permit that is issued for a period more than two consecutive shifts but
not exceeding 30 days.
3.19 Fire Watch: A trained person, certified by Fire Protection Department, assigned to observe hot-work
activities and extinguish unintended open flame, sparks, slag, and hot metal off-cuts. Fire watch shall be
provided by the receiver and agreed on by the issuer. Receiver shall not resume fire watch duty.
Note: Fire watch is required for hot work activities that involve use of open flames, such as cutting,
welding, and soldering as well as for activities which generate sparks such as grinding. In certain activities,
a fire watch is required to be provided as identified in the specific Job Safety Analysis (JSA).
Other hot work activities that does not involve use of open flames do not require fire watch. Examples
include: photography works, vehicle entry, radiography works, hydro-jetting etc.
3.20 FPD: Fire Protection Department
3.21 GFCI: Ground Fault Circuit Interrupter
3.22 Grassroots Project: PR project for constructing new facility, which is fenced and under the control of
construction agency and construction contractor until startup/occupancy. Projects located within the
restricted area of PR can be considered as grassroots provided that proponent organization has turned
over the control of the project site to construction agency.
3.23 H2S: Hydrogen Sulfide (also, H2S)

3.24 Hazardous Atmosphere: Any atmosphere that may expose employees to the risk of death,
incapacitation, impairment of ability to self-rescue (that is, escape unaided from a confined space), injury,
or acute illness from one or more of the following causes:
 Atmospheric oxygen concentration below 20 % or above 23.5 %
 Flammable gas, vapor, or mist in excess of 20 % of its Lower Explosive Limit (LEL)
 Any other atmospheric condition that is immediately dangerous to life or health (IDLH) such as
exposure to H2S above 100 PPM
3.25 HCM: Human Capital Management (Department)
3.26 Hot Work: Work activity capable of generating ignition energy for flammable and combustible materials
and any mixtures thereof. Examples include: 1) the process of joining together two pieces of metal
(welding, brazing), 2) the breaking apart of metal into two pieces (cutting) by means of extreme heat, 3)
metal grinding or other operation which produces heat, flame, and/or sparks that could provide a possible
source of ignition.
Other examples of hot work include: use of equipment not rated for the electrical classification of the area,
operation of internal combustion engines in electrically classified areas, and sandblasting, hydro-jetting
and use of flash photography, diagnostic, inspection and repair works on or near electrical equipment.
3.27 IDLH - Immediately Dangerous to Life or Health: An atmosphere or condition that poses an immediate
threat to life, would cause irreversible adverse health effects, or would impair an individual's ability to
escape from a dangerous atmosphere.
3.28 Isolation: Physical disconnection of a machine or process equipment from all sources of energy and
process materials associated with normal operation. This includes isolation from all supplies of:
 Electricity
 Pneumatic air or other gas
 Fuel gas, process air or other gases
 Hydraulic power
 Process materials
 Steam
 In situ cleaning systems

Physical disconnection means separation of pipes or hoses, which carry supplies, from their connections
to machinery or process equipment. Interruption of supplies through manipulation of a computer DCS
programme or programmable logic controller (PLC) is not isolation.
Subsequent to isolation, some mechanical components may be held in place by residual pneumatic or
hydraulic pressure. Where release of that pressure could result in movement of the components under
force of gravity, isolation needs to include its dissipation as part of the procedure.
3.29 JSA: Job Safety Analysis
3.30 LOTO: Lockout Tag-out
3.31 Lower Explosive Limit (LEL): The minimum concentration of a combustible/flammable gas, vapor, mist,
fumes and dust in air that will ignite if an ignition source is present. The monitoring instrument used to
test for combustible/flammable gases will indicate the existence of gases in term of %LEL; 0% for
atmosphere free of combustible/flammable vapor and 100% reaching the vapor LEL level.
3.32 MCP: Manual Call Point
3.33 MFT: Manufacturing
3.34 MHB: Material Hazard Bulletin
3.35 MSDS: Material Safety Data Sheet
3.36 Oxygen Deficient Atmosphere: An atmosphere with less than 20 % oxygen by volume at sea level. The
Air we normally breathe at lower elevations containing about 20.8 % Oxygen.
3.37 Oxygen Enriched Atmosphere: An atmosphere containing more than 23.5% oxygen by volume.
Oxygen-rich atmospheres expand the range of flammability, lower the ignition energy, and will cause
combustible materials to burn violently when ignited.
3.38 P&ID: Piping and Instrumentation Diagram/Drawing
3.39 PEL: Permissible Exposure Limit
3.40 PIB: Process Interface Building
3.41 PLC: Programmable Logic Controller
3.42 PPE: Personal Protective Equipment
3.43 PPM: Parts Per Million
3.44 PR: Petro Rabigh (same as PRC)

3.45 Proponent: Petro Rabigh Organization which is the owner of the facilities or other organization which is
in charge of the areas where projects are executed.
3.46 PRSS: Petro Rabigh Shift Superintendent
3.47 Restricted Areas: Those areas or activities which have been designated by PRC as requiring the work
permit procedure. These include all areas where hydrocarbons, flammable liquids or gases, or toxic
agents are handled, stored, piped or processed in bulk quantities. Confined spaces and areas near by
The following areas are examples of "restricted areas": petroleum and petrochemical processing plants,
pump stations, tank farms, loading piers/berths, hydrocarbon containing pipelines and pipeline corridors,
water or sewage treatment plants, marine vessels, gasoline service stations, product warehouses, areas
where explosives or radioactive materials are used or stored and areas within 15 m (50 ft) of power lines.
3.48 RSO: Radiation Safety Officer
3.49 SCBA: Self-contained Breathing Apparatus
3.50 SOP: Standard Operating Procedure
3.51 Standby Man or Entry Attendant: An individual trained in attendant responsibilities, confined space
hazards, and emergency procedures who has been assigned by confined space entry supervisor to
remain outside of the confined space, guard against unauthorized entry, maintain communication with
and monitor the authorized entrants inside. The standby man shall be trained by Fire Protection
Department in the use of SCBA sets, firefighting equipment with certificate issued to him. The standby
man shall be trained in Hazard Recognition, H2S Awareness, Gas Testing and Confined Space Entry by
Human Capital Management Department and certified (with the issue of a card certificate) to approve his
role as a standby man. The standby man shall be from Maintenance Department or Contractor. A standby
man shall be assigned to each confined space entry point and that head counts is carried out
continuously. The standby Man shall be conversant with the use of radio communication equipment
3.52 SVP (MFT): Sr. Vice President (Manufacturing)
3.53 T&I: Testing & Inspection
3.54 TCS: Total Complex Shut-down
3.55 TEAL: Tri-ethyl Aluminum
3.56 Toxic Atmosphere: Any atmosphere which exceeds (or could reasonably be expected to exceed) the
permissible exposure limit (PEL) for any substance that is specified in the current American Conference
of Governmental Industrial Hygienists (ACGIH) list of “Threshold Limit Values”.
3.57 WP: Work Permit

3.58 Work Permit Issuers (WPI): Supervisors and/or Plant Operators, who are trained by HCMD and certified
by their Section Head, to issue work permits for restricted areas under their supervision (also referred to
as issuers / work permit issuers).
3.59 Work Permit Receivers (WPR): Craft supervisors, craftsmen, or other company employees who have
been trained and certified by their Section Head, and contractor employees sponsored by PRC
organization heads to sign and receive work permits (also referred to as receivers / work permit receivers).
4.0 Responsibilities
4.1 Work Permit Issuer Organization
4.1.1 Department Manager shall
4.1.1.1 Ensure and review the effectiveness of the implementation of WP System and
recommend changes when necessary, in consultation with Safety Department, using
various audit findings
4.1.1.2 Discuss work permit infractions during Departmental Safety Committee Meetings
4.1.1.3 Ensure that necessary training, certification and equipment such as gas testers, LOTO
devices, WP forms etc. are provided for the job in his areas.
4.1.1.4 Ensure that adequate manpower resources such as work permit issuers are available.
4.1.2 Section Head shall:
4.1.2.1 Countersign the Work Permits requiring his level of signature as outlined in this
Instruction ( Annexure-1)
Note: Petro Rabigh Shift Superintendent (PRSS) shall countersign the Work Permits
during off-hours for unplanned jobs and emergency situations as per Annexure-1.
4.1.2.2 Ensure effective implementation of this general instruction in his Section
4.1.2.3 Ensure that updated list of Work Permit Issuers, designated representatives and Gas
Testers for his Section is maintained detailing the specific type of permits that an
individual can issue
4.1.2.4 Arrange to conduct Job Safety Analysis (JSA) for the critical jobs including all Confined
Space Entry
4.1.2.5 Ensure the Section Work Permit Issuers receive the required training such as Hazard
Recognition, Work Permit Issuer and Gas Testing. Authorize Section staff for issuing
specific permits after having successfully completed the Work Permit Issuer (WPI),
Gas Testing and Hazard Recognition (HR) trainings provided by Human Capital
Management (HCM) Department.
4.1.2.6 Ensure that the portable gas monitors to measure the gases present in his area are
available in ‘calibrated and ready to use’ condition with the required accessories.
4.1.2.7 Ensure bump test is done on daily basis for all portable gas monitors by certified gas
tester and its record shall be maintained. Defective gas monitors shall be withdrawn
from service, and sent for repairs.
4.1.2.8 Ensure that a log sheet of all open and closed work permits at a designated location
e.g. – CCR or PIB, per shift, is maintained for effectively communicating the ongoing
work activities in the area. Refer Annexure-2 for the Log Sheet Format. This log sheet
will be maintained by the Shift Supervisor and discussed during the shift turnover with
involved personnel including next shift supervisor and DCS operator.
4.1.2.9 Maintain the stock for Work Permit Forms and Lockout devices and Tags for his
Section.
4.1.3 Work Permit Issuer Shall:
4.1.3.1 Understand and follow the requirements as detailed in this instruction, issue the work
permits as per his certificate authority and shall carry the valid work permit issuer
certificate
4.1.3.2 Ensure the authorized Work Permit Receiver’s Certificate is valid for the specific type
of the work before issuing the Work Permit.
4.1.3.3 Where possible participate in JSA for critical jobs including Confined Space entry. If it
is not possible to attend the JSA, he shall read and understand the JSA before
issuing/extending the work permit.
4.1.3.4 Participate in the joint site inspection with Work Permit Receiver before issuing work
permit to ensure necessary preparations (isolation, LOTO, Gas testing, etc.) including
the safety precautions as specified in the JSA are in place before starting the job (and
joint site inspection before closing the permit). Issuer can delegate joint site inspection
to the designated representative excluding critical jobs such as open flame, welding,
confined space and service containing toxic chemicals.
4.1.3.5 Verify all blinds are in proper position as per blind list and marked up P&ID, tagged,
and identified before starting the job. Blind list shall be attached to the work permit.
4.1.3.6 Ensure vessel/equipment is isolated, purged as per SOP/JSA.

4.1.3.7 Ensure that lockout logbook and blind lists are maintained as mentioned in the General
Instruction, Isolation Lock-out and Use of Hold Tags PR/IS/SFD/GI-026
4.1.3.8 Install necessary locks and tags on the involved equipment and breakers as mentioned
in the General Instruction, Isolation Lock-out and Use of Hold Tags PR/IS/SFD/GI-026
4.1.3.9 In the presence of Radiation Safety Officer (RSO) from EOHD, Lock out and Tag out
any nuclear level gauges installed on the tanks or vessels.
4.1.3.10 Ensure the atmospheric gas testing is carried out by certified Gas Tester and recorded
on the work permit (initial gas test as well as at intervals mentioned in the work permit
by the WPI; he shall record the gas test results at the back of work permit).
4.1.3.11 Ensure a standby man (entry attendant) with an approved means of communication at
each vessel entrance as per the General Instruction, “Safety Requirements for
Confined Space Entry” (No. PR/IS/SFD/GI-033) is provided.
4.1.3.12 Verify that qualified Fire Watch is provided whenever necessary with approved
communication means such as Bravo (radio)
4.1.3.13 Countersign the work permits related to electrical equipment in substation in his area.
4.1.3.14 Mention the specific PPE required for the job and ensure workers are equipped with
the required PPEs.
4.1.3.15 Frequently visit the site to ensure all work permit conditions and requirements are
maintained.
4.1.3.16 Obtain countersignature on the work permit from the appropriate authorities as
mentioned in annxure-1 as outlined in this Instruction.
4.1.3.17 Stop the job and cancel the permit, in case of emergency in the area.
4.1.3.18 Suspend the job whenever unsafe practices or unsafe conditions are noticed until the
deviations are corrected. In case of major unsafe practices or conditions or which are
potentially IDLH, the work permit shall be cancelled.
4.1.3.19 Conduct joint site inspection with Work Permit Receiver after completion of the job to
ensure that the area is in acceptable housekeeping and maintained in safe condition
and then sign the work permit closure along with the receiver.
4.1.3.20 Communicate with the Field Operator the details of the work permits issued in his area
to monitor the work activities appropriate to the risk.
4.1.3.21 Keep the Closed Work Permits three (3) months to serve as record according to legal
requirement to be used for incident investigation, audits, etc.
4.1.3.22 Ensure presence of field operator during the initial opening/line break of the equipment
4.2 Work Permit Receiver Organization
4.2.1 Department Manager shall
4.2.1.1 Discuss work permit infractions during Departmental Safety Committee Meetings.
4.2.1.2 Ensure and review the effectiveness of the implementation of WP System and
recommend changes when necessary, in consultation with Safety Department, using
various audit findings
4.2.1.3 Ensure the Contractor Management under him comply with the following requirements.
4.2.1.3.1 Nominate employees to attend the required training per Section 5.12 of
this instruction for a work permit receiver.
4.2.1.3.2 Maintain updated list of personnel completing Work Permit Receivers and
Hazard Recognition course for his staff.
4.2.1.3.3 Participate in the JSA for the critical jobs, including confined space entry,
as requested by the Issuing section head or equivalent.
4.2.1.3.4 Ensure that the Contractor crews are well informed about the job scope,
hazards involved in the job, precautions to be taken as per work permit
and/or JSA.
4.2.1.3.5 Ensure personal protective equipment (PPE) and Flame Resistant

clothing are provided to the Contractor crew. PPE may include full body
safety harness, lifelines, and breathing apparatus.
4.2.1.3.6 Provide Standby Man/Fire Watch and ensure he is trained in the use of
SCBA sets & use of firefighting equipment and communication equipment
4.2.1.3.7 Provide all necessary equipment and tools such as fire extinguisher, fire
blanket, air blower, non-spark generated tools, warning signs and
barricades as required for the job and stated in the work permit and that
all equipment and tools are inspected and tagged by respective PRC
organization.
4.2.2 Section Head shall

4.2.2.1 Ensure effective implementation of this General Instruction in his Section.
4.2.2.2 Authorize his Section staff including contractors for receiving specific permits after
having successfully completed the Work Permit Receiver (WPR), and Hazard
Recognition (HR) trainings provided by Human Capital Management (HCM)
Department
4.2.2.3 Maintain updated list of Work Permit Receivers for his Section detailing the specific
type of permits that an individual can receive.
4.2.2.4 Ensure that the required work permit is received by authorized Work Permit Receiver.
4.2.2.5 Ensure that Section representatives are participating in the Job Safety Analysis (JSA)
as required by the issuing Section.
4.2.2.6 Ensure that the standby Man shall be conversant with the use of radio communication
equipment
4.2.3 Work Permit Receiver shall
4.2.3.1 Understand and follow the requirements as detailed in this General Instruction, receive
the work permits as per his certificate authority and shall carry valid work permit
receiver certificate.
4.2.3.2 Participate in JSA for critical jobs including Confined Space entry. If it is not possible
to attend the JSA, he shall read and understand the JSA before receiving/extending
the work permit.
4.2.3.3 Participate in the joint site inspection with Work Permit Issuer before receiving work
permit to ensure necessary preparations (isolation, LOTO, Gas testing, etc) including
the safety precautions as specified in the JSA are in place before starting the job and
perform the job accordingly.
4.2.3.4 Stay at work site continuously when the job activities are in progress.
Note: If he must leave the worksite upon concurrence of the Issuer, he shall delegate
the job under Work Permit to another certified receiver. The name of designated
person and badge & certificate number must be mentioned on the Work Permit for
reference and records.
4.2.3.5 Ensure that Crew is well informed of hazards involved, understand the work to be
performed and comply with applicable safety rules and instructions.
4.2.3.6 Provide a qualified standby man at each vessel entrance as per the procedure, “Safety
Requirements for Confined Space Entry” (No. PR/IS/SFD/GI-033).
4.2.3.7 Provide a qualified Fire Watch as mentioned in the work permit (refer to definition
3.19).
4.2.3.8 Ensure that inspected non sparking tools and approved electrical equipment are used
as per the electrical area classification requirements.
4.2.3.9 Ensure that power driven tools and equipment are connected through GFCI, inspected
tagged / certified for use in operating areas, including Confined Space.
4.2.3.10 Ensure air movers and approved pneumatic air blowers are provided and operated
continuously for adequate ventilation for the confined space.
4.2.3.11 Ensure that the certified gas tester conducts gas tests at the intervals mentioned in the
work permit by the WPI and records the gas test results at the back of work permit.
4.2.3.12 Display the hard copy of Work Permit at work site.
4.2.3.13 Stop the job safely, in the event of emergency, and ensure the crew members are
evacuated to the nearest safe assembly point, then cancel the work permit.
4.2.3.14 Suspend the job whenever unsafe practices or unsafe conditions are noticed until the
deviations are corrected. In case of major unsafe practices or conditions or which are
potentially IDLH, the work permit shall be cancelled.
4.2.3.15 Conduct joint site inspection with Work Permit Issuer after completion of the job to
ensure that housekeeping is adequate and the area is safe. Then the permit will be
closed.
4.2.3.16 Report immediately to the issuer, if there are any changes to working conditions as
mentioned in the permit.
4.3 Standby Man (Entry Attendant)
4.3.1 Refer to PR/IS/SFD/GI-033 “Safety Requirements of Confined Space Entry”.
4.3.2 The standby Man shall be conversant with the use of radio communication equipment
4.4 Fire Watch shall
4.4.1 Ensure that all combustible materials are removed from the work site.
4.4.2 Stay at work site when the job is under progress and for 30 minutes after completion of the
hot work to monitor the site condition for open flame, hot cutting and welding.
4.4.3 Observe for occurrence of fire in all exposed areas and shall try to extinguish them when
the fires are in capacity of fire extinguishers and other firefighting equipment available.
4.4.4 Not get engaged in any additional job when assigned as Fire Watch.
4.4.5 Ensure that drains remain covered and water sealed within 23 Meters (75 feet).
4.4.6 Ensure that welding sparks are contained (by use of fire blankets, water spray etc.).
4.4.7 Ensure that the portable fire extinguisher is available at site within 3 Meters (10 Feet) and
ready for immediate use.
4.4.8 Know the location of the nearest MCP and shall raise the alarm in case of any emergency
at work site.
4.4.9 Stop the hot work when unsafe conditions are developed and inform to work permit issuer.
4.5 Certified Gas Tester shall
4.5.1 Carryout the function/bump test and visual inspection for portable gas monitor as per
PR/IS/SFD/GI-025 “Gas Testing Requirements”.
4.5.2 Ensure that portable gas monitor has been calibrated and is in reliable working condition prior to
use.
4.5.3 Carryout all gas tests (LEL, Oxygen, H2S, CO) and record the results on the work permit before
start of work, after interruptions, and as mentioned in the work permit.
4.5.4 Stop the work and inform the Work Permit Issuer in case gas testing indicate abnormal gas test
results
4.6 Fire Protection Department Manager shall
4.6.1 Arrange to provide the training on use of SCBA, and firefighting for the nominated Standby Man
and Fire Watch, as per the training needs table Section 5.12.3. Issue certificate to the attendees
on completion of training.
4.6.2 Arrange to conduct refresher training at regular intervals.
4.6.3 Nominate FPD representative(s) to participate in JSA for all Confined Space Entry Permits as
requested by the Issuing Department.
4.6.4 Arrange to provide standby services with fire watch and Fire trucks as requested by the Issuing
Department.
4.7 Safety Department Manager shall

4.7.1 Provide technical safety assistance to the PRC Departments as and when required.
4.7.2 Monitor the implementation of this Instruction and make necessary updates.
4.7.3 Provide inputs to HCM Department to update the safety training material reflecting the latest
revision of this General Instruction.
4.7.4 Arrange to conduct a monthly Work Permit Audit in the field and communicate the findings to
issuers and receivers for immediate corrective action.
4.8 Human Capital Management Department Manager shall
4.8.1 Arrange to provide Work Permit related training as per the training needs table Section 5.12.3 to
the nominated PR employees and contractors.
4.8.2 Ensure the training material is updated to reflect the latest version of this General Instruction.
4.8.3 Ensure that validation test is conducted upon completion of the training and certificates are
issued for the successful attendees for WP Issuer, WP Receiver, Gas Testers, Standby Man and
Fire Watch.
4.8.4 Conduct refresher training course at regular intervals.
4.9 Environment and Occupational Health Department Manager shall
4.9.1 Provide technical E&OH assistance to the requesting Department as and when required.
4.9.2 Arrange to conduct regular checks on the field works to ensure compliance with environmental
requirements.
4.9.3 Isolate /shield the radiation source level for any vessels or tanks installed with nuclear level
gauge as requested.
5.0 Process Description
5.1 General Requirements
5.1.1 The work permit system authorizes specific construction, maintenance, inspection, or repair to
be conducted in the company's restricted areas. The system is intended to be applied to those
jobs, which represent a potential hazard to company operations, facilities, personnel, or
equipment.
5.1.2 Low risk jobs, as determined by the operating organization, may be exempted from the work
permit system. Low risk jobs are those which management determines can be conducted
safely without work permits and may include carpentry, inspections in non-hazardous areas,
cleaning or lubricating of non-hydrocarbon equipment, housekeeping and using certain
classes of non-flash photography. In such cases, the operating organization must maintain
adequate control and account for personnel in the restricted area.
Note: Work may also be subjected to requirements or regulations as stated in the Standard
Operating Procedures, Work Instructions, Risk Assessments, etc.
5.1.3 A work permit is required for jobs including, but not limited to the following:
a) Maintenance Work (Mechanical, Electrical, Instrument, Civil etc.)
b) Construction and Project Work that are not designated as grassroots
c) Alterations/Modifications
d) Process equipment cleaning activities
e) Inspection and condition monitoring
f) Work inside confined space
g) Excavation
h) Vehicle/mobile equipment entry into Hazardous area
i) Underwater maintenance, marine construction
j) Non–routine work in workshops, warehouse, control rooms, instrument rooms, etc., e.g.
Building modification, Mechanical/ Civil/ Electrical/ A/C work in these buildings.
5.1.4 A work permit is NOT required for following routine work, when carried out by the respective
crew:
a) Routine work carried out in established workshops and adjacent yards with fixed
boundaries.
b) Routine material handling work in established warehouses and adjacent lay down yards
with fixed boundaries.
c) Routine office work including cleaning, servicing, servicing of office equipment,

communication equipment, and furniture.
5.1.5 All the contractors, irrespective of their sponsoring organizations and job scope, working in the
restricted areas shall receive a valid work permit.
5.1.6 All non-routine Operational jobs which are carried out by contractors also require a valid work
permit, e.g. chemical tanker, trucks loading/unloading catalyst.
5.1.7 The Work Permit shall indicate any special additional precautions, special PPE and number of
persons working for that particular job.
5.1.8 Permit shall be cancelled under following conditions:
a) If the work did not commence within two hours of the issue of the Permit.
b) Occurrence of emergencies such as, fire, chemical spill, hydrocarbon leak etc. in the Plant.
c) In case of major unsafe practices or conditions or which are potentially IDLH
5.1.9 Personnel working on equipment containing or having the potential to contain H2S shall have
a properly prepared work site and precautions that includes, but not be limited to, the following:
a) Calibrated gas monitoring equipment and personal H2S monitors.
b) Available standby man who is trained in the hazards and effects of H2S exposure.
c) Notification of personnel in the immediate area before work begins, including the posting
of warning signs and/or barricades.
d) Contingency plan/emergency actions to take, including preplanned escape route(s) and

assembly areas, in the event of an H2S release or personnel exposure to elevated levels
of H2S.
e) During the initial opening/line break of any equipment, vessel or piping, the use of
respiratory protection equipment (i.e., SCBA or air-line respirator) is required. Continuous
use of respiratory protection equipment shall be based on subsequent atmospheric testing
per the Procedure: Gas Testing Procedures (PR/IS/SFD/GI-025) and this General
Instruction.
f) Use of the “buddy system” if atmospheric testing indicates H2S levels at or above 10 ppm.
A “buddy system” involves organizing personnel into work groups so that each individual
is designated to be observed by at least one other individual (e.g., in line-of-sight with each
other).
5.1.10 The hard copy of the Work Permit shall be given to the Work Permit Receiver. The hard copy
of the work permit shall be displayed at the work site by the Work Permit Receiver. The receiver
is expected to remain at the job site to adequately supervise the work, however, if he must
leave the job site for any reason, for example to obtain additional tools or equipment, etc., he
must, if the issuer concurs, relinquish supervisory control to another certified receiver, until he
returns. The alternate receiver’s name and badge number must be written on the permit by the
issuer.
5.1.11 Work Permit Issuer & Receiver must extend/renew or close out the Work Permit by signing
both the copies of the Work Permits at the end of each shift, at completion of work, or on
cancellation.
5.1.12 The work permits can be closed by different work permit issuers who are specifically delegated
(formally indicated in the work permit form) for the job by the original work permit issuer.
5.1.13 All issued (open/closed/delegated) work permits shall be recorded in each shift in the work
permit log sheet. See Annexure-2.
5.1.14 Changes to the filled information on the work permit are not allowed. However minor
corrections such as overwriting shall be done by issuer on both copies (original and the display
copy) and shall be initialed by both issuer and the receiver.
5.1.15 The retained copies of the Work permits shall be kept for three (3) months to serve as a record
by the Work Permit Issuer.
5.1.16 Work permit forms must be issued, as appropriate for specific work on a specific site. These
work permit forms are for all types of work in restricted areas. Work permits must be issued for
any of the work or combination of the work identified below:
a) Equipment Opening/Line Break Permit (PR/IS/SFD/F-050)
b) Hot Work Permit (PR/IS/SFD/F-051)
c) Cold Work Permit (PR/IS/SFD/F-052)
d) Entry Permit (PR/IS/SFD/F-053)
5.1.17 Job Safety Analysis (JSA)
a) Job Safety Analysis shall be carried out as per PR/IS/SFD/P-007 “Job Safety Analysis
(JSA)”.
b) A copy of JSA sheet shall be attached with Work Permit during the Job.
c) The work permit issuers and receivers during their joint site inspection shall ensure all
the precautions highlighted in the JSA are implemented in the field and communicated
to crew members prior to start of the job.
5.1.18 Gas Testing for Work Permit
a) The gas tests shall be conducted just before the work begins, starting after breaks &
interruptions, or at the time of extension of the permit as minimum.
b) Work Permit Issuer shall determine the requirement of gas test, and frequency of
repeating the test or the need for continuous monitoring.
c) Continuous Gas testing is MANDATORY for the confined space entry.
d) A Certified Gas Tester, who has been certified from Petro Rabigh HCM Department and
authorized by the Section Head (Work permit Issuer organization) and holding valid
certification card shall carry out the gas test using approved portable gas monitor.
e) Gas Tester shall wear SCBA set for Toxic test, if the presence of toxic vapor or gases is
known or suspected.
Note: For safe work limits related to gas testing refer to Annexure-8 of this Instruction.
5.2 Equipment Opening/Line Break Permit
5.2.1 Release of hazardous liquids or gases is any work that has the potential for actual or possible
release of flammable, combustible, toxic and injurious materials, in levels that can pose a hazard
to personnel, property or the environment. Use form PR/IS/SFD/F-050 (YELLOW). A equipment
opening/line break permit is not intended to authorize a release but to ensure that if there is a
potential for release, all appropriate precautions are taken. Example: Opening a hydrocarbon or
steam line to drain a vessel, Opening a flange, swinging a blind, removing a valve on a pipeline
involving hazardous material, opening a line/equipment containing H2S or nitrogen (N2) etc.
5.2.2 Under no circumstances, a Hot Work Permit and an Equipment Opening/Line Break Work
Permit be issued at the same time at the same location, if the potential release is a flammable
or combustible.
5.2.3 All ignitions sources must be eliminated in areas potentially affected by the release of flammable
liquids and gases therefore Hot Work Permits should not be issued by the proponent in these
areas.
5.2.4 In case simultaneous crane operation is required, then by maintaining safe distance from the
potential release point, crane operation may be permitted after taking preventive safety
measures to mitigate ignition source.
5.2.5 Operating organization shall follow draining and purging procedure per relevant SOP prior to
issuing equipment opening/line breaking permit.
5.2.6 In case required, the WPI, together with the WPR should block all affected roadways and inform
affected areas that the release could possibly reach, and inform emergency services.
5.2.7 If there is a likelihood of a spillage, ditches and dikes to direct the liquid away from the work area
should be arranged by the WPR, in consultation with the WPI. Suitable absorbent materials
should be made available by the WPR.
5.2.8 If the presence of pyrophoric material such as iron sulfide (in such places as knockout drums
and filters) is suspected, the work executer shall keep it wet to prevent it from catching fire. Keep
such pyrophoric material in appropriately labeled water-filled metal drums.
5.2.9 Other pyrophoric material such as TEAL shall be handled as per MSDS / MHB and established
SOP.
5.2.10 It must be assumed that equipment and / or pipelines are full, under pressure or vacuum when
specifying the PPE requirements. The work permit must specify the PPE (by the WPI), which
may include goggles, face shields, boots, rubber gloves, coverall, aprons, hoods, Canister,
SCBA Set as mentioned in MSDS when there is a potential for releasing hazardous chemicals.
Note:
 If inert gas has been used to purge the system, care should be taken to eliminate working
in an oxygen-depleted area.
 If the activity involves potential of release of toxic gases, use of SCBA is mandatory by the
executing personnel.
5.2.11 The gas test is required to be conducted by the certified gas tester (from work permit issuer
organization) for continuous monitoring of the atmosphere around the potential release location
and results shall be recorded on the work permit at 15 minutes interval (until the closure of work
permit).
5.3 Hot Work Permit
5.3.1 Hot work is any work that develops sparks, flames, or heat sufficient to cause ignition. This work
permit will apply to the use of spark or flame producing tools and equipment, including the use
of internal combustion engines in restricted areas. This work permit is also required for open
flames, welding or torch cutting within 23 m (75 ft.) of a pipeline or facility containing
hydrocarbons in non-restricted areas. Use form (red color permit: Form PR/IS/SFD/F-051).
Examples: Work on or in close proximity to live electrical apparatus or use of unapproved

electrical devices (e.g. computers, cellular phones) in a classified area, when a vehicle enters a
plant, welding, torch use, grinding, blasting, etc.
5.3.2 As a preparation for hot work, the proponent shall ensure that equipment is emptied, cleaned of
flammable materials and isolated from source of hydrocarbons by means of disconnection,
blanking or insertion of blinds and adequate LOTO is applied.
5.3.3 Certified Gas tester shall conduct the gas test and all results (O2, H2S, CO, LEL) must be
recorded on the work permit. Gas test is a must for all hot works including vehicle/equipment
entry and use of battery/power operated ordinary equipment in hazardous area. No hot work
permit is allowed if the atmosphere is above 0% LEL.
5.3.4 Work Permit Issuer and Receiver shall ensure that, within 23 m (75 feet) of a hot work site, any
sewers and surface manhole are covered and that all sources of release are properly
isolated/sealed (sealed using flame retardant tarpaulin, wet rags or metal plate) such as sample
point and relief valves outlets.
5.3.5 Precautions shall be taken to prevent the spread of sparks and molten metal by surrounding the
work area with fire-resistant/flame retardant tarpaulin or metal sheets.
5.3.6 Hot work permit area shall be barricaded by the work permit receiver and appropriate warning
signs shall be posted at the site by him.
5.3.7 Fire watch shall be made available by the WPR at the site during hot work.
5.3.8 Grounding / bonding shall be provided by the WPR to avoid static electricity hazard during sand
blasting, spray painting, refueling jobs, etc.
5.3.9 Use of lighters, non-intrinsically safe personal, cameras, and any other ordinary battery operated
appliances are prohibited in hazardous areas unless approved by the Issuing Department and
a Hot Work Permit obtained.
Note: During T&I, explosion proof/intrinsically safe lighting fixtures shall be used. Ordinary type
(non-explosion proof / non-intrinsically safe) lighting equipment are not recommended to be
used / installed during the T&I in the the process plant areas since there may still be presence
of flammable / ignitable vapors while opening certain process equipment and pipelines.
However, if ordinary portable flood lights or lamps are to be used in the plant areas during the
complex TCS/T&I, operating organization shall issue hot work permit for the use of these tools
at the selected locations, following the requirements in this Instruction.
However, ordinary lighting fixture shall not be used inside confined space.
5.4 Vehicle/Equipment Entry
5.4.1 Hot work permit is required for entry of any vehicle or mobile equipment into plant battery limits
including tank dike areas.
5.4.2 Spark producing equipment such as engine driven compressor shall be fitted with approved
spark arrester on their exhaust and are properly grounded.
5.4.3 Driver should be given clear instructions on which route to follow to enter in plant battery limits
and escorted by Issuing Department representative within the plant battery limits.
NOTE:
The guidelines outlined in the procedure “Escorting Chemical Trucks, Document No. PR/MFT/P-02/14
issued by the SVP (MFT) Office shall be followed, which covers guidelines for the escorting & movement
of trucks from the low security area to high security areas and within the high security areas – among
others.
5.5 Confined Space Entry Permit
5.5.1 Confined space entry is the entry of personnel into any space or structure (i.e., tank, vessel,
vault, excavations when 1.2 m (4 ft) or deeper, etc.) not normally intended for human occupancy,
where entry, movement within, or exit is restricted. Use Form (green color permit; Form No.
PR/IS/SFD/F-053).
5.5.2 Confined space entry is required for excavation of 1.2 m deep or more. Other requirements for
excavation work refer to the GI No. PR/IS/SFD/P-034 “Safety Requirements for Excavation” and
the Petro Rabigh Construction Safety Manual: PR/IS/SFD/M-001
5.5.3 Refer General Instruction Safety Requirements for Confined Space Entry (PR/IS/SFD/GI-033)
and Petro Rabigh Construction Safety Manual (PR/IS/SFD/M-001) for the Safety Requirements
for Confined Space Entry.
5.6 Cold Work Permit
5.6.1 Cold work is work that will not produce sufficient energy to ignite flammable atmospheres /
materials. Use Cold Work Permit Form (blue color permit) No. PR/IS/SFD/F-052. Examples are
but not limited to work with hand tools, sand removal, or repair, scaffold erection, brush painting.
5.6.2 Non-sparking tools shall be used during the job involving Hydrocarbon or oxygen services.
5.7 Issuance and approval of work permits
5.7.1 The issuer and receiver are jointly responsible for the safety of personnel and equipment in the
area. The issuer is responsible for specifying precautions so that the work can be done without
injury or loss. The receiver is responsible for performing the work in accordance with the
conditions and requirements agreed upon with the issuer and specified in the work permit.
5.7.2 Before issuing the work permit all necessary actions to approve the proposed work and/or
possible configuration changes must be completed. The issuer must verify that the receiver's
certificate is valid and approved for the type of work to be done.
5.7.3 The receiver shall request the work permits from the operations supervisor of the facility (i.e.,
the issuer) and must participate in any joint site inspection that is conducted. The receiver can
complete the initiation part of the work permit form. The initiation part of the work permit includes
the information section from the top of the form, to the section titled “Mention tools and
equipment used at the site”.
5.7.4 The issuer will issue the work permit after he (or his designated representative) has conducted
a joint site inspection with the receiver as appropriate, performed the necessary gas tests, listed
applicable precautions and restrictions, and reviewed all aspects of the job with the receiver.
The issuer's and receiver's signatures plus any other approvals and signatures must be on the
completed form as well as any additional information or checklist such as excavation checklist
and entry log. These additional approvals or signatures are required for extended permits or for
some specific jobs.
5.7.5 If required, the issuer must obtain the approval per annexure-1 and counter signature of any
other operations supervisors (i.e., issuers) whose operations will be affected, before issuing a
permit.
5.7.6 DCS/Board operators in the control room shall maintain a log of all active Hot Work permits,
Equipment Opening/Line Break permits and Confined Space Entry permits issued for their
plants.
5.7.7 During an emergency the issuer can authorize work without work permits. The work activity,
however, cannot violate any Petro Rabigh minimum safety standards. The issuer should issue
work permits as soon as possible.
5.8 Work permit renewal / extension:
5.8.1 Maximum validity of initial issue of a Work Permit shall be for the duration of the work or until
the end of the shift, whichever is less. The extension or renewal requires the signatures of both
the issuer and the receiver coming on shift. The issuer or receiver shall not sign for duration
beyond their working hours.
5.8.2 Extension of the Work Permit is permissible only for one shift.
5.8.3 Work may continue up to 1 hour while the Work Permit is being extended provided all the work
conditions remain as specified in the existing permit.
5.8.4 Signing the work permit indicates complete agreement with the conditions stated on the form
and transfers the responsibility to those coming on shift.
5.8.5 The work permit is for specific work on a specific site. It cannot be transferred except to the
following shift. Transfer from one craft to a different craft is not permitted.
5.8.6 Extended work permits may be issued for periods over 2 shifts but not exceeding 30 days for
certain extended construction or maintenance works where the job requirements remain
essentially unchanged. The permit must be approved by the Department Head or above of the
issuing Department and the following conditions must be satisfied after a JSA.
For such ‘extended’ work permits, following conditions must be met to the satisfaction of
Proponent, Executor and Safety Department:
5.8.6.1 Conditions are not expected to change which would create a serious hazard to
personnel or operating facilities.
5.8.6.2 The area is adequately isolated from existing operating areas and Emergency stop work
alarms are installed.
5.8.6.3 Both the Proponent Section Head and the Executor Section Head must be in agreement
as to job conditions and risks involved and both must sign the Work Permit.
5.8.6.4 Any work on or connected to equipment or piping containing flammable or toxic

materials shall require individual daily Work Permit.
5.8.6.5 All crane operations shall require daily Hot Work Permits.
5.8.6.6 All work in confined spaces usually requires a permit issued daily per normal Work
Permit procedure.
5.8.6.7 A logbook is maintained to account for personnel entering confined spaces as per the
General Instruction PR/IS/SFD/GI-033 - Safety Requirements for Confined Space
Entry.
5.8.6.8 Gas testing shall be carried out by the certified gas tester daily per normal Work Permit
Procedure
5.8.7 It must be highly unlikely that conditions will develop which would create an additional hazard to
personnel or operating facilities.
5.8.8 Precautions must be taken prior to starting the job, to ensure safe conditions throughout the job.
5.8.9 Both the operating Department head and the maintenance/construction Department head must
be in agreement as to the job conditions and risks involved and both must sign the work permit.
5.9 Right to stop work and cancellation
5.9.1 The issuer may stop a job and withdraw a work permit if he determines that safety of the job
does not meet the conditions specified on the work permit.
5.9.2 When work is stopped the issuer must pick up the work permit, write on the permit the reasons
for the work cancellation, the time, and other relevant information.
5.9.3 When conditions are safe again the issuer may issue a new work permit.
5.9.4 The receiver has the responsibility to stop work and advise the issuer of his action any time he
determines that the conditions of the job do not meet the conditions on the work permit. He and
the issuer shall take action to correct deficiencies and resume the job.
5.9.5 In case of major unsafe practices or conditions, which are potentially IDLH, the work permit shall
be cancelled by the issuer.
5.9.6 All unnecessary personnel whose presence adversely affects the safety of the job must be kept
away from the job site or work shall be stopped.
5.9.7 In the event of an emergencies such as a fire or toxic release all Work Permits are automatically
cancelled, Permits may be re-issued once the “all clear” has been declared and the work sites
have been returned to their pre-emergency conditions.
5.9.8 If an unsafe condition develops or when neither the issuer nor the receiver is available at the
work site, any Petro Rabigh employee has the right to stop the work and inform the issuer of
such infractions, unsafe conditions or acts.
5.10 Closing work permit
5.10.1 Both the Issuer (and/or his designated representative) and Receiver shall conduct a site
inspection to ensure that the work area has been returned to its pre-Work Permit condition
before the Work Permit is closed.
5.10.1.1 As soon as the job is completed the involved personnel must leave the job site and
the receiver must contact the permit issuer to arrange joint site inspection for timely
closure of the permit, and before leaving the site.
5.10.1.2 If the receiver has left the work site without notifying / closing the permit, the issuer
shall confirm that the work site has been left in safe and secured condition and shall
report the occurrence as a violation of the receiver.
5.10.1.3 If the work has not been completed and the activity will be continued at a later time
under a new permit, the work site shall be left in a safe and secured condition.
5.10.2 Work Permits original and hard copies shall be closed simultaneously by the signatures of either
the Issuer (or his reliever who is also an issuer) and the Receiver.
5.11 Filing Work Permits

5.11.1 Issuer shall keep the original copy of the Work Permit(s) for a minimum period of 3 months to
serve as a record according to legal requirement to be used for incident investigation, audits,
etc.
5.12 Certification
5.12.1 Work permit issuers, receivers, and designated representative shall have adequate knowledge
and experience to recognize hazards and comply with the requirements of this instruction.
5.12.2 Issuer candidates are required to successfully complete both the Gas Tester and Hazard
Recognition courses as pre-requisites before being allowed to take the issuer’s certification
exam. Both of these courses must be completed every two years.
5.12.3 Both the Issuer and Receiver require re-certification every 2 years from the date of issue
Note: For the Designated Representative, the re-certification will be every four (4) years from
the date of issue
Designated Fire Standby

Training Course Issuer Receiver Representative
Provider
Watch Man
Work Permit Issuer √ √ HCM
Work Permit Receiver √ HCM
Hazard Recognition √ √ √ √ √ HCM
Gas Testing √ √ √ HCM
H2S √ √ √ √ HCM
Confined Space Entry √ √ √ √ HCM
Lock Out/Tag Out √ √ √ HCM
SCBA √ FPD
Fire Fighting √ √ FPD
5.12.4 Work permit certificates will be issued by HCM Department to the employee’s management
indicating that they have successfully completed the certification exam for issuers, receivers,
and/or gas testers as appropriate. Only when the certificate is signed by the employee's Section
Head, or in case of a contractor by his sponsoring organization Section Head, does the
candidate become a certified issuer or receiver.
5.12.5 The signing of a certificate provides a written record of the Department manager’s acceptance
that an issuer or receiver has sufficient knowledge and/or skills to perform assigned functions in
restricted areas. This acceptance also indicates that an issuer or receiver understands the
contents of this General Instruction.
5.12.6 Any person issuing or receiving a work permit must have in his possession a valid issuer's or
receiver's work permit certificate, as appropriate, at the time of issuing or receiving permits.
5.12.7 All organizations must maintain records of their work permit issuer/receiver certified personnel.
Certificates expire two years after the date of issue.
5.12.8 When an employee is transferred to another organization, his new Department manager shall
review his past trainings, his past experience in work permit system implementation and formally
request HCM Department to reissue his certificate or he shall nominate the transferred
employee for recertification.
5.12.9 The Manager has an authority to withdraw the certification of issuers and receivers based on
his review of the performance of the individual related to work permit implementation and
observed frequency and seriousness of infractions from auditing. The reason for withdrawal
should be documented and communicated to HCM.
5.13 Work Permit Audit
5.13.1 The purpose of work permit audit is to ensure that all the requirements detailed in this General
Instructions are effectively implemented for safe execution of all permitted work activities.
5.13.2 Details of the audit requirements are mentioned under respective personnel responsibilities
(See Section-4)
6.0 Forms & Formats for Records
Sr. No. Form/Template/Log Sheet Number Description
1 PR/IS/SFD/F-014 Logbook Form
2 PR/IS/SFD/F-015 Work Permit Audit Form
3 PR/IS/SFD/F-050 Equipment Opening/Line Break Permit Form
4 PR/IS/SFD/F-051 Hot Work Permit Form
5 PR/IS/SFD/F-052 Cold Work Permit Form
6 PR/IS/SFD/F-053 Entry Permit Form

7.0 Reference
Sr. No. Document Number Title / Description
1 PR/IS/SFD/GI-026 Isolation, Lockout And Use of Hold Tags
2 PR/IS/SFD/M-001 Petro Rabigh Construction Safety Manual
3 PR/IS/SFD/GI-033 Safety Requirements for Confined Space Entry
4 PR/IS/SFD/GI-025 Gas Testing Procedures
5 PR/Safety/M-003 Petro Rabigh Safety Handbook
6 PR/IS/SFD/M-001 Petro Rabigh Construction Safety Manual
7 PR/MFT/P-02/14 Escorting Chemical Trucks
8 OSHA 29 CFR 1910.147 The Control of Hazardous Energy (Lockout/Tagout)
8.0 Document History
Revision Effective
Description of Revision Approvals
No. Date
00 12/12/2008 1st Issue Takeshi Kikuchi

Recommen Manager(Corporate
ded By Safety and Fire
Protection Department )
Concurred Yasuhiko Kitaura
By Sr. VP (Manufacturing)
Sami Iskandrani
Approved GM (General
By Administration &
Industrial Security)
01 03/08/2011 Complete Revision Mohammed A. Baaqil

Initiated By Manager(Corporate
Safety and Fire
Protection Department )
Concurred Tadaki Matsuo
Abdulaziz H. Mutwalli
VP (Engineering &
Support)
Osamah O. Fakieh
VP (Human Resources
&
Corporate Affairs)
Takashi Shigemori
VP (Market
Development)
Omar H. Alauddin
Approved VP (General
By Administration &
02 09/09/2012 Change in the following Sections: Mussad S. Juhani

Section Head (A)
Initiated By
1. Reorganized the sections (Corporate Safety
Section)
2. Added requirements for working in H2S Ghazi M. Shareef
services Manager (A)
Recommen
ded By (Corporate Safety and
3. Annexure-4 Fire Protection
Department)
4. Annexure-5 Concurred Tadaki Matsuo
5. Annexure-6
Abdullah M. Qahtani
6. Annexure-7 VP (Engineering &
Support)
7. Annexure-8 Osamah O. Fakieh
VP (Human Resources
8. Annexure-9 &
Corporate Affairs)
Takashi Shigemori
VP (Market
Development)
Omar H. Alauddin
Approved VP (General
By Administration &
Following are the changes made:

Assem M Saleh (Head,
02 • Section 5.1.14: The console operators in Initiated By SM&TS Section)
Amendme 02/19/2015 control rooms of PRC facilities shall have
nt-1 constant access to a log of all work permit Mohammed A Baaqil,
Reviewed
activities within their area of control Safety Department
By
Manager
• Corrected titles of concerned organizations

Abdullah M Idris,
• GI Format Changed as per OE guidelines Concurred
General manager
By
MF/Operations-1
Approved Abdullah M. Al-Qahtani

By VP (Industrial Security)
02 06/18/2015 Following is the addition made: Assem M Saleh (Head,

Initiated By
Amend- SM&TS Section)
ment-2 Added Sub-section 5.13 (Disciplinary Actions Mohammed A Baaqil,
Reviewed
Safety Department
on Forging the Work Permit Documents) By
Manager
Approved Abdullah M. Al-Qahtani
By VP (Industrial Security)
03 February 14,  The revision considered adopting applicable STS Section Head
Initiated By
2017 requirements of the newly issued SA Work (AMS)
Permit GI
OE&S Head (Adrian
 Added Grassroots project’s definition and
Blanck)
address its applicability to the general Reviewed
instruction requirements By
 Changed “release permit” to “equipment SFD Manager (MAB)
opening/line break permit” to reflect the
purpose of this type of work permit SVP-MFT (Seiji
 Additional certification requirements added Takeuchi)
to the issuer and receiver (LOTO and
CFO (Naoyuki Inoue)
confined space)
 Included certification requirements for VP-MD (Takashi
Standby Man, designated representative Concurred Shigemori)
and fire watch. By
VP-E&S (Tareq A. Al
 Elevated the responsibility of authorizing
Nuaim)
work permit issuer (WPI) and receivers
(WPR) from Section Head to Department
Manager to strengthen and properly affix the VP-IR (Bassam A. Al
accountability within this safety system Bokhari)
 Provided explanation for conducting joint
site inspection and hazards identification
guide (Annexure-9)
 Changed the distances to cover sewers
opening and sealing vent lines from 15 m to Approved VP-IS (Abdullah M Al
23 m for any hot work By Qahtani)
 Elaborated on the use of ordinary (non-
explosion proof / intrinsically safe) flood light
equipment and lighting fixtures during the
complex T&I
 Provided clarification on the application of

‘extended work permits’
04 August 1,  WPI, WPR, GT etc. training certificates shall G. T. Joshi

Initiated By
2018 be certified (signed) by the employees’ (Sr. Safety Engineer)
Section Heads (or the contractor proponent
Section Head, in case of contractor Mohammed Shehri,
employee WPR) (3.58, 3.39, 4.1.2.5, Head, SM&S
4.2.2.2, 5.12.4
 The re-certification requirement for the Reviewed Adrian S. Blanck
‘designated representatives’ will be four (4) By Head, CPM Unit
years (3.1.3, 5.12.3)
 The standby man shall be trained in Hazard Mohammed A. Baaqil
Recognition, H2S Awareness, Gas Testing (SFD Manager)
and Confined Space Entry; he shall be
conversant with the use of radio
communication equipment (3.51, 4.2.2.6, Seiji Takeuchi,
4.3.2, SVP-MFT
 WPI to ensure presence of field operator
during the initial opening/line break of the Adel M Ghamdi,
equipment (4.1.3.22) V.P (E&S) (A)
 HCMD to provide training for Standby Man
and Fire Watch and issue certificate (to be
signed by the employees’ Section Heads) Concurred Hiroshi Shimizu,
(4.8.3) By V.P (MD) (A)
 Standby Man to be trained in Gas Testing
also (5.12.3) Hesham H. Azzouz,
 Annexure-1: Level of Countersigning V.P (IR) (A)
Authority AND Annexure-8: Safe Work
Limits (Gas Testing): The countersigning
authority levels have been brought down to Naoyuki Inoue,
Secction Head level (from Manager level) Chief Financial Officer
 WPI Certification requirement for the Issuing

Section Head and the PRSS is deleted
(4.1.2)
 FORMS: In all four Work Permit Forms
Approved Abdullah M Al Qahtani
(HWP, CWP, Entry Permit & Equipment
By VP-IS
Opening / Line Break Permit, the revised
Gas Testing Information / table is corrected
(to align with revised level of countersigning
authrorities)
9.0 Work Permit Flowchart
1. REQUIREMENT OF WORK 6. ISSUANCE , APPROVAL AND WORK

PERMIT (COLD WORK, HOT TO BE CARRIED OUT
WORK, ENTRY & RELEASE )  Filling of Work Permit by the Issuer
Specific Construction, Maintenance,  Verifies Receiver certificates by the
Inspection or repair work to be Issuer
conducted in restricted areas  Signatures by the Issuer and Receiver
 Counter-sign by the Section
2. Hazard Identification Head/PRSS, if required
 Job Safety Analysis (if required)  Precautions by the Receiver during job
by the team (Proponent, SFD, REVALIDATION
Maintenance, Engineering,
 Conduct Joint Site Inspection by the
Contractor etc.)
Issuer and Receiver
 Pre-entry planning meeting for
 Conduct Site Gas Test and records
Confined Space Entry
results (certified Gas Tester)
3. PRECAUTIONS BY THE  Signatures by the Issuer and Receiver

PROPONENT DEPARTMENT
De-pressurization, Purging, Positive
Isolation, Lock Out Tag Out etc.
4. SITE INSPECTION 7. WORK COMPLETION/PERMIT

Joint site inspection by the Issuer CLOSING
and Receiver  Conduct site inspection by the Issuer
and Receiver
5. SITE GAS TESTS  Remove Lock and Tag (WPR & WPI)
 Specifies type of Gas test(s) and  Conduct Housekeeping (WPR)

frequency (by WPI).  Signatures by the Issuer and Receiver
 Conduct Gas Test and records  Retain copies of work permit for 3
results (by certified Gas Tester) months by Issuer and Receiver
10.0 Annexure
10.1 Annexure-1: Level of Countersigning Authority
10.2 Annexure-2: Logbook Form (Form No. PR/IS/SFD/F-014)
10.3 Annexure-3: Work Permit Audit Form (Form No. PR/IS/SFD/F-015)
10.4 Annexure-4: Equipment Opening/Line Break Permit Form (Form No. PR/IS/SFD/F-050)
10.5 Annexure-5: Hot Work Permit Form (Form No. PR/IS/SFD/F-051)
10.6 Annexure-6: Cold Work Permit Form (Form No. PR/IS/SFD/F-052)
10.7 Annexure-7: Entry Permit Form (Form No. PR/IS/SFD/F-053)
10.8 Annexure-8: Safe Work Limits (Gas Testing)
10.9 Annexure-9: Joint Site Inspection

Annexure-1: Level of Countersigning Authority
Concurring / Countersigning Concurring (Receiving

No. Type of Permit and Critical activities
(Issuing Organization) Organization)
1. Equipment Opening/Line Break Permit
Significant releases of combustible gases,
1.1 flammable liquids low flash (below 65.6 °C) liquids
or liquids at/ or above their flash point. PRC Field Maintenance
Issuing Section Head or Section Head or
Crane operation along with equipment opening/line Equivalent (PRSS during off- Equivalent (Shift Crew
1.2
break work permit hours) Supervisor during off-
1.3 Open flanges in toxic or corrosive systems. hours)
1.4 Removal of plant relief valve.

2. Hot Work Permit
Critical hot works such as open flame cutting or Issuing Section Head or PRC Field Maintenance
welding when the equipment is in operation, welding Equivalent (PRSS during off- Section Head or
2.1 on pipes or equipment containing gas or hours) Equivalent (Shift Crew
hydrocarbon under pressure, Installation of Hot Supervisor during off-
Tapped connection etc. hours)
Any work on electrical switch gear on substation in-

ESO Day Supervisor (PRSS Power System
2.2 comers, transformer feeders or tie-breakers, ESO
during off-hours) Department Supervisor
Shift Supervisor shall sign (issue) Work Permits
PRC Field Maintenance

Issuing Department Section Section Head or
2.3 Critical lifts (Lift plan is required). Head or Equivalent (PRSS Equivalent (Shift Crew
during off-hours) Supervisor during off-
hours)
3. Cold & Confined Space Entry Permits
Any work where: (1) H2S concentration is 10 ppm to Issuing Department Section PRC Field Maintenance
100 ppm (2) O2 is less than 20 %. (3) CO Head or Equivalent (PRSS Section Head or
3.1 concentration 25 ppm to 400 ppm (4) LEL 5% to during off-hours) Equivalent (Shift Crew
20% Supervisor during off-
hours)
Issuing Department Section
3.2 Initial entry into any Confined Space. Head or Equivalent (PRSS Executing Supervisor
during off-hours)
Issuing Department Manager Field Maintenance
or Equivalent Section Head or
3.3 Initial entry into any vessel with inert atmosphere (PRSS during off-hours) Equivalent (Shift Crew
Supervisor during off-
hours)
Annexure-2: Logbook Form
(Form No. PR/IS/SFD/F-014)
Time of Permit Work Time of

S/N Date Permit Description Issuer # Receiver #
Issue Type Permit No. Closure
Form No. PR/IS/SFD/F-014

Annexure-3: Work Permit Audit Form

(Form No. PR/IS/SFD/F-015)
Date conducted:
Conducted by:
Work Violation to
Issuance Work Infraction
No Permit Type Location Work Scope Receiver (R)/
Date Permit No. (1) No (2)
Issuer (I)
10
11
12
Note: (1) C: Cold, H: Hot, CS: Confined Space, R: Release

(2) Work Permit infraction numbers (See following page).
Form: PR/IS/SFD/F-015
Table: Type of Infraction
Infraction No Infraction Type

1 Incorrect Permit Issued/ No Permit
2 Issuer's Certificate Invalid
3 Joint Site Inspection Not Conducted

4 Permit Improperly Countersigned
5 Improper Gas Tests Recorded

6 Permit Improperly Closed/ Extended
7 Gas Testing Equipment Not Operational

8 Permit Not Available At Site
9 Receiver/ Delegate Not Available At Site
10 Receiver Certificate Invalid
11 Work Scope Improperly Defined
12 Equipment Improperly Identified
13 Hazards Improperly Defined
14 Precautions Improperly Defined
15 Gas Test Improperly Conducted
16 Receiver Not Following Permit Instructions
17 Barricade/Warning Signs Inadequate
18 Personal Protective Equipment (PPE) Inadequate
19 Issuer’s Lockout/ Hold Tag Inadequate
20 Receiver's Lockout/ Hold Tag Inadequate
21 Standby Man Unavailable
22 Tools In Poor Condition
23 Scaffolding Unacceptable
24 Unacceptable Excavation Procedures
25 Equipment Not Isolated/ Depressurized
26 Equipment Not Cleaned/ Purged
27 Invalid Crane Inspection Sticker
28 Invalid Heavy Equipment Operator's License
29 Housekeeping/ Storage Unacceptable
30 Health Hazards Not Addressed
31 Fire Protection Equipment Inadequate
32 Fire watch Unavailable/ Unqualified
33 Sewers Not Covered Within 22.5 m
34 Others (write in comments)
Annexure-4: Equipment Opening/Line Break Permit Form (Form No. PR/IS/SFD/F-050)

Annxure-5: Hot Work Permit Form (Form No. PR/IS/SFD/F-051)

Annexure-6: Cold Work Permit Form (Form No. PR/IS/SFD/F-052)

Annexure-7: Entry Permit Form (Form No. PR/IS/SFD/F-053)

Annexure-8: Safe Work Limits (Gas Testing)
Gas Test Information
Items Gas Tester’s Results Action/ Requirements
Above 0% LEL No Hot Work permitted
Combustible Up to 5% LEL Cold Work and Confined Space Entry permitted

Gases/
Breathing apparatus must be used and issuing Section Head must
Vapors 5% to 20% LEL
countersign on Work Permit
Above 20% LEL No work permitted
Below 10 ppm OK to work
At or above 10 PPM, Breathing apparatus must be used and issuing Section Head must
H2S but less than or equal
countersign on Work Permit
to 100
Above 100 ppm No work permitted

Below 20%
O2 countersign on Work Permit
Above 23.5% No work permitted

25 ppm to 400 ppm
CO countersign on Work Permit
Above 400 ppm No work permitted
Note 1: Use the 3-in-1 or 4-in-1 Multi Gas Monitor on continuous basis to monitor the air quality inside the
confined space. The monitor has an audible and visual alarm facility, which when activated the work
shall be suspended and the personnel in the confined space shall be evacuated.
Note 2: No confined space is to be entered without a valid Entry Permit.
Note 3: All Work Permit users shall follow the limits specified in the above table (Gas testing) for approval and
work
Note 4: For other toxic gases such as SO2 and Chlorine, no work shall be allowed when the reading is above
the one third (1/3) of IDLH value (of such gases). For a possible carcinogenic exposure (Refer EOHD),
the entry shall be allowed only with a respiratory protection.
Note 5: No work shall be permitted in areas where hazardous atmosphere exists.
Note 6: For Inert Entry, refer to specific JSA.

Annexure-9: Joint Site Inspection
1 A joint site inspection shall be conducted for all permits by the issuer (or his designated representative) and the
receiver.
2 The joint site inspection allows for the sharing of information before commencing work. The following shall be
completed by the involved parties during the joint site inspection:
2.1 Conduct applicable atmospheric gas tests per this instruction and PR/IS/SFD/GI-025 record the results on
the permit form and/or supplemental gas test records attachment.
2.2 Conduct an assessment of the work activity to be conducted (i.e., hazard analysis), including the individual
job steps, the equipment to be used and the working environment at the job site. Use JSA document if
available and discuss the identified hazards and controls.
2.3 Review the protective measures specified by the applicable work permit(s) to verify they are in place and
address the hazards of the work activity.
3 The following considerations can be used as an aid to carry out the hazard analysis :
3.1 Observe the work area and surroundings.
3.2 Take action to control any hazards that may be created because of the work activity.
3.3 Discuss experience/lessons learned when performing the same work previously.
3.4 The issuer (or his designated representative) and receiver should repeat the steps of the hazard analysis
whenever they encounter an unexpected problem.
4 The hazard analysis should evaluate/recognize the following hazards and controls, at a minimum:
4.1 Is the correct type of permit(s) issued for the work?
4.2 Have the Job Safety Analysis (JSA) and other applicable supplementary forms been communicated to the
work crew?
4.3 Are weather conditions (e.g., wind speed) acceptable to perform the work?
4.4 Are slip and trip hazards controlled?
4.5 Does the work crew have the correct tools/equipment for the job? Are they in good condition?
4.6 Do personnel have the proper certifications to perform the activity and/or operate the equipment?
4.7 Is the equipment’s inspection sticker valid?
4.8 Have all requirements for working at heights (i.e., fall protection) been applied?
4.9 Is the scaffold tag completed correctly, signed and with a valid inspection date?
4.10 Has the potential for contact with sharp objects, rotating equipment, hot/cold surfaces or live electricity been
eliminated?
4.11 Is the system/equipment properly isolated and locked out? Did all workers apply their personal locks?
4.12 Has the system/equipment been depressurized, drained and/or purged before opening it?
4.13 Has the potential for releasing flammable liquids and gases been controlled?
4.14 Are all ignition sources eliminated or controlled?
4.15 Does the fire watch have firefighting equipment readily available and know how to use the equipment?
4.16 Has the potential for exposures to high noise levels, H2S, hydrocarbons, asbestos, hazardous chemicals
or radioactive materials been controlled?
4.17 Is the correct personal protective equipment (PPE) available for use by personnel?
4.18 If the work may impact others nearby, or vice versa, have the work crews discussed their activities with
each other (i.e., simultaneous operations [SIMOPS])?
4.19 Is there an emergency contingency plan in place to respond to the work being performed?
4.20 Does the work crew know what to do in the event of an emergency, such as evacuation routes, location of
emergency equipment and where assembly areas are located?
5 Any hazards listed in Section 4.0 that are not sufficiently addressed (i.e., answered ‘NO’) shall initiate a “STOP”
point where the issuer and receiver are to analyze the hazard(s) and develop methods to adequately control the
hazard(s). The issuer and receiver shall list any additional precautions on the applicable work permit(s) and
discuss these improvements with the work crew.

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General Instruction Work Permit System

Industrial Security Function

Company General Use Restricted Confidential Government Confidential

1.0 Purpose ......................................................................................................................................................... 3

3.0 Acronyms / Definitions

3.1 CCR: Central Control Room

3.3 CO: Carbon Monoxide

3.8 CSM: Construction Safety Manual

 Significant impact on the environment by way of toxic release, pollution. etc.

3.12 DCS: Distributed Control System

3.14 EOHD: Environment & Occupational Health Department

3.15 Equipment Opening/Line Break Permit: A completed document PR/IS/SFD/F-050 authorizing to

3.16 ESO: Electrical System Operator

3.20 FPD: Fire Protection Department

3.21 GFCI: Ground Fault Circuit Interrupter

3.23 H2S: Hydrogen Sulfide (also, H2S)

 Atmospheric oxygen concentration below 20 % or above 23.5 %

3.25 HCM: Human Capital Management (Department)

 Pneumatic air or other gas

 Fuel gas, process air or other gases

 In situ cleaning systems

3.29 JSA: Job Safety Analysis

3.30 LOTO: Lockout Tag-out

3.32 MCP: Manual Call Point

3.33 MFT: Manufacturing

3.34 MHB: Material Hazard Bulletin

3.35 MSDS: Material Safety Data Sheet

3.38 P&ID: Piping and Instrumentation Diagram/Drawing

3.39 PEL: Permissible Exposure Limit

3.40 PIB: Process Interface Building

3.41 PLC: Programmable Logic Controller

3.42 PPE: Personal Protective Equipment

3.43 PPM: Parts Per Million

3.44 PR: Petro Rabigh (same as PRC)

3.46 PRSS: Petro Rabigh Shift Superintendent

3.48 RSO: Radiation Safety Officer

3.49 SCBA: Self-contained Breathing Apparatus

3.50 SOP: Standard Operating Procedure

3.52 SVP (MFT): Sr. Vice President (Manufacturing)

3.53 T&I: Testing & Inspection

3.54 TCS: Total Complex Shut-down

3.55 TEAL: Tri-ethyl Aluminum

3.57 WP: Work Permit

4.1 Work Permit Issuer Organization

4.1.1 Department Manager shall

4.1.2 Section Head shall:

4.1.2.2 Ensure effective implementation of this general instruction in his Section

4.1.3 Work Permit Issuer Shall:

4.1.3.6 Ensure vessel/equipment is isolated, purged as per SOP/JSA.

4.2 Work Permit Receiver Organization

4.2.1 Department Manager shall

4.2.1.3.5 Ensure personal protective equipment (PPE) and Flame Resistant

4.2.2 Section Head shall

4.2.2.1 Ensure effective implementation of this General Instruction in his Section.

4.2.3 Work Permit Receiver shall

4.2.3.12 Display the hard copy of Work Permit at work site.

4.3 Standby Man (Entry Attendant)

4.3.1 Refer to PR/IS/SFD/GI-033 “Safety Requirements of Confined Space Entry”.