Permit to Work

Introduction:

Instructions or procedures are adequate for most work activities, but some require extra care.

A permit-to-work system is a formal written system used to control certain types of work that are potentially

hazardous. A permit-to-work is a document which specifies the work to be done and the precautions to be

taken. Permits-to-work form an essential part of safe systems of work for many maintenance activities.
 The objectives of the Work Permit System are to exercise control over the maintenance, repair and

construction activities by assigning responsibilities, ensuring clear cut communication between interested

functions & safety considerations to the job, its hazards & the precautions required. It ensures that the work

is properly defined, authorized, operating personnel are aware what is going on, precautions to be taken are

specified and the persons executing the job understand the nature and extent of hazards involved.

Work Permit System is an important element of Safety Management System and implementation of this in

true spirit shall help in ensuring a safe working environment, thereby reducing possibility of injury to

personnel, protect property, avoiding fire, explosion & adverse affect on environment.

Learning Outcomes of Permit to Work training

Upon completion of training, participant will be familiar with essential features of a Permit-to-Work system

such as :

 Clear definition of who may authorize particular jobs (and any limits to their authority) and who is

responsible for specifying essential precautions.

 Provision for ensuring that contractors, who are engaged to carry out work, are covered by the

system.

 Training and instruction for issuing Permits.

 Monitoring and auditing to ensure that the system works as intended.

The course also covers the following aspects of Permit-to-Work systems:

 Human factors.

 Management of Work Permit systems.

 Objectives of the Work Permit system.

 Types of Work Permits required.

 Contents of Work Permits.

The training sessions would be as per industrial guidelines and best practices.

Who can take the Permit to Work training?

Any person responsible for issuing and accepting Permit to Work systems.

Benefits of Permit to Work training

Organizations become aware of the regulations concerning hazardous work activities. This training ensures

that they understand their duties and obligations in accordance with law. This training will enable

participants to assess the requirements of a particular job or task, and ensure that Permit to Work
documentation is completed correctly - and that employees undertaking hazardous activities are competent

to do so safely.

challenges with Manual Permit to Work Processes

Energy, Utility and Industrial companies of all sizes struggle with maintaining manual paper documents
and forms.  Permit to work procedures vary greatly between organizations and very few have an automated
permit to work system.  The wide variety of staffing models and organizational structures pose problems to
standardizing safety management procedures.  Power Generation, Transmission, Distribution, Oil, Natural
Gas, Manufacturing and Construction all need to have basic safety requirements based on OHSA, HSE and
other international safety regulations.  Versify’s permit to work software has been developed for these
industries with the flexibility to configure forms and workflows to support safety regulations and
compliance agencies.

In addition, the workforce, technicians and engineers have become mobile.  Paper documents, emails and
spreadsheets can be damaged, misplaced or never returned to central operations or the compliance officer. 
This increases the risk that forms aren’t being completed and closed out correctly.  Maintaining
compliance and safety standards for the Job Hazard Analysis (JHA/JSA), Permits to Work and LOTO
becomes very difficult and time consuming.

Human Error Analysis in a Permit to Work System: A Case

Study in a Chemical Plant
Mehdi Jahangiri,1 Naser Hoboubi,2,∗ Akbar Rostamabadi,2 Sareh Keshavarzi,3 and Ali Akbar Hosseini4

Author information Article notes Copyright and License information Disclaimer

This article has been cited by other articles in PMC.

Abstract
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Introduction 1.
According to investigations on industrial accidents, human errors account for > 90% of
accidents in nuclear industries, > 80% of accidents in chemical industries, > 75% of maritime
accidents, and > 70% of aviation accidents [1]. Human error also constitutes one of the direct
causes of some of the most shocking industrial accidents which have occurred around the
world such as Bhopal in India (1984), Piper Alpha in the United Kingdom (1988), Chernobyl
in Ukraine (1986), and Texaco Refinery in Wales (1994) [2].
In the worst industrial accident in world history, the Bhopal disaster, a combination of
operator error, poor maintenance, failed safety systems, and poor safety management were
identified as the causes of leaked methyl isocyanate gas from a pesticide plant which led to
the creation of a dense toxic cloud and killed > 2,500 people. The explosion and fire accident
which occurred in the Piper Alpha offshore oil and gas platform and killed 167 workers was
attributed mainly to human error including deficiencies in the permit to work (PTW) system,
deficient analysis of hazards, and inadequate training in the use of safety procedures. In the
Chornobyl accident, operator error and operating instructions and design deficiencies were
found to be the two main factors responsible for the explosion of a 1,000 MW reactor which
released radioactive materials that spread over much of Europe. Finally, the main cause of the
Texaco Refinery explosion, caused by continuously pumping inflammable hydrocarbon
liquid into a process vessel which had a closed outlet, was the result of a combination of
failures in management, equipment, and control systems, such as the inaccurate control
system reading of a valve state, modifications which had not been fully assessed, failure to
provide operators with the necessary process overviews, and attempts to keep the unit
running when it should have been shut down [3].
Human error has been defined as any improper decision or behavior which may have a
negative impact on the effectiveness, safety, or performance system [4]. A PTW is a formal
written system to control certain types of works which are identified as potentially hazardous.
This system may need to be used in high-risk jobs such as hot works, confined space entries,
maintenance activities, carrying hazardous substances, and electrical or mechanical
isolations [5]. In this system, responsible individuals should assess work procedures and
check the safety at all stages of the work. Moreover, permits are effective means of
communication among site managers, plant supervisors, and operators, and the individuals
who carrying out the work. The people doing the job sign the permit to show that they
understand the risks and the necessary precautions [6].
Although a PTW is an integral part of a safe system of work and can be helpful in the proper
management of a wide range of activities, it may be susceptible to human error itself. For
instance, a breakdown in the PTW system at shift change over and in the safety procedures
was one of the major factors that resulted in the explosion and fire accident of the Piper
Alpha oil and gas platform [7]. Also, the lack of an issued permit for the actual job was one
of the reasons for the Hickson and Welch accident in 1992 [8].
Up to now, very limited studies have been conducted regarding human error analysis in the
PTW system. Hoboubi et al [9] investigated the human error probabilities (HEPs) in a PTW
using an engineering approach and estimated the HEP to range from 0.044 to 0.383. In
another study conducted by the same authors [10], human errors in the PTW system were
identified and analyzed using the predictive human error analysis technique. The most
important identified errors in that study were inadequate isolation of process equipment,
inadequate labeling of equipment, a delay in starting the work after issuing the work permit,
improper gas testing, and inadequate site preparation measures. Moreover, findings of a study
conducted by Haji Hosseini et al [11] on the evaluation of factors contributing to human error
in the process of PTW issuing indicated a significant correlation between the errors and
training, work experience, and age of the individuals involved in work permit issuance.
However, as mentioned above, a limited number of researches have analyzed the PTW
process from the human error point of view. Moreover, except for Hoboubi et al [9], other
studies were descriptive in nature and failed to quantify the human errors in the PTW
issuance process. In this context, the present study aimed to identify and analyze human
errors in different steps of the PTW process in a chemical plant.
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Material and methods 2.

This cross-sectional, descriptive study was conducted to estimate the probability of human errors in a PTW system in an
Iranian chemical plant. In the first stage, through interviewing the personnel and studying the procedures of various tasks in
the plant, the PTW process was analyzed by the hierarchical task analysis (HTA) technique. In doing so, PTW was
considered as a goal and detailed tasks to achieve the goal were analyzed. In the next step, the standardized plant analysis
risk-human (SPAR-H) reliability analysis method, developed by the United States Nuclear Regulatory Commission, was
applied for estimation of HEP [12]. Although the SPAR-H technique was originally developed in the nuclear power industry
and its application for the estimation of HEPs in outside process and safety control tasks like those found in other industries
(such as the petrochemical industry) may be controversial in terms of type and complexity of the tasks, physical and
cognitive demands of the tasks, and physical and mental requirements to the operators, it has recently been used for human
reliability analysis (Fig. 1.) in major accident risk analyses in the Norwegian petroleum industry, offshore drilling operations
in the oil and gas industry, and managed-pressure drilling operations [13], [14].
 Open in a separate window

Fig. 1
 Schematic diagram of the human reliability assessment using the SPAR-H technique. HEP, human error probability; HFE, human failure
event; PSFs, performance shaping factors; SPAR-H, standardized plant analysis risk-human.

The SPAR-H is a structural HRA technique used to identify and calculate the probability of potential human error in the
described occupational tasks (human failure events-HFEs). It is based on a basic nominal error rate, a set of performance
shaping factors (factors that affect human error), and the error dependency between tasks.

According to Whaley et al [15], the steps for using the SPAR-H in human reliability analysis in PTW in the studied
petrochemical plant of the current research were as follows. (1) Categorizing the HFE as diagnosis and/or action. In the first
step, identified HFEs in the PTW tasks were categorized as either diagnosis tasks (cognitive processing) or action tasks
(execution) or combined diagnosis and action. (2) Evaluating and rating the performance shaping factors (PSFs). In this
stage, all of the HFEs were evaluated based on eight PSFs, including available time, stress/stressor, complexity,
experience/training, procedure, ergonomics/human-machine interface (HMI), fitness for duty, and work process. The level of
each PSF was determined based on the SPAR-H procedure (Table 1). Therefore, each PSF was examined and rated with
respect to the context of the HFE. For this purpose, operators involved in the PTW procedure were interviewed and
monitored during the PTW issuing activities. Then, the corresponding levels of PSFs were selected from the PSFs table
based on the SPAR-H procedure (Table 2) [12]. If there was not enough information available to provide an informed
judgment, the PSF was assumed to be nominal. (3) Calculating PSF-modified HEP. Once the PSF levels have been assigned,
then the final HEP was simply the product of the basic HEP and the PSF multipliers [Eq. (1)].

Prevent Accidents in the Workplace with a

Permit to Work System
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 Share
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Digital transformation of Safe Work has gained momentum. With a workforce armed with digital
devices, no longer should your organization have piles of paperwork mounting up. Even pens and
pencils have had their day with the advent of digital signatures on tablets and smartphones. Your work
orders can become visible only when approved and, crucially, digital Permits-to-Work can reduce the
risk of oversight and will provide your organization with a stronger legal case in the event of a
workplace accident.

Let’s look at why we need safety permits in the first place and what key benefits they bring to
organizations and companies.
Why Do Businesses Need Safety Permits?

Safety permits or Permit to work ensure that the worker is informed, trained, and supervised to

minimize the risk of any potential human failure events from occurring. Risk management is a key
element of any modern organization’s operating strategy that ensures risk and consequences are
considered on a daily and task-by-task basis.

There are many issues that can contribute to accidents and hazards in the workplace:

 Poor leadership
 Organizational culture
 An inadequate safety management system
 Poor recognition of hazards before or during a maintenance task
 Non-compliance with work permits
 Explosive atmospheres that fall under the ATEX directives
 Tiredness and fatigue
 Permit system communication failures

There were 5250 workplce fatalities in the USA in 2018 alone. *

 

So, you can see that these issues reinforce the statement we made earlier: we need informed, trained,
and supervised workers. Let’s look at these points individually.

Inform Workers About All Aspects of the Work

Informed – whether the worker is in maintenance, operations, or any other discipline, she or he needs to
be informed about all aspects of the work. What the task is, where it is, who to co-ordinate with, what
isolations need to be in place, what Personal Protective Equipment (PPE) is necessary, and many other
aspects. For example, is the work to take place in a potentially explosive atmosphere where the ATEX
directives and regulations require that all tools and clothing cannot cause ignition?

The traditional way to do this is by paper. Or, nowadays, in more modern companies who are adopting
the digital approach, the worker is informed when permits and work orders become visible on their
tablets or smartphones.

Safety Traininig

Trained – a fundamental cornerstone of any successful manufacturer or organization is skilled and

competent workers. Not just skilled and qualified workers in the technical and operational aspects, but
also in the safety aspects of any work tasks. A poorly skilled workforce increases business and safety
risks – sometimes to intolerable levels that can put the future of your organization at risk.

Worker skills need to be upgraded continuously by using assessments, gap analysis, and training plans.
Do your workers know how to perform risk assessments, for example? This should be an essential skill
that all employees have. Having an easy to use safety permit system adds value.

Supervision to ensure compliance with safety procedures

Supervised – Now, although you may have skilled and competent workers, you will still need a level of
supervision to ensure the safety permit system operates effectively. At the very least, you will need a
permit approver to sign off the permit and allow the work to commence.

This person is essentially supervising that the permit system has been followed, and it is safe for the
workers to proceed. The permit supervisor or approver will need to manage, inspect, and regularly
review the system.

Key Safety Benefits to the Organization

Having a safety management system in place to underpin your safety permit system will bring critical
benefits to your organization and business:

 Reduced risk of injury and death to all employees

 High-risk activities are controlled, and risks understood
 Reduced work errors by improved human performance
 Higher asset availability
 Higher workforce morale
 Improved workplace culture
 Reduced probability of fines
 Lower insurance premiums
 Better reputation with clients and customers
Most importantly of all these benefits, the safety permit system will lower the risk of injuries and
accidents to your employees. No-one wants to experience  fatalities in the workplace because of
inadequate safety systems, cultures or not adhering to the law such as the ATEX directives. It also
means that the organization or company has a better legal case in the event of an accident. In essence,
fines can be very significant for workplace accidents, and in the worst of cases, it may even mean time
in prison for senior business leaders and managers.

A Solution to Improve Your Safety Permit System

As mentioned, paperwork was yesterdays way to handle Permits-to-Work in the workplace. This usually
entailed huge size books with master pages and multicolored copies for all involved with the work. That
system was cumbersome, time-consuming, prone to errors and at the very least, very wasteful of paper.

There is a better solution nowadays for organizations that strive for operational excellence and openly
embrace the digital world. The solution is digital or e-Permits. The whole process – from permit creation
to digital sign-off - can be managed on tablets and smartphones with no paper trail in sight.

Learn more about Safety Permits: 

 What are the common types of safety permits?

 What are the common Permit-to-Work Stages?

Announcement:
Dynaway is developing a new solution for Microsoft Asset Management to manage work permits easier
and more efficient!

The Permit-to-Work module in D365FO allows users to manage permits as if it was a paper-based form.
Permit templates make it easy to create customizable checklists, questions, dropdowns and
instructions for those filling in, approving and using Permit forms. This ensures that you will have
a consistent way of creating permits. Permit forms can be modified at any time, without affecting active
and completed permits!

With the Dynaway Permit-to-Work app, users will be able to fill-in, view,

review and approve Permits on-site.

It has been noticed many a time that contractors engage workforce that is not appropriately trained for the task or is competent enough to
handle the jobs undertaken. “Permit to work” is one of the most significant tools, which if implemented effectively at site, meets or exceeds
the established Health and Safety guidelines. A permit to work provides a systematic disciplined approach to access the risks of a job and
specify the precautions to be taken when performing a job. Permit to work is issued by a supervisor to the contractor. When more than one
company/contractor is involved, a permit will be issued to the responsible person in charge of each working party involved in the work.
Permits are generally prepared in two-fold. One copy is handed over to the contractor performing the job and other is retained by the
supervisors for records. Optionally, a third copy can be prepared and handed over to security personnel, if tasks are highly critical in nature
and requires a strict vigil. A permit to work is valid for 24 hours only and should encompass all significant details sufficient enough to
ensure safety at site.Such as:

 Specification of the work to be done

 Detail of equipment to be used
 Details of contractor and supervisor
 Start and end time of the job
 Emergency contact numbers
 Precautions to be taken while performing the job
 Isolation/Draining/Flushing
 Nature of expected hazards
 Approving authority