Permit To Work Manual - Stanwell

1 Permit To Work Manual 30 December 2010 CS-PTW-01 Version Page i DOCUMENT CONTROL Document Details Document Reference/Name: CS-PTW-01 PTW Manual Version Number: Documentation Status: Approved Document Owner: Corporate PTW Committee Document Approval: General Manager Operations Next Scheduled Review Date: December 2011 Version History Version Number Date Reason/Comments 12/12/03 Review Team Draft 30/01/04 First Consultation Draft - across sites 03/2004 Inclusion of site comments and approved for release 12/2010 Full review by Corporate PTW Committee Page ii Permit To Work Manual FOREWARD Operating our business safely is CS Energy s highest priority. We genuinely care about the health and safety of our employees and contractors who undertake maintenance and refurbishment task at our sites. We also recognise that completion of the tasks in a safe, timely and quality manner is the foundation for ensuring that CS Energy continues to generate electricity safely, reliably and economically.

2 To achieve this, we use the Permit to Work System (PTW) to provide all workers safe access to plant and equipment. The PTW System is considered our primary safety system and is used widely across CS Energy s sites. The PTW System ensures a high level of control and minimisation of risk in areas that contain energy. CS Energy s PTW system has been developed to comply with the Generator s Permit to Work Code of Practice. This Manual outlines the key elements of this system such as roles and responsibilities, procedures, training, reporting and monitoring activities. Copies of this company-wide Manual are available at each CS Energy site. It is also included on the company s intranet, where additional supporting documentation, such as our hazard control procedures, isolation procedures, standard operating procedures, is also held.

3 I encourage you to familiarise yourself with this Manual . Only with the dedication of every person on every CS energy site, can we achieve our goal of zero harm. David Brown Chief Executive Page iii This Manual has been endorsed by the Corporate PTW Committee Representatives: General Manager Operations Gary Campbell .. Date: .. Operations Support Manager Don Cameron .. Date: .. Health and Safety Operations Manager Frank Welch .. Date: .. Kogan PTW Administrator Brett Date: .. Callide PTW Administrator Phil Matha .. Date: .. Swanbank B PTW Administrator Steve Date: .. Swanbank E PTW Administrator Mladenko Tunjic .. Date: .. Mica Creek PTW Administrator Barry Wells .. Date: .. PTW Manual Page 4 CONTENTS 1 7 2 SCOPE .. 7 3 PTW DOCUMENT SUITE .. 8 4 DEFINITIONS .. 8 5 REFERENCE DOCUMENTATION .. 8 6 PTW PROCESS .. 9 PTW LIFECYCLE.

4 9 7 CORE PTW ROLES AND ROLE PURPOSE .. 11 GENERAL MANAGER OPERATIONS .. 11 CORPORATE PTW ADMINISTRATOR .. 11 POWER STATION MANAGER .. 11 SITE PTW ADMINISTRATOR .. 11 SPTWO .. 11 PTWO .. 12 OIC .. 12 PERSON IN CHARGE OF WORK .. 12 WORK PARTY .. 12 ALL PERSONNEL .. 13 8 TASKS WITHIN THE PTW PROCESS .. 13 MAINTENANCE NOTIFICATION/WORK ORDER .. 13 SUBMITTING MAINTENANCE NOTIFICATION/CREATING WORK ORDER .. 13 APPLICATION FOR PTW .. 13 SUBMITTING THE APPLICATION FOR PTW .. 13 REVIEW THE APPLICATION FOR PTW .. 14 DRAFT ISOLATION SHEET .. 14 DRAFTING ISOLATION SHEET/WCD .. 14 REVIEW AND PREPARE ISOLATION SHEET/WCD .. 15 ISOLATING THE PLANT .. 15 PLANT ISOLATION .. 15 VERIFYING THE ISOLATIONS (SECOND CHECK) .. 16 ISSUING THE PTW .. 17 PTWO ISSUING THE PTW TO OIC .. 17 PERFORMING THE WORK .. 18 PRIOR TO COMMENCING WORK .. 18 DURING WORK ACTIVITIES.

5 19 END OF DAY PROCEDURE .. 20 TRANSFER OF PTW TO ANOTHER OIC .. 20 SUSPENSION OF A PTW .. 21 GENERAL RESPONSIBILITIES .. 21 PTW Manual Page 5 SUSPEND TO TEST .. 22 SUSPEND TO AVAILABILITY .. 23 SUSPEND TO RECALL .. 24 SUSPEND TO ALTER ISOLATION .. 24 SURRENDER OF THE PTW .. 25 MANAGE CONFINED SPACES .. 25 WORK ACTIVITIES COMPLETE .. 25 SURRENDERING THE PTW TO PTW OFFICE .. 26 PTWO ACCEPTING THE PTW .. 26 RESTORATION OF PLANT .. 27 DRAFT RESTORATION SHEET .. 27 RESTORE PLANT .. 27 COMPLETE PTW .. 27 9 SPECIAL PURPOSE ISOLATIONS AND PROCESSES .. 28 PERFORMING MINOR TASKS ON LIVE PLANT .. 28 PTW ISSUED FOR ACCESS .. 28 PROCESS TO APPLY FOR A PTW ISSUED FOR ACCESS .. 28 OWN ISOLATION .. 28 SPECIFIED APPARATUS .. 29 OPERATOR STAND-BY .. 29 MULTIPLE OIC PTW .. 29 ELECTRICAL ISOLATION WITH MULTIPLE FEEDS .. 29 HIGH VOLTAGE ISOLATION (SINGLE FEED) FOR ELECTRICAL WORK.

6 29 10 CS ENERGY / TRANSMISSION ENTITY INTERFACE .. 30 GENERAL REQUIREMENTS .. 30 INITIATOR OF ISOLATION .. 30 CS ENERGY .. 30 TRANSMISSION ENTITY .. 30 STATE CONTROL CENTRE .. 30 11 MINIMUM H&S STANDARDS FOR THE PTW SYSTEM .. 32 12 CS ENERGY LIFE SAVERS .. 33 13 MANAGEMENT OF KEYS AND LOCKS .. 33 LOCK AND KEY REGISTERS .. 33 PTW ADMINISTRATOR .. 33 KEY AND LOCK CONTROL .. 34 LOST RED ISOLATION LOCK .. 34 LOST RED ISOLATION KEY .. 35 LOST PTWO, OIC OR PERSONAL KEYS .. 36 UNAVAILABLE OIC OR WORK PARTY MEMBER .. 37 14 MANAGEMENT OF PTW INCIDENTS .. 39 15 REVIEW OF PTW SYSTEM AND ASSOCIATED DOCUMENTS .. 39 PTW Manual Page 6 CS ENERGY PTW COMMITTEE STRUCTURE .. 39 CORE COMMITTEE RESPONSIBILITIES FOR THE PTW SYSTEM .. 39 16 AUDITING .. 42 17 TRAINING AND COMPETENCY .. 42 INDUCTION .. 42 AUTHORISED PTW ROLES .. 42 PTW ADMINISTRATOR .. 42 18 EMERGENCY SITUATIONS.

7 42 19 RECORDS .. 43 ATTACHMENT 1 PTW ROLE TABLE .. 44 ATTACHMENT 2 BASIC LOCKING PROCESS .. 45 ATTACHMENT 3 LOCK AND KEY CHARACTERISTICS .. 46 ATTACHMENT 4 LOCK AND KEY IDENTIFICATION .. 47 ATTACHMENT 5 EXAMPLE DANGER TAG & TEST TAG .. 48 ATTACHMENT 6 EXAMPLE PTW (WORK CLEARANCE APPLICATION) ISSUED FOR WORK .. 49 ATTACHMENT 7 EXAMPLE ISOLATION SHEET (WORK CLEARANCE DOCUMENT) .. 50 ATTACHMENT 8 EXAMPLE PTW ISSUED FOR TEST .. 52 ATTACHMENT 9 EXAMPLE RESTORATION SHEET .. 53 ATTACHMENT 10 EXAMPLE PTW (WORK CLEARANCE APPLICATION) ISSUED FOR ACCESS .. 55 ATTACHMENT 11 WORK PARTY STATUS SIGN ON/OFF SHEET .. 56 PTW Manual Page 7 1 PURPOSE The purpose of this Permit to Work Manual , (the Manual ), is to provide structure and process on the Permit to Work (PTW) System. The objective of the PTW System is to: Control the access to plant and equipment Minimise the risk of injury to personnel Minimise the risk of damage to plant Comply with the Workplace Health & Safety and Electrical Safety Legislation Comply with the Queensland Electricity Generators Permit To Work Code of Practice.

8 The PTW Manual defines specific authorisations and responsibilities to establish a standard and consistent process for all PTW activities. 2 SCOPE The PTW Manual is applicable to all work being undertaken at CS Energy sites. It describes the provisions of the PTW process, framework of the PTW system and PTW suite of documents that support the system. The PTW Manual does not apply to: Plant that has been de-commissioned removed existing energies; Plant that is not yet a CS Energy asset; Plant that is being commissioned for CS Energy where CS Energy is not the Principal Contractor ( not yet handed over to CS Energy).; and CS Energy First/Emergency Response Teams or Emergency Services when executing a rescue during an emergency or crisis. Figure PTW System Framework PTW Manual Page 8 3 PTW DOCUMENT SUITE The PTW System uses a number of documents to provide direction and guidance of the process.

9 Figure displays the PTW Document Suite. Figure PTW Document Suite. 4 DEFINITIONS The PTW Definitions document provides definitions for the PTW system. It is a standalone document that is referenced in the PTW Manual and supporting Documents in the PTW Document Suite. Refer to Definitions for the PTW Document Suite. 5 REFERENCE DOCUMENTATION The PTW Reference Documentation provides a list of critical documents that was used to build CS Energy s PTW system. Refer to Reference Documentation for the PTW Document Suite. PTW Manual CS-PTW-01 Definitions CS-PTW-02 References CS PTW-03 HAZARD CONTROL PROCEDURES CS-PTW-HAZ-## Hot work Working at height Confined spaces Excavation & digging Live electrical work ISOLATION PROCEDURES CS-PTW-ISO-## Mechanical isolation Electrical Safety Management CS-OHS-31 STANDARD OPERATING PROCEDURES CS-PTW-SOP-## Authorisation & training Use of international technical experts Multiple officers in charge of work Permission to perform minor tasks PTW Change Management Audits & review of the PTW system PTW Manual Page 9 6 PTW PROCESS NOTE: a number of processes external of the PTW process are required to be completed before the application of the PTW can be requested.

10 These processes are included in Figure 1 for reference only and are not considered to be incorporated into the PTW process. The application of the PTW System incorporates 8 key elements to complete the process. The 8 Elements include: Application for PTW (APTW) Drafting Isolation sheet/Work Clearance Document (WCD) Plant Isolation PTW/Work Clearance Application (WCA) Issue Performing Work PTW Suspension (where required) PTW Surrender Restoration of Plant Each element requires key roles and responsibilities to effectively and safely apply the PTW process. Refer to Figure 1 (below) which details the process flow of the life of a PTW. PTW Lifecycle Figure outlines the elements of the PTW process. The diagram below provides the process for a standard PTW. The elements required for a PTW is subject to variation.