L4 02.02 GTR PTW-JHA Training Material

Internal

Work Leader Training
HSSE

Internal ©Petroliam Nasional Berhad (PETRONAS) 2017 2

Work Leader Training
HSSE

Internal ©Petroliam Nasional Berhad (PETRONAS) 2017 3

Internal

• Name - OPU, Contractor
• Experience in issuing & approving work permit
• Your expectation from this training

Internal

 Approving Authority – AA
 Receiving Authority – RA
 Work Leader – WL

Internal

At the end of this session you will be able to:

• Coordinate, control and record work activities using PTW
• Demonstrate competency on PTW requirements compliance
• Identify, assess and control of workplace hazards

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Internal

• On 6th July 1988, 167 men died as a result of an explosion and fire on
board of Piper Alpha platform in UK Sector of the North Sea.

• One of the primary causes from the disaster was the failure in one of
the key management systems, which is Permit to Work System (PTW)

• In March 2005, 15 people died in a refinery explosion in Texas City.

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Sharing on first fatality in PETRONAS for 2014

Subject: 1st Fatality in 04/02/2014 (PETRONAS-wide)

Dear All,
Regret to inform that PCSB/PETRONAS has recorded 1st Fatality this year,
and it is from SBO. Let us help each other in preventing Recordable Case in
SOGT.
As agreed during AIT LOCHSEC meeting yesterday, let us start with a series
awareness campaign.

First - Cleaning up our PTW Management.

Next week – cleaning up of PPE non-compliance
Thank You.

Internal

Internal

Incident Date Fatality
1
RAPID 3rd Dec.
2015 1
Backhoe fatality
incident 24th Apr.
2016
RAPID

Worker hit by
reversing vehicle

Internal

PTW – Section 1 Lesson Learnt from Fatality Incident of
Toppled Tractor at Segamat, 28 Dec 2016

A Serial No. C 0000000 PERMIT TO WORK - COLD

PGB NO WORK IS SO URGENT THAT WE CANNOT TAKE TIME TO DO IT SAFELY

OPERATING
REGIONS/DEPTS

REQUISITION.

The Permit Applicant fills in Section 1 of the Work Permit form (in triplicate) with the specific
details of the job to be done, specifying the equipment tag numbers with its exact location.
He/she must indicate the required date for work to commence and expected completion.

B SECTION 1 - REQUISITION Required On Expected Completion
Date : Date :
APPLICANT'S NAME : ..................................................................................................... DEPT. /CO.: ................................................................... Time : Time:
STAFF NO. / IC NO. : ...................................................................................................... TEL NO. : ......................................................................
LOCATION/FACILITY : .................................................................................................... AREA / UNIT....................................................................
EQUIPMENT NO. : ........................................................................................................... SAP/ W. ORDER NO.: ....................................................
WORK DESCRIPTION :

Kerja memotong rumput di kawasan SOC

Did not specify using what equipment. Manual cutting? Tractor cutting?
Internal Did not specify which specific area of SOC. Flat area of Zone A? Zone B?

Lesson Learnt from Fatality Incident of Toppled
Tractor at Segamat, 28 Dec 2016

Tractor parking spot Legend Flat Area
(zone B, E,
Incident Zone A - hillside to and part of
Location pump house Zone A at
Zone B - Office Area pointed
Location of 5 workers arrow
during the incident location)

Zone C - Parameter
fence to Segamat
RO
Zone D - Palm oil
plantation area (not in
picture and not
covered in the
contract)

Zone E - Other
related area (scrap
per yard 2nd fence)

Movement of
tractor prior to
incident

‘Kerja memotong rumput di SOC’, tetapi zon-zon yang berbeza memerlukan
mesinInternal yang berbeza. Contoh, traktor tidak patutu digunakan di cerun bukit, Zon A.

Lesson Learnt from Fatality Incident of Toppled
Tractor at Segamat, 28 Dec 2016

Figure 1: Location of related personnel during the incident

Internal

On 23rd October 2016 (Saturday) @ 1415 Hrs, one worker (sub-contractor)
suffered serious injuries after being hit by a snatched 38mm-nylon rope while
pulling HDPE pipes at KP 30-Pengerang Gas Pipeline, Sungai Lebam. The IP
was unconscious.

The IP was brought for immediate medical treatment at Klinik Kesihatan Bandar
Penawar, and later to Hospital Kota Tinggi for further treatment. The IP was
transferred to Hospital Sultan Ismail under intensive care unit (ICU).

Major Injury:
• acute right thalamic bleed with subarachnoid

bleed,
• C3 and C4 spine fracture (vertebral body of

spine),
• right lung hemothorax with liver injury and

multiple rib fractures at 9th, 10th and 11th right

ribs)

Lost Time Injury (LTI) : Contractor hit by a snatched 38mm-nylon rope during pipe lifting activity on 22nd October 2016

Internal

• No PTW on HDPE pipe pulling activity
• No Job Hazard Analysis on HDPE pipe pulling activity
• No Job Method Statement on HDPE pipe pulling activity

IP Initial IP Final
Positio Positio

n n

Method of ropes IP 8 meter Method of HDPE
being rolled over (Helper) pipe connected to
Butt Fusion
the Excavator the ropes joining HDPE
wheel track Pipes
Pushing using
Pulling using Excavator
Excavator wheel backhoe
track as ‘winch’

XXXX 4” HDPE Pipe XXXX
(Excavator 12” HDPE Pipe (Helper)
Operaor)
XXXX 36” Steel Pipe
(Helper)

804 m length XXXX

(Helper)

Lost Time Injury (LTI) : Contractor hit by a snatched 38mm-nylon rope during pip(eHXelXiflXptienXrg) activity on 22nd OXcXtoXbXer 2016
(Helper)

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Internal

Example of an integrated Safe System of Work :

Confined Ignition Working at Excavation
Space Source Height
Control

Excavation Permit to Radiation Energy
Work Isolation

Lifting PPE High
Vehicle Entry Pressure

Water Jetting

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Internal

ZeTo Rules

 ZeTo Rules stands for Zero Tolerance to ensure all activities are

carried out safely and any non-compliance is not tolerated.
 It applies to all employees and contractors.
 It is intended to supplement safety rules and regulations imposed by

PETRONAS, its OPUs and HCUs.
 Employees who do not comply will be investigated and disciplinary

action can be taken against them.
 Contractors’ failure to comply can result in appropriate action being taken

which may lead to the termination of contract.

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ZeTo Rules ZeTo = Zero Tolerance

Work with a valid work permit (PTW) required by the job

Verify energy isolation before starting work

Obtain authorisation before overriding or disabling safety critical
equipment

Obtain authorisation before entering a confined space

Protect yourself against a fall when working at height

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ZeTo Rules ZeTo = Zero Tolerance

Use the correct personal protective equipment (PPE) when

handling hazardous chemicals

Obtain authorization before excavation or entering a trench

Do not position yourself under a suspended load

Do not smoke outside designated areas or bring potential
ignition sources into process areas without authorization

Do not use your mobile phone/walkie-talkie while driving, follow
Internal the speed limit and use your seat belt

Internal

In general, PTW System is part of the safe system of work tools to
control activities carried out is in a safe manner

SAFE SYSTEM OF WORK

Hierarchy of Control  Personal Protective Equipment Lockout and tag Confined Space
out entry
1. Eliminate  Job Safety Analysis (JSA)
2. Substitution Scaffold inspection Excavation
3. Isolation Permit To Work and tagging
4. Administrative
5. Engineering  Lockout and tag out
6. PPE  Excavation
 Scaffold inspection and tagging
 Confined space entry
 Chemical and hazardous materials

handlings
 Radioactive materials handling
 High pressure hydro-jetting
 Working at height
 Equipment inspection prior to use
 Use of hand tools and portable

equipment
 Signage

Working at height Personal Protective
Equipment

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Why We Implement PTW?

Law & Regulation

OCCUPATIONAL SAFETYAND HEALTH ACT 1994

DUTY OF EMPLOYERS AND SELF  Take reasonable care
EMPLOYED PERSON for own safety and
health and of others
Safe plant and systems of work likely affected by his
Safe use, storage and handling of plant act/omissions
and substances
Information, instruction, training and  Cooperate with
supervision employer and other
Safe place of work authorities

Safe access and egress  Using the PPE as
Written general OSH policy provided by the
Not to charge employees for things done employer
or provided
Employer to report accidents, dangerous  Comply with OSH
occurrences, Occupational poisonings or instruction/measures
diseases to DOSH instituted by employer

Internal  Not to interfere or
misuse things done for
safety and health
control

1. Factory Machinery Act. (FMA ’67)
2. Environment Quality Act. (EQA ’74)
3. Occupational Safety and Health Act. (OSHA ’94)

Internal

To ensure , so far as practicable, the safety, Establish
health and welfare at work of all his safe work

system

Employees

Duty to Formulate OSH Policy Provide Analyse
 More Than 5 person safe work Risk at
 To prepare written statement environment Place at
Work
Section
15,OSHA

1994

 Appropriately revise a written statement Provide and Provide
 To carry out the policy maintain instruction,
 Revision of policy
 Notify the employees safe access training,
and exit information
to worker
route from
work area

Duties of employer to persons other than their employees

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Internal

Section 16 OSHA:PGB HSE Policy and Statements

Committed to HSE excellence in all
its activities

Take reasonable steps to prevent
and eliminate the risk of injuries,
occupational illness and damage to

properties

Take proactive steps to protect
environment and use natural

resource efficiently

Designs, builds, and operates in
accordance with appropriate legal
requirement & industry best practices

Utilize the necessary resources and
organization, engage with key
stakeholders on HSE matters.

Ensure contingency plan in place to
deal with emergencies.

Ensure continual improvement in
HSEM

All its employees and contractors to
strictly adhere to this policy at all times

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PETRONAS HSE POLICY

Take every reasonableand practicablestepto preventand eliminate therisk of injuries, health, process
hazards and damage to properties;
Protection of the environment and to efficiently manage natural resources

Comply to applicable legal requirements and best industry practices process hazards and damage to
properties

Ensure contingency plans are in place and maintained

Provide necessary resources, organization, systemandtraining

Ensure continual improvement in its HSEmanagement and performance, leveragingon people, process
and technology.

Communicate with employees, contractors, customers, suppliers and the public

To be a leading gas processing and Slide 35 of 85 Together as One
transmission company of choice

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PETRONAS DRUG AND ALCOHOL POLICY

To be a leading gas processing and Slide 36 of 85 Together as One
transmission company of choice

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PGB HSE POLICY

To be a leading gas processing and Slide 37 of 85 Together as One
transmission company of choice

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PGB HSE POLICY

To be a leading gas processing and Slide 38 of 85 Together as One
transmission company of choice

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PGB STOP WORK Policy Objective

Internal The objective of establishment PGB
Stop Work Policy is to shape
organization culture towards taking
HSE as the priority in business.

Stop Work Policy has also been
implemented at other PETRONAS
Business Unit/OPU such as
PP(M)SB, PCG, PP(T)SB, RAPID
and etc

Regulations under this act:

Internal

Part 2. Part 3.
oSect:19 . Certificate of Fitness
(From DOSH) ( Section : 26,27,28,29,29A, and 30 )

 Steam Boilers.  CERTIFICATE OF COMPENTENCY.
 Hoisting Equipment.  Drivers : Boiler, Steam Engine, Internal
 Lifting Combustion Engine.
 Pressure Vessels  Engineer : Boiler, Steam Engine, Internal
Combustion Engine.
Internal  Classification : First or second Grade Engineer,
Visiting Engineer,
Operator.

 CRANE OPERATOR.
 SCAFFOLDER.
 AUTHORISED GAS TESTER.
 CONFINE SPACE ENTRANCE.

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•
•
•

Internal

AREA NON COMPLIANCE PENALTY
Employers responsibilities RM50K, 2 years jail

General duties of designers, RM 20K, 2 years jail AREA NON COMPLIANCE PENALTY
manufacturers, imports,
suppliers Air, in-land water, soil RM100K , 5
& noise pollution years jail
General duties of employees RM 1K, 3 months jail
Discharge of oil, waste, RM500K , 5
Interference with OSH safety RM 20K, 2 years schedule waste into years jail
item RM 10K, 1year
RM5K, 6 months waters & open burning RM100K , 5
Discrimination against years jail
Safety employees EIA
Health RM2K
OSH Committee Environm Compoundable
ent offences RM25K , 2
years jail
Prohibition & stop work RM 50K, 5 years Handling hazardous
substances RM50K , 2
years jail
NADOPOD(Notification of Prohibition/stop work
accident, dangerous RM50K , 5
RM 10K, 1year Occupier of facilities years jail
occurrence, occupational
poisoning and occupational Not providing RM2K , 6
necessary information months jail
disease

Medical surveillance RM5K, 6 months

Internal

IPtGBisSETOvPeWryOoRnKePoRliecysapnodnSstaitbemilietnyts

There shall be no blame or fault put
on any employees

Calling for Stop Work order When
there is immediate threat of HSE

Stop Work Order shall be applied Work that has ceased due to
in good faith. Timing is critical. Stop Work shall not be resumed
until all HSE threats are cleared
There should not be any delay in
calling Stop Work order if the and rectified
need arises

15 January 2020 45

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OSHA 1994 – PART IV Duty of Employees

 Part IV General duties of employees at work
 Section : 24.(1)

a) Reasonable care for safety and Health of himself and
others persons.

b) Co-operation with employer and others.
c) To wear and use at all times any PPE or clothing

provided by employer for the purpose of preventing risks
to his safety and health.
d) Comply with any instructions on OSH instituted by his
employer.

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OSHA 1994 – Safety and Health Committee

Section 30.(1)
Every employer shall establish a safety and health committee at the place of work
in accordance with this section if –
(a) There are 40 or more person employed at the place of work; or
(b) The Director General directs the establishment of such a committee at the

place of work.

COMPANIES EMPLOYING 40 OR MORE WORKERS ARE
REQUIRED TO ESTABLISH SAFETY COMMITTEE

For companies employing 100 workers or less:
Minimum 2 workers representatives and 2 employers

Representatives.

And for those with more than 100 workers
Minimum 4 workers representatives and
4 employers representatives.

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OSHA 1994 – Safety and Health Committee

Function of Safety and Health committee

The safety and health committee of a place of work shall :-
a) Assist in the development of safety and health rules and safety system of work.
b) Review the effectiveness of safety and health programs.
c) Carry out studies on the trends of accident, near miss-accident, dangerous

occurrence, occupational poisoning or occupational disease which occurs at the
place of work, and shall report to the employer of any unsafe or unhealthy
condition or practices at the place of work together with recommendations for
corrective actions.
d) Review the safety and health policies at the place of work and make
recommendations to the employer for any revision of such policies.

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OSHA 1994 – Regulations

1. Employer's Safety and Health General Policy Statement
(Exception) 1995

2. Control of Industrial Major Accident Hazards (CIMAH 1996)

3. Safety and Health Committee (SHC 1996)

4. Classification, Labelling and Safety Data Sheet (CLASS 2013)

5. Safety and Health Officer (SHO 1997)

6. Use and Standards of Exposure of Chemicals Hazardous to
Health (USECHH 2000)

7. Notification of Accident, Dangerous Occurrence,
Occupational
Poisoning and Occupational Disease (NADOPOD 2004)

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The responsibilities of principal supplier and subsidiary
supplier according to the CLASS Regulations are:

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