Breaking Into Systems (Process) Permits

• Obtain a breaking-into-systems permit before opening any pipeline or vessel
• Confirm the system is isolated, drained, depressurised, and vented before work
• Identify the exact break point and method specified on the permit
• Wear the PPE specified on the permit including face shield and chemical gloves
• Slacken flange bolts gradually and unevenly to release residual pressure safely
• Check for cross-referencing with LOTO, confined space, and hot works permits
• Ensure a COSHH assessment covers any chemicals that may be present in the system
• Keep emergency eyewash and spill equipment within reach during the operation
• Brief all team members on the permit conditions and emergency procedures
• Close out the permit formally once the system is reassembled and tested

• DON'T open any pipeline, vessel, or process equipment without a valid permit
• DON'T assume the system is empty or depressurised because a valve is closed
• DON'T remove all flange bolts at once — loosen gradually to check for pressure
• DON'T break into systems containing unknown substances without COSHH assessment
• DON'T carry out the work without the correct PPE as specified on the permit
• DON'T ignore cross-references to other permits — all conditions must be met
• DON'T allow unauthorised persons to issue or accept the permit
• DON'T dispose of drained fluids without following the correct waste procedures
• DON'T re-pressurise the system until the permit is formally closed out
• DON'T rush the isolation verification — trapped pressure kills without warning

See also: Permit to Work Awareness | Process Isolation (Valves and Blinds)