PTW/General/TBT-PTW-011

Breaking Into Systems (Process) Permits

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A breaking-into-systems permit controls work that opens pipelines, vessels, or process equipment.
Breaking into a system can release pressurised fluids, hazardous chemicals, or flammable gases.
The permit ensures the system has been isolated, drained, depressurised, and made safe before opening.
Common activities requiring this permit include pipe cutting, flange breaking, valve removal, and filter changes.
Residual pressure, trapped liquids, and stored energy can remain even after isolation is confirmed.
COSHH hazards may be present from process chemicals, sludge, or biological material within the system.
The permit must specify the exact break point, isolation method, and PPE requirements for the task.
Cross-referencing with other permits such as LOTO, hot works, and confined space may be required.
Only competent and authorised persons may issue and accept breaking-into-systems permits.
The permit system is essential on water treatment works, chemical plants, and mechanical installations.

Prevent injury	Opening pressurised or chemical-containing systems without controls causes scalding, chemical burns, and toxic exposure.
Control residual energy	Even isolated systems may contain residual pressure, trapped liquids, or hazardous atmospheres.
Legal duty	CDM 2015 and PUWER require safe systems of work for maintenance on pressurised and process equipment.

Don't

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

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

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