Professional Documents
Culture Documents
SAFETY
Rev. 7
TABLE OF CONTENTS
1. INTRODUCTION ...................................................................................... 2
3. DEFINITIONS ........................................................................................... 3
4. PROCEDURE ........................................................................................... 4
5. RESPONSIBILITIES .............................................................................. 12
6. REFERENCES ....................................................................................... 12
7. ATTACHMENTS .................................................................................... 13
8. APPENDICES ........................................................................................ 13
LIFE-CRITICAL PROCEDURE
HSE-SAF-PRO-00-0012 Page 1 of 14
HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
1. INTRODUCTION
Safety, Alarm and Emergency systems are designed and installed to prevent any incidents
and/or mitigate the consequences of these incidents.
Tenet No. 3 says “Always operate with safety and environmental protection devices enabled”.
We also believe that “protecting the safety of people, process assets, and the environment is
our most important value and always our highest priority”.
However, there are situations when some of the safety, alarm and emergency systems are
required to be bypassed.
This procedure describes the requirements and steps for the bypass of these systems.
This procedure is applicable to all safety, alarm and emergency systems at the Q-Chem
manufacturing facilities in Mesaieed and Ras Laffan. It is also applicable to Q-Chem
administration facility (Head Office) in Doha.
i. The systems which require a bypass permit include, but are not limited to the following:
a) Fire water network including tanks, pumps and other associated equipments
b) Automatic fire suppression systems (e.g. FM200)
c) Fire & Gas detection system and its associated man-machine interface (FACP: Fire
Alarm Control Panel, FAP: Fire Alarm Panel, VDU: Visual Display Unit) including
alarms
d) Safety showers and eyewash stations
e) PAGA (Public Address and General Alarm) and other emergency communication
systems
f) Any DCS alarms or other audible/visual alarms of a safety system (e.g. fire water pump
local panel alarm)
g) Basic Process Control System (BPCS) interlock (i.e. DCS/PLC/MMS/Local Controller)
or SIS (Safety Instrumented System) interlock. It includes any of the sensing
element(s)/logic solver/final control element(s) associated with the interlock
h) Emergency Isolation Valves (e.g. EIV, ESD etc.,) It includes changing the mode
selector from its intended position such as Remote to Local, Auto to Manual etc.,
i) Safety and emergency system actuating devices (e.g. Transmitters, Switches, Circuit
Breakers, Relays etc.,)
j) Automatic diagnostic bypass systems in Safety Instrumented System
k) Maintenance bypass systems such as hardwired switches with timers/soft switches and
MOS-Maintenance Override Switches
l) Bypasses of other systems which can impact personnel/environment/process/
equipment safety.
m) Systems which are credited as an IPL in PHA which include, but not limited to the
following:
BPCS control valve;
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HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
3. DEFINITIONS
HSE-SAF-PRO-00-0012 Page 3 of 14
HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
NOTE 1
Only a Q-Chem/RLOC employee or a Base Load Contractor under the
direct supervision of a Q-Chem/RLOC employee is allowed to request
bypass permit.
4. PROCEDURE
4.1. Safety, Alarm and Emergency System Bypass Steps (Q-Chem Manufacturing
Facilities)
i. Discuss the reasons/justifications for the bypass with Supervisor/Section Head. Involve
the Subject Matter Experts (SMEs) and explore if there is any other alternative way to
avoid the safety, alarm and emergency system bypass. If no other options available,
follow the below section.
NOTE 2
ii. Fill the Safety, Alarm and Emergency System Bypass Permit (attachment 1) as per the
guidelines below:
a) Fill clearly;
Date/Time
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HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
NOTE 3
Safety, Alarm and Emergency Devices of similar nature and function on a
single piece of equipment or system can be grouped together for the
purpose of obtaining the bypass permit with the agreement of approving
personnel.
NOTE 4
Ensure that all associated documents (e.g. P&ID, Interlock Narratives
etc.,) are reviewed and attached to the bypass permit wherever
applicable.
e) Fill the technical basis, which indicates the intent of the safety system, the reasons
and/or justifications for the bypass.
f) Identify the potential impacts and the consequences of the bypass. This section
indicates the potential consequences when the safety system is not in service.
g) Identify the safeguards and compensating measures, which can prevent or mitigate
the consequences of the bypass, in discussion with supervisor/other applicable
SMEs.
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HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
NOTE 5
NOTE 6
A hard-wire jumper bypass can be considered only if all other means
of bypasses are not possible and used as a last resort. Under such
circumstances a Job Safety Analysis (JSA) shall be done and attached
to the bypass Permit.
a) Get the approval from Production Supervisor who is responsible for the bypass of
safety, alarm and emergency systems within production areas:
This includes fire protection systems such as fire water mains, automatic fire
suppression systems, flame/smoke/gas detection systems and Fire Alarms
(FACP/FAP/VDU). It also includes safety and emergency systems of process
control equipments.
Utilities Shift Supervisor is also responsible for the bypass of fire water storage
tanks, fire water pumps in addition to other safety and emergency systems within
utilities.
Supervisors other than Production area are responsible for the bypass of
safety, alarm and emergency systems of those equipments under their
responsibility except fire protection systems.
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HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
NOTE 7
If any fault on F&G detectors during OFF hours/weekends, appropriate
compensating measures shall be taken by the Supervisor/FSC till the
F&G Technician arrives on site and fixes the detector.
b) Get the co-approval of Fire & Safety Coordinator for “fire protection systems’ within
production area.
NOTE 8
When a section of the fire water system is required to be bypassed, the
requester shall mark-up the fire water system map or layout diagram
available at the Fire Station.
a) Person who applies bypass shall determine the best method and location and fill
the details in the form. Apply the bypass and sign in the form.
NOTE 10
The intent is to capture the location/method/details of bypass in the
bypass permit, which can help during normalization of bypass later by
other person. (e.g. extended bypasses)
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HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
NOTE 11
F&G detector bypasses during routine maintenance, do not require the orange
tag as long as the F&G technician is present.
Orange tags are not required where there is no provision for attaching the tags.
(e.g. DCS system bypasses)
The Supervisor shall ensure the information on active bypasses is made
available to affected personnel at all times while the bypass is in place.
o Production Units: Active bypass permit original shall be kept at CCR/NCR and
one copy at the actual location of the bypass (e.g. deluge station, safety
shower, fire water pump etc.,) and at the common location (e.g. FIC/FOC/
Permit Center) to communicate the affected personnel.
o Outside of Production Areas: Keep original in supervisor office, one copy at a
common place to communicate affected personnel, and one copy at the actual
location of the bypass.
o Fire protection systems outside of production area: FSC shall keep the
original bypass permit at fire station and send the copy of the bypass permit to
the affected section head to display in notice board.
v. Extension of bypass permit (more than 24 hrs) shall be done through the following steps:
a) Condition 1 (Bypass period is more than 24 hrs and less than 7 days)
In addition to approvals as per 4.1.(iii), get the approval of Shift Coordinator/other
Unit Supervisor (RLOC)
b) Condition 2 (Bypass period is more than 7 days and less than 30 days)
Supervisor of bypass requester approves and gets approval of Unit
Superintendent/Section Head.
Fill additional compensating measures if any, in the bypass permit.
Get the approval of affected Area Manager/Deputy Plant Manager (RLOC)
Get the approval of FSC (for fire protection systems)
Get the approval of PSM Coordinator for SIF interlock (SIL >=2)
Get the approval of Safety Manager/HSE Superintendent (RLOC)
Finally affected area Supervisor or FSC (as applicable) shall communicate the
affected group.
c) Condition 3 (If the bypass to be extended more than 30 days)
Initiate and manage the bypass through temporary MOC process.
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Rev. 7
Section head of the affected equipment has to enter the initiated MOC number
and signature. Bypass permit will be closed and filed once the MOC status
reaches ‘MOC implemented” status in the plant MOC application.
vi. Get the bypass removal approval as per below guideline:
a) After completion of task, the bypass requester shall fill the “Approval for bypass
removal” section and get the Supervisor/FSC (fire protection system) approvals.
b) Once approved, the authorized person who normalize the bypass sign the form.
c) Supervisor/FSC (as applicable) shall communicate the bypass removal to affected
group and make sure the bypass permit copies are removed from the posted
locations.
d) Supervisor/FSC (as applicable) shall file the original bypass permit form and retain
for the period of 1 (One) year.
vii. Fire and Gas detectors bypass removal:
a) As the off line reading not available in the F&G detectors, the F&G Technician has
to normalize the bypass and confirm the correct reading. To recalibrate, it has to be
bypassed again. Hence the F&G Technician after confirming the healthiness of all
detectors shall go for bypass removal documentation.
b) Normally single bypass permit is taken for the maintenance of multiple Fire & Gas
detectors in the same loop/system. Hence the F&G Technician after confirming the
healthiness of all detectors shall go for bypass removal approval one time for all
detectors.
4.2. Safety, Alarm and Emergency System Bypass Steps (Q-Chem Head Office in Doha)
i. Discuss the reasons/justifications for the bypass with Head Office General Services
Coordinator and Head Office Safety Representative (for Fire protection systems). Check
if there is any other alternative way to avoid the safety, alarm and emergency system
bypass.
ii. Fill the Safety, Alarm and Emergency System Bypass Permit (attachment 2) as per the
guidelines below;
a) Fill clearly;
Date/Time
Floor number
Equipment affected (Describe or identify the system/room number e.g. Room 21)
Name of Safety & Emergency Device (Describe the safety or emergency system
being bypassed. E.g. FM 200 activation)
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HSE-SAF-PRO-00-0012
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Rev. 7
Safety & Emergency Device Number(s) (Identify the specific tag number(s) being
bypassed)
b) Fill the detailed description and scope, which indicates the nature and extent of the
bypass, including system(s) and/or equipment(s) which may be affected.
c) Fill the technical basis, which indicates the intent of the safety system, the reasons
and/or justifications for the bypass.
d) Identify the potential impacts and the consequences of the bypass. This section
indicates the potential consequences when the safety system is not in service.
e) Identify the safeguards and compensating measures, which can prevent or mitigate
the consequences of the bypass, in discussion with Supervisor/other applicable
SMEs.
NOTE 12
It is intended to ensure the safe operation of the affected equipment or
safety system, when it is bypassed for a definite period of time.
a) Person who applies bypass shall determine the best method and location and fill
the details in the form. Apply the bypass and sign in the form.
NOTE 13
The intent is to capture the location, method and details of bypass in the
bypass permit, which can help during normalization of bypass later by
other person. (e.g. extended bypasses)
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Rev. 7
NOTE 14
v. Extension of bypass permit (more than 7 days) shall be done through the following
steps:
a) Condition 1 (Bypass period is more than 7days and less than 30 days)
Bypass requester shall discuss with Doha office Safety Representative (for fire
protection systems) and Doha office General Service Coordinator and get the
approval.
Get the approval of Doha office Management.
Fill additional compensating measures if any, in the bypass permit.
Get the approval of General Services Manager.
Get the approval of Safety Manager.
Doha office General Services Coordinator shall communicate the affected
personnel.
a) After completion of task, the bypass requester shall fill the “Approval for bypass
removal” section and get the approvals from Doha office Safety Representative (for
fire protection systems only), Doha office General Services Coordinator and Doha
office Management.
b) Once approved, the person who normalizes the bypass shall normalize the bypass
and sign the form.
c) General Services Coordinator communicates the affected group about the
normalization of safety system and removes the bypass permits from the posted
locations and files the original bypass permit in a file and retain it for the period of 1
(One) year.
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Rev. 7
5. RESPONSIBILITIES
i. Reviews and approves bypasses extending beyond 24 hrs but less than or equal to 7
days.
5.9. Supervisor
6. REFERENCES
HSE-SAF-PRO-00-0012 Page 12 of 14
HSE-SAF-PRO-00-0012
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Rev. 7
7. ATTACHMENTS
7.1. Attachment 1: Safety, Alarm and Emergency System Bypass-Plant Permit Form- (HSE-
SAF-SFM-00-0021)
7.2. Attachment 2: Safety, Alarm and Emergency System Bypass-Head Office Permit Form-
(HSE-SAF-SFM-00-0097)
8. APPENDICES
9. REVISION HISTORY
HSE-SAF-PRO-00-0012 Page 13 of 14
HSE-SAF-PRO-00-0012
SAFETY
Rev. 7
Venkata Roehl
6 02-Jan-2013 Complete procedure review Carl Poldrack
Chandra Bartolome
Clarification on the role of the FSC
Evaluation process for extension beyond Roehl
5 26-May-09 Jarvis Olsen Jarvis Olsen
7 days Bartolome
Modifications on the bypass permit
Minor Change: Incorporated the RLOC
4.1 30-Nov-07 Imran Malik
positions.
Clarification to Section 4.7 on hard-wire
jumpers. Revision of document and
4 17-May-07 Jarvis Olsen
permit to reflect organization title
changes
Revision of procedure, form and
3 29-Sep-05 G. Francis
formatting
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