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HSE-SAF-PRO-00-0012

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SYSTEM BYPASS PROCEDURE Page 1 of 14

TABLE OF CONTENTS

1. INTRODUCTION....................................................................................... 2

2. SCOPE & PURPOSE .............................................................................. 2

3. DEFINITIONS ........................................................................................... 3

4. PROCEDURE ........................................................................................... 4

5. RESPONSIBILITIES ............................................................................... 11

6. REFERENCES........................................................................................ 12

7. ATTACHMENTS ..................................................................................... 12

8. APPENDICES ......................................................................................... 13

9. REVISION HISTORY .............................................................................. 13

LIFE-CRITICAL PROCEDURE

Never bypass or disable critical safety equipment


without valid authorization.

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By


Change Category: Type-2 Venkata Carl Poldrack
8 17-Nov-15 Syed Rizvi
Refer Section 9 Chandra Roehl Bartolome
Next Scheduled Periodic Review: June/2017

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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.

2. SCOPE & PURPOSE

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 (Headquarters) 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;
 auto recirculation valve;

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 auto standby equipment and


 Local gauges of eSOMS reading etc.
ii. This procedure is not intended to cover or address the following:
a) Pressure Relieving Devices such as Relief Valves, Rupture Discs covered in
Production Procedure PD-PGN-PRO-00-0001.
b) Mobile emergency response equipment such as Quick Response Vehicle (QRV),
ladder truck, pumper truck etc.

3. DEFINITIONS

 BPCS: Basic Process Control System


 CCR: Central Control Room
 DCS: Distributed Control System
 EIV: Emergency Isolation Valves
 eSOMS: Electronic Shift Operations Management system. Electronically maintains
documents/checklists.
 ESD: Emergency Shutdown Device
 FACP: Fire Alarm Control Panel
 FAP: Fire Alarm Panel
 FIC: Field Information Centre
 FOC: Field Operating Centre
 Fire Protection System: It is a design features, systems or equipment in a building,
structure or other fire risk, to reduce danger to persons and property by detecting,
extinguishing or containing fires.
 FSC: Fire and Safety Coordinator
 IPL: Independent Protection Layer: A special class of protection layers that satisfy the
following conditions:
 Independent from the initiating event and any other protection layers;
 Capable of being evaluated or validated for performance;
 Must reduce the frequency of the scenario by at least an order of magnitude; and
 Must completely prevent the scenario without the assistance of any other protection
layer.
E.g. BPCS alarm, BPCS control, SIS interlock, DCS interlock and PLC interlock etc.
 ISBL: Inside Battery Limit
 MMS: Machine Monitoring System
 MOC: Management Of Change
 MOS: Maintenance Override Switch feature is designed in SIS (safety instrumented
system), to allow the periodic maintenance and testing of the critical interlock initiators and
actuators (calibrations, functional tests, etc.,) without causing unnecessary plant shutdown.
 NCR: North Control Room

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 OSBL: Outside Battery Limit


 PAGA: Public Address and General Alarm
 PHA: Process Hazard Analysis
 PSM: Process Safety Management
 P&ID: Piping & Instrumentation Diagram
 PTW: Permit to Work
 Requester: Refers to the individual requiring the bypass. (e.g. F&G Technician for F&G
systems, Board Operator for alarm disabling/MOS, Instrument Technician for PLC/MMS)
 SIF: Safety Instrumented Function
 SIL: Safety Integrity Level
 SIS: Safety Instrumented System
 VDU: Visual Display Unit

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

Follow the PTW procedure as applicable.

ii. Fill the Safety, Alarm and Emergency System Bypass Permit (attachment 1) as per the
guidelines below:

a) Fill clearly;
 Date/Time
 Unit/Area details (e.g. Utilities)
 Equipment affected (Describe or identify the major system/equipment associated
with the safety, alarm or emergency system e.g. Furnace 1, Boiler 2 etc.,)
 Name of Safety, Alarm & Emergency Device (Describe the safety or emergency
system being bypassed. e.g. reactor kill, compressor high vibration trip etc.,)

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 Safety, Alarm & Emergency Device Number(s) (Identify the specific tag
number(s) being bypassed)

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.

b) Tick the appropriate system of bypass; SIS interlock, BPCS (DCS/PLC/Local


Controller) interlock, Emergency Shutdown Device (ESD), BPCS alarm (IPL alarm),
other BPCS alarm, F&G system or others (e.g. safety shower, deluge etc.,)
c) Tick the appropriate category of the bypass.
d) 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.

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.

NOTE 5

i. If the system to be bypassed is a SIF (SIL >=2) refer the pre-


approved compensating measures which are available in the Q-
Chem/RLOC Intranet Home Page/Risk Analysis Portal (share point
location) and capture it in the bypass permit. Contact PSM group if
you would require any further assistance.
ii. Compensating measures must provide the same, if not greater,
degree of risk reduction as the bypassed system.
iii. If compensating measures cannot provide adequate risk reduction,
safety variance is required and shall be attached with the bypass
permit.

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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.

Component Bypass: Hardwire jumpers used to bypass components not


related to safety systems shall be done through the use of a Temporary
MOC – Refer Management of Change/Pre-Start-up Safety Review (QC-
PSM-PRO-00-0003)

iii. Get the bypass installation approvals as per below guideline:

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.

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.

 Fire Protection System in RLOC: ISBL Supervisor is responsible for fire


protection systems within ISBL boundary. OSBL Supervisor is responsible for
fire protection systems within OSBL boundary. In both cases the FSC approval is
required.

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 Fire and Safety Coordinator (FSC) is responsible for fire protection system
bypasses outside production areas.
NOTE 9
Supervisor of Production/other section or FSC (fire protection system
outside of Production area) are responsible to communicate the affected
personnel prior to implementation.

iv. Bypass installation

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)

 BPCS bypasses related to DCS, shall be carried out by DCS Technician.


 BPCS bypasses related to PLC, MMS and local controller shall be carried out by
Instrument Technician.
b) Identifying Safety, Alarm and Emergency System Bypasses
 Any safety and emergency system bypass shall be clearly identified in the plant
and field using the Safety and Emergency System Bypass Tag (bright orange
tags) in addition to posting the copy of bypass permit.

NOTE 11

This tag is a stock item which is available in the materials store.

 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.

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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.
 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 normalizes the bypass signs 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 review the correctness and completeness of all
the sections of the bypass permit (as required by this procedure) and sign. If there is
any discrepancy, the supervisor/FSC (as applicable) coaches the individuals to
avoid reoccurrence and document their action also in the permit. Also file the
original bypass permit form and retain as per the Records and Information Retention
Schedule QC-IMT-SHD-00-0001.

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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 Headquarters in Doha)

i. Discuss the reasons/justifications for the bypass with Headquarters General Services
Coordinator and Headquarters Safety Representative (for Fire protection systems).
Check if there is any other alternative way to avoid the safety, alarm and emergency
system bypass.

If there is no other option available, follow the below sections:

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)
 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.

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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.

iii. Get the bypass installation approvals as per below guideline:

a) Get the approval from Doha office General Services Coordinator.


b) Get the approval from Doha office Safety Representative (for fire protection
systems)
c) Get the approval from Doha office Management.
d) Communication is to be made to all personnel on the affected floor of the
removal/functionality of a safety system prior to implementation by the Doha office
General Services Coordinator.
iv. Bypass installation:

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)
b) Identifying Safety and Emergency System Bypasses
Any safety and emergency system bypass shall be clearly identified using the Safety
and Emergency System Bypass Tag (bright orange tags) in addition to posting the
copy of bypass permit.

NOTE 14

i. Original copy shall be kept at the General Services Manager’s room


at Headquarters.
ii. Post one copy at the “Notice Board” in the same floor. One copy at
the actual location of bypass.

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.

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 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.

b) Condition 2 (If bypass to be extended more than 30 days)


 Initiate and manage the bypass through temporary MOC process.
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 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.

5. RESPONSIBILITIES

5.1. Affected Area Manager/Deputy Plant Manager (RLOC)

i. Reviews and approves bypasses extending beyond 7 days.

5.2. Bypass Requester

i. Initiates the bypass.

5.3. Fire and Safety Coordinator

i. Reviews and approves bypasses of fire protection systems.


ii. Communicates to affected personnel if it is non production area.
iii. Review the correctness and completeness of all the sections of the bypass permit as
required by the procedure (quality check) and take action if there is any discrepancy to
avoid recurrence. It is applicable for bypass on fire protection systems outside of
production areas.

5.4. Process Safety Coordinator

i. Provides guidance on identification of compensating measures for interlock bypasses


(SIL 2 and above) and approve if it crosses above 7 days.

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5.5. HSE Superintendent (RLOC)

i. Reviews and approves bypasses extending beyond 7 days.

5.6. Doha office General Services Coordinator

i. Coordinates the bypasses at Headquarters.

5.7. Section Head/Unit Superintendent

i. Reviews and approves bypasses extending beyond 7 days.

5.8. Shift Coordinator (Q-Chem - Mesaieed)

i. Reviews and approves bypasses extending beyond 24 hrs but less than or equal to 7
days.
ii. Conducts monthly bypass permit audits (process unit bypasses), assigns required
actions to address the findings and upload the audit results in compliance tracker.

5.9. Supervisor

i. Reviews and approves bypasses up to 24 hrs in both manufacturing facilities.


ii. Communicates the bypass details to the affected personnel and ensures the display of
bypass permit copies on notice boards.
iii. Review the correctness and completeness of all the sections of the bypass permit as
required by the procedure (quality check) and take action if there is any discrepancy to
avoid recurrence.
iv. Conducts monthly bypass permit audits (process unit bypasses), assigns required
actions to address the findings and upload the audit results in compliance tracker. (It is
applicable only for RLOC production supervisor)

6. REFERENCES

6.1. HSE-SAF-PRO-00-0006: Permit to Work (PTW) Procedure

6.2. HSE-SAF-PRO-00-0009: Job Safety Analysis (JSA) Procedure

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)

7.3. Attachment 3: Safety, Alarm And Emergency System Bypass Monthly Audit (HSE-SAF-
SFM-00-0157)

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8. APPENDICES

8.1. Figure - Safety and Emergency System Bypass Tag

9. REVISION HISTORY

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

 Change Category: Type-2


 Additional verification of bypass permit
correctness and completeness by
supervisor/FSC added in the
Carl Poldrack
procedure. (4.1.(vi).(d)).
Venkata Roehl
8 17-Nov-15  Monthly bypass permit audit Syed Rizvi
Chandra Bartolome
requirement (plant bypasses) added
(5.3., 5.8 & 5.9) and audit check list
developed and attached. This is to
address 2014 PSM audit action plan.
(7.3)
 Periodic Revision Hari S Carl Poldrack
 Added additional definition in the Ravulaparthi; Roehl
procedure, more clarity on scope, both Selvarasa Bartolome
plant and admin facility forms update, Guhan; Kevin C Kabell
change in SIL 2 or above bypass Paul D Gary L Piana
approval process related to PSM Sureshkumar; Saleh Abdulla
Venkata
7 30-Jun-14 group, incorporated safety manual Tecku P Said K
Chandra
feedback points, process of managing Dadlani; Boshorbak
bypass above 30 days, inclusion of Hamad Al- Chad A
safety manager in approval process of Maraghi; Jennings
head office safety system bypass Mohammad N Ali Al-Marri
above 7 days and formatting. Khan; Amer M Al-
Sornavel VS Qahtani
 Added the LCP Icon Box with notes

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(Page 1)
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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