Operating Integrity training BGC assets:

MANAGEMENT OF SAFEGUARDING SYSTEMS OVERRIDES

 Training Rules

 Does everyone know what to do in case of

emergency?
 Cell phones on vibrate. Take important calls
outside the room.
 Everybody participates
 Listen actively!
 Avoid having conversations with other
participants
 If you have questions, do not ask the other
participants, rather ask the facilitator
 We take regular breaks, if and when
necessary

2
 Message from the Plant Directors

Hello BGC colleagues,

Today you are going to become part of a critical journey for the safe future of our company.
This journey is called “Operating Integrity”.

Operational Integrity is a very important part in the safe operation of production- and
processing units.
It is knowing and understanding the limits of your units and staying within them at all times.
Operating Integrity has been proven to work in hundreds of plants like ours around the
world. Listen to what these gentlemen have to say. We expect you to join this journey to
Operating Integrity with all your energy and effort.

Each day is an opportunity for all of us in BGC to be a bit better than we were yesterday.
Operating Integrity is our new way of working. Pay attention, ask questions, and put what
you learn into use immediately.
On behalf of the leadership of BGC, we wish you a safe and productive day.

Talib al-Idani Majid al-Shawaf Sajid al-Faris 3

Sabbah Mullakhasaf
 What is Operating Integrity?

"Operational Integrity is a very important part in the safe operation of

production- and processing units.
It is knowing and understanding the limits of your units and staying within
them at all times”.

The three main behaviors that are critical to make Operating Integrity a
success are:

 Always use and follow BGC standards, processes and procedures.

 Leaders and Supervisors regularly spent time on site.

They talk to and listen to staff about the status of the site and how all work
on site can be done safely.

 Staff feel that they feel comfortable with stopping any operation or activity
that is or feels unsafe.
 Course Objective – Manage Safeguarding Systems Overrides

This Presentation covers these two points:

 What to do when you think a safeguarding system needs an override?

 How to ensure that the integrity and safety of the process will not be in danger when
the override is in place?
 Overrides – Introduction

What is An Override?
 Overrides – Introduction

Examples of overrides
 Overrides – Process

 Thereare two types of overrides that are covered by this procedure:

 Instrument Override: isolate or disconnect a trip signal or trip switch
 Safety Systems Override: isolate (part of) firefighting system, emergency power
generation, etc.

 Theseoverrides can be applied by using:

 Operational Override Switch (OOS)
 Maintenance Override Switch (MOS)
 PLC / Software Overrides (DCS)
 Jumper / remove contact or cable
 Mechanical/ Physical barrier
 Overrides – Introduction

Why manage Overrides?

 Overrides – Introduction

We Want to Stop This!

 Overrides – Introduction

 Impropermanagement of overrides was a common critical contributing factor for the

occurrence of many major accidents throughout the industry.

 Therefore,following this procedure is mandatory for everyone working with or on the

process safeguarding system!

 “If you choose not to follow the rules, you choose not to work for BGC.”
 Expectations

 If you or your colleague think that a safeguarding system needs an override, report it
to the Shift Engineer immediately!

 Perform a risk assessment with the Shift Engineer and discuss whether the override is
really required

 The
Shift Engineer will determine the duration of the override: short-term, regular or
MOC

 After evaluation: follow the steps in the overrides flow chart to ensure that the
override is correctly recorded and managed
Overrides –
Flow Chart
 Overrides – Process
Start: which type of override do I need?
 Overrides – Process
Override Certificate
 Overrides – Process
Approval, registration and application of a regular override
 Overrides – Process

Design Technical
Integrity Integrity
Integrity

OVERRIDE REGISTER
Leadership

Operating
Integrity

Number of active overrides: 0

Date
Date
Date Override Date Physically
Mitigating measures Date Override Tag Override cancella- Checked
Nr Tag No. Panel No. Drawing No. Description of override activated + extension removed + Checked
taken approved Number expiry date tion By
Name date Name on
approved
Location
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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 Expectations

 When the override is active:

 Communicate the override to your colleagues and during shift handover

 Ensure no changes to production process parameters are made, that might have a
negative effect on the override

 Check whether the override is still valid

 Ensure that the override will be cancelled and removed when it is no longer required
 Overrides – Process
Managing overrides: Monthly Checks
 Override – Scenario 1

 You walk in the plant and see that this level switch is
broken and not working. Spare parts are not available.

 What do you do?

 What Override needs to be put in place?
 Is there something else to be put in place?
 Work Request?
 Additional checks?
 Complete:
 Override Certificate
 Override Tag
 Override Register
 Override – Scenario 1

 You must:
 If not safe: shut down the unit
 Perform a risk review with Shift Engineer: is it safe to
continue production without this safeguard?
 Make a work request to replace the broken switch
 When considered safe to continue: follow the process for a
regular override (>1 shift, because no spare part)
 Complete an Override Certificate
 Add a mitigating action in the certificate, for example:
‘perform an operator check every 8 hours’
 Obtain approval from the Plant Manager
 Request instrument staff to apply the override (i.e. remove
the broken switch)
 Tag the override in the field with an override tag
 Register the override in the Overrides Register
 Mention the override and the mitigating action during shift
handover and in the Shift Report
 Override – Scenario 2

 You need to completely drain vessel V-5 to provide a safe

workplace for maintenance staff (0% level). The low
level switch stops the draining at 10% level, by closing
the downstream ESDV.
 What do you do?
 What Override needs to be put in place?
 Complete a Risk Review
 Override – Scenario 2

 You must:
 Discuss and agree the need for override with the
Shift Engineer
 Perform a risk review with Shift Engineer: Is it safe
to drain the vessel by forcing the ESDV open?
 When considered safe: apply a short-term override
(< 1 shift)
 Obtain written approval from the Section Head (or
higher) on the override tag
 Request instrument staff to apply the override,
usually a jumper cable
 Tag the override, on the jumper cable, with an
override tag
 Drain the vessel until empty (manned operation!)
 Remove the override before the end of the shift
 Mention the use of the override during shift
handover and in the Shift Report
 Override – Scenario 3

 Duringa test of the low-pressure trip function, the

ESDV does not close automatically.

 What do you do?

 What Override needs to be put in place?
 Is there something else to be put in place?
 Work Request?
 Additional checks?
 Complete:
 Override Certificate
 Override Tag
 Override Register
 Override – Scenario 3

 You must:
 Make a work request to repair the trip function
 Perform a risk review with Shift Engineer: is it safe to
continue production without this safeguard?
 If not safe: shut down the unit
 When considered safe to continue: follow the process for a
regular override (>1 shift)
 Complete an Override Certificate
 Add a mitigating action in the certificate, for example:
‘Low-level alarm tested and working ok. Manually shut
down the unit when the low-pressure alarm activates’
 Obtain approval from the Plant Manager
 Tag the override in the field with an override tag
 Register the override in the Overrides Register
 Mention the override and the mitigating action during shift
handover and in the Shift Report
 Assesment of Acquired Knowledge

You must achieve a mark of 80% or higher to

receive certification
You have 30 minutes to finish the test.
 Write your ID, name and details clearly. If
your ID cannot be read or is incorrect you
cannot pass.
 Please do not disturb other people in the class
while writing the test.
 When you have completed the test, please
indicate and the instructor will collect it.

Operations Integrity: Management of Passing Valves

 Assesment of Acquired Knowledge

Multiple Choice Test.

 Mark the right answer(s) with a tick [].
If you wish to change your answer use an 
over the .

 In all cases please read all answers and

choose all that are correct.
There may be 1, 2, 3 or 4 answers.

Management of Passing Valves

 Feedback

We would like to know what you think about this training

Do you know now what is

expected of you?

In which areas do you

require more clarification?
 Overrides – Process
Risk Review

 The risk description/review of the

override is depending of the SIL
classification and the RAM score of the
particular safeguarding system:
 SIL<2 or blue RAM score: Assessment
by Shift Engineer and Section Head
 SIL>2 or yellow/red RAM score:
Assessment by Shift Engineer, Section
Head and TA-3 PACO
 When the SIL level or RAM score is not
known, the TA-3 PACO shall
support/advise on the risk review and for
determining control measures.
 Overrides – Process
Approval of a regular override
  Communication means to obtain approval for an override can be (in order of
preference):
 Hard copy: the hard-copy override certificate is signed-off by the Plant Manager.
 Soft copy: the override certificate may be scanned as pdf and sent by email to the Plant Manager.
Approval can be given by email reply. For short-term overrides, when there is no override certificate,
approval by email reply by the Section Head is sufficient.
 Phone: The Plant Manager or Section Head provides approval by phone (SMS). When this happens,
the shift engineer should sign-off for approval and mention in the box ‘Name:’ the term ‘by phone’
(at the next opportunity the Plant Manager has to sign-off the hard copy certificate). This is the least
favorable way.
 All
new overrides have to be mentioned in
 Override Register
 Shift Report
 Shift handover.
 Overrides – Process
Validity and Extension of Overrides

 An override may be active for a maximum of 12 months.

 Overrides longer than 12 months must follow the MOC procedure
 Extension: when an override is expired but still required:
 extension can be granted by the Plant Manager
 Plant Manager signs-off and mentions the new expiry date on the override certificate
 Update the Override Register with the extension date
 Extensions can only be granted one time!
 Cancellation: when an override is no longer required:
 Issue cancellation request at Plant Manager
 Mention the cancellation date on the Override Certificate
 Remove the override and tag label under supervision of the Shift Engineer
 Overrides – Process
Special situation: Managing Multiple Overrides

 Multiple overrides (simultaneously) are only permitted if they do not influence each
other.
 It is permitted to request multiple overrides as a group (on one override certificate) in
the event of:
 Install overrides for an isolation
 Install overrides for testing/purging installation (parts)
 In these cases, (a copy of) the override certificate shall be attached to the applicable
isolation certificate (as per PTW Process).
 Overrides – Introduction

Use these tools to Record and

manage overrides.
Design Technical
Integrity Integrity
Integrity

OVERRIDE REGISTER
Leadership

Operating
Integrity

Number of active overrides: 0

Date
Date
Date Override Date Physically
Mitigating measures Date Override Tag Override cancella- Checked
Nr Tag No. Panel No. Drawing No. Description of override activated + extension removed + Checked
taken approved Number expiry date tion By
Name date Name on
approved
Location
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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 Operating Integrity Scope

TOPIC SCOPE
1 Operating Envelopes Operating all our facilities within up-to-date operating
envelopes
2 Alarm Management Managing (rationalizing and know how to respond to) alarms
3 PtW effectiveness Effective use of the permit to work system, address the five
pillars of effectiveness: competence, compliance,
communication, supervision and hazard awareness
4 Communication and Clear, consistent and effective daily communications and shift
Handover handovers
5 Critical Documentation Having accessible and up-to-date documents which are
followed consistently
6 Inhibits and Overrides Have visibility of overrides, inhibits, temporary repairs and
temporary equipment and a process to manage them
7 Competence Having only competent people in all HSE critical roles all the
time
8 Statement of Fitness Ensure for each asset or part of an asset a Statement of Fitness
is in place
 Assesment of Acquired Knowledge

Override Tag and Register Exercise.

Now Fill out Tag and Register

Design Technical
Integrity Integrity
Integrity

OVERRIDE REGISTER
Leadership

Operating
Integrity

Number of active overrides: 0

Date
Date
Date Override Date Physically
Mitigating measures Date Override Tag Override cancella- Checked
Nr Tag No. Panel No. Drawing No. Description of override activated + extension removed + Checked
taken approved Number expiry date tion By
Name date Name on
approved
Location
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25

36
 Overrides – Introduction

How do we manage Overrides?

Break
Break