Operating Integrity training BGC assets:

MANAGEMENT OF PASSING VALVES.

⁰C
 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

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 Course Content.

 Overview.
 Expectations.
 Passing Valve Verification.
 Roles and Responsibilities.
 The Process Flow Chart.
 Passing Valve Tag and Register Exercise.
 Course Overview & Objectives

By the end of this session, you should be able to:

 Explain what is meant by ‘Passing Valve’.

 Describe the Hazards of a Passing Valve.
 Describe the Process for Identifying, Confirming, Registering a Passing Valve.
 Describe roles and responsibilities for Management of Passing Valves.
 Show how to Tag a Passing Valve and enter the details into the Passing Valve register.
Operating Integrity
 GOAL ZERO
 Ensure safe consistent production at all times.
 Competent, well skilled operating team that utilises clearly defined Production Operations
techniques.
 Operate and optimise the facilities with defined limits, agreed procedures and plans
including emergency response.
 Conduct ongoing equipment condition monitoring and be involved in minor maintenance
activities
OPERATIONAL REGISTERS
• Locked Open/ Locked Closed (LO/ LC)
• Fugitive Leaks (i.e. weeps and seeps)
• Passing Valves
• Temporary Equipment
• Temporary Repairs
• Hoses
• What is a Passing Valve?
 Example.

• Thermal Image example of a closed valve

that is internally passing.
• Why manage Passing Valves?
We Want to Stop This .
• How do we manage Passing Valves?
 Passing Valves Register
Unit description
Date Last Risk
Next
Identification / Date Physically Assessment Corrective
Nr Location Mitigation of Risk Approval Escalation Inspectio
Tag Number Reported Checked on (RAM WO
n Date
Location Rating)
[…..] […..] […..] dd/mm/yy dd/mm/yy […..] […..] Name […..] […..] mm/yy

Register verified by:

BGC Asset Integrity and Process Safety Date:
Signature:
Overview
• Passing valves are a significant risk to the safety of personnel
operating and maintaining equipment.

• Valves that do not seal completely could create an unsafe operating

condition when required for maintenance or emergency isolation.

• All production operating and maintenance personnel are responsible

for the identification and reporting of passing valves.
We Must Ensure that:

• The risk of leaving a passing valve in service is evaluated.

• Required mitigations, controls and audits must be in place if left in service.
• Continued operation is correctly authorised.
• Corrective maintenance or replacement must occur as soon as possible.
• A process that manages and reports passing valve status must be
sustained.

• Until the situation is rectified at the earliest possible opportunity (e.g.

shutdown) a thorough Risk Assessment of how the passing valve impacts
the facility shall be carried out to ensure that the risks associated with its
continued operation is understood and managed.
Break
Passing Valve Identification and Verification

• When a critical valve is suspected passing the valve should be

tested.

• We can Isolate the process and monitor the build up in pressure

• In BGC we also use the VPAC™ leak detector device.

• VPAC is can be used to test if the Valve is passing

(Yes/No, Big/ Small.)

• It is highly recommending that every valve which is suspected

passing is checked with the VPAC before a work request will be
made.
 ROLES AND RESPONSIBILITIES

 Operators/Technicians:

• Identifies the valve that is passing and attaches an information tag that
identifies:
• The date the problem was found.
• The work request number for repair/replacement of the valve and passing valve
register reference number.
• the nature of the problem with the valve.
• Enters the Work request for the passing valve into the shift log and
communicates this to the incoming operator via handover and permit
coordinator.
• Discusses the passing valve with the Shift Engineer (at the shift team meeting.)
• Carryout a visual inspection at least once per month of the passing valves listed
in the passing valve register to monitor that the identifying tag is in place in the
relevant zone or area and report any deterioration or observations (this refers to
the tag or to the valve, not clear) to their supervisor.
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 ROLES AND RESPONSIBILITIES

ROLES AND RESPONSIBILITIES - Production Shift Engineer or Shift Supervisor:

• Records the passing valve in the shift log and communicates this to the incoming Shift
Engineer and Supervisor. Include changes to the operational registers as a topic in the shift
team meetings.
• Register the passing valve in the passing valve register which includes a risk assessment,
mitigations, review and approval for continued operation, indicate when the passing valve can
be repaired or replaced e.g. plant shut down or in normal operation.
• Following authorization of continued operation with the passing valve, print out the updated
Passing Valve Register and file in the control room for record purposes.
• Visit the passing valve on site with the section head and maintenance discipline head to
agree repair/replacement plan and isolation action plan.
• Lead risk assessment during the initiation of the passing valve in the passing valve register
and identify mitigations/actions required. Verify when the passing valve can be
repaired/replaced.
• Review the risk assessment in case an isolation is required.

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 ROLES AND RESPONSIBILITIES

ROLES AND RESPONSIBILITIES - Production Shift Engineer or Shift Supervisor

continued:

• Review the Passing Valve Register for continued operation with the
passing valve dependent on the residual risk (refer to the Passing Valve
Register role matrix).
• Confirm in shift log a Work Request has been raised in respect of the
passing valve.
• Reviews the Passing Valves Register for the asset and ensures the visual
inspections are carried out at least once per month to verify the condition
of the passing valve identification tags.
• Review the compliance audit form and ensure it is endorsed by
Department Manager and filed for auditing purposes.
• Manage the close out of any identified issues in the audits.

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 ROLES AND RESPONSIBILITIES

 ROLES AND RESPONSIBILITIES - Production Department / Section Head:

• Confirms that risk from the passing valve are adequately identified and
mitigated and approves the passing valve register for continued operation
dependent on the residual risk (refer to passing valve register role matrix).
• Close out the passing valve register when the passing valve is repaired or
replaced.
• Endorses the passing valve compliance audit at least once per quarter and
ensure findings are closed out.
• Provide visible support of the process by communicating importance,
acknowledging compliance, participation in audits and spot checks on
management of passing valves in the facilities.
• Ensures that this procedure is within its review date.

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 ROLES AND RESPONSIBILITIES

 ROLES AND RESPONSIBILITIES - Maintenance Discipline Lead:

• Visit the site of the passing valve with the Section Head and arrange for repair/replacement of
the passing valve.
• Responsible for the repair/replacement of the passing valve.

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 ROLES AND RESPONSIBILITIES

• ROLES AND RESPONSIBILITIES - Permit Coordinator:

• Be aware of passing valves and ensure they are considered during isolation for maintenance
work.

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• THE PROCESS FLOW
• The major process steps
involved in the
management of passing
valves

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Break
 Recap.

• Lets take a look at the main Steps.

• E.G. Who is Responsible for the
identification and reporting of
passing valves during their day to
day activities.
• Roles and Responsibility Quick
Questions…?

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 How We Record Information.

• PASSING VALVE TAG

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 How We Record Information.

 PASSING VALVE REGISTER

Passing Valves Register

Unit description
Date Last Risk
Next
Identification / Date Physically Assessment Corrective
Nr Location Mitigation of Risk Approval Escalation Inspectio
Tag Number Reported Checked on (RAM WO
n Date
Location Rating)
[…..] […..] […..] dd/mm/yy dd/mm/yy […..] […..] Name […..] […..] mm/yy

Register verified by:

BGC Asset Integrity and Process Safety Date:
Signature:

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 Compliance Audit.
 Guidelines for completing the temporary repair compliance audit check sheet.
 Review roles, responsibilities and activities required by this procedure.
 Verify `as-found' performance against requirements identified in the procedure.
 Highlighting areas of non-compliance in the ‘Remarks’ column.
 Report audit findings to Line Management, identifying any remedial actions required including a closure plan
with accountable person identified.

PASSING VALVE COMPLIANCE AUDIT Checklist

Auditors:
Date of Audit: Y N Remarks
Have any passing valves been identified and recorded in shift  
handover log since last audit? How many?    
Have all the passing valves for the asset been registered in the passing  
valve register? How many on the asset?    
Have SAP notifications been raised for repair/replacement of the  
passing valves?    
Have the passing valves in the passing valve register been risk  
assessed with appropriate mitigations and correctly reviewed,    
approved and authorized?
Has when the passing valves will be repaired or replaced been  
identified in the passing valve register?    
Have the passing valve entries been closed out when repaired or  
replaced?    
Has the operator routine visual inspection of all the passing valves  
been carried out and any defects recorded and rectified?    
Select 20% of the passing valves and verify in the field that the  
condition is satisfactory, List those inspected.    
 Summary

You Should now be able to:

 Explain what is meant by ‘Passing Valve’.

 Describe the Hazards of a Passing Valve.
 Describe the Process for Identifying, Confirming, Registering a Passing Valve.
 Describe roles and responsibilities for Management of Passing Valves.
 Show how to Tag a Passing Valve and enter the details into the Passing Valve register.
 Summary
Production Operator
Identify & Verify
Passing Valve
 Identify Passing Valve
 Verify Passing Valve
• VPAC Acoustic Test
¨ Passing: Yes / No
Start
¨ Passing: Big / Small
 Attach Passing Valve tag
Visually Monitor
Condition
 Inspect valve at least once
every month.
 Check Condition of
Passing Valve Tag.
 Check if passing valve
condition has deteriorated.
Production Operator
Production Technician
Production Shift Engineer
Production Shift Supervisor
Risk Assess, Agree
Mitigations & Register
 Valve required for?:
• Emergency Isolation
• Frequently used Isolation
• Criticality of isolation
 Risk of passing?
 Determine Controls
required to allow use
 Record Passing Valve in
Register
Verify Condition
Monitoring
 Verify that visual
inspection has been
correctly carried out at
required frequency.
 Verify any actions that
have been taken
Production Section Head
Production Shift Engineer
Production Shift Supervisor
Production Section Head
Raise Work Request
 Inform Maintenance
Section Head
• Visit Passing Valve
 Visit Site with Section
Head and Maintenance
Dept. to inspect valve.
 Agree with when
Maintenance can take
place.
 Make Work Request.
Verify Procedure
Compliance
 At least once every 3
months review Passing
Valve Register and check
accuracy and compliance.
Production Section Head
Production Department Head
Production Operator
Production Shift Engineer
Production Section Head Production Shift Supervisor
Authorise Continued Communicate new
Operation Passing Valve
 Review Risk Assessment  Write in Handover
 Verify Control measures  Discuss at shift handover
 Inform Permit to work
 Authorise in Passing Valve Coordinator.
Register
 Print Authorisation
 File in Control Room
Remove Valve from
Register
 When Passing Valve is
repaired/replaced, remove
from Passing Valve
register End
Production Shift Engineer
Production Section Head
Production Department Head
 Assesment of 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

 TITLE

 PASSING VALVE TAG Exercise.

Now Fill out Tag and Register

Passing Valves Register

PASSING VALVE TAG SHLGB
Unit description
DATE: MOC NUMBER: TAG NUMBER: Date Last Risk
Next
Identification / Date Physically Assessment Corrective
NOTIFICATION/WORK ORDER   Nr Location Mitigation of Risk Approval Escalation Inspectio
NUMBER:  
Tag Number Reported Checked on (RAM WO
n Date
Location Rating)
NATURE OF THE PROBLEM  
[…..] […..] […..] dd/mm/yy dd/mm/yy […..] […..] Name […..] […..] mm/yy
WITH THE VALVE:  

NAME OF THE PERSON THAT

 
IDENTIFIED THE PROBLEM:

 
MITIGATION  
 

Register verified by:

BGC Asset Integrity and Process Safety Date:
Signature:

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