Title: Safety System Valve Lock Out Procedure. Individual Unit Function: Health and Safety Procedure No.: BMEHS-002.
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1 Procedure No.: BMEHS Page: 1 of 9 When ever Revision Number Revision Description Revised By Revision Date New Considered as starting document for revision change table
2 Procedure No.: BMEHS Page: 2 of 9 1. PURPOSE To develop a procedure to identify what valves to instruments, pressure devices are correctly locked (in open/closed position) that could affect the safety systems of the plant. To develop an inspection checklist and Safety System Valve Form for the BASF Beaumont Site for the purpose of ensuring identified safety critical valves are locked in correct position. 2. DEFINITIONS 3. SCOPE This procedure will be used when a safety system valve position is changed (from OPEN CLOSED or CLOSED OPEN) which is not covered by the Beaumont Lock, Tag, and Try Procedure. This procedure also provides details for operations to create a checklist to identify safety critical valves to, instruments, equipment and protection devices that need to be locked in the correct position while plant is in normal operation that could affect the safety systems of the plant. It describes the type of lock device that can be used to secure the valve position. Inspection guidelines to be used for normal operations and for startup after maintenance activities have been completed. 4. PROCEDURE 4.1 Approvals Area OM or Designee I/E Engineer or Designee If root valves on transmitters are involved EHS Manager or Designee
3 Procedure No.: BMEHS Page: 3 of 9 4. PROCEDURE cont d 4.2. Documentation The form found in Attachment A shall be used to document the information necessary to perform the safety system valve position change as well as the required approvals. All information must be printed legibly Section I General Information The following information must be supplied in Section I: Date / Time Required shall be noted in the following format: Dates - mm/dd/yy. Times - military time. Expiration Date / Time shall be noted in the following format: Dates - mm/dd/yy. Times - military time. In addition, the following time limitations apply: 24 hours The form must be updated daily if the status change must be extended over 24 hours. NOTE: It is the responsibility of the Shift Supervisor on duty when the Safety System Valve Position Change approval is due to expire to ensure that the valve is restored to the correct position or a new approval form is generated. Unit location of the valves; System and/or equipment involved; The initial valve position Circle LC (Lock Closed) or LO (Lock Open) The person responsible for restoring the valve position shall sign the form in this section when the work is complete and the valve is restored Section II Reason for Safety System Valve Position Change This section must be completed by the originator. The originator must legibly print their name at the bottom of the block.
4 Procedure No.: BMEHS Page: 4 of 9 4. PROCEDURE cont d 4.2. Documentation cont d Section III Valves Affected This section must be completed with input from Operations Personnel Section IV Additional Precautions Required Any additional safety or equipment protection precautions that are required must be specified in this section Section V - Approvals Approvals shall be documented in the section in accordance with Section 3.1. Signatures shall be legible. Approvals may be made verbally at the discretion of the Approver Section VI Additional Notifications At the discretion of the Originator and the Shift Supervisor additional notifications may be made as necessary. The notifications shall be documented in this section Notifications to Affected Personnel A copy of the Safety System Valve Position Change Documentation Form shall be posted in a designated area in the control room The Shift Supervisor will determine which Operations and Maintenance personnel must be notified of the valve position change It is the responsibility of each Shift Supervisor to ensure that their shift personnel, as necessary, review the information Termination of the Safety System Valve Position Change For termination of the safety system valve position change, signatures and dates from the I/E technician (if root valves on transmitters are involved) and the unit operations technician are required in section V of the form.
5 Procedure No.: BMEHS Page: 5 of 9 4. PROCEDURE cont d 4.5. Valve Position Checklist: Each Area Operation Coordinator (Bmt-N, DMTA, MPP and WOD) or their designee will create a checklist indicating what valves to instruments, and pressure relief devices are to be locked out. Should include valves that are indicated on P&ID s. Any valve that requires to be opened/closed for safe operation as determined by operations. Needs to express the desired position, opened/closed The checklist should include: Check off box indicating the correct position, to be initialed by inspector. Need to have a box indicating the correct position required (open / Closed). Need to have a box indicating the correct P&ID number. Need to have a box giving detail description of valve, instrument, or pressure element that is to be locked out The appropriate area Operations Manager will review the list for final approval The Area Operation Coordinator (Bmt-N, DMTA, MPP and WOD) or their designee will be responsible for maintaining up to date checklist.
6 Procedure No.: BMEHS Page: 6 of 9 4. PROCEDURE cont d 4.6. Inspection Requirements: Area Operations Coordinator (Bmt-N, DMTA, MPP and WOD) will ensure that routine inspection of locked out valves will occur. Inspection will occur once a quarter. Area Ops Coordinator will enter request for inspection in Action Tracker, requesting Shift Supervisor to initiate quarterly inspection. The request will also be copied to OM s. Process Techs will be conducting the inspection. Using the Inspection sheets attached to the procedure, the inspection sheets will be dated, and signed off by Shift Supervisor or Process Tech. Shift Supervisor will sign off the inspection action item in action tracker once the inspection has been completed. Inspection sheets will be returned to the Area Operations Coordinator for review, corrections will be implemented, and then a copy of the inspection sheet filed for record keeping purposes During startup after maintenance activities, inspections will be conducted for required locked valve position affecting safety systems. This inspection must be conducted prior to startup. Area Ops Coordinator will enter request for inspection in Action Tracker, requesting Shift Supervisor to initiate start-up inspection. The request will also be copied to OM s. Shift Supervisor will ensure the inspection takes place prior to startup. Using the Inspection sheets attached to the procedure, the inspection sheets will be dated, and signed off by Area Team Lead or Process Tech. Area Supervisor will sign off the inspection action item in action tracker once the inspection has been completed. Inspection sheets will be returned to the Area Operations Coordinator for review, corrections will be implemented, and then a hard copy of the inspection sheet filed for record keeping purposes. The inspection sheets will be kept in Area Operations Coordinator office.
7 Procedure No.: BMEHS Page: 7 of 9 PROCEDURE cont d 4.7. Approved Locking Device: Only Black and Orange Locks shall be used. Chain or cable can be used to lock valves in required position Each of the operating areas will have sets of locks that are commonly keyed within the set, but keyed differently from the lock set for the other operating areas. 5 RESPONSIBILITIES 5.1. Beaumont Site Leadership Team Has primary responsibility for implementation of this procedure Area Operations Manager Has primary responsibility for the initiation, re-issuance, administration, and/or interpretation of this procedure. 5.2 Beaumont Site Employees and Contractors Have primary responsibility for adherence to procedure including identifying deficiencies in the procedure, and identifying, reporting and correcting activities not in compliance with the procedure. 5. RELATED DOCUMENTS ATTACHMENT A Safety Valve Position Change Form Safety Valve Position Inspection Form BMEHS Control of Hazardous Energy Lock, Tag, and Try
8 Attachment A Section I General Information: Date / Time Required: Expiration Date/Time* Note: The maximum duration for safety valve position changes is 24 hrs. The form must be updated daily to extend this limit. Unit System or Equipment Initial Valve Position_(circle) LC / LO Section II - Reason for Safety Valve Position Change: Originator Name: Section III - Valves Affected:* *Attach additional sheets as necessary Section IV - Additional Precautions Required: Section V Approvals (for verbal approvals, write the approvers name and write verbal next to it): Termination of By-Pass: Work has been completed Name: Date: Area OM* If root valves on transmitters involved (I/E Technician) Valves have been restored Name: Date: Supervisor - I&E* (Operations Tech.) If root valves on transmitters involved Operations have been restored Name: Date: EHS Manager* to normal (Operations Tech.) *Approvals may be made by the person specified or their designee Section VI - Additional Notifications: Individual Required (Y/N) Date /Time Individual Required (Y/N) Date/Time Area OM Mechanical Engineer Area OE Controls Sys. Engineer Eng./TES Manager
9 Beaumont Site Safety Critical Valve Inspection Type of Inspection: Frequency of Inspection: Unit / Department: Inspection Date: Inspector s Name: Shift: Lock Valve Check Sheet Quarterly Position O K P&ID # PSV / Equipment Number Upstream Valve Locked Line # Downstream Valve Locked
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