smart summit 2013 1 improving safety with intellipermit tm henry boshoff principal consultant 1

SMART Summit 2013 11

Improving Safety with IntelliPERMITTM

Henry BoshoffPrincipal Consultant

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Discussion Framework

• OpsuiteTM Overview• IntelliPERMITTM overview• IntelliPERMITTM components• Benefits

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Operations Suite

Incident/Non-conformance Management

Investigation

Root Cause Analysis

Corrective Actions

Scheduled Inspections

Work Order Management

Spares Management

Preventative Maintenance

Equipment Modifications

Shift logs

Downtime records

Batch sheets

Standby and Shift Rosters

Quality records

Meeting Minutes

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Operations Suite

Permit to Work

Isolations

Risk Assessment

Hazards

Rules for safe work

Contractor Management

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What is IntelliPERMIT?

A computer based permit to work system that reduces the risks of working in hazardous environments by ensuring that equipment is correctly isolated and that appropriate measures have been taken to protect workers from hazards. The permit certificate provides proof that the work is authorised and that everything reasonably practicable has been done to mitigate risks to workers and the environment

Permit process and audit trail

Hazard ID and

controls

People and competencies

Isolation and

lockout

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• Predictive Hazard Identification (patented technology)

• Associate safe work “rules” with hazards

• Elimination of “rote” permits• Users are coached during permit preparation• Guidance provided on Business rules (OK,

warn, exception, disallow)

• Powerful isolation management• Isolations are cross referenced and based on

your detailed procedures• Powerful key safe and lock management

• Extremely flexible• Designed to fit your processes, not the

other way round• Supports multiple permit types

• Control competencies• Biometric ID

• Integrates easily with plant maintenance systems

• Continuous improvement• System health checks• Learning from incidents translate to new

or modified rules

How IntelliPERMIT improves safety

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Predictive Hazard Identification

Hazards

Plant Area

Permit Type

Equipment

Activities

Preparations

Precautions

PPE

Keywords

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Requesting a Permit

Only prompts for items relevant to the hazards identified

Alert, Raise Exception or Disallow

“We did not anticipate what a useful training tool IntelliPERMIT would turn out to be. The system serves as a constant reminder of what the correct procedures are”

Gary Clancy, Operations Manager, Anchor Yeast

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Modelling the Permit Process

Permit status change subject to:1. User identification through electronic

signature2. User competencies3. Business rules

Enforce compliance System configured to match your

process Minimise retraining Rapid system adoption


Competency

Area

Permit Type

Transaction(e.g. Issue)

Activity

Control authorities with competencies

Competencies are granted following training, and are set to expire. Reminders for refresher training are automatically created for the training department.

Benefits: Control authorisation of work, ensure refresher training is planned and provided, prevent unauthorised persons signing permits, ensure work done by competent persons only


Moving permit status from A to B

User IdentityPassword / Biometric

CompetencyScope & Validity

Question Responses

Ignore / Alert / Exception /

Disallow

Business Rules

Ignore / Alert / Exception /

Disallow

Status A

Status B


Business Rules

• Controlling workflow

• Isolation procedures

• Enforcing safety

• Notifications

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Biometric Signatures

In use since 2005>10000 users in heavy industrial environments have registered over 5 million transactions using the technology.

Benefits: Improved integrity of signatures, faster processing, no need to maintain passwords


Visibility of work in progress

Alert for overdue permits


Details of work to be performed

Audit trail of signatories

Required PPE

List of isolations & locks

Only prints hazards & questions relevant to the task

Sample


Click to print isolation tags

Click on red bar to open lockbox list

Details of master permit – click to

expand /collapse

Details of isolation tags and GIB/lockbox link

tag


“Permit Hut”


Isolation Management

Benefits: Design information can be embedded into isolation procedures and enforced. Avoid removing of isolations where multiple linked permits exist. Enforce isolation procedures

Equipment Isolation Procedures

Permit

Isolations

Equipment

Type

Activity

Tags

Previous Permits

“Master“Permits

X-ref

Copy

Prompt


Cross Referencing Permits

• More efficient isolations and permits

• Control dependencies between multiple jobs

• Rules force consistency between master and slave permits


Key Safe Hierarchy

• Track complex dependencies

• Re-commission plant more efficiently after outages

• Identify relevant isolation sets


Permit A• Area• Type• Activity• Equipment• Isolation Method

Permit B• Area• Type

• Activity• Equipment

• Isolation Method

Photo: Cape Preston - Les Walking


Permit Revisions • Plant isolated and

tagged• Permit issued and

accepted• Work proceeds

PTW 20000

• Scope of work changed• Permit Suspended by Issuer and Acceptor• “New Revision” signature revokes

PTW20000 and creates PTW20000/1

PTW 20000/1

• Each new revision Issued and Accepted

• Tags with original PTW number remain valid

PTW 20000/2

Benefits: Improved control over scope changesRe-commission systems faster


DeletedChangedAddedNo Change


Measure and monitor permit request statistics

Go Live

Benchmark: 80% of permits <5 minutes

Average 300 permits/week

Benefits:Reporting on permit request time allows benchmarking between individuals, departments and sites. Too long could indicate a training requirement, too short could indicate that inadequate attention is being paid to assessing risks.


Shutdown Support• Improve planning

• Prepare template permits and isolation procedures• Clear instructions for when permits need to be prepared by

• Control large numbers of contractors• No work without minimum required competencies and medicals etc.

• Cross reference “master” isolations• Better management of isolation dependencies between tasks

• Permit suspension for testing• Safely direction test motors etc.

• Permit revisions for re-commissioning• Efficiently track isolations still required • Reduce outage time


Direct Benefits

Improved

Safety

Control

Visibility

Consistency

• High quality permits that comply with procedures

• Effective delegation of responsibility• Only competent and authorised persons

can sign• Management notified of

deviations/exceptions• Constant reinforcement of training

• High visibility of work in progress• Better communication

• Improved efficiency of permit process• Templates, pre-loaded procedures• Track complex isolations and cross

references• Improved governance of safety

• Better auditing

• Improved governance of safety• Better auditing


Integration Options

• Import functional locations / equipment

• Use work order data to populate permit

• Update work order status with permit status

• Use 3rd party system user and competency data

• Link to access control system

Integration via web services


Key Success Factors

Leadership supportSuitable super users / administratorsClear project objectivesDetailed, documented designThorough testingTraining attendanceEffective change managementSystem health checks and audits

Photo: Mt Isa – Scott Bredin


Thank you!

Questions ?Henry [email protected] Henry Boshoff

smart summit 2013 1 improving safety with intellipermit tm henry boshoff principal consultant 1

Documents

smart summit

competencies competencies

permit certificate

safety slide

lockout slide

operations suite permit

user competencies

environment permit process