Improving Safety with IntelliPERMIT TM

1. Improving Safety with IntelliPERMITTM Henry Boshoff Principal Consultant

2. Discussion Framework • OpsuiteTM Overview • IntelliPERMITTM overview • IntelliPERMITTM components • Benefits

3. Incident/Non-conformance Management Investigation Root Cause Analysis Corrective Actions Scheduled Inspections Work Order Management Spares Management Preventative Maintenance Equipment Modifications Operations Suite Shift logs Downtime records Batch sheets Standby and Shift Rosters Quality records Meeting Minutes

4. Permit to Work Isolations Risk Assessment Hazards Rules for safe work Contractor Management Operations Suite

5. 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

6. How IntelliPERMIT improves safety • 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

7. Predictive Hazard Identification Plant Area Preparations Permit Type Hazards Precautions Equipment PPE Activities Keywords

8. 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

9. Modelling the Permit Process Permit status change subject to: User identification through electronic signature User competencies Business rules • Enforce compliance • System configured to match your process • Minimise retraining • Rapid system adoption

10. 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

11. Moving permit status from A to B Status A Status B

12. Business Rules • Controlling workflow • Isolation procedures • Enforcing safety • Notifications

13. BiometricSignatures 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

14. Visibility of work in progress Alert for overdue permits

15. Sample Details of work to be performed List of isolations & locks Required PPE Only prints hazards & questions relevant to the task Audit trail of signatories

16. Click on red bar to open lockbox list Click to print isolation tags Details of master permit – click to expand /collapse Details of isolation tags and GIB/lockbox link tag

17. “Permit Hut”

18. Isolation Management Previous Permits Equipment Type Copy Equipment Permit Isolations Isolation Procedures Prompt X-ref Activity Tags “Master“ Permits Benefits: Design information can be embedded into isolation procedures and enforced. Avoid removing of isolations where multiple linked permits exist. Enforce isolation procedures

19. Cross Referencing Permits • More efficient isolations and permits • Control dependencies between multiple jobs • Rules force consistency between master and slave permits

20. Key Safe Hierarchy • Track complex dependencies • Re-commission plant more efficiently after outages • Identify relevant isolation sets

21. Photo: Cape Preston - Les Walking

22. Permit Revisions Benefits: Improved control over scope changes Re-commission systems faster

23. Deleted Changed Added No Change

24. Measure and monitor permit request statistics Benchmark: 80% of permits <5 minutes Go Live 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. Average 300 permits/week

25. 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

26. Direct Benefits • 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 Control Improved Safety Consistency Visibility • Improved governance of safety • Better auditing

27. 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

29. Key Success Factors • Leadership support • Suitable super users / administrators • Clear project objectives • Detailed, documented design • Thorough testing • Training attendance • Effective change management • System health checks and audits Photo: Mt Isa – Scott Bredin

30. Thank you!Questions ? Henry Boshoff Henry.Boshoff@adaptit.co.za LinkedIn Henry Boshoff