Petrotechnics Integrated Safe System Of Work. OPERA Meeting 24 February 2004

Transcription

1 Petrotechnics Integrated Safe System Of Work OPERA Meeting 24 February 2004 Alan Day Business Development Petrotechnics Limited Pavilion 5, Craigshaw Business Park, Craigshaw Road, Tullos, Aberdeen AB12 3QH P: +44 (0) F: +44 (0) W:

2 Petrotechnics History Provide Safety Management systems and services 14 years working with oil & gas clients Strong reputation for innovation Expertise people, processes & technology Focus on safety & competency Commitment to frontline operations 2002 Institute of Petroleum Award 2003 Institution of Chemical Engineers Award and Scottish Enterprise Software Product of the Year

3 Petrotechnics Business People Operational Integrity Technology Process We enable people to be safe and effective by using technology to improve operational processes.

4 Typical challenges we help clients with Workforce Turnover New systems or technologies within operations Safety incident or near miss Regulatory compliance pressures Corporate directives Human resource Lack of safety integration Best in class initiatives Quality Interventions Lack of behavioural safety Lack of safety metrics Leadership changes

5 Our Work Products Training Competency Assurance People Operational Integrity Technology Sentinel Pro ISSOW Software Management Control and Reporting Systems Competency Management Systems Process Health Check process evaluation Validation Conformance to corporate mandates Regulatory conformance Process Redesign Management Control and Reporting Tools

6 HSE Survey A third of all accidents in Chemical Industry are maintenance related, the largest single cause being a lack of, or deficiency in, permit to work systems HSE Chemical and Hazardous Installations Division, 2002

7 HSE Survey - Reasons Two thirds of companies are not checking systems adequately Two thirds of permits did not identify potential hazards Half dealt poorly with isolation of plant, electrical equipment etc. A third of permits were unclear on what PPE was needed In many cases little thought had been given to permit form design

8 What is Sentinel Pro/ISSOW? Sentinel Pro is an Integrated Risk Assessment, Isolations Control and Permit to Work System. Compared to paper based systems, Sentinel Pro delivers: Greater efficiencies Improved process rigor More effective risk assessment Better communication Greater re-use of learning Standardisation of safety processes Resulting in : Improved safety performance Reduced workplace management costs

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10 ISSOW Key Benefits Risk Assessment notpermit output! - at the core. Ensures risk assessment completed, creates an Issue Aware culture, focuses onus on personal & team safety Web Based rapid wide-area deployment, no client software required, remote/onshore working, common operating environment Graphical Views ease of use, immediate overview capability, reduced training requirements, ease of navigation Integrates and manages main safety critical activities (PTW, RA, IM) enforces safety process, ensures rigor, improves communication Re-Use of Learning rapid adoption of new processes, incorporates Lessons Learned database, reduces re-work/re-planning effort Electronic Authorizations eliminates paper trail, ensures security Auditability full audit trail record, details full authorization history

11 UKCS ISSOW Usage

12 Shell Sentinel Pro Case Study All UK Upstream Facilities Current Deployment 19 Offshore + 5 Onshore 3,500 Users Project Objectives Measured reduction in LTI (2004) Reduce manpower cost by 3Million (Q1) Reduce indirect PTW costs by 2Million (Q1) Remove 15% PTW rework/re-planning (Q1) Pilot Site Live November 2003 All sites Live April 2004 Process for change & training completed Q1 STEP Change Harmonisation

13 Shell ISSOW Metrics Expected 5M direct cost savings per year. Less than 6 month ROI payback. Expected increase in safety performance. Integration of COSHH, LOLER, Manual Handling. Creation of Workpack Module.

14 BP Sentinel Pro Case Study All UK Upstream Facilities First deployed Everest Oct offshore + 5 onshore 4,800 users BP, AMOCO, ARCO. 3 different companies, 3 different systems. Results to Date Over 500,000 permits-55,000 isolations Approx 25,000 permits per month 22 facility years of system operation Technical reliability 100% All sites deployed on schedule/budget Increased use of routines and ORA s Improved shift handover Improved permit meetings Transition Period = 7 Days

15 BP Sentinel Pro Metrics 500k direct cost savings per year. Less than 2 year payback. 3-fold increase in safety performance. The Company's - 12 month rolling DAFWCF Days Away From Work per 200,000 mh Commence ISSOW Implementation Complete ISSOW Implementation 0.00 Dec-99 Apr-00 Aug-00 Dec-00 Apr-01 Aug-01 Dec-01 Apr-02 Aug-02 Dec-02 Apr-03

16 Sentinel Pro Operation Easy to Use Graphical Overviews ensure rapid operational acceptance at all levels and reduce training requirements.

17 Sentinel Pro Operation Ease of Use ensured by use of rapidly identifiable shaped and colour coded icons to identify work type and status at a glance. WCC TYPE Hot Work Naked Flame Hot Work Spark Potential Cold Work Cold Work Breaking Containment Operational Risk Assessment Confined Space Entry Certificate Routine Template (Cold Work) STATUS Requested Pending Authorized Issued Live Job Complete Routine Template

18 Sentinel Pro Operation Easy to Use Graphical Overviews ensure rapid operational acceptance at all levels and view of all work tasks.

19 Sentinel Pro Architecture Configuration at the rules layer ensures faster, less costly build and a stable, supportable and easily upgradeable product. Example Build Instances Configurable XML layer to define Process Rules Rules Layer Functionality Components Stable core code of application

20 Sentinel Pro/ISSOW Feedback Most personnel consider SPro a better system than paper SPro is much easier and quicker to raise permits Safer process due to improved ownership by area authorities Improved consistency of permit standards Better overall control of work activities Greater visibility increases peer pressure to do things right Risk assessment process is far superior to old paper method Much better control of simultaneous operations Shift handovers greatly improved Permit meetings are more productive Performing Authority has more input Supervisor It saves me at least 10 minutes per permit

21 Sentinel Pro Development 2005 Regulations & Standards Safety Alerts 2004 Accident and Incident Reporting Competency Management 2003 Risk Assessment Isolation Control PTW COSHH Assessment CMMS/ERP Interface Manual Handling Assessment

22 Petrotechnics Sentinel Pro / ISSOW System Presentation Alan Day Business Development alan.day@petrotechnics.com Petrotechnics Limited Pavilion 5, Craigshaw Business Park, Craigshaw Road, Tullos, Aberdeen AB12 3QH P: +44 (0) F: +44 (0) W: