1. SMART Summit 2013 1 Improving Safety with IntelliPERMIT TM Henry Boshoff Principal Consultant 1

2. SMART Summit 2013 2 Discussion Framework Opsuite TM Overview IntelliPERMIT TM overview IntelliPERMIT TM components Benefits

3. SMART Summit 2013 3 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

4. SMART Summit 2013 4 Operations Suite Permit to Work Isolations Risk Assessment Hazards Rules for safe work Contractor Management

5. SMART Summit 2013 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 Permit process and audit trail Hazard ID and controls People and competencies Isolation and lockout

6. SMART Summit 2013 6 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

7. SMART Summit 2013 7 Predictive Hazard Identification Hazards Plant Area Permit Type Equipment Activities Preparations Precautions PPE Keywords

8. SMART Summit 2013 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. SMART Summit 2013 9 Modelling the Permit Process Permit status change subject to: 1.User identification through electronic signature 2.User competencies 3.Business rules Permit status change subject to: 1.User identification through electronic signature 2.User competencies 3.Business rules Enforce compliance System configured to match your process Minimise retraining Rapid system adoption

10. SMART Summit 2013 10 Competency AreaPermit 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

11. SMART Summit 2013 11 Moving permit status from A to B User Identity Password / Biometric Competency Scope & Validity Question Responses Ignore / Alert / Exception / Disallow Business Rules Ignore / Alert / Exception / Disallow Status A Status B

12. SMART Summit 2013 12 Business Rules Controlling workflow Isolation procedures Enforcing safety Notifications

13. SMART Summit 2013 13 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

14. SMART Summit 2013 14 Visibility of work in progress Alert for overdue permits

15. SMART Summit 2013 15 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

16. SMART Summit 2013 16 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

17. SMART Summit 2013 17 “Permit Hut”

18. SMART Summit 2013 18 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 Isolation Procedures Permit Isolations Permit Isolations Equipment Type Equipment Type Activity Tags Previous Permits Previous Permits “Master“ Permits “Master“ Permits X-ref Copy Prompt

19. SMART Summit 2013 19 Cross Referencing Permits More efficient isolations and permits Control dependencies between multiple jobs Rules force consistency between master and slave permits

20. SMART Summit 2013 20 Key Safe Hierarchy Track complex dependencies Re-commission plant more efficiently after outages Identify relevant isolation sets

21. SMART Summit 2013 21 Permit A Area Type Activity Equipment Isolation Method Permit B Area Type Activity Equipment Isolation Method Photo: Cape Preston - Les Walking

22. SMART Summit 2013 22 Permit Revision s 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 changes Re-commission systems faster

23. SMART Summit 2013 23 Deleted Changed Added No Change Deleted Changed Added No Change

24. SMART Summit 2013 24 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.

25. SMART Summit 2013 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. SMART Summit 2013 26 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

27. SMART Summit 2013 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

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29. SMART Summit 2013 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. SMART Summit 2013 30 Thank you! Questions ? Henry Boshoff Henry.Boshoff@adaptit.co.za LinkedIn Henry Boshoff Henry Boshoff Henry.Boshoff@adaptit.co.za LinkedIn Henry Boshoff 30