© 2009, iomosaic corporation; all rights reserved. do not copy or distribute without the express...
TRANSCRIPT
© 2009, ioMosaic Corporation; all rights reserved.Do not copy or distribute without the express written permission of ioMosaic Corporation
Process Safety Culture Change ioXpress - Information Systems Solution
ACC Responsible Care
© 2009 ioMosaic Corporation. All Rights Reserved. DO NOT distribute or copy in any form without the express written permission of ioMosaic Corporation
Business Confidential Document
SALEM OFFICE93 Stiles RoadSalem, New Hampshire 03079Tel: 603-893-7009Fax:603-251-8384Email: [email protected]: www.iomosaic.com
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MINNEAPOLIS OFFICE401 North 3rd Street, Suite 410Minneapolis, Minnesota 55401Tel: 612-338-1669Fax:832-553-7283Email: [email protected]: www.iomosaic.com
An iOiQ ProductAn ioMosaic Product
Slide 2
Process Safety Culture Change Agenda
Afton’s Challenges – Why Change?
Afton’s Expectations
Examples of “Old verses New” Systems
Demonstration of live system
Culture Shift Challenges to Plant
Future Plans
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 3
Afton’s Challenges – Why Change?
Old Information Systems Technologies Utilized
“Lotus Notes” databases
Spreadsheets & Word documents
Paper Copies
Most systems initiated as Responsible Care Process Safety Code initiative
Preceded OSHA’s PSM Standard
Existing systems made to “fit” the PSM Standard
Plant culture has migrated away from baseline expectations in key elements
Existing systems not robust – multiple independent systems
Process Safety Information not easily retrievable
Compliance Audit tool needed
Need to streamline Corrective Action follow-up
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 4
Expectations of New System
Streamline compliance with resource restrictions
Enhance PSM & RMP compliance
Improve documentation reflecting compliance
Migrate existing systems (Not redesign)
Address key NEP issues
Sustainable and robust
Transition friendly
Integrate with legacy systems and documentation
Cost effective© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic
Corporation
Slide 5
Expectations of New System
Leading Edge Technology
Abandon Lotus Notes
Combine all systems into one Technology
Centralized Corrective Action Tracking
Electronic Authorizations
Customizable and User Friendly Reports
Include non – PSM / RMP items
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 6
Old “Lotus Notes” System for Management of Change
Change Description, Basis and Impact Statements
Assignment of PSM Actions and Approvals
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 7
Old “Lotus Notes” System for Management of Change
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Document location referenced, but not linked
Document location referenced, but not linked
Old system tracks, but does not control sequence of change
Slide 8
New System for Change Management
Workflow system with:
Approvals and actions completion before proceeding to next step
Ability to link all documents to the change
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 9
New System for Change Management
Dynamic online forms for all modules
Example from MOC Work flow.
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 10
Old System – PSI
PSI in multiple locations – No single management system
Electronic files in Word, PDF, Excel,….
Hard copy equipment specifications
Independent system for ERS Design calculations
Independent MSDS system
Identical information in variety of locations
Not readily retrievable - fragmented
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 11
New System – PSI
PSI Module with all requirements packaged and tied to PHAs.
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 12
Old System – Process Hazard Analysis
Three methods utilized:
Potential Problem Analysis (PPA) for small changes
“What – if” analysis for new process PHAs
“Revalidation” for 5-year PHA
Various, fragmented, systems utilized to track PHAs and Action items
MS Word for final PHA report
MS Excel for PPAs
Lotus Notes Database for PHA Revalidations and PPA Action Items
Separate Lotus Notes database for New Process PHAs
Issues:
Tracking action items to completion
Risk Ranking System not standardized across all action items
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 13
Old System – Process Hazard Analysis
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
2 Lotus Notes databases, paper, and Excel spreadsheets to track PHAs, PPAs and action items
Slide 14
New System – Process Hazard Analysis Software
PHA Module and software with link to export action items directly to ioXpress
PHA Software “HAZOPtimizer” Multiple Methodologies (LOPA, What-if, Checklist, What-if Checklist, Human Factors,...)
Standardized Risk Ranking
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 15
Old System – Incident Investigation
Paper system with Lotus Notes tracking of action items
Difficulty tying two systems together
Which is the “Official Report”?
Document control and distribution
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 16
New System – Dynamic Incident Investigation Form
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 17
Old Action Item Management System
Independent systems for individual topics
Combination of Hard Copy reports plus Lotus Notes Incident Investigations
Process Changes – 2 separate Lotus Notes systems
JSAs
Audits
PHAs
Duplicate Entry
Not Linked to Job, Audit,
Investigation or PHA Report
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 18
Global Action Item Management
Each Element of PSM/RMP can be included Global Action Item Management – All Elements ++
PSSR
MOC
Incident Investigations
PSM /RMP Audits
JSAs
PHAs
Hot Work Permit Audit
Any audit…
Any project
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 19
Global PSM Management
Previously a Global System not utilized
New – Each element of PSM/RMP including:
Hot Work Auditing Tool
PHA software
ioAuditing tool for Compliance Audit
PSSR / II Dynamic forms available
Preloaded templates for Procedures, i.e. Employee Participation
Operating Procedures
New Web-based application
Accessible remotely
Multiple Security Levels Group and Object Permissions
Documents automatically indexed for search
Notification when data object/document changed© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic
Corporation
Slide 20
Quick View of Live System
Hot Link to Afton ioXpress System
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 21
Key Challenges-To Culture Shift
Change is difficult…
Identified need to change in phases
Implemented Change Management Module first
Workflow prevents implementation phase until action items closed, i.e.
Operating Procedure Updates
Operator Training
Redlined P&IDs
Launched global action item management ….
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 22
Plans for Future
Expand to other management systems
RC-14001?
EPA compliance?
Expand to other locations
R&D?
Plants?
Corporate?
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 23
Summary Results
Advantages
Compliance more clearly demonstrated
Standardized
Embedded tools (i.e. Annual Operating Procedure Certifications, Employee Participation, Incident Investigation forms…)
Saves on development time
Reduced resource time on information gathering
Information easily managed and retrieved
“Audit Ready” at all times
Dynamic System
Modify or add forms on the fly© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic
Corporation
Slide 24
Summary Results
Advantages
Modules can be added
Opportunities to grow and mature other systems
Less on memory of what to do – verses electronic management of “to-dos”
Unlimited number of reports generated based on needs and/or requests
Manages unstructured data and electronic documents
Manage via libraries and dynamic forms
Database for HHC Inventories (Above and below TQs)
Solution being implemented on quick timeline
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 25
QUESTIONS
COMMENTS
Please stop at ioMosaic’s Booth to get a full software Demo or
to schedule Personalized On Line Web Demo
© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Slide 26 © 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation
Founded by former Arthur D. Little Inc. executives and senior staff, ioMosaic Corporation is the leading provider of safety and risk management consulting services. ioMosaic has offices in Salem, New Hampshire and Houston, Texas, and Minneapolis, Minnesota.
Since the early 1970's, ioMosaic senior staff and consultants have conducted many landmark studies including an audit of the Trans-Alaska pipeline brought about by congressional whistle blowers, investigation of the Bhopal disaster, and the safety of CNG powered vehicles in tunnels. Our senior staff and consultants have authored more than ten industry guidelines and effective practices for managing process safety and chemical reactivity and are recognized industry experts in LNG facility and transportation safety.
ioMosaic Corporation is also the leading provider of pressure relief systems design services and solutions. Its pressure relief system applications are used by over 250 users at the world's largest operating companies. It holds key leadership positions in the process industries' most influential and active pressure relief system design, and chemical reactivity forums, and plays a pivotal role in defining relief system design, selection, and management best practices.
SALEM OFFICE93 Stiles RoadSalem, New Hampshire 03079Tel: 603-893-7009Fax:603-251-8384Email: [email protected]: www.iomosaic.com
HOUSTON OFFICE2650 Fountain View, Suite 410Houston, Texas 77057Tel: 713-490-5220Fax:713-490-5222Email: [email protected]: www.iomosaic.com
MINNEAPOLIS OFFICE401 North 3rd Street, Suite 410Minneapolis, Minnesota 55401Tel: 612-338-1669Fax:832-553-7283Email: [email protected]: www.iomosaic.com
About ioMosaic Corporation