© 2009, ioMosaic Corporation; all rights reserved. Do not copy or distribute without the express written permission of ioMosaic Corporation Process Safety

© 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

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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


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


Slide 6

Old “Lotus Notes” System for Management of Change

Change Description, Basis and Impact Statements

Assignment of PSM Actions and Approvals


Slide 7

Old “Lotus Notes” System for Management of Change


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


Slide 9

New System for Change Management

Dynamic online forms for all modules

Example from MOC Work flow.


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


Slide 11

New System – PSI

PSI Module with all requirements packaged and tied to PHAs.


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


Slide 13

Old System – Process Hazard Analysis


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


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


Slide 16

New System – Dynamic Incident Investigation Form


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


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


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


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 ….


Slide 22

Plans for Future

Expand to other management systems

RC-14001?

EPA compliance?

Expand to other locations

R&D?

Plants?

Corporate?


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


Slide 25

QUESTIONS

COMMENTS

Please stop at ioMosaic’s Booth to get a full software Demo or

to schedule Personalized On Line Web Demo


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