Yokogawa Advanced Solutions

Mark Carter & Niels Huttenhuis

Consulting Director for Business Development
Business Manager
Development

May 2020
| Yokogawa RAP Limited | 2020 |
© Yokogawa Electric Corporation
Yokogawa electric cooperation

As a company,
our goal is to contribute to society
through broad-ranging activities in
the areas of measurement, control,
and information.

Individually,
We aim to combine good citizenship
with courage to innovate

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
1
Yokogawa Advanced Solutions & Innovation

 Advanced Control
 Alarm Management & Rationalisation
 Control of Work
 Cybersecurity
Yokogawa RAP Ltd
 Digitalisation & IIOT
 Risk Assessment
 (Functional) Safety Management
 Supply Chain Management

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
2
RAP Clients & Locations

30 Countries UK Europe 20,000+ Users

The Americas
Asia &
Middle East
26 Languages 10mil+ Permits

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
3
RAP Modules

| PTW & Options

Isolations

GIS Risk
Assessment /
JHA
Barcoding & Permit to Utilities &
Offline Work Infrastructure

Turnaround Reporting

Mobile

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
4
 The Causes of Accidents (HSE, UK)

◼ Underlying causes of accidents (The Dirty Dozen)

◆ Inadequate hazard analysis / risk assessment
Data derived from:
Underlying Causes of Offshore Incidents
FP/09/21
The Causes of Major Hazard Incidents and
How to Improve Risk Control and Health and
Safety Management: A Review of the

◆
Existing Literature HSL/2006/117
Poor management practices e.g. inadequate supervision
◆ Pressure and stress, mental fatigue
◆ Inadequate safety management systems especially Permit to Work
◆ Failure to learn lessons from previous incidents
◆ Communication and reporting issues e.g. between shifts, between personnel
◆ Inadequate reporting systems
◆ Complacency
◆ Violations/ non-compliance behaviour
◆ Inadequate training and lack of competency
◆ Modification/ updates to equipment
◆ Inadequate/ insufficient / erroneous maintenance
| Yokogawa RAP Limited | 2020 |
© Yokogawa Electric Corporation
5
 The Causes of Accidents (HSE, UK)

◼ Underlying causes of accidents (The Dirty Dozen)

◆ Inadequate hazard analysis / risk assessment
◆ Poor management practices e.g. inadequate supervision
◆ Pressure and stress, mental fatigue
◆ Inadequate safety management systems especially Permit to Work
◆ Failure to learn lessons from previous incidents
◆ Communication and reporting issues e.g. between shifts, between personnel
◆ Inadequate reporting systems
◆ Complacency
◆ Violations/ non-compliance behaviour
◆ Inadequate training and lack of competency
◆ Modification/ updates to equipment RAP can eliminate
◆ Inadequate/ insufficient / erroneous maintenance
| Yokogawa RAP Limited | 2020 |
© Yokogawa Electric Corporation
6
 The Causes of Accidents (HSE, UK)

◼ Underlying causes of accidents (The Dirty Dozen)

◆ Inadequate hazard analysis / risk assessment
◆ Poor management practices e.g. inadequate supervision
◆ Pressure and stress, mental fatigue
◆ Inadequate safety management systems especially Permit to Work
◆ Failure to learn lessons from previous incidents
◆ Communication and reporting issues e.g. between shifts, between personnel
◆ Inadequate reporting systems
◆ Complacency
◆ Violations/ non-compliance behaviour
◆ Inadequate training and lack of competency
◆ Modification/ updates to equipment RAP can eliminate
◆ Inadequate/ insufficient / erroneous maintenance RAP can help
| Yokogawa RAP Limited | 2020 |
© Yokogawa Electric Corporation
7
What is RAP (Risk
Assessment Process)?

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
8
How is it normally done?

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
9
Risk Assessment in RAP

Risk Assessment
✓ Hazards
✓ Controls
✓ Risk Level RAP
Standards
✓ Mandatory Controls
✓ Gas Tests • More than a replacement
✓ PPE
Competence for paper
✓ Training
✓ Experience
Others
• Risk assessment at its
✓ Exclusion Zones heart
✓ Messaging
✓ SIMOPS
✓ Documentation
Compliance THE ICON • Built for learning
✓ Regulations
✓ Company Standards
✓ Site / Local Policies

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
10
 The Power of Knowledge
Best Practice Experience

Common
Learning
Sense

THE ICON

Area, Site and

Legislation
Company Standards

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
11
Some screens in RAP
Using the knowledge base

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
12
First, configuration……

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
13
 Set up the maintenance
workplace from the available
icons – choose the ones that
apply to you

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
14
 Select each icon and
configure it according to your
methods and procedures
(controls, authorisations,
PPE, …..etc)

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
15
 Set up the ‘selectable’ risk
assessment for your chosen
icons

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
16
Now you’ve set up the
knowledge base, you can use
the system

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
17
 Create your jobs according
to area, equipment or pull
them in from your MMS
system

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
18
 Risk assess each task
according to the icons that
describe it…….

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
19
 …….in any language

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
20
Case Studies

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
21
 Chemical Production Plant

• Replaced inefficient paper-based

Site: Louisiana
Old paper-based permit and
isolation systems inefficient
Costly maintenance practises,
especially Turnarounds
systems
• Online PTW and Isolation systems
• Improved Maintenance efficiency
and increased production
• Estimated $500k improvement per
annum
• Larger benefits for scheduled
Turnarounds

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
22
 Steel Plant

• Standardizing on PTW across all

geographic sites
• RAP is multilingual allowing cross-
country implementation
• RAP very flexible so adding Process
and Site specific items is simple
• Increased efficiency and decreased
Site: UK downtime
Old inefficient paper-based
Permit-to-work (PTW) systems
• Electronic PtW supported by
Several sites – required Insurance provider as a means of
upgrade and standardization
demonstrating safe work practices

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
23
 Energy

• Utilised RAP PtWCloud - a fully

managed Software as a Service
(SaaS) platform
• Covered multiple processes and
equipment including Wind Turbines,
tanks and Jetties
• Increased efficiency and decreased
Site: NL
Needed fast PTW & Isolation
downtime
systems implementation
Multiple processes

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
24
 Chemical Plant
• Combined sites
• Top-tier COMAH site - toxic,
corrosive, flammable chemicals
• Largest Turnaround - reduced by a
number of days due to preparation
with RAP
• Huge savings in time and
Site: UK
accelerated production
12 Units in 3 Operating Areas
~ 5 Shifts @ 21 Operating staff
per shift
6 Permit issuers on Days

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
25
Benefits

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
26
 Overall Benefits
IMPROVED SAFETY
Efficient Working
• Better Work Practices
• Improved Turnarounds
• Integration of Systems
Compliance as Routine Learning
• All risks covered • ‘Close the Loop’
• Authorisations complete • Make it Stick
• Track and record all events • Instant fix
• Focus on Risk • Any Language
• Standard Setting • CHANGE CULTURES
| Yokogawa RAP Limited | 2020 |
© Yokogawa Electric Corporation
27
 Efficiency Gains

Reduced Increased Faster approvals Identification of Automated

application time “Tool time” process work conflicts distribution to all
relevant staff
– Reduced manual – Automated cross- – Reduced manual – Check permits – Added to operator
entry checking entry issued in the same logbooks
production area
– Links to MMS – Automated form – Electronic distribution – Added to shift-
completion – Mobile technology handover reports
– Better focus of skills
= – Emailing to key staff
More time on the job

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
28
Implementation

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
29
 RAP Implementation Roadmap Key Points

Kick-off Workshop Base-system

Ev aluation Roll-out
Meeting setup and FAT

Aw areness Master data UAT / Pilot Modifications

sessions collection

(6 – 9 months typically)

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
30
Summary

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
31
 Summary of Benefits
Implemented
Integration with
in over
ERP and MMS
145 locations worldwide
systems

75%
Enhanced
Step reduction in accidents
compliance
and incidents

ONE Permit Implemented

ONE Copy in over
ONE Way of 30 countries
Work. worldwide

IMPROVED Over
Improved Safety
25 languages
Culture SAFETY worldwide
PERFORMANCE
Process Alignment Increased
and Simplified Efficiencies and
Work Practices Cost Savings

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
32
 Thank you for
your attention

The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.

| Yokogawa RAP Limited | 2020 |

© Yokogawa Electric Corporation
33