REAL-TIME SAFETY MEETS PERMITS, SAVING LIVES AND TIME

In 2019, the in-house firefighting team at an established refinery in Italy was looking for a gas detection system. As a producer of fuels, combustibles and raw materials for the petrochemical sector, the team needed a way to improve worker safety by detecting potentially toxic gases (like hydrogen sulfide and carbon monoxide) and combustible gases (like hydrocarbons) that could arise from the production process. The team also needed a way to monitor oxygen levels to ensure safe working conditions. Because it’s a major local employer with a large footprint, the refinery wanted to uphold its commitment to prioritize safety and keep innovating through new technology.  

The refinery already worked with Blackline’s Channel Partner, GIS, developer of the Safework platform–a digital system designed to streamline and simplify the request and issuance of Permits-to-Work (PtWs) in industrial plants. The refinery was interested in GIS’s proposal to use Blackline’s G7c cloud-connected gas detection devices, because they could be integrated through an API with the Safework software to create a complete safety ecosystem. This integration would enable live gas readings from the devices to be delivered directly into the digital PtW system. This seamless delivery would save the team time and remove the errors previously encountered with their former manual processes.

As part of the evaluation process, the refinery trialled a number of devices and ran them through several emergency simulations. One of the key features, in which they saw value right away, was G7’s real-time communication capability. Whereas their previous gas monitors alerted only locally in the case of a gas exposure, G7 delivered real-time alerts to offsite or remote monitoring personnel as well. 

Building on the success of the evaluation, GIS successfully won a tender for the development and supply of a complete turnkey system at the site. This included the roll-out of G7 devices to protect 320 workers, with a three-year service agreement. The agreement included a GIS service desk and a dedicated on-site team member to keep the refinery’s substantial fleet of G7 devices, docks, gas cylinders and accessories running smoothly. GIS also undertook face-to-face training with key team members on the devices, who then passed on the training internally.

The G7 implementation also ensured that routine maintenance tasks such as bump tests and calibrations could be easily recorded and controlled. The previous manual systems across hundreds of workers were prone to error. Plus, as the refinery operates a night shift, G7’s lone worker functionality, including fall and no motion detection, helped protect solitary members of the team while carrying out tasks at night. 

The refinery monitors the Blackline fleet of devices themselves through their on-site firefighters’ control room. The devices can detect up to five toxic and combustible gases and have Push-to-Talk (the ability to be used like a walkie-talkie) so the control room can easily talk to workers across the site. When alerts are triggered, location technology in each device immediately enables monitoring personnel to quickly locate workers and send a response. 

Live gas readings now integrate directly into the refinery’s digital Permits-to-Work system, reducing errors, saving time and allowing work to begin without delays.  The refinery now is developing a proprietary solution to model the emissions, based on APIs from Blackline G7 devices and other fixed area monitors. This would be another facet to the wide safety ecosystem they are building at the refinery thanks to GIS, Safework and the Blackline solution. 

With G7 deployed for in-house workers, the refinery is exploring expanding to third-party contractors to strengthen visibility of alerts, emergencies and overall safety—ensuring full site-wide coverage.