The plant dashboard for chemicals and petrochemicals
Continuous process, explosive atmospheres and scheduled shutdowns.
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- 9 standard units loaded
- 8 lockout energy sources
- 5 reference standards
How the work is done in chemistry
A continuous process with scheduled shutdowns: the plant is not touched while running except for an assessed exception. All work comes in through a permit and lockout/tagout is the common language.
The jobs that set the pace
- Unit shutdowns (turnaround)
- Breaking into lines and equipment containing product
- Chemical cleaning and inerting
- Work in an ATEX zone
- Hot work next to the process
The units it comes with as standard
- Unit 200 · reaction
- Unit 300 · distillation
- Tank farm
- Tanker loading bay
- North pipe rack
- Control room
- Wastewater treatment plant
- Control laboratory
- Chemical store
Lockout/tagout, with isolation point and verification
The dashboard does not ask “what energies does your equipment have?”: in the chemistry profile they are already there, each one with where it is isolated and how you check that it is isolated. It is what an inspection asks to see in writing.
| Energy | Isolation point | Verification |
|---|---|---|
| Electrical | Power breaker in MCC | Verification of the absence of voltage with a two-pole detector |
| Chemistry (in-line product) | Isolation valve + blind flange | Draining, washing and inerting with N₂; LEL reading |
| Steam | Steam line block valve | Bleed and check of the casing temperature |
| Pneumatic | Instrument air isolation valve | Surge vessel bled, gauge at 0 bar |
| Hydraulics | Power pack isolation valve | Accumulator discharge, gauge at 0 bar |
| Nitrogen / inert gas | N₂ line valve | O₂ measurement before opening |
| Stored mechanical energy | Shaft chocking and locking | Check that the impeller has come to a complete standstill |
| Thermal | Electrical heat tracing isolation | Contact thermometer below 45 °C |
The high-risk procedures, written down
Five procedures specific to chemistry, written in the vocabulary of the sector and available inside the dashboard so you can adapt them to your plant.
Multi-energy LOTO lockout
Equipment almost never has a single supply: product, steam, nitrogen and electricity are locked out together.
Line break
A specific permit: the line is drained, washed, inerted and measured before the first flange is loosened.
Confined spaces
Reactors, tanks and chambers: their own permit, continuous monitoring and an attendant with rescue arranged.
Hot work permit
With an LEL reading at the point of work and a fire watch afterwards.
Management of change (MOC)
No process change without assessment: a temporary fix is a change too.
Equipment and reference regulations
Equipment typical of this profile
- Centrifugal pump
- Screw compressor
- Heat exchanger
- Distillation column
- Control valve
- Reactor agitator
- Online analyser
- Wastewater plant blower
- Filter press
Regulations that frame the work
- RD 681/2003 · explosive atmospheres (ATEX)
- RD 840/2015 · major accidents (Seveso III)
- RD 656/2017 · chemical product storage (APQ)
- RD 614/2001 · electrical risk
- Regulation (EC) 1907/2006 · REACH
Current references the dashboard uses to organise the documentation. IndustriaKit is a documentation tool: it does not replace the risk assessment or legal advice.
- Explosion protection document
- Seveso safety report
- Safety data sheet for the product in the line
What the dashboard does with all this
Contractors and coordination of activities
Contractors working on site join free, upload their documentation and the traffic light decides who can work. RD 171/2004 coordination with minutes and signature.
Permits with QR codes
Work permit with a printable notice: in the field it is scanned and signed from a phone. LOTO warning when the job calls for it.
Maintenance and OEE
Queue prioritised by criticality, statutory maintenance schedules with their date, counters based on real usage and an OEE panel per line with a Pareto of stoppages.
Personnel and training
Fitness for work, training and health surveillance by job role, with the medical data kept outside the dashboard by design.
Open it with the chemistry profile and compare it with your folder
The demo opens with no card and no sales call. You choose this same sector and walk into a plant that looks like yours, with sample data you can play with without breaking anything.
The other industries in the dashboard
Each profile brings its own vocabulary, its own areas, its own energies and its own procedures. There are sixteen.