Solution · Conduct of Operations

Operational Discipline you can measure.

Doing it right every time is a behaviour — but it is also data. Cerasus turns the safe operating envelope, the shift routine, the drift in the plant and the lessons from incidents into one closed loop, so discipline is visible on a dashboard rather than assumed on a poster.

0Steps in the loop
0Leading indicators
1Index per unit · month
Why discipline decays

Nobody decides to bypass a safeguard. It just stays bypassed.

Investigations rarely find a missing procedure. They find a procedure that was followed less and less, by people who could not see that it mattered.

Deviation becomes normal

A loop left in manual, an alarm shelved, a reading skipped on the round — each one reasonable that day, and invisible by the next month.

→ See the drift
Overrides outlive the shift

The bypass that was meant for two hours is still there on Monday, because the handover said "as before" and nobody counted the hours.

→ Follow them every shift
Handovers lose the thread

The information existed — in a paper log, an e-mail, a memory — but it did not reach the person who needed it at 06:00.

→ Measure it
The closed loop

Five steps, each one instrumented by a Cerasus service or application.

Because the same team delivers the studies and builds the software, the limits defined in the PHA are the limits the logbook enforces and the KPIs count.

Know the limits

Define the safe operating envelope and the safeguards that must be honoured — and keep them current.

Delivered withCeraPHA StudioCeraVentPHA PSV Validation
Follow them every shift

Rounds, readings, overrides and handovers are structured, signed and carried forward. Nothing lives only in someone's head.

Delivered withCeraShiftImplementing PSM
See the drift

Loops in manual, alarms suppressed, limits approached and excursions predicted — surfaced before the trip, not after.

Delivered withProcessVisionCeraPIDKairosProcess Monitoring Alarm Rationalisation
Measure the behaviour

Override hours, missed rounds, unsigned handovers and PM backlog become leading indicators and one Operational Discipline Index.

Delivered withCeraPulseProcess Safety Audits
Learn when it fails

Incidents are traced to the missed step and the system behind it — not the person — and fed back into the PHA and the procedures.

Delivered withCauseIQTechnical Training
Operational Discipline Index

One number a plant manager can put on the wall.

Built in CeraPulse from data the other applications already generate — no extra forms. Scored per unit, trended monthly, benchmarked across sites.

OD Index · Unit 100 · illustrative
78 / 100

Up from 61 twelve months ago. Biggest contributors: override hours halved, round completion above 95 %.

Example data — not a customer result
Safeguard override hoursper month, all IPLs312 hCeraShift · CeraPHA Studio
Loops in manual% of control loops9 %CeraPID · ProcessVision
Rounds completed on timefield rounds, all shifts96 %CeraShift
Handovers signed by both shiftswith open items carried99 %CeraShift
Alarm rate per operator-hourISA-18.2 target ≤ 64.8ProcessVision · Alarm Rationalisation
Overdue safety-critical PMtasks past due date3CeraShift · CeraPulse
Standards

What the auditors will ask — answered continuously, not annually.

CCPS Risk Based Process Safety

Conduct of Operations and Operational Discipline elements.

OSHA 29 CFR 1910.119(f)

Operating procedures, safe limits and consequences of deviation.

API RP 754

Tier 3 and Tier 4 leading indicators built from operating data.

ISA-18.2 / IEC 62682

Alarm performance metrics as a discipline signal.

How we deliver it

Assess, instrument, review.

A service-and-software programme, run by engineers who have held the shift.

Phase 1 · 6 weeksOD Assessment & baseline
  • Audit of rounds, handovers, overrides and MOC practice against RBPS
  • Baseline OD Index from existing logs and historian data
  • Gap report and 12-month target
Phase 2 · 3–4 monthsInstrument the loop
  • CeraShift for logbook, rounds and handover
  • CeraPulse OD Index with your indicator set
  • ProcessVision / CeraPID drift monitoring where needed
Phase 3 · ongoingQuarterly OD review
  • Index review with Operations and HSE leadership
  • Shift-supervisor workshops on the findings
  • Incident learnings closed into PHA and procedures
Request a consultation

Tell us about the unit and the problem.

Send a short brief — plant, service of interest and what you need to achieve — and a Cerasus engineer will respond with a proposed scope and next steps.

Prefer email or phone? sales@cerasus.ai · +974 5506 2743