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Transformation in Operations with Two Innovative Safety Projects in Mahshahr Utility Hub:

Implementation of Electrical Isolation System and Electronic Permit-to-Work System at Fajr Energy

Implementation of Electrical Isolation System and Electronic Permit-to-Work System at Fajr Energy
With the implementation of two major projects — establishing an Electrical Isolation System and digitalizing the Permit-to-Work (PTW) process — Fajr Energy Persian Gulf has taken a significant step toward enhancing occupational and process safety, reducing risks, and aligning with global standards.

According to the Public Relations Department of Fajr Energy Persian Gulf, in line with its goal of improving safety, minimizing operational hazards, and enhancing performance in occupational and process safety, the company executed two key projects over the past year. These initiatives — the Electrical Isolation System and the digitalization of the PTW issuance process — have not only improved efficiency and safety in operations but have also advanced alignment with international standards and contributed to incident and accident prevention.


Enhancing Operational Safety with the Electrical Isolation System

Accidents and near-misses caused by the unintended release of energy remain one of the primary challenges in operational and maintenance activities. Understanding the significance of this issue — and based on global analyses showing that isolation systems can reduce incidents by up to 50% — Fajr Energy Persian Gulf launched a structured project to implement the Electrical Isolation System.

This initiative aimed to reduce operational risks, document isolation processes, and boost employee engagement in fostering a culture of process safety. Enhanced capabilities in conducting both internal and external audits have been another key outcome. The pilot phase began at Air Separation Unit 2 and is now being expanded to other operational sites, including power plants, dispatching centers, water treatment, wastewater treatment, and interconnecting pipelines.

As part of the project, the company delivered 10 training courses totaling 4,828 man-hours, covering operations, maintenance, safety, and technical services. The work included identifying critical points and equipment in need of isolation, procuring and installing standard isolation equipment, and designing lockout–tagout (LOTO) systems.


A Major Leap with Digital Permit-to-Work Issuance

The traditional manual PTW process often suffered from human errors, process delays, and an inability to accurately track historical records — posing challenges to safety performance and operational efficiency. In pursuit of digital transformation, Fajr Energy Persian Gulf launched the Electronic PTW System.

The system was designed to improve precision in managing safety activities, shorten permit issuance times, facilitate audits, and reduce paper consumption within the broader digital transformation framework. Additional features include automated alerts for incomplete information or unresolved hazards.

The project encompassed selecting the proper software platform, designing electronic forms for different work activities, conducting training for supervisors, executors, and HSE experts, piloting the system in a single operational unit, refining it based on feedback, and then rolling it out across all operational and non-operational departments.

The digital PTW system has accelerated and improved permit processes, reduced human error, strengthened safety procedures, and lowered paper usage. It also enables real-time monitoring of high-risk activities and digital recordkeeping of control measures. As a result, with the issuance, audit, classification, and assessment of 100,000 electronic work permits, permit errors have been dramatically reduced to just 3.5%.


Alignment with International Safety Standards

These two flagship HSE projects have positioned Fajr Energy Persian Gulf for compliance with leading global standards such as OSHA and CCPS, marking a fundamental transformation in operational safety management. The successful experiences of global companies such as Shell, BP, and Total in implementing similar systems further underscore the importance of these steps in reducing safety risks and improving process efficiency.

The implementation of the Electrical Isolation System and the Electronic PTW process once again demonstrates Fajr Energy Persian Gulf’s firm commitment to enhancing safety and operational performance. Harnessing global best practices and leveraging domestic capabilities, the company continues its path toward becoming one of the leading HSE organizations in Iran and the region.

Sep 20, 2025 15:08
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