Exploiting the Virtual Plant Asset to achieve business benefits across the facility s life-cycle

Transcription

1 Exploiting the Virtual Plant Asset to achieve business benefits across the facility s life-cycle Adrian Park Global Executive Director, Owner Operator Solutions

2 Industry Trends faced by Owner-Operators External pressures Globalization and competitive cost pressures Regulations, stringent enforcement and penalties Focus on process safety and asset integrity Internal challenges Qualified resources Complexity and compressed project timeframes Aging assets Acquisitions and JVs

3 Business Impacts Risk of losing license to operate External pressures Higher fines, penalties & insurance rates Production Loss & LPOs Threat of legal sanction Increasing rate of incidents and cost of recovery Internal challenges Higher cost of plant shutdowns & modifications Increased cost and effort to recruit, train and retain resources Rising cost of handover Significant project overruns Higher cost of compliance 11/10/2013 3

4 Enabling Better Processes & Decisions Management of Change Asset information that is Accurate & Validated Consistent & Complete Accessible & Secure Timely & Actionable Asset Lifecycle Information Management System Process Hazard Assessment Compliance Audits Operating Procedures

5 The Engineering Design Basis Process and Instrumentation Diagram Instrumentation and Electrical schematics Process Data sheets and tag indexes 3D Model and derived documentation Engineering Design Basis Vendor Documentation

6 A staged approach to Information Management Leveraging Structured Information Managing Structured Information Visual Training using Laser scans Incorporation of Photo-realistic Laser scans Managing Unstructured Information

7 Brownfield Legacy Data The vast majority of Plants today have information collected over many years from different sources and it exists in multiple formats Large quantities of Paper PDF & image formats CAD & Office formats Created in multiple versions of software Often residing in windows file systems... Not easily accessible by a large community... With data naming and numbering inconsistencies... Often not reflecting the as-built state of the plant VS. Legacy, uncontrolled & unstructured information is present in our organisations our ability to react to situations will be constrained by how well we deal with it

8 Brownfield Data Capture - Use Cases Rebuild/Expansion Projects Acquisition of a brownfield asset Greenfield Handovers Turnarounds $ Time critical plant information access $ Minimising travel $ Information mobility $ Time spend searching for valid information $ Data quality & Integrity

9 Case Study - The Brownfield site The Ngujima-Yin is moored 50 kilometres off the Western Australian coast. It is 333 metres long and the largest FPSO in Australian waters. The Ngujima-Yin operates at a depth of 350 metres and has a daily production capacity of 120,000 barrels of oil. IAC Presentation 2012 Slide 9

10 To bridge this gap we need.. STRUCTURED INTEGRATED OPERATIONAL INFORMATION ONE SOURCE Re-purpose (Re-use) QA/QC (Improve) Link and cross-reference Identify Masters Rapid capture MULTIPLE SOURCES UNSTRUCTURED NON-INTEGRATED INFORMATION IAC Presentation 2012 Slide 10

11 The result *** Merged AVI of Point Cloud + End result including TruView IAC Presentation 2012 Slide 11

12 A staged approach to Information Management Leveraging Structured Information Managing Structured Information Visual Training using Laser scans Incorporation of Photo-realistic Laser scans Managing Unstructured Information

13 Better Training = Better Results Intergraph Corporation. All Rights Reserved.

14 A staged approach to Information Management Leveraging Structured Information Managing Structured Information Visual Training using Laser scans Incorporation of Photo-realistic Laser scans Managing Unstructured Information

15 Managing Facility Life-cycle Information and leveraging it to provide added value Project Execution Requirements Management & Traceability Systems Completion Operating Plant Mobile Apps SPO Core Fusion VTL Handover

16 LEVERAGING STRUCTURED INFORMATION EXAMPLE: SPO SYSTEMS COMPLETION AND MOBILE APPLICATIONS 16

17 How SPO drives results Maintains quality lifecycle Info Supports collaboration Enforces work processes Provides management visibility Ensures auditable traceability Integrates with existing solutions Enterprise Systems SPO Engineering Design Basis Operational Systems

18 Benefits Solution Challenges Brownfield Case Study GASSCO (Norway) Improving plant asset integrity in an environment of different and complex legacy systems, with information of varying quality, and in multiple data formats SPO Core Document/ Transmittal management Tag management SPO Operating Plant SAP PM integration Management of Change Integrated design tools SPI SPID Improved Management of Change to demonstrate compliance Improved collaboration with maintenance & modification contractors Consistency of information between SPO and SAP Reduced customisation

19 Benefits Solution Challenges Greenfield Case Study INPEX Improve collaboration across the project Ensure information consistency and accuracy across all engineering contractors Provide operations team with early access to design and operational data SPO Core SPO Project Execution SPO Operating Plant SPO VTL and Handover Design tools: S3D, SPI, SPID, SPEL Integrated information management system with a single point of access Rapid commissioning and start-up Reduced data handover costs

20 Impacting Real Business Processes Reduce CAPEX Shorten Project Schedule Reduce OPEX Virtual Asset Increase Uptime Minimize Health & Safety Risks Ease Demonstrable Compliance Physical Asset

21 Impacting Real Business Processes Project Management of Change CMMS Building Alarm & Set Points Management Small Projects Engineering Interface Management Site Receipt Verification Leak Detection & Repair Plant Management of Change Non-conformity Management Installation Qualifications Plant Staff Training DCS Change Management Technical / Site Query Management Operational Qualifications Turnaround Planning Model / Asset Management Risk Management (ALARP / ALARA) Mechanical Completions Instrument Calibration Maintenance Planning Requirements Management Commissioning Spare Parts Management Intelligent Plant Manuals HAZOP Preservation Management Lock-out / Tag-out Inspection Planning planning CAPEX/OPEX Projects Operational Readiness Operations & Maintenance Eng. Registers & Lists Documents & Transmittals Work Breakdown Structure & Packages Plant Breakdown Structure Vendor Data Information Validation & Transformation Legacy Information Capturing Information Handover Lifecycle Information Management

22 Impacting Real Business Processes Improved Execution Better Decisions Powerful Business Impact Trustworthy Information SPO Management of Change Interface Management Site Receipt Verification Small Projects Engineering Plant Management of Change Non-conformity Management Installation Qualifications Technical / Site Query Management Operational Qualifications Model / Asset Management Risk Management Mechanical Completions Instrument Calibration Requirements Management Commissioning Intelligent Plant Manuals HAZOP Preservation Management Inspection planning Eng. Registers & Lists Documents Transmittals Work Breakdown Structure Plant Breakdown Structure Vendor Data Data Validation & Transformation Legacy Information Capturing Information Handover

23 Summary An increasingly regulated, competitive and complex business environment Need for consistent use of trustworthy information for improved business operations Chronic disconnects between lifecycle phases, disciplines, processes and systems. SPO SPO provides effective work processes and represents a single source of quality information SPO solutions reduce implementation risk and shorten time-to-value Industry leaders are achieving substantial benefits from SPO

24 SAFETY QUALITY PRODUCTIVITY THE FUTURE OF ENGINEERING TODAY