Ensuring Process Safety & Asset Integrity Leveraging Plant Asset Information
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1 Ensuring Process Safety & Asset Integrity Leveraging Plant Asset Information Adrian Park Vice President, SmartPlant Enterprise Solutions, Intergraph Process, Power & Marine
2 Progressive Safety and Asset Standards 1992 U.S. Occupational Safety and Health Administration OSHA 29 CFR Center for Chemical Process Safety CCPS 2008 British Standards Institute PAS55 Adopted as ISO in UK Energy Institute 2011 U.S. Bureau of Ocean Energy BOEMRE 30 CFR Part 250, Subpart S Intergraph Corporation. All Rights Reserved.
3 2015 Intergraph Corporation. All Rights Reserved. Importance of Asset Life-cycle Information for Asset Integrity of Change Asset information that is Accurate & Validated Consistent & Complete Accessible & Secure Timely & Actionable Asset Lifecycle Information System Process Hazard Assessment Compliance Audits Operating Procedures
4 59% see trustworthy information critical for Process Safety Mgt. and 47% for Asset Integrity Mgt. 54% see trustworthy information critical for Turnarounds, Shutdowns etc. 62% see trustworthy information critical for supporting Maintenance & Reliability 65% see trustworthy information critical for Modifications, Revamps and Maintenance Changes 2015 Intergraph Corporation. All Rights Reserved.
5 TechValidate Survey Results Only 39% were completely confident in their ability to find information to support an emergency situation! SOURCE: TechValidate survey of professionals in process industries (March 2014) 2015 Intergraph Corporation. All Rights Reserved.
6 Extracting Value from Engineering Information A Significant Opportunity Reduce CAPEX Shorten Project Schedule Reduce OPEX Virtual Asset Increase Uptime Minimize Health & Safety Risks Ease Demonstrable Compliance Physical Asset Intergraph Corporation. All Rights Reserved.
7 Achieving Asset Integrity Enabling Integrity / Safety Relevant Work Processes Project of Change CMMS Building Alarm & Set Points Small Projects Engineering Interface Site Receipt Verification Operating Procedures Plant of Change Non-conformity Pre-start-up Installation Qualifications Safety Checks Plant Staff Training DCS Change Technical / Site Query Operational Qualifications Turnaround Planning Model / Asset Risk (ALARP / ALARA) Mechanical Completions Instrument Piping Inspection Calibration Maintenance Planning Requirements Commissioning Design Integrity Intelligent Plant Manuals HAZOP Preservation Lock-out / Tag-out Inspection Inspection Planning Planning/Records CAPEX/OPEX Projects Operational Readiness Operations & Maintenance Eng. Registers & Lists Vendor Data Documents Work Breakdown & Transmittals Structure & Packages Information Validation & Legacy Information Transformation Capturing Lifecycle Information Plant Breakdown Structure Information Handover Intergraph Corporation. All Rights Reserved.
8 Achieving Asset Integrity Enabling Integrity / Safety Relevant Work Processes Project of Change CMMS Building Alarm & Set Points Small Projects Engineering Interface Site Receipt Verification Operating Procedures Plant of Change Non-conformity Pre-start-up Installation Qualifications Safety Checks Plant Staff Training DCS Change Technical / Site Query Operational Qualifications Turnaround Planning Model / Asset Risk (ALARP / ALARA) Mechanical Completions Instrument Piping Inspection Calibration Maintenance Planning Requirements Commissioning Design Integrity Intelligent Plant Manuals HAZOP Preservation Lock-out / Tag-out Inspection Inspection Planning Planning/Records CAPEX/OPEX Projects Operational Readiness Operations & Maintenance Eng. Registers & Lists Vendor Data Documents Work Breakdown & Transmittals Structure & Packages Information Validation & Legacy Information Transformation Capturing Lifecycle Information Plant Breakdown Structure Information Handover Intergraph Corporation. All Rights Reserved.
9 Enables Process Safety Programs OSHA 29 CFR1910 defines 14 elements 1. Employee Participation 2. Process Safety Information 3. Process Hazard Analysis 4. Operating Procedures 5. Training 6. Contractors 3D Pact Training SPO SP Process Safety Contractor Portals SPO Tag/Doc Mgt Electronic Dossiers SPO Tag/Doc Mgt 3D Pact Training 7. Pre-Startup Safety Reviews Systems Completions 8. Mechanical Integrity 9. Non-routine Work Authorization (Lock Out/Tag Out) 10. of Change 11. Incident Investigation 12. Emergency Planning & Response 13. Compliance Audits 14. Trade Secrets Data Access Control Inspection Assistant SPO Effectivity Mgmt of Plant Change 3D Pact Training Design Rules Workflows SPO Tag/Doc Mgt Lock/Out Tag/Out Non- Conform Mgmt Permit to Work Via third party Intergraph Corporation. All Rights Reserved. 9
10 Asset Lifecycle Information Tree Structure and Registers Plant Breakdown Structure Document Classification Discipline Structure Organization Structure Tag Classification PSI and Safety Critical Equipment Registers PSI Categories 2014 Intergraph Corporation. All Rights Reserved. PSI Documentation
11 Vision vs. Reality Trusted Source Reality! 2015 Intergraph Corporation. All rights reserved.
12 TechValidate Survey Results 40% or more of information in plant is unstructured SOURCE: TechValidate survey of professionals in process industries (March 2014) 2015 Intergraph Corporation. All rights reserved.
13 Asset Lifecycle Information Handover Project Mgmt. of Change Mon-conformity Technical / Site Queries CMMS Building System Completions HAZOP Intelligent Laser Scan Scan Based Modeling SP Fusion SPO/E Smart Data Validator Physical Asset i Legacy Asset Information i Plant Mgmt. of Change Lock-out / Tag-out Owner Operator Business Processes SPO/E Handover Projects / Suppliers (SPE) i Turnaround Planning Maintenance & Inspection Planning Projects / Suppliers (no SPE) Document SPO/E Smart Data Validator i Operating Procedures SmartPlant Enterprise for Owner Operators 2015 Intergraph Corporation. All rights reserved.
14 SmartPlant Fusion Extracting Intelligence from Legacy Documents DUPLICATE Pump P-7701B Up and running Weeks Rapid Capture Identify Masters Extract Intelligence Quality Control Link & Cross Reference 2015 Intergraph Corporation. All rights reserved.
15 Intuitive Single Point of Access Save time Less exposure to on-site risk Improve collaboration 2015 Intergraph Corporation. All rights reserved.
16 Validation from Multiple Sources OO / PMC Target Systems Legacy Systems Report Approve EPC Contractors i Transform Validate Syntax Rules (ENS) Uniqueness validation Relationship cardinality Date/Time validation Integer validation String validation Pick-List validation Unit of Measure validation Mandatory fields Cascading errors
17 SPO in the Enterprise IT Landscape Asset Performance Enterprise Content Significant investment Plant Automation Systems SPO BUT systems operate in silos Enterprise Asset Established knowledge base HSE Systems Asset Integrity 2015 Intergraph Corporation. All Rights Reserved.
18 of Change in SPO Operating Plant Create Change Request Relate to affected objects Initiate workflow Review Change Board Review Discipline Review SPO SAP EAM Approve/Reject Approve for Engineering Approve for Implementation Implementation Complete Engineering Implement as Notification or Turnaround As-built update Implementation Notification Job Package for Turnaround 2015 Intergraph Corporation. All rights reserved.
19 Synchronization of design basis with SAP Filtration and Transformation i Create / Update FL record Tag Creation, Update or Termination i SPO NetWeaver PI SAP EAM Tag Tag FL EQ Relationships i Equipment Install / Dismantle Generic process enabling synchronization with any third party system 2015 Intergraph Corporation. All rights reserved.
20 Synchronizaton with SAP SPO SAP Synchro - nisation Intergraph Corporation. All Rights Reserved.
21 Engineering Information for Asset Integrity Summary & How to get started Engineering Information is a key enabler for Safety and Asset Integrity Asset Lifecycle Information represents a big opportunity for you Do you know where you stand? We will help you to improve: Step by step Fast Track Intergraph Corporation. All Rights Reserved.
22 SAFETY. QUALITY. PRODUCTIVITY.
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