Ensuring Process Safety & Asset...

22
Ensuring Process Safety & Asset Integrity Leveraging Plant Asset Information Adrian Park Vice President, SmartPlant Enterprise Solutions, Intergraph Process, Power & Marine

Transcript of Ensuring Process Safety & Asset...

Page 1: Ensuring Process Safety & Asset Integrity22ea14a17aab46330f20-9794b6ee8d79adac6f8a4384eee37d67.r87.cf1.rackcd… · Ensuring Process Safety & Asset Integrity Leveraging Plant Asset

Ensuring Process Safety & Asset Integrity Leveraging Plant Asset Information

Adrian Park Vice President, SmartPlant Enterprise Solutions, Intergraph Process, Power & Marine

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Progressive Safety and Asset Management Standards

1992

U.S. Occupational Safety and Health Administration

OSHA 29 CFR1910 119

2007

Center for Chemical Process Safety

CCPS

2008

British Standards Institute PAS55

Adopted as ISO 55000 in 2014.

2010

UK Energy Institute

2011

U.S. Bureau of Ocean Energy Management

BOEMRE 30 CFR Part 250, Subpart S

© 2015. Intergraph Corporation. All Rights Reserved.

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Asset Lifecycle

Information

Management

System

Importance of Asset Life-cycle Information for Asset Integrity

Management of Change

Process Hazard

Assessment

Compliance Audits

Operating Procedures

Asset information that is…

Accurate & Validated

Consistent & Complete

Accessible & Secure

Timely & Actionable

©2015 Intergraph Corporation. All Rights Reserved.

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©2015 Intergraph Corporation. All Rights Reserved.

65% see trustworthy information

critical for Modifications, Revamps and

Maintenance Changes

62% see trustworthy information

critical for supporting Maintenance &

Reliability

59% see trustworthy information

critical for Process Safety Mgt. and

47% for Asset Integrity Mgt. 54% see trustworthy information

critical for Turnarounds, Shutdowns

etc.

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TechValidate Survey Results

SOURCE: TechValidate survey of professionals in process industries (March 2014)

Only 39% were completely confident

in their ability to find information to

support an emergency situation!

©2015 Intergraph Corporation. All Rights Reserved.

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Virtual Asset

Physical Asset

Shorten Project

Schedule

Reduce CAPEX

Reduce OPEX

Increase Uptime

Minimize Health &

Safety Risks Ease Demonstrable

Compliance

Extracting Value from Engineering Information

– A Significant Opportunity –

© 2015. Intergraph Corporation. All Rights Reserved.

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Lifecycle Information Management

Operations & Maintenance CAPEX/OPEX Projects Operational Readiness

Project Management of Change

Interface Management

Non-conformity Management

Technical / Site Query Management

Risk Management (ALARP / ALARA)

Requirements Management

HAZOP

CMMS Building

Site Receipt Verification

Installation Qualifications

Operational Qualifications

Mechanical Completions

Commissioning

Preservation Management

Alarm & Set Points Management

Operating Procedures

Plant Staff Training

Turnaround Planning

Instrument Calibration

Design Integrity

Lock-out / Tag-out

Small Projects Engineering

Plant Management of Change

DCS Change Management

Model / Asset Management

Maintenance Planning

Intelligent Plant Manuals

Inspection Planning

Eng. Registers & Lists

Vendor Data

Documents & Transmittals

Information Validation & Transformation

Work Breakdown Structure & Packages

Legacy Information Capturing

Plant Breakdown Structure

Information Handover

Project Management of Change

Interface Management

Non-conformity Management

Technical / Site Query Management

Requirements Management

Site Receipt Verification

Pre-start-up Safety Checks

Operational Qualifications

Mechanical Completions

Commissioning

Preservation Management

Eng. Registers & Lists Documents

& Transmittals

Information Validation & Transformation

Work Breakdown Structure & Packages

Legacy Information Capturing

Plant Breakdown Structure

Information Handover

Piping Inspection

Plant Management of Change

Model / Asset Management

Inspection Planning/Records

Intelligent Plant Manuals

Risk Management (ALARP / ALARA)

HAZOP

Vendor Data

Small Projects Engineering

Plant Staff Training

Achieving Asset Integrity

– Enabling Integrity / Safety Relevant Work Processes –

© 2015. Intergraph Corporation. All Rights Reserved.

Page 8: Ensuring Process Safety & Asset Integrity22ea14a17aab46330f20-9794b6ee8d79adac6f8a4384eee37d67.r87.cf1.rackcd… · Ensuring Process Safety & Asset Integrity Leveraging Plant Asset

Lifecycle Information Management

Operations & Maintenance CAPEX/OPEX Projects Operational Readiness

Project Management of Change

Interface Management

Non-conformity Management

Technical / Site Query Management

Risk Management (ALARP / ALARA)

Requirements Management

HAZOP

CMMS Building

Site Receipt Verification

Installation Qualifications

Operational Qualifications

Mechanical Completions

Commissioning

Preservation Management

Alarm & Set Points Management

Operating Procedures

Plant Staff Training

Turnaround Planning

Instrument Calibration

Design Integrity

Lock-out / Tag-out

Small Projects Engineering

Plant Management of Change

DCS Change Management

Model / Asset Management

Maintenance Planning

Intelligent Plant Manuals

Inspection Planning

Eng. Registers & Lists

Vendor Data

Documents & Transmittals

Information Validation & Transformation

Work Breakdown Structure & Packages

Legacy Information Capturing

Plant Breakdown Structure

Information Handover

Project Management of Change

Interface Management

Non-conformity Management

Technical / Site Query Management

Requirements Management

Site Receipt Verification

Pre-start-up Safety Checks

Operational Qualifications

Mechanical Completions

Commissioning

Preservation Management

Eng. Registers & Lists Documents

& Transmittals

Information Validation & Transformation

Work Breakdown Structure & Packages

Legacy Information Capturing

Plant Breakdown Structure

Information Handover

Piping Inspection

Plant Management of Change

Model / Asset Management

Inspection Planning/Records

Intelligent Plant Manuals

Risk Management (ALARP / ALARA)

HAZOP

Vendor Data

Small Projects Engineering

Plant Staff Training

Achieving Asset Integrity

– Enabling Integrity / Safety Relevant Work Processes –

© 2015. Intergraph Corporation. All Rights Reserved.

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Enables Process Safety Management Programs

OSHA 29 CFR1910 defines 14 elements

9

1. Employee Participation

2. Process Safety Information

3. Process Hazard Analysis

4. Operating Procedures

5. Training

6. Contractors

7. Pre-Startup Safety Reviews

8. Mechanical Integrity

9. Non-routine Work Authorization (Lock Out/Tag Out)

10. Management of Change

11. Incident Investigation

12. Emergency Planning & Response

13. Compliance Audits

14. Trade Secrets

Electronic

Dossiers

Systems

Completions

SP Process

Safety

Effectivity

3D Pact

Training

Non-

Conform

Mgmt

Inspection

Assistant

Mgmt of

Plant

Change

Contractor

Portals

Design

Rules

Data Access

Control

SPO

Tag/Doc

Mgt

SPO

Tag/Doc

Mgt

3D Pact

Training

Lock/Out

Tag/Out Permit to

Work

Workflows

3D Pact

Training

SPO

SPO

Via third party

SPO

Tag/Doc

Mgt

© 2015. Intergraph Corporation. All Rights Reserved.

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Asset Lifecycle Information – Tree Structure and Registers

© 2014 Intergraph Corporation. All Rights Reserved.

Plant Breakdown Structure

Document Classification

Discipline Structure

Organization Structure

Tag Classification

PSI Categories

PSI and Safety Critical

Equipment Registers

PSI Documentation

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Vision vs. Reality

! Trusted Source Reality

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© 2015 Intergraph Corporation. All rights reserved.

TechValidate Survey Results

SOURCE: TechValidate survey of professionals in process industries (March 2014)

40% or more of information in

plant is unstructured

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SPO/E Smart Data Validator

Intelligent Laser Scan

Scan Based Modeling

SPO/E Handover

SP Fusion

SPO/E Smart Data Validator

i

i

i

i

Asset Lifecycle Information Handover

Owner Operator

Business

Processes

SmartPlant Enterprise for Owner Operators

Plant Mgmt. of Change

Lock-out / Tag-out

Maintenance & Inspection Planning

Document Management

Operating Procedures

Turnaround Planning

Project Mgmt. of Change

Mon-conformity Management

CMMS Building

System Completions

HAZOP

Technical / Site Queries

Projects / Suppliers (no SPE)

Projects / Suppliers (SPE)

Legacy Asset Information

Physical Asset

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© 2015 Intergraph Corporation. All rights reserved.

SmartPlant Fusion – Extracting Intelligence from Legacy

Documents

Pump P-7701B Up and

running

1 2 3 4

Weeks

DUPLICATE

Rapid

Capture

Identify

Masters

Extract

Intelligence

Quality

Control

Link &

Cross

Reference

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Intuitive Single Point of Access

Save time

Less exposure to

on-site risk

Improve

collaboration

© 2015 Intergraph Corporation. All rights reserved.

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Validation from Multiple Sources

OO / PMC Target

Systems

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

EPC Contractors

Legacy Systems

Validate

i Transform

Report Approve

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Established knowledge base

Significant investment

BUT… systems

operate in silos

SPO in the Enterprise IT Landscape

Asset

Performance

Management

Plant

Automation

Systems

Enterprise

Asset

Management

Asset Integrity

Management

HSE

Systems

Enterprise

Content

Management

SPO

©2015 Intergraph Corporation. All Rights Reserved.

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Management of Change in SPO Operating Plant

Implementation • Complete Engineering

• Implement as Notification or Turnaround

• As-built update

Create Change Request • Relate to affected objects

• Initiate workflow

Review • Change Board Review

• Discipline Review SAP EAM

SPO

Implementation • Notification

• Job Package for Turnaround

Approve/Reject • Approve for Engineering

• Approve for Implementation

© 2015 Intergraph Corporation. All rights reserved.

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Equipment Install /

Dismantle

Tag FL EQ

Relationships

EAM SAP

Filtration and Transformation

Tag Creation, Update

or Termination

Create / Update

FL record

SPO

Synchronization of design basis with SAP

i

i

i

Tag

NetWeaver PI

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Generic process enabling synchronization with any third party system

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Synchronizaton with SAP

–Synchro

- nisation

SAP SPO

© 2015. Intergraph Corporation. All Rights Reserved.

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Engineering Information for Asset Integrity Management

– Summary & How to get started –

Engineering Information Management is a

key enabler for Safety and Asset Integrity

Management

Asset Lifecycle Information Management

represents a big opportunity for you

Do you know where you stand?

© 2015. Intergraph Corporation. All Rights Reserved.

We will help you to improve:

• Step by step

• Fast Track

Page 22: Ensuring Process Safety & Asset Integrity22ea14a17aab46330f20-9794b6ee8d79adac6f8a4384eee37d67.r87.cf1.rackcd… · Ensuring Process Safety & Asset Integrity Leveraging Plant Asset

SAFETY.

QUALITY.

PRODUCTIVITY.