Ensuring Process Safety & Asset Integrity

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

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

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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

Importance of Asset Life-cycle Information for Asset Integrity

Management of Change

Process Hazard Assessment

Asset information that is…

 Accurate & Validated  Consistent & Complete

 Accessible & Secure  Timely & Actionable

Asset Lifecycle Information Management System

Compliance Audits

Operating Procedures

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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 & 65% see trustworthy information Reliability critical for Modifications, Revamps and Maintenance Changes

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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)

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Extracting Value from Engineering Information – A Significant Opportunity –

Reduce OPEX

Increase Uptime

Shorten Project Schedule

Virtual Asset

Reduce CAPEX

Physical Asset © 2015. Intergraph Corporation. All Rights Reserved.

Minimize Health & Safety Risks

Ease Demonstrable Compliance

Achieving Asset Integrity – Enabling Integrity / Safety Relevant Work Processes – Project Management of Change

CMMS Building

Alarm & Set Points Management

Small Projects Engineering

Interface Management

Site Receipt Verification

Operating Procedures

Plant Management of Change

Non-conformity Management

Pre-start-up Safety Checks 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

Piping Inspection Instrument Calibration

Maintenance Planning

Requirements Management

Commissioning

Design Integrity

Intelligent Plant Manuals

HAZOP

Preservation Management

Lock-out / Tag-out

Inspection Inspection Planning Planning/Records

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 © 2015. Intergraph Corporation. All Rights Reserved.

Achieving Asset Integrity – Enabling Integrity / Safety Relevant Work Processes – Project Management of Change

CMMS Building

Alarm & Set Points Management

Small Projects Engineering

Interface Management

Site Receipt Verification

Operating Procedures

Plant Management of Change

Non-conformity Management

Pre-start-up Safety Checks 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

Piping Inspection Instrument Calibration

Maintenance Planning

Requirements Management

Commissioning

Design Integrity

Intelligent Plant Manuals

HAZOP

Preservation Management

Lock-out / Tag-out

Inspection Inspection Planning Planning/Records

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 © 2015. Intergraph Corporation. All Rights Reserved.

Enables Process Safety Management Programs OSHA 29 CFR1910 defines 14 elements 1.

Employee Participation

SPO

2.

Process Safety Information

3.

Process Hazard Analysis

4.

Operating Procedures

5.

Training

SPO Tag/Doc Mgt SP Process Safety Electronic Dossiers

3D Pact Training

Contractor Portals

SPO Tag/Doc Mgt

3D Pact Training

6.

Contractors

7.

Pre-Startup Safety Reviews

8.

Mechanical Integrity

9.

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

Systems Completions

Inspection Assistant

Permit to Work

Via third party

SPO

12. Emergency Planning & Response 13. Compliance Audits 14. Trade Secrets

Lock/Out Tag/Out

Mgmt of Plant Change

10. Management of Change 11. Incident Investigation

Design Rules

Effectivity

3D Pact Training Workflows

SPO Tag/Doc Mgt NonConform Mgmt

Data Access Control

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9

Asset Lifecycle Information – Tree Structure and Registers

Plant Breakdown Structure

Document Classification

Discipline Structure

Organization Structure

Tag Classification

PSI and Safety Critical Equipment Registers

© 2014 Intergraph Corporation. All Rights Reserved. PSI Categories

PSI Documentation

Vision vs. Reality

Trusted Source

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Reality

!

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.

Asset Lifecycle Information Handover Physical Asset

Project Mgmt. of Change Intelligent Laser Scan Mon-conformity Management Scan Based Modeling

i

Technical / Site Queries CMMS Building

Legacy Asset Information SP Fusion

System Completions

SPO/E Smart Data Validator

HAZOP Owner Operator Business Processes

i Projects / Suppliers (SPE)

Plant Mgmt. of Change SPO/E Handover Lock-out / Tag-out

i

Turnaround Planning

Projects / Suppliers (no SPE)

Maintenance & Inspection Planning Document Management Operating Procedures

SmartPlant Enterprise for Owner Operators © 2015 Intergraph Corporation. All rights reserved.

SPO/E Smart Data Validator

i

SmartPlant Fusion – Extracting Intelligence from Legacy Documents

Pump P-7701B Up and running DUPLICATE

1

2

3

4

Weeks

Rapid Capture

Identify Masters

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Extract Intelligence

Quality Control

Link & Cross Reference

Intuitive Single Point of Access

Save time

Less exposure to on-site risk Improve collaboration

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Validation from Multiple Sources

OO / PMC

Legacy Systems

Target Systems

Report

Approve

i Transform

EPC Contractors

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

SPO in the Enterprise IT Landscape Asset Performance Management

Enterprise Content Management Enterprise Asset Management

Significant investment

SPO Plant Automation Systems

HSE Systems ©2015 Intergraph Corporation. All Rights Reserved.

BUT… systems Established knowledge base operate in silos

Asset Integrity Management

Management of Change in SPO Operating Plant

Create Change Request • •

Relate to affected objects Initiate workflow

SPO

Review • •

Change Board Review Discipline Review

SAP EAM

Approve/Reject • •

Approve for Engineering Approve for Implementation

Implementation • • •

Complete Engineering Implement as Notification or Turnaround As-built update

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Implementation • •

Notification Job Package for Turnaround

Synchronization of design basis with SAP

Filtration and Transformation

Tag Creation, Update or Termination

i

Create / Update FL record

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.

Synchronizaton with SAP

SPO

–Synchro - nisation

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SAP

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?

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We will help you to improve: • •

Step by step Fast Track

SAFETY.

QUALITY. PRODUCTIVITY.