Asset Data Solution WorleyParsons Digital Enterprise
Asset Data Solution | Capability and experience
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The asset data solution Recognizing that asset information will drive the digital plants of the future, the Asset Data Solution is the WorleyParsons Digital Enterprise initiative for the creation of a centralized information asset to enable plant operability and performance improvement throughout the asset lifecycle. Owner operators are increasingly focused on the management of critical asset information across the asset lifecycle. Compilation of valid, accurate and complete asset information during the project phase or for an existing facility is essential to support the start-up, commissioning, maintenance and sustaining capital requirements of the asset. Other sources of asset data collected during the asset operational phase including those from condition monitoring, inspection and process control systems, must be leveraged to support defect elimination, performance improvement and optimization activities. A key challenge for owner operators is to provide a structured platform for asset information management that delivers a single source of truth whilst providing the tools necessary to leverage asset information for decision support and continuous improvement activities. To overcome these challenges, WorleyParsons Digital Enterprise has developed its own Asset Data Solution comprising an integrated technology platform empowered by a complementary set of consulting services that delivers an asset management system for use throughout the asset lifecycle. The Asset Data Solution provides a means to author, capture, validate and deliver critical asset information to better inform owner operators for effective decision making and improve asset operability and performance.
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WorleyParsons Digital Enterprise
Key capabilities: • System architecture and execution planning
• Enterprise asset management (EAM) solution maintenance and integrity build
• Project management
• Reliability program development and optimization
• Solution implementation services including technical installation, configuration, integration and training
• Brownfield ‘as-found’ information capture • Geospatial data integration
• Materials quantity assessment and optimization
• Engineering design and data environment
• Content management services, including cataloguing, SPIR data processing, material master and bills of material development
ASSET DATA SOLUTION ARCHITECTURE Owner Operator Load Collaborate Validate Leverage
3rd Party Sub Contractors
EAM Authoring Asset Performance Management
Engineering Environment
Load Collaborate Validate Leverage
Asset Hierarchy
Criticality / Risk
Tags & Data
EPC Contractor Vendors
Tags & Materials
Content Management
Equipment Strategies
RBI
Documents Materials Catalogue
Reference Data
Maintenance Plans
RCM Procedures Asset Health
SPIR Mobility SPIR Data Usage Qty ROP, Min / Max
Spare Parts Optimization
Asset Class
Assets ierarchies Class
BOMS EAM Build
Strategy Optimization
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Usage Qty ROP Min / Max
O o
Content Man
ntractor Co
Load | Collaborate | Validate | Leverage
m age en
EPC
E co
t
Asset Data Solution | Capability and experience
Owner Operator
Content Management
Load | Collaborate | Validate | Leverage
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Access to high quality asset information drives continuous improvement Availability of structured, accurate and content rich asset master data is a pre-requisite for developing maintenance strategies, engineering plant improvements and for carrying out day-to-day plant operations. Access to critical asset information to determine what is currently in place, its condition and performance allows owner operators to make informed decisions around plant optimization, process safety and capital planning. Similarly, asset health information, which is often spread across disparate electronic and paper-based repositories, must be amalgamated and presented graphically to aid decision making and drive asset performance improvement.
Content
Tags & Data
SPIR
Documents
SHAREcat’s web-based content management solution (CMS) comprises four modules that can be deployed individually or as one fully integrated solution. Together, they provide a complete content management solution for the capture, validation, enhancement and delivery of high quality asset information for any phase of your asset lifecycle.
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WorleyParsons Digital Enterprise
Content Management Solution (CMS) Configuration of the plant asset for operational readiness and ongoing operations and maintenance requires delivery of high quality supplier / OEM documents and data from the project phase. This requires the data to be validated for accuracy and completeness for reliable use and re-use throughout the asset lifecycle. WorleyParsons Digital Enterprise’s global solution for project supplier and OEM information, spare parts and SPIR Information Management is SHAREcat. SHAREcat is a web-based collaborative environment for the gathering, storage, collation, verification and delivery of project supplier and OEM information directly related to equipment and spare parts.
SHAREcat capabilities include: • An extensive global catalogue containing standard equipment, parts and materials data and documentation • A web portal for gathering all technical information through all project phases • Automated validation of engineering metadata (key lists) from structured project formats • Fully controlled data / document review support, adaptable to any process or phase, including automated verification against the centralized and validated SHAREcat catalogue data • Centralized repository of all information (across revisions, roles and phases)
SHAREcat references the world’s largest pre-qualified and validated catalogue of re-usable supplier data and documentation. Data is captured once and once only for re-use by all parties involved in the project lifecycle.
• Visibility and control of supply chain deliveries – online from live data
Brownfield assets can benefit from the validated catalogue to populate a large percentage of vendor information for existing assets.
• Feeding of quality information to any requested project or operations IT system via secure standard interfaces
• Standardization and re-use of equipment, parts and materials information across many projects
Asset Data Solution | Capability and experience
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Asset performance management (APM) To improve asset reliability and performance, owner operators must draw on all available sources of condition monitoring information to continually assess asset health, anticipate the onset of failures and make timely and informed proactive maintenance decisions to mitigate risks. Asset Performance Management provides the platform to collect, consolidate and act on all of the condition data needed to optimize asset performance and reliability.
• In-built leading practice strategy development methodologies – asset prioritization, RCM / FMEA / RBI / RCA and reliability strategy selector tools • Strategy development accelerators including Ivara® EXP Online, Smart Copy and strategy template libraries • Full EAM integration and strategy implementation capabilities
WorleyParsons Digital Enterprise’s preferred solution is Bentley Assetwise Performance Management (APM). Bentley APM draws upon the supplier / OEM data delivered from the SHAREcat CMS to build, implement and manage the entire equipment reliability program.
• Mobile computing
WorleyParsons Digital Enterprise’s global asset management team can access APM tools from the cloud to develop the RCM and RBIbased maintenance and inspection programs for equipment. We can efficiently implement these through integration with APM mobile computing tools, condition monitoring and inspection data repositories and EAM solutions.
• Maintenance optimization through integration with Isograph Availability Workbench
WorleyParsons Digital Enterprise’s ability to both develop and implement the entire reliability and integrity program for an asset is a key differentiator which delivers a platform to owner operators for managing reliability and driving continuous improvement throughout the life of the asset.
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APM capabilities include:
WorleyParsons Digital Enterprise
• Integration with external condition monitoring systems and data historians • Centralized asset health and performance monitoring
Asset information impacts on operability The IPA Institute ranks operability as the driver with the most leverage on delivering value for capital projects, more so than schedule or capital cost.
Operability Capital CostSchedule Results -0.5 -20 -2 -1.6 -0.25 -10 0 0 0 0 2 1.6 0.25 10 0.5 20
Change in Internal Rate of Return (IRR) % 2
Operability
1.5
A project that produces at half the intended rate has effectively doubled its capital cost per unit of production, and the operating costs have gone up even more. Delivery of high quality asset information contributes to improved operator and maintainer preparedness, optimized maintenance strategies, reduced part shortages and availability of necessary documentation for start-up and operational readiness which can greatly impact operability and is a significant contributor to project NPV.
Capital Cost
1
Schedule
0.5
Poorer Results -20
Better Results
0
-10
0
10
20
-0.5
-1
-1.5
-2
Source: IPA Institute
Asset Data Solution | Capability and experience
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Spare parts optimization Deciding which spares to hold and in what quantities to support commissioning, start-up and ongoing maintenance and operations is a complex problem that is seldom optimized. This can result in either over investment in spare parts, or significant start-up delays and operational risks caused by stock-outs. The assessment of spare parts in very large quantities requires a structured methodology underpinned by a technology platform able to manage the large volumes of SPIR data generated from projects with the flexibility to adapt to different inventory management models and business rules. WorleyParsons Digital Enterprise uses Oniqua’s analytics software (OAS) combined with our proprietary quantity assessment methodology to determine the optimal spare parts requirements. OAS is a cloud-based solution that leverages project SPIR data delivered from the SHAREcat CMS, forecasted demand rates and other modeling parameters to optimize spare parts quantities. OAS’ sophisticated algorithms and analytics capabilities enable WorleyParsons Digital Enterprise to intelligently balance costs and risk to determine optimal inventory levels.
Con gure Equipment Hierarchy Collect Equipment Data & Documents Validate Data Interchange-ability Assessment
Quantity Assessment Tools
1. Collect Data & Validate
Quantity Assessment Process
Ops, Maintenance & Shutdown Philosophy Business Impact Cost Model Inventory Characteristics
2. Construct Models
Specialist
Asset Manag emen t Exp erti se
Material Masters
Inventory Segmentation Business Rules
Fine Tuning Update Inventory Master
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WorleyParsons Digital Enterprise
3. Optimize
Statistical Modeling
Poor data management leads to significant capital waste For a major hydrocarbons operator’s mega project, only 40% of the required data was handed over to Operations at start-up and 50% of the initial spare parts ordered were not required. The Operator estimated the waste on a $20B TIC project due to poor data management exceeded $600M. OAS includes a constant data feedback loop into transactional systems to continue the optimization process throughout the asset lifecycle. OAS extracts historical consumption data from ERP, EAM and other transactional systems, before advanced data segmentation and profiling methodologies take over to help dynamically align inventory levels with production imperatives, cost objectives and business risk.
The WorleyParsons Digital Enterprise Asset Data Solution is a value creator The Asset Data Solution creates value by delivering high quality, enriched asset information from project outset. The Asset Data Solution improves operational readiness, reduces start-up delays, enhances capital planning and delivers superior operational performance and process safety throughout the asset lifecycle. This is achieved by: • Provision of a collaborative asset information portal to enable the efficient capture, validation, enrichment and standardization of asset data and documents during project execution • Specialized tools and services for classification, linking and cataloguing of all equipment and spare parts within a single repository for unique identification • Use of world class technologies and methodologies for efficient build of the asset reliability and integrity program and direct integration with EAM systems • Delivery of an integrated platform for APM that consolidates sources of asset condition data for enhanced decision support and continuous improvement • Integrating owner operator enterprise systems with structured asset data repositories to enable users to efficiently access valid asset information • Provision of staging areas for asset master data authoring, structuring and validation prior to delivery into EAM systems thereby ensuring that data is fit for use Asset Data Solution | Capability and experience
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Enterprise Asset Management system (EAM) authoring The authoring of maintenance and integrity master data for a new maintenance build must be validated to meet corporate master data standards and seamlessly align with the EAM configuration to ensure an efficient and high quality maintenance build process. WorleyParsons Digital Enterprise utilizes NRX as its preferred EAM authoring solution. NRX is a cloud-based solution that integrates and synchronizes with multiple types of EAM to facilitate efficient and effective data build. NRX provides owner operators with live access to the maintenance build process for full transparency and oversight while WorleyParsons Digital Enterprise controls the maintenance build in real-time from delivery centers anywhere in the world. NRX draws upon maintenance strategies, supplier and OEM information, SPIR and tag master data delivered from SHAREcat and Bentley APM and provides tools to allow the structuring and enhancement of the data to ensure alignment with master data standards and configurations prior to EAM migration. WorleyParsons Digital Enterprise uses NRX to load the approved EAM build directly into the EAM test system, eliminating the requirement for excel spreadsheet templates and delivering improved EAM compliance and greater build efficiency while reducing operational risk and improving business performance.
INPEX Ichthys maintenance and integrity build CUSTOMER: INPEX LOCATION: PERTH, WESTERN AUSTRALIA
The Ichthys Project involves the development of offshore gas and condensate reserves located in the Browse Basin at the western edge of the Timor Sea in Western Australian waters. The project will involve the construction of offshore infrastructure comprising CPF, FPSO, an 850 km subsea gas pipeline, and an onshore liquefied natural gas processing facility. Scope The project comprises the full maintenance build for the facilities with NRX as the cloud-based EAM authoring solution to capture all the master data requirements. The scope of work included: • • • •
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Preparation of bills of material for all equipment Recommendation of spares holding requirements Identification of the maintenance strategies via studies such as RBI, RCM & SIL Populating the equipment master data into NRX to align with INPEX SAP PM master data requirements
WorleyParsons Digital Enterprise
APM solution implementation Roy Hill Iron Ore Project CUSTOMER: HANCOCK PROSPECTING LOCATION:
WESTERN AUSTRALIA
Hancock Prospecting is developing a 55 million tonne per annum (Mtpa) iron ore project in the Pilbara region of Western Australia known as Roy Hill. The Roy Hill Project includes a new iron ore mine at the Roy Hill deposit, a mine process plant, a heavy haul railway system from mine-to-port and new port facilities south west of Port Hedland, Western Australia. As part of their operational readiness plans, Roy Hill engaged WorleyParsons Digital Enterprise to implement the Bentley AssetWise performance management solution to support maintenance tactics development and asset performance improvement. Scope Full implementation of the Bentley AssetWise performance management solution including: • • • • • •
Consulting and advisory to assist with overall solution architecture Software technical installation and configuration to align with customer requirements Integration with SAP PM and condition monitoring repositories Development of maintenance tactics for critical mine processing equipment Deployment of mobile technology solution for operators and technicans Ongoing technical support, training, coaching and mentoring
Supplier OEM content management - offshore platform CUSTOMER: CONFIDENTIAL LOCATION:
NORTH SEA
The project comprises a new wellhead platform tied back to the existing platform, via a new multiphase subsea pipeline and riser platform connected via a link bridge. The customer adopted an approach to managing all project information that recognizes the full project information lifecycle from creation to operational handover. Scope The project comprises the full maintenance build for the facilities with NRX as the cloud-based EAM authoring solution to capture all the master data requirements. The scope of work included: •
• • •
Provision and management of supplier / OEM content management services using SHAREcat to support the complete project lifecycle supply chain and the customer’s concept of the digital plant Collection, consolidation, structuring and handover of high quality compliant data and information to support operational readiness Verification of equipment information capture and management from the project supply chain Provision and deployment of a web-based gathering, review and approval service to deliver tag-based purchase agreement data and document deliverables, including tag-to-manufacturer / part number (source data) cross-references Asset Data Solution | Capability and experience
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Brownfield digital plant services At WorleyParsons Digital Enterprise, we draw on our extensive EPC and on-site facilities service experience supporting customers worldwide to deploy Information Management (IM) solutions across multiple asset classes. We use 3D design and intelligent schematics and configure systems to work in an integrated environment to bring customers a unified, single-source data warehouse to enable data mining across all applications. We are vendor agnostic and select solutions based on customer needs. We use our deep understanding of engineering, procurement, construction and technology to ensure the IM solution and digital asset fit the required business context and commercial goals.
Operating efficiency:
Capital efficiency:
• Decreased cost and schedule for leading operating systems
• Significant cost reduction for capital projects through ready access to digital plant information
1. Reduced time to find critical operating information
• Reduced requirement for significant surveys which can cause delay
2. Reduced modification cost through improved access to correct information
• Faster materials deployment leading to increased productivity
3. Improved and more effective ongoing asset management
Information integrity:
4. Reduced maintenance costs
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Accurate and reliable engineering data is an essential element for any organization to operate safely and efficiently:
• Provision of safety-in-design and operations features
• Information governance leading to improved control and communications
• Availability of design and manufacturer’s information for safe operations and maintainable environment
• Validation of multiple data sources
• Eliminating downtime
• Ensuring fully effective asset handover from the EPC to the owner operator
WorleyParsons Digital Enterprise
• Elimination of duplicate tags • Validated tag, document and data information
Our services range from extracting data from non-intelligent based documents right through to the provision of a hosted and managed IM environment.
TDRR Tag document relationship reporter
Creation of intelligent 2D schematics
Production of 3D intelligent digital plant models
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validate and report document tags check files for invalid tags work with individual files, or batches of files manage tag to document relationships report documents that do not contain searchable text
• intelligent schematic and associated databases • tailored reports to meet customers’ needs • use of applications to create high quality deliverables
• intelligent 3D models and associated databases • site surveys to gather data for digital plant models including laser scanning • use of tools such as Smart3D or PDMS for multidiscipline modeling and visualization
Integration of the 2D systems and 3D models in conjunction with a data warehouse solution
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Provide project information management and application specialists to support the facility lifecycle information strategy
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Provide a hosted and managed environment for a partially or fully integrated system
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integrate 2D and 3D environments with a data warehouse solution with additional benefits such as: -
•
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data mining across various applications’ data sources generation of standard and ad-hoc reports online access via desktop or mobile device improved interface management
utilize WorleyParsons Digital Enterprise’s global network of information managers and application support specialists at local and global level create / support integrated information management solutions for lifecycle of the plant
WorleyParsons Digital Enterprise hosts the information management facility including data and document warehouse, 3D CAD models and 2D schematics customer access to latest plant information is via online or Citrix connection
Asset Data Solution | Capability and experience
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ADMA-OPCO digital plant project for USSC and Das Island CUSTOMER: ADMA-OPCO LOCATION:
ABU DHABI, UNITED ARAB EMIRATES
WorleyParsons was selected by ADMA – OPCO to execute its digital plant campaign project for offshore and Das Island facilities. The project comprises • • • •
Consolidating existing design information for the facilities Laser scanning Creation of point cloud data and associated primitive models Creating 3D digital plant models using Aveva’s PDMS
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Creating intelligent schematics and associated databases using Aveva’s P&ID, Electrical and Instrumentation systems Using Aveva Net to warehouse the above data to provide quick and easy access for ADMA’s Engineering
• • •
Project Duration: 36 months Completion: September 2015 CAD platforms: Aveva suite, AutoCAD
Scope The digital plant campaign will provide ADMA with a fully accurate digital asset of the facilities. In addition to the reduction in time spent searching for data and documents, it will provide a reliable platform for further brownfield modifications. The project is due for completion in 2015. • •
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Full digital plant of 60 units / facilities at USSC and Das Island P&ID digital plant of 96 wellhead towers at UMM Shaif field EIMS – custom Aveva Net implementation
• •
Existing archive: > 101,640 documents (various formats) Deliverables: • Aveva P&ID, IN, PDMS databases (including environment set-up)
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>6000 drawings (selection of) and reports Engineering: > 150,000 mhs Engineering execution in WorleyParsons Abu Dhabi and India
CoSyn Lifecycle information management project CUSTOMER: SYNCRUDE LOCATION:
CANADA
A key part of any successful venture is having the right information to analyze a situation and then making the appropriate decisions. In 1991, CoSyn (an Alliance of WorleyParsons and Syncrude) became involved in a document management verification and update with Syncrude. Soon after that, TDocs management became part of CoSyn’s key focus in that area. In 2002, process safety management initiatives reinforced the importance of process safety information, and CoSyn provided support through to project completion earlier this year. In 2005, CoSyn’s InTools (SPI) revision management support augmented Syncrude’s efforts to improve and maintain important engineering information throughout the equipment and instrumentation lifecycle. Throughout the Alliance’s history, CoSyn has contributed to Syncrude’s access to high quality information for engineering, operations, and maintenance of the facility. Scope 73 plant areas had LCIM updated to as-found conditions taking over 1M man-hours. The process safety information process was broken down into six major steps:
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WorleyParsons Digital Enterprise
• • • • • •
Development of the field verification package Field verification Engineering discipline review Engineering inter-discipline review Issue of the PSI ‘as found’ package Issue of ‘hard revs’
GASCO ASAB – 1 Phase III – Piping digital plant CUSTOMER: ABU DHABI NATIONAL OIL COMPANY (ADNOC), SHELL, TOTAL AND PARTEX LOCATION:
ABU DHABI, UNITED ARAB EMIRATES
Abu Dhabi Gas Industries Ltd. (GASCO) is a joint venture between the Abu Dhabi National Oil Company (ADNOC), Shell, Total and Partex. The Asab NGL extraction plant has been in operation since 1981. It receives the associated gas (capacity 300 MMSCFD, single train) coming from ADCO. GASCO identified the documentation for its existing facility was not up to date and this was limiting its plant operating and capital upgrade performance. As part of their improvement strategy, GASCO engaged WorleyParsons to implement a digital plant program for the ASAM-1 plant above and below ground piping. Scope •
Deliverables:
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Project Duration: 12 months
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Completed: November 2012
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PDS model
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CAD platform; PDS, Microstation
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Updating of 3D model and isometrics, above ground and underground and underground piping network GA drawings
9,500 isometrics, above ground GAs: 350 and UG GAs: 60
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Engineering: > 27,000 mhs
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Executing in WorleyParsons Abu Dhabi and India
Checking and verification of documentation in line with plant by site survey and updating as required
GASCO ASAB - 0 Phase III – Instrument digital plant project As part of its improvement strategy, GASCO engaged to continue the digital plant build of the ASAM-1 plant with the inclusion of instrumentation. Scope • • • •
Project duration: 15 months Completed: February 2013 CAD platforms: SPI, Microstation Scope: updating of instrument database, loop drawings termination drawings, instrument location drawings and F&G location layouts
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Deliverables: • 6528 drawings • Instrument datasheets approx. 8000 Engineering: > 24,000 mhs Execution in WorleyParsons Abu Dhabi and India
Asset Data Solution | Capability and experience
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Geospatial data management for digital assets Increased operational efficiencies through rapid and consistent access to data. Geographic information systems (GIS) provide a tried and tested method of spatially managing data to enable a greater understanding of the built and natural environments, which in turn enables decision makers to better understand the scale, patterns, processes, relationships and implications of operation and development activities. WorleyParsons Digital Enterprise seamlessly integrates relevant information to provide location-based visualization and retrieval of key site and field data, providing improved information access and a tangible efficiency benefit throughout the whole asset lifecycle. Our data-centric approach means we provide agile and responsive systems with supporting tools and workflows to increase the potential for project success.
Hosted services Quickly understand information available at a location. WorleyParsons Digital Enterprise provides a bespoke, hosted web GIS that offers decision support tools alongside a framework for users to interrogate a geographic representation of assets and click through to connected systems to retrieve information. This integrated approach connects information to an asset’s location including: • Engineering interfaces
• Native CAD drawings
• Documents and schematics
• Maintenance schedule and history information
• Tag or commodity information
• Multimedia databases
This connected information is located and retrieved based on its location, all from one spatially-enabled search portal. Access is provided on a pay-as-you-go basis for a fixed monthly price. The solution can be deployed in weeks, not months delivering significant cost savings in software, hardware, maintenance, project, operations and unforeseen issues caused by poor understanding of the situation on the ground.
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WorleyParsons Digital Enterprise
Delivering cost reduction, improved efficiency and connected working Sharing geospatial data across organizations enables site or field information to be securely shared and re-used, ensuring a common operating picture and more efficient integrated working. We enable controlled data sharing with subcontractors or other operators in the case of joint ventures, without compromising data integrity, quality or ownership. By enhancing the communication and collaboration on site-specific information: • The communications loop is shortened • Double handling of data-related tasks is eliminated • Printing and printouts are reduced • Turnaround times are reduced because of the self-service approach
Digital field services (data management for pipeline fields): • Pipeline data management for the whole field lifecycle, from concept to decommissioning, using standardized data structures including PODS database schema for onshore and subsea pipelines • Consolidated system of record for pipeline centerline • Route optimization • Survey planning and data capture • Highly efficient and cost-effective automated alignment sheet generation • Inspection and integrity data management • Two-way live integration with CAD design data and tracking systems
Asset Data Solution | Capability and experience
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WorleyParsons Digital Enterprise
Corporate overview WorleyParsons is a leading global provider of professional services to the resources and energy sectors, and the complex process industries. We cover the full asset spectrum, both in size and lifecycle, from the creation of new assets, to services that sustain and improve operating assets. Our business has been built by working closely with our customers through long-term relationships, anticipating their needs, and delivering inventive solutions through streamlined, proprietary project delivery systems. Strong growth continues to characterize our performance both through organic development and through strategic acquisition as we strive to provide tailored services wherever our customers need us.
HYDROCARBONS INFRASTRUCTURE MINERALS, METALS & CHEMICALS
EcoNomics™ provides our customers with the systems, technologies and expertise to optimize and balance financial, social, and environmental outcomes, improving sustainability performance while enhancing profit and long-term viability. WorleyParsons’ vision is to be a leader in sustainability by helping our customers capture new markets and business opportunities created by the new energy economy.
Zero Harm is our corporate vision for health, safety and the environment (HSE). We are committed to our vision and apply it to all operations, at all times, in all locations, and at all levels of responsibility. We will actively work to align our expectations and behaviors to achieve Zero Harm in our dedication to continuous improvement. These expectations are reflected in our integrity management framework, OneWay™, and linked to our global systems and procedures.
Asset Data Solution WorleyParsons Digital Enterprise digital.enterprise@worleyparsons.com
www.worleyparsons.com
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WorleyParsons Digital Enterprise