With the launch of the new Intergraph PP&M website, we have moved the location of the GetSmart! Blog. Please visit http://ppm.intergraph.com/blog to find current posts.
With the launch of the new Intergraph PP&M website, we have moved the location of the GetSmart! Blog. Please visit http://ppm.intergraph.com/blog to find current posts.
Posted by GetSmart! Team on Aug 17, 2016 in - 3D Modeling & Visualization, - Engineering & Schematics, - Information Management, - SaaS, : Construction, : EPC, : Fabrication, : Owner/Operator, : Procurement, :: Chemical, :: Consumer Goods, :: Metals & Mining, :: Nuclear & Power Generation, :: Offshore, :: Oil & Gas, :: Pharmaceutical, :: Shipbuilding, Events, GetSmart! Webinars, HxGN LIVE, Press Releases, Success Stories, Videos | Permalink | Comments (0)
The first step an owner operator typically makes, beyond getting their documentation into a document management system, is to get all documents linked to the relevant tags. This is still the approach used in the majority of handover specifications incorporated into EPC contracts and equipment purchase orders today.
This approach makes sense from a project perspective, as data is static. A particular make and model of equipment is installed, given a tag location in the facility, and only one piece of equipment with a given serial number will be installed. This approach does not work will for operations.
During operations it is common to replace equipment with another of the same specification. During modifications one manufacturer’s model/type of equipment at a given tagged location may be replaced with another that is better suited for the duty at that location. In both of these cases the documentation linked to the tagged location has to be evaluated. In the first case simple “Replacement in Kind” documents linked to the individual equipment item, such as a pump performance curve or certificate, are replaced by the new equipment’s documents. In the second case, all the vendor documents describing the model/type of the replaced equipment need to be located and disconnected from the tag and replaced by the new documents linked for the new manufacturer’s model/type.
This is a resource intensive process, prone to error and not always done as well as it should because of limited resources available to manage documentation on operating facilities. As a result the original documentation for equipment is often lost or discarded, engineering staff resort to calling vendors to attain the information they need, and historical asset data is hard to locate.
The curse of multiple copies of vendor documents
The linking of all documentation against tags also gives rise to multiple copies of the same documentation handed over, thereby increasing handover cost and complexity. It is quite common for projects to agree to standardize on bulk equipment items such as valves, light fittings, motors, instruments, and many more from selected manufacturers and even selected predefined models and types. This standardization is done to simplify the work of requisitioning engineers, to get preferential discounts, and to reduce the cost of spare parts inventory. In such projects it is the usual case that each equipment package vendor will incorporate documentation for these standardized items within its vendor data books. This results in the same set of vendor documents for these standardized items being delivered from the original equipment manufacturer to each package supplier, for the document to be reviewed by each package responsible engineer and then be linked to the relevant tags within the package and be incorporated into the final documentation handed over to the owner operator. This leads to unnecessary costs and inefficiencies being propagated through the value chain which must ultimately be paid for by the owner operator.
How SmartPlant Enterprise for Owner Operators and EPCs (SPO/E) Core helps eliminate the problem
SPO/E Core simplifies the process by grouping the types of information into three areas, Tag, Model, and Asset. This provides the ability to link tags against manufacturer model/types of equipment and serialized assets. In this way design documentation for an equipment package such as P&ID diagrams and design calculations can be cross-referenced against the tag. Documents describing the manufacturer’s model such as the manufacturer data sheet and type certificated can be held against the model. Documentation related to a specific serialized rotable item (an item that can be repaired/serviced and set aside for re-use) such as pump performance curves, NDT tests etc., can be held against the asset.
When this is done, and data and documentation are handed over in this structure, the replacement of one serialized piece of equipment by another, or switch of one manufacturers model/type by another, just requires the relevant relationship to the model/type or asset be redirected to the new model/type or asset.
Reducing Package Equipment documentation volumes by 60 percent
This can be taken a step further by establishing a library of standard equipment documentation of the standardized model/types to be used on a facility. EPCs and package equipment vendors can be given access to this. Instead of providing this documentation in their final handover EPCs can simply provide a cross reference between relevant types and the model/type in the library which could be provided by a third party content supplier or maintained by the owner operator. The volume of vendor documentation for a complex equipment package such as a compressor can be reduced by 60 percent and the resulting documentation package is far simpler to maintain during operations.
How to implement a new approach for vendor documentation
Whilst SPO/E Core can provide an environment to address the issue of efficient structuring of vendor documentation it is not the only prerequisite. Firstly, a strategic decision needs to be taken to implement the necessary steps ideally during the FEED phase of a project, so that long lead items are addressed and the bid package is defined correctly. A detailed handover specification needs to be prepared for issue to EPCs and vendor package suppliers. The standardization on equipment model/types needs to be agreed upon and a library of documentation for the chosen model/types needs to be established either on a project basis or via a third party document content supplier. With these in place it should be possible to greatly reduce the volumes of vendor documentation handed over and increase the efficiency and reduce costs of managing change on operating facilities.
Interested in how this looks in the software? Let us know!
Tune in to the HxGN Radio episode Pressure Makes Diamonds featuring Patrick Holcomb, executive vice president of global business development and marketing for Intergraph Process, Power & Marine (PP&M), about the fiscal necessity to shorten the supply chain and how automating work processes is creating the need for consistent data and higher quality deliverables. (Read the full transcript below.)
Holcomb has an engineering background and previously worked for Exxon and Accenture doing work process design and market strategy. In his current position he sets the overall market strategy and marketing communications plan for Intergraph PP&M. This is a dynamic time for the company and his team.
Intergraph has a long history of innovation. From innovating technology hardware in the 1960s to creating the first successful plan and design system, PDS, in the 1980s, to today. PP&M is leading the way in advanced work package planning for construction, and with SmartPlant Fusion, is managing millions of unstructured documents and turning them into valuable information used in a data-centric work process.
The industry is changing, and PP&M is changing with it. Rather than build another application for another discipline, PP&M is asking “How do we make the whole value chain compress? How do we empower the whole value chain to work together more effectively?” PP&M is focusing less on manual hand-off, and manual checking, and more on automated hand-off and streamlined work processes by:
To listen to more episodes produced by HxGN Radio, visit the HxGN Radio channels on iTunes, SoundCloud, and Stitcher, or visit hxgnradio.com for more stories from Hexagon’s global network of brands. (Recorded live during HxGN LIVE 2015 in Las Vegas, June 1 - 4, 2015.)
Welcome to HxGN Radio. This is your host, Kathleen McNeil. Thank you for joining us for today’s podcast episode brought to you by Intergraph Power, Process & Marine. In today’s podcast, we’re talking to Patrick Holcomb, who is executive vice president of global business development and marketing for Intergraph PP&M.
KM: Thank you for joining us, Patrick.
PH: It’s good to be here Kathleen. Thank you.
KM: So, can you start by telling us a little bit about yourself and your role at Intergraph PP&M?
PH: Sure. I’ve got a unique opportunity in the job that I have, and I think it’s probably the best one in the world. My background is in engineering. I used to work for Exxon, and I also used to work for Accenture doing work process design and market strategy. So, now my job is literally to set the overall market strategy and marketing communications plan for Intergraph PP&M. So, my organization literally defines all the R&D priorities, all the user requirements across all the software that we’re creating in order to make sure that it fits the market, and we find the right need. And there’s a lot of change going on in the market right now. So, it’s a particularly dynamic time for us.
KM: I’m sure. It sounds very exciting. Innovation has been a cornerstone at Intergraph PP&M and has served as the foundation for some of the smart technologies, as you refer to them. Could you tell us about those technologies that are involved in making plants smart?
PH: Sure. Intergraph has a long, long history of doing this, of innovating in different ways, whether you go all the way back to the 60s when Intergraph was innovating in technology hardware up into the 80s when we created the first successful plant and design system called PDS. And even to what we’re doing here at the show today, where we’re taking steps forward in advanced work package planning for construction, managing millions of unstructured documents and turning them into useful things that you can use in a data-centric work process. We’ve got a pretty long history of that, in fact, internally many people comment that we’re very good at doing things that are complex. Unfortunately, it also means that if it’s not complex we can make it complex which is, I suppose, an internal culture that we have to resist, but we’ve been constantly innovating in all areas for a long time in this highly complex field of engineering and design.
KM: I know that times have changed so much with technology and operations. What are some of the innovations and advancements that Intergraph PP&M has been a part of?
PH: Well, some of the most exciting things that are happening now in the industry – the industry is going through a change. We used to write technology that was effectively all designed to automate single discipline work processes, and all of our applications and all of our competitors. This is nothing new. All evolved the same way, because that’s how clients were purchasing technology.
However, what we started to see is that starting to run out. The opportunity for growth for us is not in building another app for another discipline, because for the most part they’re generally covered. Likewise, the industry is under a lot of pressure right not because oil prices fell in half. And that causes a lot of pressure on profitability. So, the pressure right now – and I’ve used this term before – that pressure makes diamonds, and I can assure you there is no shortage of pressure. The question is how do we make the whole value chain compress? How do we get the whole value chain to work together more effectively? And that’s what’s exciting. That’s really what’s kind of leading edge now. We saw early today comments from people like Bechtel and Fluor where they’re really starting to compress their value chain with data-centric work processes. So, less manual handing off, less manual checking, more automated hand-offs and a more streamlined work process. It’s a change. It’s a real work process change and a technology change. But it’s starting to happen in the industry.
KM: Absolutely. As you just mentioned, the industry is going through a difficult period with lower crude prices and reduced expenditures. Given this landscape, how is Intergraph PP&M helping organizations reduce costs while at the same time staying competitive?
PH: It is tough. It really is. It’s tough out there and I won’t make any jokes about that. It is really difficult. Owners want. They still want to get these projects in, but sometimes the upside – the revenue on the expectations – is not as high as it used to be. And that means they’ve got to get the project in for less money, and that’s really what we’ve been focusing on.
Probably the single biggest area where that can be impacted is in construction. If you look, most studies will show that there’s anywhere between 30-40 per cent idle and wait time on construction projects. Now this is in an industry where around 70 per cent of all projects are delayed and have overruns, and at the same time you’ve got 30 and 40 per cent idle and wait times going on inside the construction phase of the project. So, you might think very simply well just stop all the idle and wait time, and then everything else will be good. And in some ways it is that simple, but you’ve got to do that one person at a time. Investing in the technology to really enable advanced work packaging so that people can begin to make construction as efficient as manufacturing is, is a borrowed concept from manufacturing. Just-in-time materials, just-in-time information – that’s what eliminates all that idle and wait time because all of that can be turned into schedule improvements and profit. And I think that’s probably the single biggest area where the industry is focused today.
KM: Absolutely all about efficiency, I’m sure.
KM: Intergraph PP&M works with oil and gas partners around the world. What are some of Intergraph PP&M’s biggest projects that have been maybe the most impactful?
PH: We’ve been on a host of global flagship projects. For example, the largest manmade floating thing in the world is the Shell Prelude. It’s massive – it’s almost half of a kilometer long that was designed with our software. Likewise, if you saw the video earlier this morning, ITER which is a multinational collaboration to build the first scaled up nuclear fusion reactor. So, it literally will operate at 150 million degrees Celsius, the temperature of the sun.
Those are projects that we’re supporting with our technology, and from those mega, mega projects all the way down to very small projects. We saw today, projects that are maintenance projects that could be no more than $5 million using our technology. And so, as a result of that it’s given us a really great breath to see what’s happening and how we can begin to help the industry become more efficient. There’s certainly lots of automation to do. We’re seeing as a result of our portfolio breath – we’re seeing lots of opportunities in lots of little places, to just shorten up the supply chain, stop manual checking, automate work process, and it’s starting to happen. We saw it earlier today. Lots of the industry vanguards are starting to make real differences.
KM: We’ve touched on the importance of efficiency a little bit, but low risk is also a very big goal for global energy industries. How does Intergraph PP&M approach this challenge?
PH: If you’re doing it right it all tends to happen together. When you automate something, and you remove manual checking processes and manual handovers what tends to happen is quality goes up at the same time that costs go down for the same reason that your average car that you buy today on a real dollar basis is actually much cheaper than it was in the 70s, and it’s much higher quality at the same time. And so, it’s really a win-win in the end for the consumer as that begins to happen.
A good example of that is a new technology we just announced here at the show this year. Master Tag Registry, which is an integration product, forces project people to have consistent tagging rules. This might sound simple, but if you get a few hundred or maybe a thousand designers all working there’s a little – creativity creeps in, and it turns into a bit of chaotic mess later on when everyone’s trying to consolidate that and figure out if this document with this tag number is the same as that document with that tag number. It would become a real mess. And so with Master Tag Registry we can enforce consistency. We can also automate all the tag registers, which is this huge deliverable information product, on projects that used to be done manually. We would have people running around for weeks pulling these together and trying to piece together out of all this inconsistent data, trying to pull those together for the handover. And now we can automatically do that at the push of a button, and that’s great example where we’ve got both speed and efficiency and a much higher level of quality in the deliverables.
KM: Absolutely. Low oil prices won’t be around forever. What do you foresee for the industry and Intergraph PP&M, let’s say, in the next 1-3 years?
PH: Well, this is something I learned while I was at Exxon, which is it’s important to focus on what you can control. The first thing I’ll say, anyone that tells you where oil prices are going to be three years from now is either fabulously wealthy or delusional. Nobody really knows. Nobody saw this coming. No one saw the last downturn coming, and no one knew what the shape of the curve would be going up, and we don’t know that either. So, the only thing we can focus on is helping people be more efficient in their work, making sure that our technology really contributes toward an industry improvement in the deployment and operational capital projects. And so, that’s what we’re focused on today. We’re just going to make people better at what they’re doing, lowering costs, improving quality, improving speed, and the market will work itself out as to where crude prices land.
KM: Definitely. Well, Patrick thank you so much for your time today. We appreciate it.
PH: Thank you Kathleen. It was fun.
And you can learn more about Intergraph at intergraph.com/ppm. And tune into more episodes from HxGN Radio on iTunes or SoundCloud or visit hxgnradio.com for more stories from Hexagon’s global network of brands. Thanks for listening.
In today’s competitive market, profits are lower and the drive to minimize costs is stronger than ever. Demanding schedules coupled with growing size and complexity are putting projects at risk. To put it simply – projects can no longer be executed the way they were 20 or 30 years ago. We must start sooner, plan better, and work smarter to ensure that projects are successful.
Better understanding is needed of the impact to the project when changes occur. This requires more visibility of the design and how the components and deliverables interrelate. When the start-up/commissioning team is engaged early on in the project, they can identify design issues that otherwise would be found in the field. These late changes are one of the leading causes for project delays during handover and commissioning.
Effective punchlist management is another key to success. Too often punch items are not properly prioritized which can lead to a minor issue bottlenecking progress. Reducing the overall number of punch items and properly evaluating them to ensure that resolution is aligned with the overall start-up schedule is essential for a smooth transition.
Finally, the quality of the information used to execute systems completion has a direct impact on the project in terms of resolving questions in the field, scoping activities, number of punch items and non-conformities, coordination, and communication.
We have created a new report discussing these issues - "Completion, handover and commissioning: The ultimate 7-step checklist for faster operational readiness - in response to the ongoing feedback we receive from our customers. We hope it opens the door for the industry to discuss the issues that are commonly experienced during project completion and commissioning.
You can download the report here. We hope that you find it useful.
As many of us know, revisions and new versions are the nature of engineering. Within any given project, vast amounts of documents are generated and need to be managed. Data integrity becomes crucial for both efficiency and safety of operations and maintenance.
Intergraph® Smart™ Yard provides engineering-oriented document management functions that enhance accessibility of information, management of change, and decision support. The solution brings together engineering, procurement, project planning, fabrication, construction, and completions within a single, collaborative knowledge management environment.
Intergraph Smart Yard is chosen by leading shipyards globally, including OceanMight and SapuraKencana. “By leveraging Smart Yard, we have the capability to develop new and more productive ways of working, minimizing risks and delivering projects in a timely fashion,” OceanMight states on the Smart Yard video. To learn more about the solution, please visit the Intergraph Smart Yard website.
Another chance to see real life project examples with Smart Yard is during the 17th annual International Conference on Computer Applications in Shipbuilding (ICCAS) in Bremen Germany on 29th of September – 1st of October 2015.
During the event, Intergraph will be presenting on the topics:
• How Intergraph Smart Yard leverages the engineering design basis to improve work processes across the project life cycle (Jeff Bashir, Intergraph Singapore)
• How to integrate design and manufacturing efficiently with complete insight and traceability of all information required: Case study of the integration of Smart Production into Smart™ Yard Implementation for piping fabrication (Rachel Yee, Intergraph Singapore)
You can of course also contact us directly regarding any questions about Intergraph Smart Yard, or ICCAS 2015.
Intergraph® PP&M is happy to launch an eVision-Intergraph Workshop on Operational Excellence, taking place at the Squaire in Frankfurt, Germany on 22 September 2015. As announced during HxGN LIVE Las Vegas earlier this year, the strategic partnership between Intergraph and eVision aims to improve the effectiveness and reduce the risk of work processes conducted on process, power and marine facilities.
The 1-day workshop focuses on how to increase HoTT (Hands-On Tool Time) and reduce MTTR (Mean Time to Repair) through improved collaboration between engineering, planning, and front-line workers.
By joining this workshop, you can see how real-time access to digital plant and equipment data can make working processes significantly faster, bringing these benefits:
This interactive workshop is a must-attend for Operations, Maintenance and HSE (Health Safety and Environmental) Managers that seek to reach new heights in operational safety and efficiency. You can view the preliminary event agenda here and for any questions regarding the event, please contact Kristin Wingendorf.
Seats are limited, so ensure your attendance by registering here.
Intergraph PP&M is looking forward to seeing you in Frankfurt!
Intergraph® Process Power & Marine will be present at the Asset Integrity Management (AIM) Summit, taking place in Aberdeen, Scotland on 28th – 30th of September. As the vast majority of platforms in the North Sea is nearing the end of their life cycles, an implementation of a robust asset integrity program is crucial for companies operating in the region. Both engineering, procurement and construction (EPCs) companies and plant operators struggle with a continuous flow of unstructured information arriving from multiple sources, including brownfield data capture, handover documents, and engineering partners. This way, ensuring information reliability and data accessibility is essential to both safety and efficiency of operations.
Intergraph joins the 10th Annual AIM Summit to discuss the possibilities of leveraging engineering information for improved safety and efficiency. Michael Theobald, Manager Strategic Alliances for Intergraph Global Business Development, will be presenting during AIM on the subject “Ensuring Process Safety & Asset Integrity - Leveraging Engineering Information”. Other speakers include Mark Wilson from ConocoPhillips, Neil Currie from eVision and John Nicholson from Centrica Energy E&P. You can download the agenda of the full event here.
In addition, AIM & Intergraph offer a possibility for Complimentary Guest Pass. To know whether you qualify for a free complimentary pass, please register here.
Intergraph PP&M is looking forward to meeting you in Aberdeen!
Intergraph® PP&M approached Adrian Park, VP of SmartPlant® Enterprise solutions, to get a sneak peak into his presentation, and recommendations for the OO representatives attending HxGN LIVE Hong Kong.
INGR: You will be presenting on the topic of Addressing Owner Operator challenges with SmartPlantEnterprise for Owner Operators (SPO) – could you give us some the highlights of the presentation?
AP: Owner operators are facing unprecedented challenges with low commodity prices, increased competition and higher than ever demands from regulators to comply with stringent environmental and safety regulations. My presentation features how SPO manages the virtual plant asset and leverages it through out-of-the-box, preconfigured work processes to enable multiple benefits for the user, including:
• Reducing CAPEX and OPEX
• Shortening project schedules
• Improving uptime
• Reducing HSE risks
• Demonstrating compliance to regulatory authorities
I will also discuss several real-life project examples featuring our latest case studies, illustrating how existing customers globally have taken advantage of the SPO capabilities.
INGR: Would you have any other tips for the HxGN LIVE Hong Kong visitors?
AP: There are two local Chinese customer presentations (English speaking) in the Owner Operator track that I would definitely recommend. The first is an implementation of SPO at Wanzhou Thermal Power Plant to support project handover and steady state operations. The second is by Sinopec Ningbo Engineering Co., Ltd (SNEC). SNEC is an engineering contractor that uses SmartPlant Enterprise for Owner Operator solutions to ensure the quality and consistency of engineering data, management of information and data, improve the workflow and meet Owner Operator requirements.
One of the other presentations to look out for is our Introduction for SmartPlant Fusion. We have two separate Fusion sessions, one focusing on business value and other on technical aspects of the software. In addition Samsung BP in Korea is presenting about their Fusion implementation. SmartPlant Fusion is an exciting, award winning new technology that enables the capture of unstructured documentation and drawings as well as extraction of intelligence using techniques, including optical character technology and hot-spotting. Samsung BP have completed a six-month implementation of Fusion to provide rapid, reliable access to facility documentation via multiple access routes including tag numbers.
INGR: What are you looking forward at HxGN LIVE Hong Kong?
AP: I'm looking forward to meet local owner operators to discuss the specific challenges they are facing, and how we can assist them with our solutions.
INGR: Any additional pointers you would like to mention regarding the conference?
AP: I would recommend that attendees spend time in the Zone to see our solutions demonstrated in real life. This includes latest innovations, such as integration with control of work solutions, our mobile solutions and the latest versions of SmartPlant Enterprise for Owner Operators and SmartPlant Fusion.
We are looking forward to see Adrian’s presentation and would like to take this opportunity to invite you to look at the preliminary event tracks. Join Adrian, and many others, at this year’s HxGN LIVE Hong Kong– don’t miss out and register here!
Owner operators in the process industries manage massive facilities using a myriad of advanced business processes to get all the necessary work done. There are many advanced software solutions out there, providing plenty of features and functionality to potentially support for example business processes in the engineering information management area. However, features and functions just provide potential benefits and only when fully and correctly exploited will they provide real benefits to help improve owner operators’ work processes. So how to best match the needs and processes of an owner operator organization with the engineering information management software? How to stay focused so that the implementation meets its goals in a reasonable time frame?
Rather than beginning with a wide tool box of features and functionalities that can be used to create Owner Operator solutions with a potentially long and uncertain implementation duration, Intergraph SmartPlant Enterprise for Owner Operators (SPO) provides preconfigured solutions. These out of the box, preconfigured solutions typically provide a 60-80 percent fit for most organizations and reduce the cost and efforts of implementation and accelerate and increase Return on Investment. They include work process descriptions, configuration and documentation that leverage industry best practices and lessons learned from many owner operator implementations Intergraph has executed over the years.
The delivery of these template work processes is at the heart of SPO. Intergraph developed a highly structured methodology to define these work processes, and categorize them at three levels of detail:
The SPO workflow diagrams provide both a model and basis for the consistent development of the work processes delivered in SPO, but they are available to customers as a published web-based help system. The published diagrams provide an intuitive guide to the user, showing the work process provided in SPO. Simple hyperlinks drill-down to increasing levels of detail and annotated videos represent how work process steps will be executed. This provides a simpler, more interactive form of user assistance than lengthy function/feature-based help documentation, and promotes rapid learning and consistent use of the solutions.
Interested in an example? Let us know!
In this episode of the Engineering Coffee Break Frank Joop discusses the very important topic of safety. Joop discusses how Intergraph PP&M can help you make your facility safer.
Make safety are part of your culture. Keeping in mind all involved, you have to build and operate in a safe way. Can’t put a price on safety, and there will always be risk no matter what but understanding the risk is key to mitigating it. As more plants get built and as plants get more complex there are more risks associated.
The best risk mitigation is to design for safety. You can do this with:
Listen to Joop’s whole discussion on Plant Safety here.