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“Engineering Enterprise in the Lifecycle” “ A Guide to Engineering Data Management for Owner Operators”. Dr Bill Van Butzelaar & Richard Harris Production Division. WOODSIDE - Engineering Data Management. Key Points Woodside - Who we are Our key engineering interfaces
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“Engineering Enterprise in the Lifecycle”“A Guide to Engineering Data Management for Owner Operators” Dr Bill Van Butzelaar & Richard Harris Production Division
WOODSIDE -Engineering Data Management • Key Points • Woodside - Who we are • Our key engineering interfaces • Rational & road map for moving to a digital plant environment • Engineering Data Management road map • Dealing with legacy data • Using & developing software systems • Lock Out & Tag Out • Return On Investment • The Future of engineering technology
WOODSIDE ENERGY- AUSTRALIA Woodside is one of Australia’s top ten companies by market capitalisation, and the nation’s largest publicly-traded oil and gas exploration and production company. Based in Perth, Western Australia, Woodside has major operational assets and exploration and development interests in five continents including Australia and the United States. In 50 years we have grown from a pioneer oil and gas explorer to Australia’s largest independent producer of oil and gas and one of the world’s largest producers of LNG. Woodside operates Australia’s largest resources project, the North West Shelf Venture in Western Australia, which produces about 40 per cent of Australia’s oil and gas. In 2010, Woodside will complete construction of its $12 billion Pluto LNG Project near Karratha – Australia’s second biggest resources project. Woodside is also seeking to progress its Sunrise LNG development in the Timor Sea and the Browse LNG development in northern Western Australia. With a proved plus probable reserves to production ratio of 25 years at 2007 production rates, Woodside is poised to help meet growing global demand for clean energy.
Business Improvement & Engineering Data Management RolesA life time partnership ! Bill van Butzelaar - 27 years experience in both technical and managerial roles, in industries as diverse as pharmaceutical, food and alcohol, mining and minerals processing, and oil and gas. Roles include internal consultant to improve operational effectiveness through the design, implementation and continuous improvement of integrated business management processes. Bill has worked for companies such as Rio Tinto, BHP Billiton and Woodside Energy where he currently has responsibility for Business Improvement. Bill holds a Doctorate in Business Administration, Masters degree in Biochemistry and Post Graduate Diploma in Process Engineering. Richard Harris - 35 years experience in both technical and management roles, in a variety of industries including Aviation, Power Generation, Oil & Gas & Manufacturing. Involved in engineering data management arena for the last 15 years covering computerised maintenance management systems, project handover, legacy data conversion & custodianship of engineering design tools. Current role has included selection, configuration and deployment of an integrated suite of engineering design tools. Richard has worked for companies such as Rolls Royce, NEI Parsons, Saudi Consolidated Electric Company & Woodside Energy where he currently has responsibility for Engineering Data Management Group.
EDM TEAM – ENGINEERING SUPPORT GWA Angel Cossack NRA & NRB Enfield EDM Facility Overview Pluto Offshore Northern Endeavour Thylacine Vincent KGP Pluto Onshore Otway
Strategy for Greenfield Projects ALIS (Engineering Portal) Project Owner Operator Engineering & Design Phase Operate & Maintain Phase Sub Projects Operations HSE, Competency) • Progressive Data Transfer: • QA Data • Population of Operational systems Onshore Pipeline Procurement Materials Mgt Subsea Facilities Maintenance & Inspection Maintenance Mgt Topsides Turret / Mooring Well Constr’n Engineering Engineering Systems Project Domain Corporate Domain Corporate DMS Project DMS • Progressive Document Transfer: • Controlled Drawings For Operations • Controlled Documents For Operations 1 – 3 Years3 – 40 Years
The Challenge - Diversity of end users • Operations • Onshore & offshore facilities operating since 1983 • Legacy data non electric format of 320,000 drawings • Multiple styles & ways of collecting data (EPC dictated) • Legacy satellite systems • No single source master repositories • Brownfield Projects • Multiple joint venture partners & systems • Variety of engineering deliverables • Move to electronic handover from 1998 • Diverse set of engineering design tools • Legacy data not linked to physical areas, units or equipment • Greenfield Projects • Multiple EPC's • Variety of electronic engineering tools • Electronic handover specified as standard • Use of multiple engineering warehouses and libraries • Variety of Standards
Strategic Requirements for managing Woodside EDM • Provide ready access to engineering information • Establish links to all related engineering data and information • Rationalise engineering applications and data sets • Improve the engineering data Management processes • Enable efficient handover of project information to Operations from EPC’s • Bring WEL standards and procedures up-to-date with Best Practice EDM processes • Enable identification and rectification of data and information inconsistencies • Improve data integrity • Improve access to legacy (20 years+) non-electronic information
EDM Roadmap - Operations • Define key engineering deliverables, and develop process maps • Revise engineering standards & guidelines to reflect today's requirements • Develop a single metadata profile • Deploy a fully integrated suite of engineering design tools, and engineering software system & libraries ( All design 2D & 3D systems) • Implement common software platforms • Develop gateways to our key systems (SAP, document management system, commissioning system, sharepoint.) • 7. Develop an intelligent set of corporate datasheet • 8. Replace legacy systems & migrate to new tools • 9. Link data to engineering portal • Measure, evaluate effectiveness & achieved cost savings
Operations Information Management Standard (OIMS) OIMS Operations Information Management Standard Metadata Standard Archiving and Destruction Standard Operations Information “Creation and Updating Standard” Numbering Standard E-VEM Standard Engineering Portal Standard 2D & 3D SP3D Models Standard SPE, SPI , SP P&ID, & SPO Standard Engineering & P&ID Warehouse Tagging Standard (Corporate) Engineering Library PBS Plant Breakdown Structure ANG Corporate Datasheets MDR Standard ALIS Portal Guideline 2D & 3D SP3D Models Guidelines Engineering & P&ID Guidelines SPE, SPI, SP P&ID & SPO Guidelines COS Plant, Area, Unit & System Coding Datasheet Web Validation Tool GWA Eng SAP-PM Standard KGP Eng SAP-MM Standard NE NG NRA OTW
Engineering Portal relationship to EDM applications SAP PM Engineering Portal (ALIS) PHD SAP LOAD TOOL DMS Data Publishing Engineering database Instrumentation database Intelligent P&ID 3D Model 2D CAD Document publishing
Legacy Data Migration Documents & Drawings Datasheets 2D Drawings Excel & Access Microfilms Engineering List Key List Hard Copy Electronic Electronic Scan to PDF Scan to PDF OCR Populate Engineering Master Repositories OCR Create Tag Relationships Create Tag Relationships Create Query Forms “Key Lists” Create Tag Relationships ALIS - Engineering Portal
Media Gallery 2009 Major Shutdown Tag: 2KT1420 HP Rotor Overview Stage 1-4 HP Blades Guide Van Pins HP Rotor - N D E Stage 5-11 HP Blades LP Blade Section LP Stator Blades LP Rotor Section LP Rotor in Situ LP Rotor Shaft & Brg 2009 Major Shutdown Active Thrust Pad Brg Thrust Pad T/C’s 4Brg Thrust Ring Assy Thrust Pad Hot Spot1 Thrust Pad Hot Spot2 Thrust Pad Normal v2 Half Moon Thrust Pad Thrust Pad Carrier Thrust Pad Shoes Thrust Pad Normal v1 2009 Major Shutdown HP Tilting Pad Brg 4U HP Tilting Pad Brg 4L HP Tilting Pad Brg 4L Scaffolding Arrangement Tilting Pad Assy Brg 4 Lifting Beam Install Scaffolding Arrangement Enclosure Scaffolding Enclosure Scaffolding HP Stators Topside Engineering Portal Media Gallery
Electronic Permit System – Lock Out & Tag Out Mechanical Isolations Valves, Spades & Spectacle Blinds Electrical Isolations Local & Panel Instrument & Control Local, Panel & Control System ISSoW (Electronic Permit to Work System) SAP-PM Equipment Hierarchy & Work Orders Engineering Portal DRIMS D .M. S RFID 3D Model PDS/PDMS Intelligent P&ID PDF P&ID Hand Held PDA’s
Return On Investment • Quantified Benefits: • 10% more efficient Information Searching • 86% more streamlined Data Handover • 93% reduction in Supported Applications • 93% reduction in Training costs • Unquantified Benefits • Handover of engineering data for sold assets • Reuse of engineering data and designs • Improved IM quality resulting in safer workplace and reduced unplanned shutdowns • Strategic sourcing opportunities of EPC’s • Hyperlink to published ROI study : • http://www.deloitte.com/view/en_AU/au/services/consulting/article/4ba0f25acb2a3210VgnVCM100000ba42f00aRCRD.htm
ROI Payback Period Net cumulative current value benefits Payback period Woodside’s “EDM” project achieved full payback in 3.4 years or by mid 2007. The following graph describes the cumulative current value costs versus the cumulative current value benefits. The point of intersection represents the project’s breakeven point. From 2009, project costs began to stabilise as the implementation reached its final stage. Benefits increase dramatically from 2007 due to realising the benefits from the Angel LNG handover and as user adoption increases.
Angel “Overall” winner WA Engineering Excellence Award 2009 • Integration and innovative use of computer automation, intelligence, modelling systems or multi-media techniques . Angel was the first project to deliver a fully integrated set of information to the company for use prior to start-up. • The portal allowed access to all engineering, maintenance and operations information and allowed for two views, a project view and an operations view. • The project view allowed project personnel to use the portal for project execution while the operations view allowed for the integration of information assisting the development of maintenance and operations information well in advance of facility start-up. • ALIS was established on an extranet (new Woodside infrastructure) which was accessible by third parties involved in the design, fabrication and installation processes. • Integration of information was primarily via a tag paradigm & included access to & from the following: • . Intelligent P&IDs . 3D models • . Computerised Maintenance Management System . All engineering data • . Documents and drawings . Subsea Inspection System • . Geographical Information System (GIS). . Photographs • . Equipment manuals & certification & traceability dossiers • Hyperlink : http://www.engineersaustralia.org.au/ieaust/index.cfm?4B274629-D2B5-F3D1-EC4C-DA5201D2A5E5
Current Opportunities and Activities • Integration with electronic permit to work system • Integration with handheld devices • Use of Radio Frequency Identification (RFID) • Photogrammetry and Media Galleries • SAP Integration Portal • Integration of Sub sea GIS / GPS Technologies • People / location management • Conversion to SP P&ID legacy Assets • Establish Digital Plant requirements with our EPC’s • Influence ISO 15926 Direction
Success factors • Understand Human Behaviour – “what’s in it for me” duck management • Drive Intuitive solutions – “Internet banking approach = less training” • Drive System (software) Integration – “configuration not customisation” • Embrace Operations and Maintenance processes • Demonstrate financial returns • Standardise Metadata – “Google type wildcard search” • Standardise standards and deviation process – “one size fits all” • Draw the line – “Address legacy data separately” • Use “internet” portal technology • Drive process through “Engineering” not “IT”
EDM Discussion Points • EPC’s to Owner Operator data alignment • Driving emerging engineering software solutions • The benefits of moving to a HD digital plant