R. Eric Bevevino, Business Manager, Industrial and Integrated Solutions, ChevronTexaco
Learn how a newly developed, web-based, lubrication-focused CMMS can effectively address the often-missing aspect of lubrication in today's mainstream CMMS offerings. The large expense and time needed to develop a CMMS-specific lubrication module can be avoided. Whether you are using this newly developed software or developing your own module, this session describes the critical success factors for development and desired outcomes of a fully functional lube management CMMS.
Jehu Burton, Project Manager, Dupont Engineering
Data integration has become a key component of both Facility Life Cycle Data Management and interoperability. This presentation will discuss why this is important from an Owner/Operator's perspective, and introduce recent action taken by a group of process industry representatives to drive forward a common process industry data integration strategy.
Brian Chang, Chairman and Chief Executive Officer, Yantai Raffles
Integrated PLM (Product Lifecycle Management) is the combination of several methodologies and of digital applications on a common platform and environment. When integrated PLM is applied at the initial stage of the product (project), where most of the delivered cost and product quality is committed, the returns can be significant. "Front loading," and therefore digital analysis during the basic design phase of the product behavior during different operating conditions, results in delivery of a fit and optimal product. The integrated digital environment, where all data resides in the same system, allows for shortened simulation times and guarantees a higher product quality level within the vice-like timeframe of proposal making. High quality and optimal product cost are among the top priorities of Yantai Raffles. We have employed integrated PLM and are providing our customers with the ability to digitally validate the quality of our designs before they are manufactured. This presentation shows several simulations in an integrated PLM environment of an innovative offshore platform design. The strength requirements of this SSP vessel are analyzed and checked by designers in parallel with the design progression. Moreover, without any data transfer, structural analysis is extended to complex CFD (Computational Fluid Dynamics) simulation, in the event that the vessel is in severe weather conditions. Crash simulation of the vessel with an oil tanker is also performed. Finally, the downstream design progression and the collaboration between the design office and the owner are demonstrated.
James Close, Senior Systems Analyst, Alstom Power Inc.
The design of fossil steam generators (otherwise known as boilers) has CAD requirements that do not fit cleanly into any one CAD system genre. There is a similarity in this to shipbuilding, except the "hull" is on the inside and the "plant" is wrapped around it. Currently, plant modelers do not perform well with high detail MCAD data, and MCAD systems cannot handle the volume of data in a plant modeler. This presentation addresses the need for a careful balance to produce/translate models to an efficient representation for a given task, without adding undue overhead. It will also address the challenges presented by the management of multiple representations.
Troy Di Natali, President and Principal Engineer, READCo, Inc.
After years of powerful natural disasters striking the Gulf of Mexico and inflicting severe damage on offshore oil and gas production platforms, rapid and efficient recovery and restoration strategies have become imperative to the success of the industry. In September 2004, ChevronTexaco's Petronius Deepwater Platform was devastated by Hurricane Ivan, sustaining damage to production equipment, deck structures and crews' quarters. The platform was totally shut-in for several months following the event. This presentation discusses how new laser scanning technology (LADAR) was used to assess the damage on Petronius to accurately evaluate engineering design options and also explores the techniques used by READCo to shorten the rehabilitation and restoration process, comparing these with traditional methods. Laser scanning and the associated engineering workflows reduced the platform shut-in time by as much as 26 days as compared with using traditional methods. It outlines the scope of work including dimensional control, 3D modeling, forensic analysis and the repair engineering design.
Tim Finigan, Senior Director, Performance Technologies, Operations & Maintenance, Fluor Corporation
This presentation depicts a structured methodology for assessing, planning, and executing operational and support requirements necessary for the operational lifecycle phase of a new capital asset program. The presentation focuses on operational readiness planning to minimize risks associated with startup and launch, while simultaneously driving operational programs based on best practices to optimize lifecycle asset performance. To reach targeted levels of production, thousands of tasks must be accomplished and deliverables prepared. Achieving planned startup depends on managing these challenges. The speaker reviews a comprehensive set of startup methodologies that enable new plant launches to reach production and quality targets as soon as possible after startup, while meeting or exceeding the financial plan for a new facility. This process includes a Risk and Readiness Review (R&RR) to integrate the risk assessment with readiness reviews performed in parallel with the program’s front-end engineering design and following through all EPC phases, from design through production startup. This ensures that expectations, responsibilities, and operations and maintenance needs are identified and addressed prior to startup.
Participants will come away with information about achieving successful startups of a significant capital investment through a structured process that includes Risk Assessment and Readiness Review and other service modules, each of which is designed to fulfill specific startup requirements.
Ziyad M. J. Ghulam, Engineering Drawing Services, Saudi Aramco
During the design stage of mega projects, the contracted engineering firms use intelligent design applications to cut the design cost and to deliver accurate design information in the shortest possible time. At the end of the project, the engineering database and the 2D drawings are to be used for the construction, operation and maintenance of the industrial facility but the turnover of these design databases have not been successfully used by operations and maintenance departments. This session will address the concerns from the plant operator point of view.
Jerry Gipson, Director of Integrated Engineering Solutions Technology Center, Dow Chemicals
In the global, competitive, and ever-changing environment in which the industry operates, there is a strong requirement for sustained focus on both continuous and step-change improvement. Engineering workflow and plant asset lifecycle management are key enablers of success for the larger enterprise. For the past five years, Dow Chemical has been engaged in an ambitious program with Intergraph to develop and implement next-generation tools, methods, and data integration schemes, which will enable a higher level of long-term performance for the industry. While continuing with a strong shared vision and commitment to success, Dow and Intergraph have also learned together, ultimately enhancing the understanding of long-term solutions and the probability of success. In revisiting the original drivers, progress to date, key learnings, and path forward, the intent is to facilitate further dialogue, consensus, and cooperation within the industry, standards groups, and solution providers.
Rosli Abdul Hamid, CEO, GB3 Sdn. Bhd & Head of LCAIM, Malakoff Berhad
In 2004, TJSB decided to implement a world-class lifecycle asset information management process and system (LCAIM). The main objective of this implementation was to ensure the availability of all information, in the form of structured data, required for quick decision-making in operation and maintenance. In order to evaluate the methods and tools to use, TJSB first launched a pilot project at the Lumut Power Plant, located on the west coast of Peninsular Malaysia. TJSB was able to restore a major part of engineering data and plant documentation through this pilot project. To achieve the desired result, all information was consolidated inside a state-of-the-art engineering environment, which TJSB then linked to both the plant control system and their SAP-based maintenance management system. As a basis for streamlining the information-gathering and consolidation processes, TJSB employed international standards, particularly the ISO 15926 Reference Data Library and the IEC 61355, to classify the O&M documents. Due to the huge success of this pilot project, Malakoff Berhad / TJSB have decided to implement a complete LCAIM approach in one of their new projects, viz., the Tanjung Bin 3x700 MW coal-fired power plant located in southernmost part of Malaysia, opposite Singapore. For this project, the NIST Capital Facilities Information Handover Guide (CFIHG) was used in addition to the tools and methods developed for the Lumut Power Plant. The first part of this presentation will focus on the very first successful example of using these standards in the electricity supply industry. The presentation will highlight the benefits that accrue to the users of LCAIM. It will focus on the importance of establishing LCAIM early in the EPC phase to achieve best results. Specifically, TJSB will explain how it runs an engineering environment side-by-side with its EPC contractor to minimize information erosion during the project, before the actual hand-over of the plant.
Dirk Hanewacker, Head of Business Development, Alstom Power
Alstom developed a methodology for managing plant lifecycle complexity from customer specification to products & plants in operation. This includes integrated project management, integrated engineering (including suppliers), logistics-transport and information asset management. Transparency during the entire EPC phase avoids margin deterioration and enables preventive actions and structured hand over procedures from sales to execution and from EPC to O&O. This, in turn, saves time and money. Up-front investments in project management and engineering pays off across the entire lifecycle information chain -- product structuring and hand over capability between tender/engineering/procurement/construction & operation reduces cycle time by 30% and total costs by 15% to the EPC. In essence, Alstom can deliver two working plants: one in data & one in steel.
Dean Harvey, Global Technical Training Manager, Applied Technologies, Baker Energy
With the price of oil hovering around $60 a barrel, reaching first oil as quickly as possible is a primary goal for the major energy companies in the offshore segment. To do so requires a team of operators that can hit the platform running. Getting access to the offshore platform during the construction and commissioning phases for operator training and assessment is a difficult and expensive endeavor. Learn about a state-of-the-art multimedia training application and methodology as it was applied to operator systems training and competency assessment on the ExxonMobil Kizomba B project. This new approach reorganizes engineering design and CMMS information into a virtual model to enable comprehensive plant/platform specific training to occur even before the facility is fully constructed. This presentation also discusses the cost benefits of multi-media training versus traditional training techniques and the impact to the project and asset lifecycle costs.
Raju Hingorani, Vice President, IT Operations Services, Jacobs Engineering
There are frequent discussions on the globalization of project delivery and success in workshare using technology. This presentation takes the additional step of relating the global marketplace to another critical crisis identified – the coming personnel crisis.
The global perspective that will be a required prerequisite of project delivery and the data-centric approach will make these challenges greater and simpler. Making technology leadership an element of recruiting, retention in addition to value-added project delivery, and the application of integration technology will define the strategic leaders in the industry. Jacobs is meeting these challenges today and for the future with a core value of ‘relationship’ to the customer, a focused approach to work share, and technology to leverage the quality, cost and delivery of projects to our clients.
Kevin Hunter, IT Manager, Business Solutions, Lyondell Chemicals
Lyondell Chemical has grown significantly during the last decade through mergers, acquisitions and joint ventures. Management of engineering data continues to present significant challenges. This discussion will provide insight into Lyondell's pursuit of best practices for asset information management, with a focus on the effective integration of business processes and IT solutions.
Faith Junghans, Director, Technology Communications,CH2M Hill
The transformational impact of information technology on engineering and construction has barely begun. Ever increasing global cost pressures and commoditization of services thwarts the industry from advancing technology for delivery. Our flattened world is also creating a growing demand from customers to deliver project lifecycle information, as well as sustainable and secure capital projects. Various design-oriented software tools are available today, with many espousing the benefits of a lifecycle approach. The industry mantra to 'improve interoperability' is familiar to all of us. Even so, effectively transitioning design models and data to enhance construction activities remains difficult. This session will explore the partnering between E and C on several large and small projects that is increasing return on investments for both owner/operators and EPCs. Other innovative approaches enhancing 'getting it built' that are also pushing the industry forward will be discussed. Insights as to what is and is not working will be summarized with respect to: simulation/constructability; earned value (statusing); fabrication; procurement; startup; and information handover.
Douglas H. Lenz, Director, Marketing & Sales, FALCONEER Technologies
FALCONEER Technologies LLC offers FALCONEER IV Process Performance Solution to a wide range of manufacturing industries including chemical / petrochemical, energy, and waste water treatment. FALCONEER IV provides process information management and process performance monitoring & advising. This solution helps maintenance, engineers, operators and managers to focus on the information that's most critical to control costs and operations - because it's not WHAT you know; it's WHEN you know it that really counts. And, as a senior BASF engineer explains, the process always tells on itself!
For a fraction of the cost of smart sensor technology, FALCONEER IV can transform sensors into "smart sensors" and the process into an "intelligent process" quickly for validation, reliability, fault detection, process safety & security and cost reduction. Our software monitoring solution is more comprehensive and complete than other products. With other sensor or loop or equipment condition specific diagnostic software, only about 25%-35% of plant instrumentation and process is being monitored, validated or diagnosed for problems. FALCONEER IV's high-level monitoring system & method coupled with its sensor & point level monitoring system can provide up to 100% diagnostic coverage, alarming and reporting of a plant's instrumentation, equipment and process conditions. Recent customer examples of cost savings from identified problems include ~$30,000 from one abnormal process condition alert on a thermocompressor vacuum system, ~$50,000 steam savings from failed meter identification and reconciliation, and thousands of dollars per alert in raw material and natural gas savings in waste water treatment plants.
Curtis Kelly, Senior Business Consultant, Invensys
In today’s economic environment, refineries are pushing their assets harder than ever and are dependent upon their equipment performing beyond design and for longer periods of time between maintenance. This means that the historic reactive nature of companies to equipment issues is more expensive and costly than ever. Plant operations groups need a method and a set of tools to automate performance prediction and monitoring so that they can become proactive in addressing maintenance issues before costly unexpected shutdowns occur. This presentation describes the issues and the advantages of taking the proactive approach to asset performance monitoring and improvement.
Tim Killen, Bechtel Group, Inc. (retired)
Tim Killen, Bechtel Group, Inc. (retired), will reveal his experiences, lessons learned and best practices managing under fire the fast-tracked rebuilding of the power generation and distribution infrastructure in Iraq. The challenges were immense, the learning curve was steep, and yes, it was a hostile environment. Don't miss this opportunity to learn how mega-projects are managed under extremely adverse conditions.
Junichi Masukawa, Deputy General Manager, IT Management Center, Chiyoda Corporation
As an EPC, Chiyoda participates in many mega projects such as the Six Trains 7.8MTA LNG plants in Qatar. To execute such large-scale projects reliably and to meet the new demands for better information management, Chiyoda is implementing a comprehensive plant lifecycle engineering (PLE) system. EPCs need more powerful IT systems to help them deliver the comprehensive plant asset information that owners and operators are asking for today. EPC data warehouses with multi-domain architectures are the most promising solutions for this. These warehouses as well as key issues and solutions for PLE will be discussed in this presentation.
Tony Paulin, President, Paulin Research Group
Mr. Paulin will cover two maintenance topics: 1. The analysis of a leaking flange and 2. When a shaking pipe means a leak in your future. 'The analysis of a leaking flange' will address Kamm profile, RTJ, PTFE, spiral wound and composition as the most common types of gaskets, but other types do exist and understanding how they seal can point to what is making them leak. 'When a shaking pipe means a leak in your future' addresses the fact that design codes do not predict failure. New methods by Dr. Pingsha Dong give the standard deviation from the failure line and can be readily used to more accurately predict the chance of a welded components failure due to stress.
Frank-Peter Ritsche, PMP, Project Management Initiative, Framatome ANP Germany
Framatome ANP is currently leading a $3 billion project in Finland for the turnkey construction of the Evolutionary Power Reactor (EPR) in Olkiluoto. Framatome ANP is defining its strategies toward Plant Data Life Cycle Management in preparation for the data handover to the Owner Operator, and with regard to the future markets for the EPR, especially in France, China and the US. The EPR project in Olkiluoto is one of the most significant power projects in the world today, being Europe's first new nuclear power development in ten years. The EPR design could set a new precedent in power generation in many countries and is attracting the attention of governments and engineering companies across the globe. This presentation will provide invaluable insight into the information management system that has been implemented for the Finnish and all future plant projects of Framatome ANP, as well as Framtome ANP's strategies toward Plant Data Life Cycle Management.
Jere Schneck, Director, Global Engineering, Air Products & Chemicals
This presentation will discuss benefits and challenges around the global retooling of Air Products' integrated engineering work processes and the related implementation of a new set of COTS software. The presentation will explore in detail the fragile balance among work process requirements, technology options and change management needs. Driven by the corporate SAP implementation, the objectives of Air Products' Project Phoenix were to replace front-end engineering work processes and IT tools and to standardize globally on best practices. Although there have been challenges associated with engaging several hundred impacted individuals and gaining their support, Air Products is expecting increases in productivity and reduction in project cycle time
Shashank Shah, Senior Principal Process Engineer, Air Products & Chemicals
Modular mini-plants have been on the horizon for some time now. However, the limited range of successful applications suggests that despite the attractiveness of the concept, the variety of process specifications in actual practice demands significant customization and greatly reduces potential benefits. To fully leverage the economy of pre-manufactured, mass-produced components, the principle of modularity must be taken much deeper into the process design phase. We demonstrate how such a product-based approach (PBA) leads to an innovative methodology, where plant and process design may be conducted in parallel, utilizing components with pre-determined specifications and capacities and where operational details emerge uniformly and predictably. With extensive re-use of modular components, specialized field installation, customized piping and structural design can be nearly eliminated.
Yogesh Srivastava, Senior Project Information Manager, Fluor Canada Ltd.
The interoperability costs faced by the construction and operations industry are not simply the result of failure to take advantage of emerging technologies, but also the result of a series of disconnects that exist within and among organizations. The stage is set by technology in online collaboration tools now available in the market. When exploited thoroughly, the benefits can be many, including improved project progress communications; reduced time for clarifications and managing changes; shortened time to completion; increased ownership of the work process and accountability; and improved record keeping and documentation. This presentation takes a real project implementation of an electronic collaboration process and highlights how some of the benefits have been realized in the engineering phase of a project.
Luis A. Uriarte, President, S&C Technologies
S&C Technologies, who is currently one of the world’s largest provider of laser scanning services, has executed very large revamp oil & gas projects for companies such as Petrobras. Luis will detail how S&C executed three large on-shore and off-shore 3D retrofit engineering projects in Brazil and Singapore.
John Voeller, Representative to the National Science & Technology Committee, Office of Science and Technology Policy, Executive Office of the President, Department of Homeland Security; Senior Vice President, Chief Knowledge Officer, Chief Technology Officer, Black & Veatch
The ability to leverage the information and knowledge required to design, build, operate and maintain complex facilities is child's play compared to where we are going and what will be possible. This session will discuss what is already being readied and the business implications both internally and for new forms of external interaction.
Jay West, Technology Development Manager, BE&K
This presentation addresses many questions, including what this new breed of applications/systems is; how it differs from traditional computerized maintenance management systems (CMMS); how/where it fits in the typical IT environment in an industrial plant; what functionality or capability it has; what the business value is; how it supports a plant-wide equipment reliability improvement program; who the vendors are and what you should look for in selecting a solution; what a typical project looks like and what the keys are to success. This is perfect for companies that are rolling out a reliability improvement program or are thinking/planning in that direction. The reliability movement is relatively young (for most industries) and the supporting information technology is even younger.