Dummies Guide to Engineering Data Management for Owner Operators. Dr Bill Van Butzelaar & Richard Harris Production Division

Transcription

1 Dummies Guide to Engineering Data Management for Owner Operators Dr Bill Van Butzelaar & Richard Harris Production Division

2 Disclaimer and important notice This presentation contains forward looking statements that are subject to risk factors associated with oil and gas businesses. It is believed that the expectations reflected in these statements are reasonable but they may be affected by a variety of variables and changes in underlying assumptions which could cause actual results or trends to differ materially, including but not limited to: price fluctuations, actual demand, currency fluctuations, drilling and production results, reserve estimates, loss of market, industry competition, environmental risks, physical risks, legislative, fiscal and regulatory developments, economic and financial market conditions in various countries and regions, political risks, project delay or advancement, approvals and cost estimates. All references to dollars, cents or $ in this presentation are to Australian currency, unless otherwise stated. References to Woodside may be references to Woodside Petroleum Ltd. or its applicable subsidiaries. Slide 2

3 Strategy for Greenfield Projects Project ALIS (VNET Engineering Portal) Owner Operator Engineering & Design Phase Operate & Maintain Phase Sub Projects Onshore Pipeline Progressive Data Transfer: QA Data Population of Operational systems Operations HSE, Competency) Procurement Materials Mgt Topsides Subsea Facilities Maintenance & Inspection Maintenance Mgt Turret / Mooring Well Constr n Project Domain Corporate Domain Engineering Engineering Systems Project DMS Progressive Document Transfer: Controlled Drawings For Operations Controlled Documents For Operations 1 3 Years 3 40 Years Corporate DMS Slide 3

4 Evolution of data management Cave Paintings Main Frames Desk & Laptops Stone Tablets Scrolls & Books Hand Held PC s Slide 4

5 EDM Engineering support NRA & NRB GWA Angel Cossack Enfield EDM Facility Overview Pluto Offshore Northern Endeavour Thylacine Vincent KGP Otway Pluto Onshore Slide 5

6 EDM Team 2009 Management Core Team Contract Support Richard Harris Team Lead Bill van Butzelaar Business Improvement Manager Snr Intergraph Eng VNET Portal Administrator ALIS/VNET VPE & Data Hub Administrator, IT Eng 2D/3D, PDS,PDMS, Microstation, AutoCAD Snr Des Eng Snr Instrument & Electrical Eng Conversions, & Legacy data Snr Designer 2D & Database Systems Process Systems Engineer 2D Eng Data Coordinator EDM Services 2D Legacy Data & Software Developer Electrical Engineer Data Team B Instrument Data Conversions / CDRP Corporate Information Management Group (DRIMS) Data Team A ISSoW / P&IDs / legacy Electrical Engineer EX data Slide 6

7 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 Slide 7

8 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 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 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 Slide 8

9 EDM Roadmap - Operations 1. Define key engineering deliverables, and develop process maps 2. Revise engineering standards & guidelines to reflect today's requirements 3. Develop a single metadata profile 4. Deploy a fully integrated suite of engineering design tools, and engineering software system & libraries ( VNET, VPE, VP P&ID, Instrument db, Electrical db, Data Hub, PDS, PDMS) 5. Implement common software platforms 6. 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 10. Measure, evaluate effectiveness & achieved cost savings Slide 9

10 EDM Roadmap Brownfield and Greenfield Projects Brownfield Projects Deploy software systems & standards Provide project access to Portal & design tools Train & develop internal resources Support projects, review implementation, fine tune Greenfield Projects Promote WEL software systems Enforce standards Provide up-front information engineering support Ensure our engineering library is adopted (VPE, SPF, E-Warehouse) Issue seed files (VPE, VP P&ID, Instrument, Electrical, Data Hub) to EPC's Slide 10

11 Engineering Portal relationship to EDM applications SAP PM Engineering Portal (ALIS) PHD SAP LOAD TOOL DMS Data Publishing Engineering Instrumentation Intelligent 3D 2D database database P&ID Model CAD Document publishing Slide 11

12 Engineering data interfaces ALIS (VNET Engineering Portal) VPE SAP-PM Equipment Nameplate Data Virtual Bookshelf DRIMS D.M. S AVEVA Products System Datasheet s, Key Lists, 2D & 3D 2D 3D Mechanical Approved SAP Measuring points X1 Approved Data Hub System Data sheet s, Key Lists, 2D & 3D Excel Bulk Datasheet Load Tool Approved Photogrammetry Intelligent VP P&ID 3D Model PDMS Excel DS Eng Design Process Case1 Case 2 Case 3 3D Model PDS Intelligent P&ID Comms Tele & Security Instruments System Electrical System Woodside Engineering Library Slide 12

13 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 Slide 13

14 Operations Information Management Standard (OIMS) OIMS Operations Information Management Standard Operations Information Creation and Updating Standard Metadata Standard Archiving and Destruction Standard Numbering Standard E-VEM Standard VNET (ALIS) Standard 2D & 3D Models Standard Electrical, Instrumentation & Data Hub Standard VPE VP & P&ID Tagging Standard (Corporate) Engineering Library PBS Plant Breakdown Structure MDR Standard ALIS Portal Guideline 2D & 3D Models Guidelines Electrical, Instrumentation & Data Hub Guidelines Eng SAP-PM Standard VPE VP & P&ID Guidelines ANG COS GWA KGP NE Corporate Datasheets Datasheet Web Validation Tool Plant, Area, Unit & System Coding Eng SAP-MM Standard NG NRA OTW Slide 14

15 Legacy Data Migration 2D Drawings Documents & Drawings Datasheets Excel & Access Microfilms Electronic Hard Copy Electronic Key List Engineering List OCR Create Tag Relationships Scan to PDF Scan to PDF OCR Populate Engineering Master Repositories Create Tag Relationships Create Tag Relationships Create Query Forms Key Lists ALIS (VNET Engineering Portal) Slide 15

16 EDM Project: January 2005 to October 2009 DAD SPI * 3D CAD Engineering Workbench Line List, Datasheets Intelligent P&IDs 2D/3D Management Laser Scanning & Photogrammetry Maintenance SAP PM DRIMS Documents & Drawings (Operations) SubSea Database Subsea Inspection SAP MM (not implemented) Procurement Production PHD ALIS (VNET Engineering Portal) Complete Planned Slide 16

17 Strategic Management Slide 17

18 Engineering Standards Slide 18

19 Process Mapping Slide 19

20 Engineering Portal Configuration Slide 20

21 EDM Photogrammetry Slide 21

22 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 v1 Thrust Pad Normal v2 Half Moon Thrust Pad Thrust Pad Carrier Thrust Pad Shoes 2009 Major Shutdown HP Tilting ad Brg 4U HP Tilting Pad Brg 4L HP Tilting Pad Brg 4L Tilting Pad Assy Brg 4 Scaffolding Arrangement Lifting Beam Install Scaffolding Arrangemet Enclosure Scaffolding Enclosure Scaffolding HP Stators Topside Slide 22

23 Return On Investment Quantified Benefits: 1. 10% more efficient Information Searching 2. 86% more streamlined Data Handover 3. 93% reduction in Supported Applications 4. 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: Slide 23

24 ROI Payback Period Net cumulative current value benefits Payback period Woodside s EDM project achieved full payback in 3.4 years or by mid 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. Slide 24

25 Keys to success Total and effective users including contractors Describes the number of existing and new Woodside Portal users per annum; including contractors. In the initial years of the implementation it is assumed that due to user inexperience and the amount of data in the system at the time, the full benefit of the system may not have been realised. To account for this, the number of users have be multiplied by an effectiveness rate. This rate was assumed at 50%, 60%, 80%, 90%, in years 2005, 06, 07, 08, respectively. Full user effectiveness (100%) was assumed from 2009 on. The Effective Users have been used for calculations when total users are required. New users are people who are new to using the system in a given year. This was determined by the additional users added each year, plus the replacement of existing users due to attrition. Slide 25

26 ROI Cost Reduction Slide 26

27 Award Winning Performance! 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 electronic information asset was delivered within an integrated VNET Angel Project Portal ( branded in Woodside as ALIS Asset Lifecycle Information System). 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. Slide 27

28 Angel Platform - Engineering Excellence Award 2009 Integration of information was primarily via a tag paradigm & included access to & from the following: ƒ. Intelligent P&IDs ƒ. 3D models ƒ. Computerised Maintenance Management System ƒ. All engineering data ƒ. Documents and drawings ƒ. Subsea Inspection System ƒ. Geographical Information System (GIS). ƒ. Photographs ƒ. Equipment manuals & certification & traceability dossiers Many of these engineering applications were new. All information was progressively passed into the Woodside systems after quality checks were done. It was a benchmark, with 100% of all project information established within the Woodside systems at the ready for start-up phase, including all hazardous area inspection and pressure safety valve certification. The project integrated the asset information, which traditionally has been restricted to topsides plant, with all the substructure (jacket) and Subsea infrastructure. The project 3D models were the prime mechanism to navigate this information, using associations with relevant information and systems. For Subsea, this included integration with the Subsea inspection system (COABIS) and the GIS. All 3D models were as-built and fully tagged with x-refs, an innovation for the industry. Hyperlink : Slide 28

29 EDM Statistics Tag Association References Physical tags in ALIS Otway, Angel, Cossack, Enfield, GWA, Angel Cossack Enfield GWA Karratha Northern End NRA Otway Otway, NRA, Angel, 8000 Cossack, Enfield, Angel Cossack Enfield GWA Karratha Northern End NRA Otw ay Total Total Documents in ALIS ALIS - Daily Page Requests Northern End, Otway, Angel, NRA, Cossack, Enfield, GWA, Angel Cossack Enfield Angel, 5723 OTW, 2234 NGA, 3578 NE, 3839 Pluto, 820 NWS, NWS KGP Angel Karratha, GWA Karratha Northern End NRA KGP, NE NGA OTW Otway Pluto Total Total Slide 29

30 Current Opportunities and Activities 1. Integration with electronic permit to work system 2. Integration with handheld devices 3. Use of Radio Frequency Identification (RFID) 4. Photogrammetry and Media Galleries 5. SAP Integration Portal 6. Integration of Sub sea GIS / GPS Technologies 7. People / location management Slide 30

31 Success factors 1. Understand Human Behaviour what s in it for me duck management 2. Drive Intuitive solutions Internet banking approach = less training 3. Drive System (software) Integration configuration not customisation 4. Embrace Operations and Maintenance processes 5. Demonstrate financial returns 6. Standardise Metadata Google type wildcard search 7. Standardise standards and deviation process one size fits all 8. Draw the line Address legacy data separately 9. Use internet portal technology 10. Drive process through Engineering & not IT Slide 31

32 EDM summary & Digital Plant Philosophy Allows you to Slice Information The Digital Plant Dice s Information The Digital Plant Even Comes with a Set of Steak Knives Limited Offer first 5 customers See details for terms & Conditions of Supply Offer ends Slide 32

33 Engineering Data Management Questions & Answers! Slide 33