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By: AJAY Mathur Managing Physical Assets to deliver business outcomes cost effectively Mumbai 12/10/17 Slide1 ENGINEERING SERVICES SOLUTIONS

ENGINEERING SERVICES SOLUTIONS Managing … · Managing Physical Assets to deliver business outcomes cost effectively ... SAFOP, System Assurance and Reliablity Solutions NEBB Certified

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By: AJAY Mathur

Managing Physical Assets to deliver business

outcomes cost effectively – Mumbai 12/10/17

Slide1

ENGINEERING SERVICES SOLUTIONS

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

AGENDA

1. Background

2. Cx Requirement

3. How Cx helps in AM

4. Challenges and opportunities

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

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OUR 21ST CENTURY WORLD

• We live in complex , 24x7 world

• Critical infrastructure include:

➢FPSO/RIGS/Refineries

➢Rail/Airports/Ports

➢Power Generation

➢Data Centre/Telecom

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OUR WORLD

– Any failure or Downtime is not acceptable!

• Fukushima’13/Chernoby’86

• Piper Alpha’88/GOM Deepwater Horizon’10

• BHN (Bombay High North) Platform Fire;05

• Texas City Refinery’05/Union Carbide ‘77

• US Northeast power blackout ‘03

• Mumbai Flooding during monsoons

– This means asset should be in managed well through its life cycle

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Cx and ISO 55000

• ISO 55001 AMS also covers the design, construction, commissioning, O&M and decommissioning / replacement of plant, equipment, facilities, as well as fixed assets and digital / IT assets

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IS0 55500 and Cx

• The standard spells out the general principles for good management and governance of the AMS and processes.

• However, it leaves it up to the owner operator to decide how and at which level of detail to implement the standard.

• So Cx gets limited attention in AMS

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Managing Risk with Assets and make them Profitable

• Commissioning is a Key Element of AMS which impacts an assets ROI

4 O

& M

3 Test &

Comm

issioning

2 Plan and

Construct

1 Design

&

Procu

re

5 Retire/Decommission

ASSET MANAGEMENT

AND

COMMISSIONING

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Why Commissioning makes Sense!

Lif

e C

ycle

Co

st %

100%

50%

20%

2YEARS 3Month 20 Years1

Year

Design and ConstructAcquire

CO

MM

ISS

ION

ING

O&M

Re

tire

an

d

recy

cle

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

Commissioning : Not a New Field

ClientCommissioning

Engineer

Construction

Team

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12

Project Development: Typical Project Framework

Project Planning Project Implementation

Evaluation &

Definition

FEED

Contracts

PEP

Estimate

Engineering and Procurement

Fabrication

Construction

Commissioning

Operations

Startup

Concept

Project Approval

Plan the

Work

Work the

Plan

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Commissioning Process

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CONTRACT REQUIREMENTS

DRAWINGS

PROCESS/SYSTEM

DESCRIPTION

FUNCTIONAL SPECS

O&M MANUALS

SIMULATIONS

FMCEA/RELIABILITY

APPOINT CX MANAGER

PREPARE CX PLAN & SCHEDULE

PREPARE MOS & SOP

PREPARE CHECKLIST

ALIGN CX & CONSTR. SCHDL.

PRE COMMISSIONING PHASE 1

MECHANICAL COMPLETION AS BUILT

DRAWINGS

INSPECTION RECORDS

PERFORMACE GUARNTEE INFO

PUNCH LIST

WISH LIST/NICE TO HAVE

PERFORMANCE OPTIMIZATION

TEST RECORDS

OPERATE COMMISSIONING

PHASE 2(DRY)

INTEGRATION/RELIABILITY/ACCEPTANCE TEST

COMMISSIONING PHASE 3 (WET/ERFORMACE)

INPUTS OUTPUTSCOMMISSIONING PROCESS

FORM CX TEAM

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

Cx examples

• Sub Sea Tunnel Fire Test

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Cx examples

• EHV Power Cable Tunnel- Integrated Cx

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Cx examples

Metro train

–Interference Performance

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Cx examples

• Semi Sub Rig

-Thruster String

VFD

Make- SIEMENS , 4160V,

3 Phase,60Hz 4000kw,

Star, 680A, pf-0.84,

Duty –Single Quadrant Vector Drive,

11 KV,3ph, 60 Hz.

MV

SWITCHBOARD

FLEXIBLE

CT

HIOKI

LOGGER

M

THRUSTER 6

Make- LOHER, 4160V, 3

Phase,60Hz

4000kW, Star, 680A,

pf-0.84, Duty -S1,

2x 3core,

3 phase

cable

THRUSTER TRANSFORMER

Make- TRANSFOR, 4800kVA, 3 Phase ,60Hz

V1-11kV (225A)/2200V(638A), Dd0.25

V2-11kV (225A)/2200V(638A), Dd11.25

DC

FLUKE

LOGGER

FLEXIBLE

CT

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

Cx examples

• BSL Lab

- Energy Performance

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Cx Examples

• LNG Plant

- Gas Metering Validation

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ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

Some AM Challenges

–Teething Problems

–Premature failures and breakdowns

–Energy inefficiency

–High Opex

These issues are linked to Cx!

Proper Cx can go long way to reduce impact on above issues

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Challenges in Infra CX

• Project never gets 100% complete

• Start up loads/output • Optimization challenge• Long infra life 60-100 years• High Cost of Decommissioning

( Nuclear/offshore > OPEX)

• Continuous upgrade• Needs continuous Cx

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Future Opportunities

• AM plans must align with Cx standards that guide investment and mesh with overall strategy.

• AM Strategies that have adopted Cx and Continuous Cx report strong

benefits and satisfaction.

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Conclusions

• The current state of both Cx and AM is far from ideal, leaving companies/govt exposed to greater costs and risks than necessary.

• India as fast developing infrastructure economy has is in right moment to embrace AM and Cx

• EPC and BOT contracts could benefit by incorporating AM and Cx process as part of project delivery

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Queries?: Mr. Ajay Mathur, B. Eng, M.Tech., M.Sc.Hp: ++ (65) [email protected]

Your Partner for Engineering

Services & Solutions

www.PowerQTech.com [email protected]: (65) 67790225 Fax: (65) 67790155

21 Bukit Batok Crescent #07-73WCEGA Tower, Singapore 658065

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Speaker Profile

• Technical Director in PowerQ technology Pte Ltd Since 2000

➢ B.E. , M.Tech. degree –India

➢ M.Sc., NUS

➢ BOSIET Certified for Offshore

➢ NEBB USA Certified for Cx Professional

➢ BCA - CSCPM

• Involved in Cx of following projects :

➢ Pharma (GSK, Novartis, Abbott,Pfizer, Roche)

➢ Biosafety labs (GSK, MSD)

➢ Tunnels ( 400kV Tx Tunnel, MCE Tunnel)

➢ Semiconductor plants (Micron, Samsung Siltonics, Seagate)

➢ Oil and Gas ( P81 Platform, Neste Oil refinery)

➢ Buildings (MBS, SSH, Terminal 4)

➢ Metro (MS-RTS/Jakarta LRT), Metro CD shelter

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About PowerQ

▪ Inc. in 2000 as Pte Ltd Co in Singapore.

▪ Co. Reg. No. 200003680R

▪ ISO 9001, OSHAS1801and NEBB USA Cx certified

▪ Active in Projects in Asia

▪ Equipped with Software, Instruments and trained design and engineering staff

▪ Professionally audited Company

▪ Company, Staff and Third Parties insured

▪ Investment in own office, vehicles etc.

▪ Proven track record

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

About PowerQ

▪ Inc. in 2000 as Pte Ltd Co in Singapore.

▪ ISO 9001, OSHAS1801, Biz Safe Star and NEBB USA Cx certified

▪ Active in Projects in Asia

▪ Equipped with Software, Instruments and trained design and engineering staff

▪ Professionally audited Company

▪ Company, Staff and Third Parties insured

▪ In house Clean room, Labs etc.

▪ Proven track record

ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS

PowerQ Services

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PowerQ technology Pte Ltd operating through Singapore

Since 2000

Services

Projects and Commissioning Management

Specialized Engineering Consultancy.

SKM/ETAP/EDSA Power System Design and Analysis.

Electrical Power Quality EMF/EMC Quality Solutions

SAFOP, System Assurance and Reliablity Solutions

NEBB Certified Commissioning of Mechanical, Environmental ,

HVAC & Plant Utilities System.

Control System Integrated Testing.

Plant Operation & Maintainenece Audits, Validation

Troubleshooting & Optimization

www.powerqtech.com