Ep Plant Asset Information Lifecycle Management

8/10/2019 Ep Plant Asset Information Lifecycle Management

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Plant Asset Information Lifecycle Management 2

EXECUTIVE SUMMARYIn todays highly competitive global economy, plant operators in the Energy, Process & Utilitiesindustry are under constant pressure to maximize output while minimizing costs. In addition,they are facing increasingly stringent regulatory requirements for environmental, safety, andsecurity issues. These requirements impose signicant penalties, including plant shutdowns,should plant operations fail to comply.

For several years, plant operators put in place organizations, as well as information systems,focusing on specic processes, but without providing a global end-to-end view of the plantlifecycle. To operate effectively and efciently under these demanding conditions, plantoperators need to implement new best practices and processes with supported solutionsthroughout their organizations.

This paper examines Plant Asset Information Lifecycle Managementwhat it is, how it tsinto an existing plant information system, and the benets it provides to plant owners bynot only signicantly increasing the value of plant information systems, but also optimizingoverall asset performance. The paper also emphasizes the value provided by an efcient DigitalPlant to support activities related to projects, to assets, and any kind of related information,such as records and reference data.

Rapid retrieval of given equipmentposition in the Digital Plant


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THE CURRENT INFORMATION SOLUTION DOES NOT FULFILL OVERALL PLANTOWNER NEEDSEnergy, Process & Utilities is an asset-intensive industry. It requires huge investments (CAPEX)to build new plants or modify existing ones, as well as signicant costs (OPEX) to safely operatethese facilities. The hope is that plant operations will produce energy or other valuable end-products that generate good revenue and make this a protable business with a positive end-to-end Return On Assets (ROA).

ROA is the ultimate key performance indicator (KPI) of overall plant lifecycle:

At the initial strategic planning stage, the plant owner needs to evaluate the expectedROA of a potential new facility or the revamping of an existing one. To launch such aplant project, the ROA needs to exceed the companys target rate for investment with theassociated level of risk.

Then the plant owner needs to measure and manage this ROA over the entire life ofthe facility to ensure protability of the investment. After the three- to ve-year plantconstruction project investment phase, most of the effort centers on optimizing the long(30 to 60 years) operations and maintenance phase, where benet or loss is realizeddepending on operational performance.

1. The challenge of organizationThe plant owners main objective is to get the best value from their operations while minimizingmandatory costs related to maintenance, regulatory compliance, and safety. They put in placea specic organization inside the plant to manage those activities. The only focus and objectiveof this organization is to generate acceptable net income from the use of the facility, focusingon trying to optimize overall plant equipment effectiveness (OEE = Utilization (%) x Rate (%)x Prime (%)). The organization is divided into two major groups that are in charge of separateprocesses with different goals and performance measurements:

Operations is in charge of optimizing production. Operators are responsible for using theasset to produce energy. They are measured against quantity, quality, and unit costs.

Maintenance is in charge of keeping the asset operational and improving it. Maintenancepersonnel are measured against availability lifetime (capability relative to specications).

These organizations do not share the same objectives. They mostly work independently. Yet theROA of the plant (the ultimate KPI) depends on the overall interconnected performance of thesetwo activities.

Plant owners also put in place another organization (at the plant and/or company level) tomanage asset investment. This organization is responsible for project activities. Its objective is tominimize CAPEX and optimize project scheduling.

2. The challenge of the plant information systemDuring the last two decades, plant owners have implemented Plant Information Systems tocontrol the daily, weekly, and monthly activities related to operations/production, as well astracking safety, traceability for audit, and equipment maintenance to ensure the best utilizationrate for the longest lifetime.


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Current Plant Information Systems are very efcient at handling activity records that showtransactions of events:

Real-time/on-time status: project status, production status, procurement, inventory, etc.

History: project history, production history, maintenance history, inspection records,incident reports, people certications, etc.

Commercial: nancial analysis, purchasing records, warranty and repair records, operation

and maintenance service agreements, etc.However, these systems are not suited to manage lifecycle-related asset information, the KeyReference Data that requires management of changes:

Functional: process specications, process models, process calculations, ow diagrams,equipment calculations, equipment specications, and functional designs

Design: process design, piping and instrumentation diagrams (P&ID), equipment layout,as-installed bill of materials (BOM), and as-maintained BOM

Procedures: project management, installation tests, description of operations, operatingprocedures, inspection and maintenance procedures, certication requirements, andlockout/safety requirements

To achieve higher operational efciency and improve asset utilization, organizations need toupgrade the traditional Plant Information System and enable it handle and manage valuablelifecycle-related information and related processes.

Process specications: P&ID(Piping and InstrumentationDiagram)


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PLANT ASSET INFORMATION LIFECYCLE MANAGEMENT(THE DIGITAL PLANT APPROACH)Organizations must go beyond traditional plant Information Systems and move to a more global

Virtual Asset/Digital Plant approach to obtain the best value from the facility. Information playsa vital role. For many people working in the plant itself or supporting it, the information theycan access is their only interaction with the physical asset. They need current information tounderstand how to best operate the facility and how to diagnose defects.

The Digital Plant must be comprehensive, accurate, and exible to enable these users to accessand use information efciently. It must contain all the information that any stakeholder wouldneed to answer any reasonable question about the asset and its performance at any time.

Even though the lifecycle of an asset is traditionally represented using a linear stage gateapproach, this is not the case in real life. Projects and operations need to work together andbe presented with the help of an efcient, integrated information system for the Digital Plantthat can:

Handle project information management and asset information management

Handle any kind of informationactivity records and key reference data

Enable project performance management and asset performance management

Virtual Reference PlantLife-like Virtual Plant Experienceto access Plant Information

Multi-Views and DisciplinesPlant ModelExtensible reference data model tostructure asset information withmulti-views and disciplinesthrough lifecycle and changes

Real-Time Indexingand OrchestrationConnect and index heterogeneousreal-time information sources

The Plant Asset Information Lifecycle Management (PAILM) system is the backbone of theDigital Plant. It enables integration of inter- and intra-enterprise capabilities and technologies.

The Digital Plant must handle the following operation and maintenance processes:

Production management Operation management

Quality management

Facility management

Health, Safety, and the Environment (HSE) management


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The Plant Asset Information Lifecycle Management should cover the followingsupport functions:

Document and data management

Change management

Security management

Human resource management

Procurement management

The Digital Plant must enable relevant data to be pulled from legacy business systemssupporting most of those processes (ERP, SCM, CRP, ECM, EAM, SCADA, OTS, Historian, MES,LIMS, etc.), as well as provide these additional valuable technologies to accelerate improvement:

Plant Design, 3D models, and laser scanning

Tagged Item data model that enables lifecycle management of all plant objects

Active 3D models that can simulate equipment assembly, as well as material beingprocessed into nal products

Virtual reality 3D models that enable simulation of human avatars executing criticaloperation and maintenance tasks

Process models of plant operations that enable simulation of new control strategies

Equipment information consistentfrom database to 3D layout


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Ultimately the Digital Plant should be a relevant collection of valuable technologies andapplications, and superintendent (and more), providing an efcient cockpit to monitor the plantbusiness with the following critical capabilities:

Event and corrective action module to get reports on any non-conformance (any conditionthat is undesirable) in the plant related to process, equipment/instrument, and persons, aswell as the related corrective actions.

Indicators module to monitor plant performance. Performance indicators are calculated usingprocess and equipment data on various time bases and with various presentation formats.

Configuration module to manage the changes that occur in the plant over time relatedto hardware and procedure. These changes go through various stagesfrom initiation toreviews, approval, implementation, issue, certication, and maintenanceand need to bemonitored.

Plant documentation

Instruction for maintenance on asimulated operating plant


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DASSAULT SYSTMES PROVIDE BEST-IN-CLASS TECHNOLOGIES TOIMPLEMENT THE FULL DIGITAL PLANT ENVIRONMENT

Dassault Systmes Safe Plant Operation 3DEXPERIENCE provides an end-to-end virtualplant operation approach to create the Digital Plant

The Safe Plant Operation 3DEXPERIENCE leverages the Dassault Systmes ENOVIA PlantAsset Information Lifecycle Management system as the backbone to the Digital Plant


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Our 3D EXPERIENCE platform powers our brand applications, serving 12 industries, and provides arich portfolio of industry solution experiences.Dassault Systmes, the 3DEXPERIENCE Company, provides business and people with virtual universes to imagine sustainable innovations. Its world-leadingsolutions transform the way products are designed, produced, and supported. Dassault Systmes collaborative solutions foster social innovation, expandingpossibilities for the virtual world to improve the real world. The group brings value to over 170,000 customers of all sizes in all industries in more than 140

countries. For more information, visitwww.3ds.com .

Europe/Middle East/AfricaDassault Systmes10, rue Marcel DassaultCS 4050178946 Vlizy-Villacoublay CedexFrance

AmericasDassault Systmes175 Wyman StreetWaltham, Massachusetts02451-1223USA

Asia-PacicDassault Systemes K.K.ThinkPark Tower2-1-1 Osaki, Shinagawa-ku,Tokyo 141-6020

JAPAN

THE VALUE (ROI) OF PLANT ASSET LIFECYCLE INFORMATION MANAGEMENTPlant Asset Lifecycle Information Management creates a collaborative virtual asset infrastructurethat enables efcient management of physical and human assets. It provides business benetsand Return On Investment (ROI) in ve domains:

Capital project savings

Production cost savings

Information Technology cost savings Improved organizational efciency

Increased revenue

Better management of information across the asset lifecycle could help your organization realizethe following savings:

Management of change savings: 2-3% of CAPEX

Interoperability savings (during construction, test, and handover): 1% of installed cost,mainly for EPC

Operation & maintenance savings: 3% of asset value (30% of improvement inmaintenance efciency)

Equipment update savings on old facilities: 30% of engineering costs

To learn more about Dassault Systmes and experience our cutting-edge3DEXPERIENCE solutions, visit www.3ds.com/industries/energy-process-utilities

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Ep Plant Asset Information Lifecycle Management