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FIATECH & ISO 15926: What, Why, What Else?
Nicole Testa Boston, CAEDeputy Director The FIATECH Consortium
PCA Forum and Members MeetingKuala Lumpur, MalaysiaOctober 21, 2008
Global Market Factors
Oil & gas industry will lose 60% of its employees by 201090% of engineering, procurement, construction (EPC) project work is performed outside the USA and growingThe East graduates many more engineers than Western universities (India 4:1 & China 8:1)
Global teaming is a must to complete our work
More Global Market Factors$100 billion spent on gas projects in North Africa and Middle East in 2005In 2006, Russia was the second highest spender on construction projectsPetrochemicals and pharmaceuticals continue to grow in Middle East & ChinaIn the past 18 months, market for international projects tripledglobally
Even More Market Factors
50% of EPCs lost money in 2004 & 2005 on upstream offshore projects due to poor biddingNew projects getting very large ($5-$10 billion), more complex and owners more demandingTime to market and completing a project on time is more important than project cost
Owners WantBetter integration between conceptual design, engineering and operationsMaximized value from engineering data and minimized re-entry of informationValidated and accurate information from AECs/EPCsBetter management of engineering and business process changesAnalyzed data information to support future projectsImproved connection and integration with the whole enterprise
EPCs Want
Streamlined support for distributed executionTechnology to support parallel execution and schedule compression Improved design reuse and leveraged design knowledge Improved internal integration with suppliers and subcontractorsReduced risk by applying better engineering quality controls and change managementImproved performance and progress measurementImproved ability to meet handover requirements
FIATECH is a Consortium…
FIATECH At a GlanceIndustry-led Consortium– Approx. 70 owners, contractors, suppliers, researchorganizations, universities– Formed in 2000, part of the College of Engineering at the University of
Texas in Austin
Mission– Provide global leadership in identifying and accelerating the
development, demonstration and deployment of fully integrated and automated technologies to deliver the highest business value throughout the life cycle of all types of capital projects.
Guide: Capital Projects Technology Roadmap– Industry-wide, global research agenda (not just FIATECH)
Mechanism: Implementation projects– 35+ delivered products
FIATECH Technology Roadmap Provides Way To…
Leverage scarce resourcesWork Together– Private Industry – Associations & Organizations– Universities– Research Centers & Labs– Government– Technology Developers & Equipment Suppliers
Reduce– Fragmentation– Wasteful overlap and competition
Orchestrate and leverage international initiatives
FIATECH’s Active Projects (2008)
1. El.2 - Automated Design Workflow Mapping and Checklists 2. El.3 - Global Valve Cross-Reference e-Catalog 3. El.3 - Automating Equipment Information Exchange 4. El.4 – RFID Cookbook 5. El.4 - Leveraging Technology to Improve Construction
Productivity6. El.5 - Operational Facility Roadmap Directory 7. El.6 - Streamlining Building and Land Use Regulatory
Processes8. El.8 – User Acceptance of Mobile IT 9. El.8 - Attracting the Next Generation Workforce 10. El.8 - Developing Core Technology Competencies 11. El.9 - Accelerating Deployment of ISO 15926
“Computer, show me …”
Where Are We Now?
Where Do We Want To Be?
How Are We Going To Get There?
Identify the most appropriate standard for the industry.Find ways to accelerate its development and deployment.Do it and use it.
“Now that this project has delivered on its promise, we want to spread the message that there is no longer any reason to wait before using it. We also want to encourage all those with whom we do business to begin the process of adopting it. In fact, each of the members of the FIATECH Board of Directors is in the process of doing exactly that within our own companies: owners and contractors to require it in their contracts, and software developers to implement it. We expect that in the not-too-distant future, it will be a requirement for doing business all across the process industry.”
-James B. Porter, Jr.Chief Engineer and Vice President, Engineering & OperationsDuPont
17
Plan Going Forward•ADAPT
Mapping our classes to ISO 15926 [IDS-ADI]
•ADOPT
Use ISO 15926 Reference Data from the RDS WIP to match our requirements
•DEMAND
Demand our contractors and suppliers provide us data in ISO 15926
Manage data independent from native applications
FIATECH’s Active Projects (2008)
1. El.2 - Automated Design Workflow Mapping and Checklists 2. El.3 - Global Valve Cross-Reference e-Catalog 3. El.3 - Automating Equipment Information Exchange 4. El.4 – RFID Cookbook 5. El.4 - Leveraging Technology to Improve Construction
Productivity6. El.5 - Operational Facility Roadmap Directory 7. El.6 - Streamlining Building and Land Use Regulatory
Processes8. El.8 – User Acceptance of Mobile IT 9. El.8 - Attracting the Next Generation Workforce 10. El.8 - Developing Core Technology Competencies 11. El.9 - Accelerating Deployment of ISO 15926
Automated Design Workflow Mapping and Checklists Project
Opportunity– “Quality of information provided from design
systems and tools was inconsistent between projects, the level of detail was often inappropriate compared with the need, and changes to information were not well managed.”
Objective– Improve the workflows for the exchange of
information between design and construction by defining and mapping the minimum information requirements.
Project Scope Limited to Industrial Projects
Minimum requirement definition for:– Piping Commodities
• Spools, hangers, lines, welds
– In-line components • Valves, specialties
– Process equipment– Instrumentation and controls– Electrical items– Structural elements
Information Exchanges Were Classified by Project Phase
Phase 2 3 4
Description Conceptual (10-30%) Detailed Design (30-65%)
Construction (65%+)
3D Model -Breakdown of construction areas-Initial equipment layout-Pipe routing
-Source of issued drawings: Isos, hanger drawings-Constructability Reviews: 30%-60%-90%
Interference-free 3D modelused at jobsite for:-Extraction of ortho’s-Visualization (status, complexity, etc)-Work packaging
Documents -Major equipment list-Process line list-Piping specs-2D drawings: GAs/Plot Plans, etc.
-Intelligent P&IDs-Welding procedures-Vendor documents-Erection drawings
-Final Intelligent P&IDs-As-built 2D drawings -Final master tag index-Storage and maintenance requirements-Operations & Maintenance manual
Status of Project
Definitions for industrial projects have been completed.Documentation and implementation check lists are completed.Include supplier’s & manufacturer’s construction information needs in 2009.Create a similar project for building information modeling (BIM) projects.
GVCC Benefits Work Process Sample valve order of 20 different types of valves
*2 hours per TYPE of valve is conservative estimate.
Existing Process – Manual Research to Validate Valves Submitted
Manual Technical Evaluation
4 Valve ManufacturersApprox. 2 hours*/valve type
Or 20 x 2 = 40 hours
Place Order
Receive Quotes
Select Valves
that meet Technical
Requirements
Automatic Technical Evaluation
4 Valve ManufacturersApprox. 2 hours total
Place Order
Receive Quotes
Select Valves
that meet Technical
Requirements
Proposed Process – Using Online Valve Matcher Catalog System
GVCC Objectives
PIP valve catalog characteristics (in XML)become comparison basis for any catalog.Suppliers & manufacturers map valve characteristics and equivalents to PIP standard valves.Owners & contractors load valve characteristics and equivalents, mapped to PIP standard valves.– Internal number mapped to PIP number
Everyone uses their preferred catalog numbers.– Electronically cross-referenced to other users as needed
Automated comparison of valve model numbers & characteristics.– Feasible for standard and non-standard valves
Automating Equipment Information Exchange (AEX) Project
Objective– Automate equipment design and delivery work
processes through software interoperability
Approach– Focus on high benefit problems– Demonstrate incremental working solutions– Schemas available on “royalty free” basis– Get vendors to implement
Products– XML schemas, industry guidelines and example
files– AEX specs given to standards organizations
FIATECH AEX Project Strategy
Produce and publish XML specifications available on royalty free basis to publicPublish XML schema development guidelines and implementation guidelines that are available onroyalty free basis to publicFocus initially on centrifugal pumps and shell & tube exchangersDefine a practical, repeatable methodology for developing XML specificationsDevelop partnerships with industry groupsObtain broad industry review and support
Owner Operator
EPC
Supplier
Conceptual
Design
Preliminary Design
Design ReviewBudget Quote
AuthorizationEstimate
Authorize
Project
Design Review Bid Quote
Review
Fab Review &Approval
FabricateShip
Invoice
Receipt &Inspection
Review Pay
ApprovalDrawings
ProductionDesign
BidPackage
Bid Award
Receive PO
Phase VI: Operations and Maintenance
access engineering information
Transfer #2
Transfer #3
Transfer #4
Transfer #5
Transfer #6
Transfer #7Transfer #8
Transfer #9
Transfer #11
Transfer #12
Transfer #13
Transfer #14
Transfer #15
Transfer #16
Transfer #1
Transfer #10
Transfer #17
Phase I:Equipment Data
DevelopmentPhase II:
Budget Estimate
Phase III: Equipment Specs
& RFQ
Phase IV:Purchase Order /
Vendor Drawings & Models Phase V: Fabrication and Delivery
Impress Demo
Pump Life Cycle Work Process
AEX Equipment Schema Status
CompletedIn processInvestigating business value
Heat Exchangers & Fired Equipment
Shell & tube HXAir cooled HXBoiler + Furnace
Rotating Equipment
& Accessories
Centrifugal pumpCentrifugal fanCentr compressorRecip compressorScroll compressorPos displacement pumpVertical pumpRotary pumpReciprocating pumpMixer / AgitatorMech seals (API 614/682)
Steam turbine (API 611)
Electrical
MotorMotor cntrl centerStarterTransformerVar frequency driveGenerator
Other
DryerConveyorCycloneTankVessel
HVAC&R
Air handling unitAir chillerAir compressorAC unitHeat pumpWater chiller Proc refrigeration
Block valveControl valveMotor operated valvesPress relief valveTransmitter
Instrumentationand Valves
Legend
Smart Chips Project
Started in 2002 to accelerate deployment of chip technology in construction.Short-term goals– Identified potential high return
applications – Assessed applications in realistic
field trials, technical capabilities, economic feasibility
– Publicized results so that potential users can make informed decisions about commercial products
Long-term goal– Guide chip suppliers to produce
products geared for our industry
7 Smart Chip Demo Applications1. Field Study of Wireless Strain
Monitoring Technologies2. Field Study of Concrete Maturity
Method in Very Cold Weather3. Field Tests of RFID Technology for
Construction Tool Management4. Field Trials of GPS Technology for
Locating Material in Laydown Yards5. Materials and Asset Tracking Using
RFID6. Field Trials of RFID Technology for
Tracking Fabricated Pipe7. The Use of the Concrete Maturity
Method in the Construction of Industrial Facilities
Proposed New Projects for 2009
Scenario-based Project Planning Predictability Model Requirements Gathering (Element 1) submitted by Wisconsin DOASpecification Automation (Element 2) submitted by S&BBIM Workflows & Checklists for Information Exchange Between Design and Construction (Element 2) submitted by CH2MHILLSupplier Information Exchange to Support Construction (Element 2) submitted by BechtelEfficient Site Initiative (Element 4) submitted by COMITYellowPages (Element 4) submitted by Bentley SystemsBusiness Process Automation (Element 8) submitted by CoreworxUniversal RDL Infrastructure (Element 9), submitted by NRXISO 15926 - ISO/PAS 16739 Interoperability (Element 9), submitted by Noumenon
Opportunities
Weekly Technology Tuesday webinars on new technologies & research.
CETI Awards (April 7 in Las Vegas)
Call for Presentation Available Now
FIATECHNicole Testa Boston
Deputy Director
(202) 669-3935 (m)[email protected]
www.fiatech.org
You are invited to join us…in spring 2009…
Thank you!
