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By Valentijn de Leeuw and Florian Gueldner
ARC WHITE PAPER
OCTOBER 2012
Good Asset Information Management
Practices Improve Reliability and Reduce
Operational and Safety Risks
Executive Summary ...................................................................... 3
Analyzing and Managing Operational and Safety Risks ...................... 5
The Potential of Accurate Asset Information ..................................... 8
Use Case: Data-Centric Operation .................................................. 9
Use Case: Immersive Operator Training ........................................ 14
Recommendations ...................................................................... 16
References ................................................................................ 16
VISION, EXPERIENCE, ANSWERS FOR INDUSTRY
ARC White Paper • October 2012
2 • Copyright © ARC Advisory Group • ARCweb.com
Number of Major Accidents in EU-15, 1996-2004
Reporting in EU’s Major Accident Reporting System (Christou, 2008)
Trend in World-Wide Refinery Material Damage Costs In Millions of Dollars per Year (Schouwenaars)
0
100
200
300
400
500
600
700
800
1965 1970 1975 1980 1985 1990 1995 2000
DA
MA
GE
(m
illio
n $
/yea
r at
200
0 p
rice
s)
Raw data
5-year average
Linear trend line
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 3
The Cost of Accidents and Lack of
Reliability
The combined cost of accidents and
incidents and lack of reliability could be
as high as one to three percent of
turnover on an annual basis, and in
addition a cost in the range of $500
million to five billion per major disaster.
For a super oil major, this would
happen on average every 20 years.
Executive Summary
Corporate performance for process manufacturers is typically measured
against criteria such as earnings and margin. However, other metrics such
as regulatory compliance, process and worker safety, or sustainability re-
cently have gained more importance as performance criteria. Influencing
the latter indicators implies costs, but also offers benefit opportunities. This
white paper looks at the need for enhanced operational and safety man-
agement measures via the correlation between correct and up-to-data asset
information and reduced operational and safety
risks. After that, available solutions with the poten-
tial to improve current industry practice are dis-
discussed.
The costs of maintenance and process safety im-
provement measures are well known, but their
impact on reliability and process safety are difficult
to grasp because they are correlated and because
accidents and incidents are infrequent and occur at
irregular intervals. Incidents and accidents are
viewed as operational and safety risks, an independent statistical pheno-
menon. This paper shows that the combined cost of accidents and incidents
and lack of reliability could be as high as one to three percent of turnover
on an annual basis, and in addition a cost in the range of 500 million to five
billion dollars per major disaster. For a super oil major, this would happen
on average every 20 years, in a range of every four to 100 years depending
on the safety and reliability practices.
Initiatives to improve safety and availability are strongly and positively
correlated. Occupational safety improvement measures have little impact
on process safety, but process safety improvement measures have a positive
impact on occupational safety. Since the sources of most safety and reliabil-
ity issues are human, to be effective, reliability and process safety measures
need to integrate asset management and HSE with the reliability of human
behavior and of executing processes. For effective and efficient reliability-
centered maintenance planning and execution, asset information must be
accurate and up-to-date. Any maintenance activity or plant change must be
recorded and be made available to all personnel. This allows decisionmak-
ers to concentrate on the analysis of the problem, knowing that they are
already working with correct (as-built or as-maintained) data.
ARC White Paper • October 2012
4 • Copyright © ARC Advisory Group • ARCweb.com
Reliability and Process Safety
Require Accurate Asset
Information Management
To be effective, reliability and safety
measures need to integrate asset
management and HSE with the
reliability of human behavior and of
executing processes. For effective
and efficient reliability-centered
maintenance planning and
execution, asset information must
be accurate and up-to-date
The Siemens’ COMOS asset data hub for engineering, maintenance and
operations enables this real-time visibility on asset state and health. The
availability of up-to-date asset information is also
paramount to decision making in emergencies and
reducing potential damage. Within COMOS, existing
3D models of installations are kept up-to-date and
can be used for immersive operator training in a safe
environment. The technology reduces training time
and cost and improves operational readiness. 3D
viewing also supports maintenance and operations.
Business benefits include reduced operational and
safety risk, increased productivity of engineering,
maintenance and operations, faster operational
readiness of assets and operations personnel, and
better regulatory compliance. To illustrate this, two
use cases will analyze the cost and management of operational and safety
risks.
ARC's Asset Information Management Solution Map
!
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 5
Correlation Between Financial
Performance, Risk, Safety and Asset
Reliability
• Asset reliability and process safety strongly
impact financial performance.
• The average financial impact of major
industrial accidents is strongly
underestimated
• The risk of major industrial accidents can be
greatly reduced by maintenance and the
establishment of a safety culture.
• Safe and reliable operations are compatible
with effective cost management.
• Occupational safety improvement has strong
impact on injuries and fatalities but not on
major accidents. Process safety needs to be
addressed in addition to occupational safety.
• To be effective, an integrated approach to
safety, reliability and human behavior is
required.
• Examples of measures are up-to-date asset
information for operational, maintenance
decisions and operator training.
Analyzing and Managing Operational
and Safety Risks
Many companies today are using metrics such as regulatory compliance,
process and worker safety, or sustainability and environmental footprint as
performance criteria in addition to purely financial metrics. Influencing the
latter measures implies costs, but also contains
benefit opportunities. For example, benefits of
energy efficiency improvements as part of sus-
tainability initiatives offer a quick payback on
investments (Farrell and Remes, 2008). The
costs and benefits of sustainability improvement
metrics are likely to evolve over the years, but
are fairly stable can be predicted with confi-
dence.
Process safety and asset availability improve-
ments have a direct impact on sales. Incidents,
accidents and unwanted shutdowns, instead
have the opposite effect, and in the worst case
they can cause injuries, fatalities, damage to
environment and assets, with the associated cost
and negative impact on the brand. However,
accidents and incidents are infrequent and occur
at irregular intervals. They are viewed as oper-
ational and safety risks that can be managed,
but cannot be reduced to zero.
Human Error and Safety
The ASM Consortium estimates that about 40 percent of unwanted shut-
downs in the process industry are attributed to equipment failure, 20
percent to failing to follow processes, and around 40 percent to human er-
ror (ASM Consortium, cited by O’Brien, 2010)). Investigations by Total on
the impact of human behavior on process safety, together with comparisons
with best practices from the nuclear industry and airlines, indicate that the
risk of human error can be reduced by a factor of at least 100 by applying
rules and principles (Van Roost, 2010), and by establishing a safety culture
(Ghosh and Woll, 2007). Their analysis of a series of industrial accidents
and near misses reveal that causes often include human error.
ARC White Paper • October 2012
6 • Copyright © ARC Advisory Group • ARCweb.com
Efforts to improve occupational safety have strongly reduced the number of
injuries and fatalities in recent years, but have had little impact on major
industrial accidents, which have declined only very slowly over time
(Schouwenaars, 2008;, Haesle et al., 2009). These facts corroborate the find-
ings of Total and others that occupational and process safety should be
treated separately.
The EU has recorded a frequency of about three major accidents per 1000
industrial establishements per year (Christou, 2008) with at least one fatali-
ty and more than €2.5 million worth of damage. Major disasters, such as
the Toulouse, the Texas Refinery or the Buncefield explosions, are at anoth-
er scale: the average cost are $2 billion and range from $500 million to $5
billion, with a record of at least $40 billion reported
for the Deepwater Horizon spill in the Gulf of Mex-
ico. For a typical super oil major with a turnover of
$300 billion and an operating margin of eight per-
cent or $24 billion, the likely frequency of a major
accident according to the EU definition is around
three accidents every two years. ARC estimates that
major disasters have a much lower frequency, pos-
sibly one every 20 years, for this size of company
this comes with an average annual costs of around
$100 million or a few percent of profit. The frequen-
cies for major accidents and disasters vary by a
factor of at least five depending on the safety culture and reliability practic-
es of the company and could be as high as a major accident every two
months, or a major disaster every four years. A typical super oil major
could lose money a given year in the worst scenario, as happened to BP in
2010. For a smaller oil company, the worst case scenario would create such
a loss that the company would probably not survive.
Processes and Asset Reliability
Since the correlation between expenses for maintenance and reduction of
the number of accidents is not obvious, the temptation exists to reduce
maintenance and inspection costs to improve profitability. A McKinsey
study (Laurens and Van Der Molen, 2009) reported that world class oil &
gas producers have 95 to 98 percent asset availability even for older assets.
At the same, they make the right decisions about cost reduction, avoiding a
downward spiral in reliability performance. McKinsey found that world-
class companies apply preventive and condition-based maintenance ap-
proaches, and flawlessly execute plans and processes. A realistic
40%
20%
40%
EquipmentFailure
NotFollowingProcesses
HumanError
Sources of Downtime and Slowdown
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 7
improvement in plant availability is one to three percent while lowering
maintenance costs by 25 to 30 percent according to Williams (2001). This
translates to one to three percent of turnover in supply-constrained mar-
kets.
Correlation of Causes Calls for Integration of Measures
Asset reliability and process safety improvement measures both have an
important impact on financial performance and risk. Initiatives to improve
safety and availability are strongly and positively correlated. Since the
sources of most safety and reliability issues are human, to be effective, re-
liability and safety measures need to integrate asset management, HSE, and
human behavior.
Measures to Reduce Risk and Improve Availability
Although statistics for incidents, accidents and shutdowns are readily
available, the advent of such an event always seems a surprise. The human
mind can assess those risks, but intuitive estimations and decisions regard-
ing risks are likely to be incorrect (Kahnemann, 2011; Tversky and
Kahneman, 1974).
Management does have the possibility to take the
right decisions: the risk and the staggering average
financial cost of accidents and unwanted downtime
can be strongly reduced by relatively small efforts
and investments. In a comparison to the aviation
industry, Total showed that risks of human error
could be reduced by relatively simple means such
as dividing responsibilities among two people and
double-checking decisions. In addition, operation-
al and safety risks can be reduced considerably by
having an accurate picture of the assets and their
health.
Up-to-date asset information is paramount to making correct decisions in
maintaining assets. It is equally important when training people on
processes and behavior. Both appropriate behavior and up-to-date know-
ledge become critical when making decisions in emergency situations.
Location, year Estimated cost in
billions of dollars
Piper Alpha, 1988 3.4
Enschede, 2000 0.45
Toulouse, 2001 1.8
Skikda, 2004 >3
Buncefield, 2005 2
Texas City, 2005 1.5
Deepwater Horizon, 2010 40
Cost of Major Industrial Accidents
ARC White Paper • October 2012
8 • Copyright © ARC Advisory Group • ARCweb.com
Benefits of Integrated Engineering
and Operations
The usage of a single, consistent and up-to-
date database for design, engineering,
construction, handover, operations and
maintenance in conjunction with 3D plant
visualization can help reduce operational risk,
increase productivity, accelerate operational
readiness, and improve regulatory compliance.
The Potential of Accurate Asset
Information
The use of a single, consistent and global data hub such as COMOS, kept
up-to-date at all times by all disciplines, creates instantaneous and complete
transparency of information for each plant object and for all parties. Using
configurable workflows, the different disciplines can collaborate using a
structured process. As a result,
• Plant engineering and construction is of higher quality, and time to
operational readiness is shortened significantly.
• The documentation provided at handover is an up-to-date ‘as-built’
asset database, that, when maintained, becomes the ‘as-maintained’ da-
tabase. Reducing engineers’ time to enter and find information delivers
substantial productivity improvements.
• The regulatory obligation of up-to-date plant documentation is fulfilled
at all times.
• In urgent situations, reliable decisions can be made based on up-to-date
plant information. Faster and more appropriate reactions reduce opera-
tional risks considerably.
With COMOS Walkinside’s 3D virtual reality viewer,
3D data developed during the engineering stages can
be reused through all lifecycle phases of the plant in
operations, maintenance planning, simulation and
workforce training. Specifically designed for opera-
tions, the tool is easy to use for operators and
engineers, providing a fast and realistic rendering of
complex models, creating a perception of being
present on site. Typical use cases include project
progress reviews, problem solving sessions, off-site
immersive training, spatial context for engineering and maintenance tasks,
and spatial analysis and decision support during emergencies.
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 9
Immersive Operator Training with COMOS Walkinside
The immersive training experience strongly reinforces learning objectives,
reduces traditional on-site operator training, and has proven to enhance
operational readiness of the operators.
Use Case: Data-Centric Operation
Modern Asset Management during Operate-Maintain
Phases
Asset management is gaining importance in the process industries as a
process to determine the strategy for maintaining and modernizing assets.
The goal is to ensure that these assets provide the production capability
required while lowering costs over the asset lifecycle. Asset management
improves performance, for example by coordinating debottlenecking and
maintenance actions as well as interactions between assets. An asset ma-
nagemen solution can support a decision to clean a heat exchanger limiting
production in summer, in the spring rather than in autumn and to delay an
expense. Another example is that changing a control valve after an ad-
vanced process control (APC) project may destroy the economic benefits of
the APC.
One of the most important aspects of asset management is providing accu-
rate and contextual information to users. As asset management uses
ARC White Paper • October 2012
10 • Copyright © ARC Advisory Group • ARCweb.com
COMOS
COMOS is Siemens’ solution for plant engineering,
operations and maintenance from process design to
decommissioning in the process industries. COMOS
supports process engineering, P&ID, 3D, electrical,
instrumentation and control engineering. In addition,
COMOS supports operations management, e.g. with
document management including workflow and approval
processes or the maintenance management with risk
evaluation for a risked-based maintenance approach.
With its object-oriented approach and single database
for all lifecycle phases and disciplines, COMOS provides
instantaneous and complete transparency of information
related to a plant object for all stakeholders.
Configurable workflows enable different disciplines and
roles in engineering and operations processes to
collaborate in a structured manner.
Based on these capabilities:
• Engineers have direct access to information changed
by colleagues in other disciplines. This can increase
the degree of parallel engineering.
• Object-orientation enables modular engineering.
Applied throughout the enterprise, it improves
standardization that generates time and cost
benefits, facilitates cooperation and increases
flexibility in personnel assignment
• The time to find information is reduced substantially
which leads to productivity improvements.
• Operational readiness can be predicted more reliably.
• The regulatory obligation of up-to-date plant
documentation is fulfilled at any point in time.
• In urgent situations reliable decisions can be made
on on-line plant information. Faster and more
appropriate reactions reduce operational risks
considerably.
multiple sources and tools, such as equipment documentation, engineering
data, maintenance history, real-time data, root cause analysis and reliability
centered maintenance tools, work plans or spare parts availability.
Operations need to make decisions in real-time
to operate plants in an optimal way and accord-
ing to a production schedule. They need access
to the state and health of parts and components
of the plant to make the right decisions. They
need to know if a pump has been replaced or
not, and if this allows them to increase
throughput and to which level. They need to
know which parts of the plants are locked out
for maintenance. In case of trouble or urgency
they need to take reliable decisions to avoid
damage or spills. Maintenance is subprocess of
asset management that has the goal of restoring
the health of an asset.
The Most Frequent Application:
Document Management
Engineering, procurement and construction
companies (EPC) do all of their engineering
work with computer-aided software, and the
same is true for their subcontractors. When a
plant is commissioned, in a majority of cases,
documentation is handed over on paper.
Sometimes electronic versions of the docu-
ments are provided. However the owner-
operators do not benefit from the EPC’s engi-
neering system’s capabilities.
In practice, owner-operators often rely on doc-
uments for operations and maintenance.
Changes are documented as hand-written cor-
rections on printed documents. In the best case
electronic documents are updated afterwards.
This process is time consuming and error prone, information is regularly
out of date, and interactions between disciplines lead to unnecessary itera-
tions. Many engineering databases and systems do not have the
functionality to support operations and maintenance and, as a result, a
maintenance management system must b
tion, extracted from the hand
do debottlenecking, troubleshooting, or wants to embark on
tion or improvement project, the search for as
starts as input to the engineering systems. One can easily imagine the time
this takes and the risk of data losses this implies
The Road
Up-to-date
any time to
place that
rity measures, engineering and maintenance contractors, equipment and
other providers can all safely share the as
image of the plant,
after handover, during maintenance or operation. Instead of maintaining
documentation, the different players update data records, simplifying and
speeding up the process enormously.
Owner/Operators and EPCs Collaborate Effectively when Using the Same,
Owner-operators
sistent and modular engineering for all their refineries.
investment
workflow,
data, the usage of COMOS and the Petrobras workflow is mandatory for
every contractor. After h
by operations and maintenance personnel. For maintenance the use of a
single system with both maintenance functions and engineering data is
comfortable and easy to use.
Certain EPCs,
ing jobs, have also understood the benefits of using a single, consistent and
up-to-date engineering database that enables
modules. They explain the benefits of using such sys
ARC White Paper
Copyright © ARC Advisory Group • ARCweb.com •
maintenance management system must be primed with ‘as
tion, extracted from the hand-over documents. When the owner needs to
do debottlenecking, troubleshooting, or wants to embark on
tion or improvement project, the search for as-built and as-maintained data
as input to the engineering systems. One can easily imagine the time
and the risk of data losses this implies.
Road Less Traveled: Data Centric Operation
e plant data for operations and maintenance can be provided at
any time to any user of a platform such as COMOS, provided
that guarantees that data are kept current. With appropriate IT sec
rity measures, engineering and maintenance contractors, equipment and
other providers can all safely share the as-built and as-maintained data
image of the plant, whether it is before or during construction, before or
after handover, during maintenance or operation. Instead of maintaining
documentation, the different players update data records, simplifying and
up the process enormously.
Owner/Operators and EPCs Collaborate Effectively when Using the Same, Consistent Asset Information
operators such as Petrobras have understood the benefits from co
sistent and modular engineering for all their refineries. Petrobras has made
investments in infrastructure, software, setting up a cross
and defining engineering modules. To ensure up
data, the usage of COMOS and the Petrobras workflow is mandatory for
every contractor. After handover, the plant data ‘model’ is kept up
by operations and maintenance personnel. For maintenance the use of a
single system with both maintenance functions and engineering data is
comfortable and easy to use.
Certain EPCs, in particular those that do specialized and complex enginee
ing jobs, have also understood the benefits of using a single, consistent and
date engineering database that enables the use of
modules. They explain the benefits of using such systems
White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 11
e primed with ‘as-built’ informa-
over documents. When the owner needs to
do debottlenecking, troubleshooting, or wants to embark on a moderniza-
maintained data
as input to the engineering systems. One can easily imagine the time
ance can be provided at
as COMOS, provided a process is in
. With appropriate IT secu-
rity measures, engineering and maintenance contractors, equipment and
maintained data
it is before or during construction, before or
after handover, during maintenance or operation. Instead of maintaining
documentation, the different players update data records, simplifying and
Owner/Operators and EPCs Collaborate Effectively when Using the Same,
as Petrobras have understood the benefits from con-
Petrobras has made
in infrastructure, software, setting up a cross-company
and defining engineering modules. To ensure up-to-date plant
data, the usage of COMOS and the Petrobras workflow is mandatory for
the plant data ‘model’ is kept up-to-date
by operations and maintenance personnel. For maintenance the use of a
single system with both maintenance functions and engineering data is
do specialized and complex engineer-
ing jobs, have also understood the benefits of using a single, consistent and
pre-engineered
to the client. If
ARC White Paper • October 2012
12 • Copyright © ARC Advisory Group • ARCweb.com
the client has a preference for another engineering data format, they can
convert the COMOS information to the most common other formats with-
out compromising on the engineering tool.
ARC's Asset Information Management Solution Map
Data Centric Operation with Context from a 3D Plant Model
A 3D view of the equipment within its plant environment is a tremendous
help in conjunction with tabular, text or 2D information. Using COMOS
Walkinside, maintenance personnel can look up where the equipment is
located, if it is accessible from the floor, or if scaffolding or a crane is neces-
sary. The other way around, using the link with COMOS, the engineer can
directly access equipment characteristics, maintenance history, documenta-
tion, by clicking through on the equipment in the 3D view. Vice versa, if
the engineer was working with the engineering and maintenance database
he can click through to the 3D view of the equipment and see the spatial
context.
To improve productivity, companies in sectors such as oil & gas and other
process industries aim to reduce manual intervention and increase the pro-
portion of unmanned operation. For personnel that are not often on-site, a
3D view of the plant helps to understand where equipment is located and
how it is connected. This helps personnel to pre-plan interventions before
arriving on location.
!
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 13
Spatial View of Two Pumps in COMOS Walkinside
A 3D view can help to get a spatial perception of locations where work
permits are issued, and to assess the risk factors of those locations in terms
of presence of dangerous substances, hot surfaces or interactions with the
process.
If personnel are equipped with RFID chips, they can be located at a glance
in a 3D representation during an emergency and be guided to a safe loca-
tion.
2D Process Flow Diagram with Two Pumps (cyan)
ARC White Paper • October 2012
14 • Copyright © ARC Advisory Group • ARCweb.com
Use Case: Immersive Operator Training
Immersion in a virtual environment (VE) is used in many different forms in
modern training because it has proven to shorten learning and strengthen
memorization. Within the context of computer-generated images, the VE is
called immersive (IVE) when the user or gamer can directly control the
avatar, giving him the perception he is part of the environment (Bailenson,
2008). To train field operators and maintenance personnel of industrial
process plants, it is more effective to provide them with a 3D simulation
environment in which they can virtually move around, make decisions on
their route and their interactions with equipment, than showing them a
movie.
A global player in upstream has decided to
train its field operators for a new Floating
Production Storage and Offloading vessel
(FPSO). These are offshore production facil-
ities that house both processing equipment
and storage for produced hydrocarbons.
They used COMOS Walkinside’s immersive
training simulator (ITS) for this purpose.
During a five-week period, operators
“walked around” a 3D graphical model for
eight hours each day with sufficient detail
and realistic colors to create the perception
of reality. The primary purpose was to fa-
miliarize themselves with their future work
environment to know where on board they
are located, where to find equipment and
how to go there efficiently. A second pur-
pose was to teach them to operate
equipment and execute standard operating
procedures (SOP). They were tasked to execute real SOPs such as locating
equipment on deck, going there, finding out its status, and taking appro-
priate action. For example: “Go to valve V112, check its position, then
close it!” By executing tasks correctly, operators earned points. They could
also be penalized in terms of points for improper actions. To create a posi-
tive learning environment, emphasis was put on stimulating improvement
rather than punishing errors.
Floating Production Storage and Offloading Vessel
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 15
COMOS Walkinside
VRcontext, a spin-off of GDF Suez and recently
acquired by Siemens, took on the challenge to build a
viewer for very large 3D models, such as process
plants, that combines a realistic view with fast
navigation for non-specialists, such as operations or
maintenance personnel. COMOS WalkInside converts
3D plant models from well-known 3D design
applications into a suitable format to reach this
performance. Features include:
• Realistic visualization and navigation within models
containing several million objects.
• Automatic model conversion. Model cleaning of
temporary design objects also can be automated.
• A software development kit allows the user or the
integrator to develop plug-ins for any application.
Applications of COMOS Walkinside include:
• Reviews of EPC designs together with or by the
owner-operator, without complex 3D CAD tools.
Closer cooperation between OO and EPC allows
earlier detection of problems and helps to solve
problems, resulting in earlier operational readiness.
• Immersive Virtual Training for operations or
maintenance where the user can move with his
avatar and experience the plant as in reality. The
application saves time and increases effectiveness.
• 3D plant and equipment viewing in conjunction with
asset management or operational tasks. COMOS
Walkinside provides access to engineering,
operations, maintenance and business planning
information.
All operators who had used PCs before were capable of “walking inside”
with only half a day of introduction to the tool. The operators readily ac-
cepted the tools and described the training as “practical”, as opposed to
“theoretical”. Of course the two are necessary to give the operator a full
understanding of the meaning of their tasks.
The instructor has the possibility to look
virtually over the operator’s shoulders by
observing their screens in real-time. He
creates procedures with prompts that
guide operators through their tasks.
These can be executed in an automated
way, guiding the operator step by step
through the execution of an action list. In
the multi-user environment, the instructor
can create scenarios that imply coordi-
nated actions of several operators, each
with his own avatar.
The user reported that immersive training
compared favorably with traditional train-
ing. It is common practice to send the
future operators for a few months to the
shipyard where the FPSO is built. Since
the ship and the equipment are under
construction, equipment can be missing or
inaccessible, or auxiliary installations may
be present that are not relevant to their
work. Most often the shipyards are in
other parts of the world, involving ex-
penses for travel and living. The immer-
sive training simulator saved training
time and was more effective. As a result
the operators were more operational than
with classical training. This could imply
higher utilization rates and fewer errors with economical or environmental
impacts. Since the FPSO mentioned above was delivered one month earlier
than scheduled, and the operators’ training was shorter than usual, the
training did not delayed the commissioning of the ship, resulting in an
overall shortened time to production, and an increased cash flow.
ARC White Paper • October 2012
16 • Copyright © ARC Advisory Group • ARCweb.com
Recommendations
Based on the research conducted for this paper, ARC Advisory Group re-
commends to:
• Conduct mechanical, process and automation related risk analysis as
well as analysis of risk in applying procedures and appropriate beha-
vior. Design layers of protection by integrating types of protections:
technical, human behavior and organizational.
• Base decisions for operations and maintenance on up-to-date asset in-
formation and guarantee the accuracy of this information through a
data centric IT approach and appropriate processes for all disciplines
acting upon asset data.
• Train operations and maintenance personnel using a safe virtual envi-
ronment that references up-to-date asset data. Complement this with
process and automation-oriented operator training simulation.
• Institute benchmarking on maintenance, reliability and process safety to
monitor the level of excellence and the available improvement poten-
tial.
References
Abnormal Situation Management (ASM) Consortium, cited in: O’Brien, L.,
2010, “We need a Better Approach to Procedural Automation”, ARC Strate-
gies, ARC Advisory Group, September, 2010.
Bailenson J.N., N. Yee, J. Blascovich, A.C.Beall, N. Lundblad and M. Jin,
2008, “The Use of Immersive Virtual Reality in the Learning Sciences: Digi-
tal Transformations of Teachers, Students, and Social Context”, The Journal
Of The Learning Sciences, Vol. 17, pp. 102–141.
Christou, M., 2008, “Major Accidents: Examples, statistics and remarks on
their prevention”, Presentation on behalf of the Major Accident Hazards
Bureau, of the European Commission, XI EWHN Conference, October 2008.
Farrell, D. and J.K. Remes, “How the world should invest in energy effi-
ciency”, McKinsey Quarterly, July 2008, pp. 1-11.
ARC White Paper • October 2012
Copyright © ARC Advisory Group • ARCweb.com • 17
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ARC White Paper • October 2012
18 • Copyright © ARC Advisory Group • ARCweb.com
Analyst: Valentijn de Leeuw, Florian Gueldner
Editor: David Humphrey
Acronym Reference: For a complete list of industry acronyms, refer to our
web page at www.arcweb.com/Research/IndustryTerms/
2D Two-dimensional
3D Three-dimensional
AIM Asset Information Management
APC Advanced Process Control
EPC Engineering Procurement and
Construction company
FPSO Floating Production Storage and
Offloading vessel
IT Information Technology
IVE Immersive Virtual Environment
PC Personal Computer
ROA Return on Assets
RFID Radio Frequency Identification
SOP Standard Operating Procedures
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