SmartPlant® P&ID Benefits for Owner Operators - A Resume

SmartPlant® P&ID: Benefits for Owner/Operators

A Résumé

Process, Power & Marine

August 2004 DDPP271EB1

Prepared by Intergraph Process, Power & Marine, a division of Intergraph Corporation Intergraph, the Intergraph logo, SmartPlant, INtools, MARIAN, PDS, SmartSketch and FrameWorks are registered trademarks and IntelliShip is a trademark of Intergraph Corporation. SupportModeler and SupportManager are trademarks of Pelican Forge Software Corporation. Other brands and product names are trademarks of their respective owners.

Intergraph believes the information in this publication is accurate as of its publication date. Such information is subject to change without notice and is subject to applicable technical product descriptions. Intergraph is not responsible for inadvertent errors. ©2004 Intergraph Corporation, Huntsville, AL 35894-0001.

SmartPlant P&ID Benefits for Plant Owner/Operators Résumé Page 2


SmartPlant® P&ID: Benefits for Plant Owner/Operators

ppm.intergraph.com 1-800-260-0246 (U.S.)

1-256-730-3707

OBJECTIVE Increase your return on assets by safely reducing expenses and improving operational efficiency.

Page

EXECUTIVE SUMMARY

Keep your P&IDs accurate and as-built. Improve, optimize, and refine work processes, increase design quality, and lower costs.

5

SMARTPLANT P&ID: A TOOL FOR THE PLANT LIFE CYCLE

Create, manage, store, and access accurate, up-to-date P&IDs throughout the plant life cycle.

6

THE BENEFITS Realize the business benefits of creating and maintaining intelligent P&IDs, and take advantage of powerful functionality and integration.

8

WORKFLOW VALUE PROPOSITIONS

HAZOP / Inspection / Environmental Shorten the pre-inspection data assembly process. Improve inspection manage-ment and resource allocation, contributing to safe facility operation and production. Reduce the time, cost, and resources required to perform HAZOP analyses.

10

Construction / Plant Modifications

Perform projects while maintaining data integrity with the as-built and project environment. Provide a single source of accurate, consistent data where all plant personnel can access the information needed to perform their duties.

11

Operations / Process

Enhance plant operations by interfacing with upstream process analysis tools. Assure P&ID data/design accuracy and consistency through enforcement of design rules. Ensure the P&ID accurately reflects the as-built plant at all times.

12

Training

Provide an excellent training tool for describing plant configuration and functions to new operators. Allow display and interrogation of critical systems and safety systems, including safety equipment.

13

Reliability

Access accurate plant configuration data to help minimize plant downtime. Enable timely preventive maintenance, conserve resources and minimize costs, and avoid unscheduled shutdowns and lost productivity.

14

Research / Development / Engineering

Provide the research team with accurate infrastructure and data pertaining to current plant operations. Filter and document existing plant systems. Check and verify changes to the existing plant design.

15

Maintenance

Automatically generate critical component and blinding lists for turnarounds and scheduled plant downtimes. Assist in the creation of maintenance packages.

16


Utilities

Assist plant personnel in maintaining, repairing, and upgrading plant utilities by providing fast, easy access to P&ID data, updates, and/or modification tools. Use the P&ID data to calculate demands and plan for expansions or relocation of distribution due to process updates.

18

Coordination / Technical Services

Improve checking of plant configuration, equipment, and instruments to monitor product quality and determine if adjustments need to be made. Verify product quality and quantity with the combination of process data and plant configuration P&ID information.

19

SERVICES – VALUE-ADDED IMPLEMENTATION

Reduce your risk by outsourcing to Intergraph Services. Optimize the use of SmartPlant P&ID with existing system(s) using Intergraph’s system configuration and engineering IT services. Enjoy maximum return on your IT investment and increased productivity through effective legacy data migration.

20

SMARTPLANT P&ID IN USE

Who Has Chosen SmartPlant P&ID and Conversion Services? 22

References Degussa Corporation BP p.l.c.

22

ADDITIONAL INFORMATION

Resources

Access additional information about SmartPlant P&ID and our technology partners.

23

Glossary 23

Return On Investment Calculation Worksheet Explanation 23

RETURN ON INVESTMENT CALCULATION WORKSHEET

Determine the Return on Investment that SmartPlant P&ID can offer with a customized analysis. The product pays for itself in one year through savings in maintenance funding.

25

WHY CHOOSE SMARTPLANT P&ID?

Add value to your company’s work processes and bottom line. Maximize productivity, and realize a substantial ROI for the life of your plant. Choose Intergraph, the global leader in engineering information systems for the plant life cycle.

27

REFERENCES John Little Degussa Corporation

6

Marcin Sliwinski ALSTOM Power Sp. z o.o.

12

Rayong Olefins Co. Ltd. 14

Cees Cornelissen Lyondell Chemical Company

15

Thomas Vaughn BP p.l.c.

16

SmartPlant P&ID Benefits for Plant Owner/Operators Résumé


Executive Summary The Challenge The piping and instrumentation diagram (P&ID) – the “roadmap” of the

plant – is developed, accessed, shared, and modified throughout the plant life cycle. Therefore, it is critical that the P&ID is continually kept up-to-date, accurately reflecting the as-built plant at all times. However, as the plant is operating, maintenance and modifications take place, introducing discrepancies between the P&ID and the field configuration. Inaccurate information, inconsistencies, and non-compliance with design specifications result in lost time, productivity, and money.

In addition, plants often keep a drafting person on staff or contract to process updates. This resource, often not familiar with the plant, has to cycle changes many times between Engineering and Operations prior to the final drawing.

The Solution In the current difficult economic environment, you can safely reduce your expenses with SmartPlant® P&ID. Intergraph designed SmartPlant P&ID to meet your needs as an innovative approach to P&ID development and management. SmartPlant P&ID helps you keep your P&IDs accurate and as-built. Improve, optimize, and refine work processes, increase design quality, and lower costs across the plant life cycle. Focused on the plant asset rather than document creation, SmartPlant P&ID is a rule-driven solution for creating and managing P&IDs throughout the plant life cycle. The product pays for itself in one year through savings across many plant functions and disciplines.

SmartPlant P&ID: A Tool for the Plant Life Cycle

What Our Customers Say About SmartPlant P&ID:

Degussa Corporation benefits from the software's intelligent P&IDs.

"We appreciate SmartPlant P&ID's strong reporting capabilities along

with the Web browser access to P&IDs, reporting, and data," said

John Little, Piping Design, Systems and Drafting Manager at the

Mobile, AL, USA manufacturing facility of Degussa Corporation.

"We chose SmartPlant P&ID for its simple user interface;

powerful reporting capabilities; and data-centricity, version,

and revision control," Little said. "SmartPlant P&ID is highly

customizable through its automation layer."

Focused on high-yield specialty chemicals, Degussa is Germany's

third largest chemicals company and the world leader in specialty

chemicals. Degussa has developed high-efficiency customized

system solutions for clients in more than 100 countries.

A member of Intergraph’s SmartPlant family of products, SmartPlant P&ID provides an engineering environment for the operational team to create, manage, store, and access accurate, up-to-date P&IDs for the life of the plant or project. Any owner who has upcoming work that includes major unit, outage, HAZOP, or revamp projects can make use of SmartPlant P&ID. SmartPlant P&ID’s asset-centric approach to P&ID management makes the solution a perfect fit for all phases of the plant life cycle, helping you: • Execute design rules against plant components, ensuring an

accurate design and data consistency across the entire project • Maintain a true connectivity model – all components comprising

a system can be reported on a line list that lists the components in order, checked, and used for the flowsheet transposition into the 3D model/physical design

• Find and report on specific pieces of equipment, both in graphical and tabular formats, saving time and providing quick and easy access to data to support downstream tasks such as instrumentation

• Optimize the engineering design process as well as plant operations and maintenance activities, saving time and increasing data quality, consistency, and ease of access because of a single source of rule-verified data

SmartPlant P&ID protects your investment in data and knowledge. Plant data and relationships are stored in a database, protecting you from the challenges of CAD format changes and data incompatibilities. SmartPlant P&ID provides a safe path forward for the life of the plant, which may be 40 or more years – more than eight times the life of a typical software product. SmartPlant P&ID helps ensure that all plant and project personnel have the information they need, in the format they need, when they need it. The software optimizes the work processes for plant owners at every stage in the life of a plant – from front-end engineering, through detail design and construction, to commissioning and operations. The P&ID is a report or view of the data and therefore can be formatted to meet users’ demands and best facilitate their task.

SmartPlant P&ID allows you to make the right decisions early in the design process. This eliminates rework down the line, saving time and money.

Make the Right Decisions Early

Cost of poor design is 15% (ABB)Ripple through of errors

Piping

Instrumentation

Equipment

Electrical

P&ID


SmartPlant P&ID: A Tool for the Plant Life Cycle SmartPlant P&ID can be used by many groups within the organization

throughout the plant life cycle. This diagram shows the types of solutions that are typically used by plant departments and how SmartPlant P&ID and other Intergraph solutions are a valuable part of the workflow.

Who is Intergraph? Intergraph Process, Power & Marine is the undisputed leader in the process, power, and offshore plant creation market, with a revenue share of approximately one-third of the market worldwide. We offer integrated engineering enterprise solutions for the design, construction, and operation of process and power plants, offshore rigs, and ships. Our unique IT solutions enable our customers to find innovative ways to make better and faster operational decisions in an environment where knowledge retention is not a given – while at the same time ensuring a safer environment for everyone.

What is The Engineering

Framework?

SmartPlant P&ID’s integration with The Engineering Framework (TEF) helps you take advantage of new technology for increased productivity. TEF, enabled and housed by SmartPlant Foundation, is the integration architecture for the sharing and re-use of plant information throughout the plant life cycle. The initial implementation of TEF is in the front- end engineering design (FEED) environment, with the integration of Intergraph's SmartPlant P&ID, SmartPlant 3D, and INtools® in addition to Aspen Zyqad. However, TEF is not a prerequisite for SmartPlant P&ID.


The Benefits

SmartPlant P&ID delivers efficiencies for plant owners throughout the plant life cycle to provide a substantial ROI. In a typical plant configuration, SmartPlant P&ID and SmartPlant Explorer licenses, training, and implementation services would total less than $60,000 US. *Prices subject to individual project requirements. Any data migration costs are dependent on P&ID formats. The configuration can be scaled up or down depending on the plant size. This sample configuration should serve as a reference for the benefits, savings, and specific ROI examples provided in the Workflow Value Propositions section on pages 10 – 19.

Reduce total cost of ownership

• Enjoy low learning curve with an extensive referen• Decrease IT costs if deployed with thin-client tech

software upgrades, back-ups, etc. are performed f• Meet specific users’ needs with a configurable use• Save money by eliminating CAD skills requiremen

P&ID is not powered by a CAD engine

Improve plant uptime, safety, and compliance

• Improve responsiveness to unplanned events throto plant data during emergency maintenance or op

• Protect revenue and avoid penalties due to regula

Reduce project hours and costs

• Interface with upstream/downstream tasks like AspenAspenTech and Intergraph’s INtools™

• Facilitate faster plant project executions because rather than documents

• Manage data ownership and synchronize project d

Streamline everyday work processes

• Eliminate manual tasks, such as finding critical cobased Inspection (RBI), maintenance, turnaround,thanks to interrogation and reporting capabilities

Data-Centri“Single source of truth” for P&ID data

• Improve personnel efficiency and response to unpstreamline change management and project informfaster access to accurate, current data

Create intelligent P&IDs

• Shorten the commissioning cycle and bring the pla

Ensure data consistency

• Compress project schedules by reducing unplannchanges, and the length of shutdowns – design rurelationships between components and lines are eand data quality is increased

Application data sharing and document sharing

• Improve as-built compliance and streamline changthrough the rapid propagation of changes across rrelated documents

Facilitate data and design reuse

• Significantly reduce design time with accurate, upreference information that is ready for the next maor revamp

Refine and add data throughout the project

• Keep track of the last change that was made to a with version comparisons and time-stamping

SmartPlant P&ID Benefits for Plant Owner/Operators Résumé

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Page 8

The Benefits

Streamlined Work Process BenefitsRisk-based Inspections (RBIs)

• Support RBIs by enabling safety personnel to quickly assemble inspection packages, find and document critical systems, and report their findings for the audit trail and possible engineering changes

Accurate early material take-off

• You can perform an early material take-off from the P&ID, feed it into MARIAN or another procurement system to perform material cost estimating, and interface with Aspen Kbase™ for project estimating

Faster updates from redlines to blacklines

• Comply with regulatory requirements such as OSHA, EPA, and FDA and provide up-to-date information to plant operations personnel with change filtering and automatic updating features

Scenario analysis • Use filtering capabilities to examine design scenarios, feedstock scenarios, associated costs, and operational impacts, and compare the scenarios using color schemes

• Improve maintenance, turnaround planning, production adjustment, and re-analysis of processes

Emergency maintenance

• Pinpoint the problem to assess potential impacts to safety or production and shorten the possible downtime or hazardous situation with fast, accurate access to system information

Turnaround planning

• Give status to plant components and assess the impact on related systems, such as checking if all blinds are installed

Integration BenefitsReliability solutions • Better predict failure with solutions such as Meridium from Meridium Inc.,

helping you schedule resources and preventative maintenance while avoiding unscheduled shutdowns

HAZOP analysis tools

• Provide safety verification and help to ensure OSHA and regulatory compliance by interfacing with a HAZOP analysis system. For example, interface with HAZID from Hazid Technologies Ltd. or your own internal HAZOP program.

Third-party or homegrown tools

• Complement the design process with these tools through the SmartPlant P&ID automation layer, thus forming an integral part of The Engineering Framework (TEF) overall solution

Up- and downstream tasks

• Eliminate the need for data re-entry and increase data quality for tasks like process design (Aspen Zyqad), instrumentation (INtools), electrical design (SmartPlant Electrical), and physical design (PDS™/SmartPlant 3D) through TEF implementation

Business systems • Manage associated financials and return on assets with third-party business systems such as SAP


Workflow Value Propositions

HAZOP / Inspection / Environmental

The DriversInspection is directly related to the plant strategy. For example, if minimizing plant downtime is the main objective, inspections will be focused on meeting this goal. Prior to conducting inspections, documents must be gathered from several sources, a very time-intensive task. An important aspect of operations is the HAZOP analysis of the plant or plant units, costly both in terms of resources required and time spent to execute and document the results.

The SolutionWith the P&ID, you can filter for the critical systems or components of interest. The P&ID view and related reports can then be quickly and easily composed for the inspection work. By simply querying for systems having a specific process condition or located in a certain area, or for a particular pipe specification, SmartPlant P&ID will return a report and a graphic depiction on the P&ID to facilitate the inspection work. The inspection results can then be entered into the system and incorporated in the P&ID, allowing the team to check, for instance, which circuits have been tested over the past two months. This helps you better manage the entire inspection process.

SmartPlant P&ID can significantly reduce the time, cost, and resources required to perform HAZOP analyses. SmartPlant P&ID works in conjunction with HAZOP analysis solutions, such as HAZID from Hazid Technologies Ltd., to dramatically decrease the time required to perform HAZOPs as well as the associated costs.

The Value Proposition

Task Traditional Approach SmartPlant P&ID Approach

Annual Savings Hours Saved

Risk-based Inspection

Involves locating and documenting all critical systems, requiring an average of 4 hours per system.

SmartPlant P&ID’s querying capabilities enable the location of system and process data and documents in approximately 15 minutes.

100 circuits per year x 3.75 hours saved per circuit x $50/hour =

$18,750 saved.

3.75 hours saved per circuit.

HAZOP Analysis

On average, there are 1-2 HAZOPs per plant each year. Each HAZOP execution involves 8 personnel from the following disciplines: Ops; Health, Safety & Environment; Maint.; Tech.; and Control System Engineering. Assume 30 HAZOPs corporate-wide per year. Prep time for the HAZOP is 1 person for 80 hours.

SmartPlant P&ID’s filtering capabilities allow rapid access to systems and safety components. There are no action items due to missing data during HAZOP execution. Direct markup of the P&ID is enabled. Rules enforce data consistency across the project.

2 HAZOPs per year per plant x 185 hours saved per HAZOP x

$100/hour = $37,000 saved.

8 people x 80 hours each =

640 hours, + 100 hours prep time =

740 hrs. Savings yielded is

25%. 25% of 740 hours =

185 hours saved per HAZOP.

Note: See example configuration on page 8. The ROI cases are based on input from various sources, and averages and assumptions are made to present these cases. For development of your own specific ROI, please complete the attached worksheet on page 25 and contact your local sales representative.


Workflow Value Propositions Construction / Plant Modifications The Drivers

A plant begins to undergo change as soon as it becomes operational. Engineers receive requests from other groups, such as operations, maintenance, or process, to make changes and ensure that they are correctly implemented and documented. Some of these changes are executed internally, and some of the larger projects may be subcontracted to external EPCs. This presents a very complex scenario.

The SolutionSmartPlant P&ID will eliminate the confusion that can result when too many copies of the P&ID are in too many hands. SmartPlant P&ID helps you ensure that the P&ID accurately reflects the as-built plant at all times through the fast update and modification features, and you can maintain data accuracy through the engineering rules. You can provide accurate infrastructure data pertaining to current plant operations when requested, and check and verify changes to the existing plant design.

SmartPlant P&ID enables you to create and modify data through an easy-to-use, alphanumeric interface. This enables engineers to keep the P&ID up-to-date, without having to perform drafting work, because the updates are reflected in the P&ID drawing, which is a report from the database.

Worksharing capabilities allow the distribution and sharing of work among several subcontractors. When the P&IDs are returned, you can view the changes made by the contractor.

When systems need to be isolated for upgrades or maintenance, the connectivity in SmartPlant P&ID can find block valves or flanges that need to be blinded off to safely remove items. For example, a piece of equipment can be selected, and through filtering, all related first block valves can be identified and impacts to the overall process can be assessed.


TuPl

UEx

UAs

Nmc

Sm

Task Traditional Approach SmartPlant P&ID Approach Annual Savings Hours

Saved

rnaround anning

Involves creating the document set for the shutdown, and the changes to be made, as well as collecting various documents, checking accuracy/ consistency, and highlighting systems to be changed. Requires an estimated 2,000 hours to plan one turnaround.

SmartPlant P&ID makes turnaround planning faster and more efficient through its filtering capabilities. It saves 50% in man-hours and increases overall data quality.

Assuming 2 turnarounds per year and 1,000

hours savings at $50/hr. Savings:

1,000 hours x 2 turnarounds x $50 = $100,000.

1,000 hours saved per

turnaround.

pgrade/ tension

Same as above, with the addition of the involvement of a third-party engineering company. Requires an estimated 2,000 hours for planning and scope definition.

Same as above.

Based on 1 project/yr. and 1,000 hours savings

at $50/hr. Savings: 1,000 hours x 1 project x

$50 = $50,000.

1,000 hours saved per

project.

pdate Requires an estimated 15 hours to SmartPlant P&ID can significantly Based on 100 P&IDs per 7.5 hours
-built update the P&ID to as-built status. reduce the update cycle time via its
modification features and design rules to ensure data consistency. It can result in an estimated 50% savings in the update cycle time.

year and 7.5 hours saved per P&ID at $50/hr. Savings:

100 P&IDs x 7.5 hours x $50 = $37,500.

saved per P&ID.

ote: See example configuration on page 8. The ROI cases are based on input from various sources, and averages and assumptions are ade to present these cases. For development of your own specific ROI, please complete the attached worksheet on page 25 and

ontact your local sales representative.

artPlant P&ID Benefits for Plant Owner/Operators Résumé Page 11


Operations / Process The Drivers

The market, regardless of the product, is a moving target. Plant owners must be flexible to comply with market demands and work with available materials in order to produce their product in the right quantity, with the right quality, at the lowest possible cost.

The operations and process team plays a key role in this scenario. If product demand increases, they must ramp up production. If demand decreases, they must reduce production while ensuring the plant still runs safely and efficiently. Or, if the feedstock changes, they must adjust the process accordingly to ensure the same, or higher, product quality.

The SolutionSmartPlant P&ID enhances plant operations/processes by interfacing with upstream process analysis tools, such as those provided by AspenTech. The rules built into SmartPlant P&ID also play an important role by ensuring data/design accuracy. If any inconsistent data is introduced into the P&ID design, the rules will automatically flag the error, and the engineer will be alerted that a discrepancy exists across the complete system or project. For example, if pressure and temperature do not comply with an assigned pipe specification, the system will automatically flag the inconsistency. This helps designers, engineers, or process administrators make changes quickly and correctly, and avoids after-the-fact surprises that may result in higher costs and delayed production.


What Our Customers Say About

SmartPlant P&ID:

Engineers and designers at ALSTOM Power Sp. z o.o. in Lodz, Poland, use SmartPlant P&ID. “We chose SmartPlant P&ID because it was easy to customize to meet ALSTOM

requirements,” said Marcin Sliwinski, designer for the

ALSTOM Power Plants Engineering division.

With SmartPlant P&ID, various European ALSTOM Power offices can simultaneously perform extensive design

work on the same project. “SmartPlant P&ID’s

worksharing capability gives us great success in our processes and helps us

save time in engineering coordination,” said Sliwinski.

The site previously used a CAD system, but as Sliwinski notes, “we can now train our

operators more quickly because SmartPlant P&ID

is easy to learn.”

“SmartPlant P&ID is integrated with our PDS

reference database,” said Sliwinski. “To maintain data

quality, it is very important that we use the same

database master and common standards in all site locations.”

ALSTOM serves the energy market through its activities

in power generation, delivering total solutions

from components to turnkey power plants.


Annual Savings

Hours Saved

Production Changes

Activities include updating process model and PFD/ P&ID/ equipment data once a month. An estimated 100 hours are required to investigate engineering-related data and update the P&ID.

Enable quick updating of engineering-related data, and easy identification and resolution of engineering inconsistencies, resulting in a 50 percent savings.

50 hours savings each

month at $50/hour. Savings:

50 x 12 x $50 = $30,000

saved.

50 hours saved each

month.

Feedstock Changes

Same as above. Same as above. $30,000 saved.

50 hours saved.



Workflow Value Propositions Training The Drivers

Following project completion, new or existing plant operations personnel will require training to bring them up-to-speed on the new facility changes resulting from a project, such as revamps, capacity changes, and new process lines. Training is important to ensure that all personnel know how to act and react under both normal and abnormal conditions.

The SolutionBecause the P&ID depicts most lines, equipment, and instrument functions, it is an ideal starting point for explaining the plant configuration and functions. SmartPlant P&ID serves as an excellent training tool, because the P&ID can be projected onto a screen, and the equipment and systems can be displayed and interrogated using SmartPlant P&ID’s filtering capabilities. Critical systems and safety systems can be displayed, including first-aid equipment such as eyewashes and firewater systems.

Using SmartPlant Explorer along with SmartPlant P&ID can enhance the training process by allowing the P&ID to be viewed through a Web browser. Related data such as detailed instrument loops or the 3D model representation can also be shown, enabling viewing of the physical facility layout, including stairwells, corridors, and escape routes. This allows comprehensive training to be conducted entirely in the classroom, without the need to disturb the production process or request special permits. SmartPlant P&ID makes the training process much more efficient, and provides plant owners with well-trained operators who can capably care for the facility and keep it running smoothly.


Task Traditional Approach SmartPlant P&ID Approach Annual Savings Hours Saved

Training of New Operators

Involves understanding of the plant and process systems. The P&ID provides the roadmap to the plant, helping new operators understand the plant configuration, critical systems, and/or hazardous locations. A traditional approach could involve the use of paper P&IDs, which could be inaccurate and/or outdated.

Using SmartPlant P&ID, different plant systems can be highlighted, and the connectivity between equipment and systems can be easily shown. The software also enables filtering on critical process conditions, which results in better-trained personnel.

$5,000 estimated

savings, since training varies

based on individual plant requirements.

Varies.




Reliability What Our Customers

Say About SmartPlant P&ID:

Rayong Olefins Co. Ltd. (ROC) selected SmartPlant P&ID, SmartPlant Explorer,

training, and consulting serv-ices. Realizing that accurate information is crucial for the plant life cycle, they decided to convert their existing data. ROC used contract staff and

in-house services for the conversion of their hardcopies

and AutoCAD P&IDs to the SmartPlant P&ID format.

Intergraph customized the initial reference database, with

ROC staff members performing the drafting and

conversion work.

The entire conversion process lasted about six months for

drafting and checking of the converted P&IDs. ROC then

released the documents to the Operation and Maintenance team. The ROC plant facility

was designed and built using Intergraph solutions.

ROC is a producer of upstream petrochemicals

mainly used as a feedstock for polyethylene and polypropylene resins. ROC is a division of Siam

Cement Group, one of Thailand’s largest businesses and a petrochemical leader in

the Asia-Pacific region.

The DriversInstruments and equipment that break down unexpectedly are unwelcome surprises for any operator. Not only must the item be repaired – if it is critical to production, it can impact productivity and plant safety. Preventive maintenance, of course, is key to assuring uninterrupted production, but the question remains – what should be checked, and when?

The SolutionTo better plan the replacement process, take advantage of SmartPlant P&ID’s reporting and query functionality to determine all the tasks that need to be performed. For example, if a plant item were due to be replaced in three months, a report would highlight the system to be replaced and help you schedule the different tasks that need to be performed.

Through the enforcement of its design and connectivity rules, SmartPlant P&ID can help take the guesswork out of preventive maintenance. It allows maintenance personnel to locate potential problem components, minimizing plant downtime. The querying capability also enables the automatic generation of critical component lists for turnarounds and scheduled maintenance downtimes, such as critical flange lists.

By teaming SmartPlant P&ID with a reliability solution, such as Meridium, and using the solution’s query capabilities, the plant reliability team can plan the scheduling of preventive maintenance in a timely manner, conserving resources and minimizing costs, while avoiding unscheduled shutdowns and lost productivity.

SmartPlant P&ID helps on the front end to find and manage components. Based on the history of certain components and process conditions, your reliability analysis system can help you determine how well different components perform. For example, the reliability system may report that one component typically lasts longer than another type of component. This means that you can choose the best-of-class solution for a certain process, improving productivity and revenue.


Equip

InstruAnaly

Note: Smade tocontact

Smart

Task Traditional Approach

SmartPlant P&ID Approach Annual Savings Hours Saved

ment Analysis 50 hours for data collection and verification per analysis run.

Allows direct interface to the reliability analysis, avoiding data re-entry. Consolidates all disparate data into SmartPlant P&ID, providing a single source of truth.

30% savings over the traditional 50 hrs. 15 hours savings per equipment item, for an estimated 10 major equipment

items. Savings: 15 hours x $60 x 10 items = $9,000.

15 hours per

equipment item.

mentation sis

50 hours for data collection

Allows direct interface to the reliability analysis, avoiding data re-

30% savings is 3 hours per critical loop. Analyzing 200 critical loops per year.

3 hours per critical loop.

and verification per analysis run.

entry. Consolidates all disparate data into SmartPlant P&ID, providing a single source of truth.

Savings: 200 loops x 3 hours x $60 = $36,000.

ee example configuration on page 8. The ROI cases are based on input from various sources, and averages and assumptions are present these cases. For development of your own specific ROI, please complete the attached worksheet on page 25 and

your local sales representative.

Plant P&ID Benefits for Plant Owner/Operators Résumé Page 14


Research / Development / Engineering The Drivers

The drivers of research and development are similar to those of operations/ process. Depending on market demands, the plant owner may decide to change facility processes and begin producing other products, or alter the composition of the existing product.

Research, development, and engineering groups primarily focus on simulation-type software and laboratory work, but at some point in time, this research must be converted for use in the physical production facility. The first step toward achieving this end is through the process flow diagram (PFD) to the P&ID.

The SolutionSmartPlant P&ID can assist the research team by providing the infrastructure and data associated with current plant operations. They can use SmartPlant P&ID’s querying (filtering) capabilities to interrogate, highlight, and document existing plant systems and associated data. When changes are introduced to the existing design, they will be checked and verified by SmartPlant P&ID’s rules to ensure the design is consistent throughout the entire facility. This drastically reduces time spent on design verification, and can result in significant cost savings. In addition, the SmartPlant P&ID design can be viewed via a Web-based browser (using SmartPlant Explorer) for ease of review by management. The end result is a faster and more efficient pathway to a new design that will meet new market demands.


What Our Customers Say About

SmartPlant P&ID:

Lyondell Chemical Company chose SmartPlant

P&ID for their new world-scale propylene oxide (PO) facility, known as the PO-11 plant, in Rotterdam, The Netherlands.

“We selected SmartPlant P&ID because we already use or plan to use several

Intergraph products, including INtools and SmartPlant Foundation,” said Cees

Cornelissen, Senior Application Engineer at

Lyondell Chemical Company. “Also, our EPC contractor

is delivering our PO-11 plant P&IDs in the

SmartPlant P&ID format.”

Process engineers and the project organization will use

SmartPlant P&ID. Operations and maintenance may also

use the software.

“In the future, we will possibly integrate SmartPlant P&ID

with SmartPlant Foundation,” said Ferry Zuiderwijk,

Application Engineer from Cadview, a Dutch service

provider for engineering tools, on-site at Lyondell

Chemical Company.

Lyondell Chemical Company is a leading producer of

propylene oxide (PO) and PO derivatives, including

propylene glycol, butanediol and propylene glycol ethers. Headquartered in Houston, Texas, its operations span

the United States, South America, Europe and Asia.

PC

SmartPlant P&ID Benefits for Plan



roduction Activities associated with SmartPlant P&ID’s 500 hours saved 500
hanges production changes, such
as studies of existing process facilities and run capacities, plus specifications of lines, equipment, and instrumentation, require an estimated 2,000 engineering hours per year.

design rules and interfaces to up- and downstream tasks can save an estimated 25% of the engineering hours associated with FEED design.

per year x $50/hour =

$25,000 saved.

hours saved

per year.


t Owner/Operators Résumé Page 15


Workflow Value Propositions Maintenance What Our Customers

Say About SmartPlant P&ID:

SmartPlant P&ID is used as a design communication tool for

the BP Grangemouth Fluid Catalytic Cracker Unit (FCCU)

revamp project. The key documents for the project

are the piping and instrument diagrams and the line

information, which combine to form the contract scope document. This document plays a central role in the design process for data,

serving as the basis to design, update, and check

the 3D model.

"SmartPlant P&ID helps us better integrate our process

mechanical design infor-mation, and the line list is

centralized. The links to PDS and INtools give us

greater information integrity, and one engineer can

control the database," said Thomas Vaughan,

engineering manager for the BP Grangemouth

FCCU project.

BP p.l.c. is the holding company of one of the

world's largest petroleum and petrochemicals groups.

Grangemouth is BP's only U.K. site that has three of

the company's major businesses – Exploration, Oil and Chemicals – together in

one location.

The DriversWhether plant maintenance is scheduled or unscheduled, maintenance personnel turn to the P&ID for the information they need to perform their tasks. They need quick access to up-to-date information, and they also need tools to help them update the P&ID to accurately reflect the as-built plant.

The SolutionSmartPlant P&ID allows maintenance personnel to locate potential problem components, minimizing plant downtime. You can add information about a component, such as the last inspected date and its approval status, to the P&ID. Because SmartPlant P&ID is a data-centric solution, you can perform filtering or reporting using certain criteria. For example, you can filter on all the instruments that have failed inspection in the last month. The P&ID itself does not perform analysis, but it can be a powerful front end to management or reliability analysis tools by helping you identify the plant elements needed for analysis.

SmartPlant P&ID’s querying capability helps you quickly search for the location of critical instruments within a process system, or for specific equipment components. The querying capability also enables the automatic generation of critical component lists to minimize scheduled maintenance downtimes. Additionally, by making maintenance information readily available, SmartPlant P&ID helps ensure safe plant operation and shutdowns, which promotes compliance with OSHA 1910 and other regulatory standards.

Creating maintenance packages, which include all information associated with a particular system, is a major, time-intensive task. SmartPlant P&ID speeds up the process. SmartPlant P&ID also provides access to related data, such as instrumentation data in INtools. This significantly reduces the time spent searching for data, yielding a higher quality, more consistent representation of the data requested. Fewer documents and less data are created and managed over the life of the plant, because SmartPlant P&ID presents views of the data which can be turned off after the work is complete and updates have been made and stored in the SmartPlant P&ID database.

SmartPlant P&ID enables you to maintain multiple versions of the P&IDs to make comparisons and roll back your design to earlier versions if desired, even across projects. One of SmartPlant P&ID’s strengths is that its rules will automatically check to ensure that changes do not violate any of the design standards across the entire project. SmartPlant P&ID is also simple to use. Small modifications such as a new or upgraded instrument or piping jumpover could be updated on the P&ID by an operations, engineering, or maintenance administrator very quickly. SmartPlant P&ID also supports the approval workflow.



PrM

EmM

Ou

Smar

Task Traditional Approach SmartPlant P&ID Approach Annual Savings Saved eventive aintenance

Involves collection of current data and organization per circuit, requiring approximately 4 hours per system.

SmartPlant P&ID’s filtering capabilities provide access to data in a matter of minutes. Line list data and equipment list data are automatically consolidated, saving substantial time. The interface to Meridium enables efficient organization of maintenance data.

Assuming 100 circuits per year, 3.5 hours per circuit, and

$50/hour. Savings: 3.5 hours x 100 circuits x

$50 = $17,500.

3.5 hours saved per

circuit.

ergency aintenance

Involves locating related system information (P&IDs and instrumentation data) and determining the impact on the process, requiring approximately 3 hours and possible production shutdown.

Using SmartPlant P&ID, data can be located via a simple query, and the link to instrument systems quickly provides an accurate data set to promptly address emergency maintenance issues.

Assuming 50 incidents per year, at 3.5 hours an incident, and

$50 an hour. Savings: 3.5 hours x 50 incidents x

$50 = $8,750.

3.5 hours saved per incident.

tages Standard methods are not Using intelligent P&IDs can Assuming $800,000 per day per 0.3 percent
effective at reducing outages. reduce outages. unit in shutdown costs. Savings:
$800,000 x 365 days x 0.3% = $876,000 / unit.

reduction in shutdowns.


tPlant P&ID Benefits for Plant Owner/Operators Résumé Page 17


Utilities

The DriversIn many plants, a special team is responsible for the utilities needed to keep the plant running. These utility installations are often large and complex, and are vital to the plant. They not only require regular maintenance – often, they also require changes of capacity or additional distribution points as a result of plant process changes.

The SolutionSmartPlant P&ID can promote the maintaining, repairing, and upgrading of plant utilities by providing fast, easy access to the P&ID data, updates, and/or modification tools. The same powerful query capabilities and rules that drive the features used by the other groups can assist the utility team in locating utility systems, checking capacity, and verifying that any changes made are compliant with accepted engineering practices. This significantly improves the efficiency of the utility team and helps ensure that the plant has a reliable utility network. Through its connectivity, SmartPlant P&ID offers the ability to check on impacts across the plant unit.


SysUp

Ma

Notemadcont

Smart



tem grades

Involves calculation of utilities consumption and needs and adjusting or upgrading the system accordingly. Must access process data and P&IDs. Approximately 1,000 engineering and planning hours are required per upgrade.

SmartPlant P&ID allows ease of data exchange and design verification. It also highlights the changes via a simple filter to make them readily apparent to construction/maintenance personnel. Saves an estimated 50% in man-hours.

2 utility checks & upgrades per year x 500

hours saved per upgrade x $50/hour =

$50,000 saved.

500 hours saved per upgrade.

intenance Involves accessing systems, SmartPlant P&ID’s filtering 50 systems per year x 3.5 hours

identifying critical systems, and determining impact of failures or shutdowns. Requires access to P&IDs and equipment datasheets, and an estimated 4 hours per system.

capabilities provide access to data in a matter of minutes. Line list data and equipment list data are automatically consolidated, saving substantial time. The interface to Meridium enables efficient organization of maintenance data.

3.5 hours saved per system x $50/hour =

$8,750 saved.

saved per system.

: See example configuration on page 8. The ROI cases are based on input from various sources, and averages and assumptions are e to present these cases. For development of your own specific ROI, please complete the attached worksheet on page 25 and act your local sales representative.

Plant P&ID Benefits for Plant Owner/Operators Résumé Page 18


Coordination / Technical Services The Drivers

Maintaining optimum product quality to keep and expand your market position is of utmost importance. Within the plant, the technical services group is responsible for closely monitoring product quality. This group monitors the end products as well as the base products or feedstock supplied by third parties.

Although this work is performed in a laboratory environment with tools and analysis software outside of the P&ID scope, the P&ID still plays a role in the technical services team’s work processes. Since feedstock composition and quality need to be adjusted frequently, the P&ID is used to check the plant configuration, equipment, and instruments to determine if adjustments need to be made in order to handle the intake of additional chemicals or modified feedstock.

The SolutionSmartPlant P&ID provides the ability to trace a complete stream, based on certain properties, helping to verify the physical components in that stream against the new conditions.

This process is traditionally very time-consuming, and plant owners often employ outside contractors to assist in handling the workload. By using SmartPlant P&ID, these resources can be used more efficiently, and can be tasked with critical production-related issues.


Task Traditional Approach SmartPlant P&ID Approach Annual Savings

Product Quality

Requires access to equipment and instrumentation data and process information to check production quality and adjust as needed. An estimated 50 hours per month are required to locate accurate P&ID data.

SmartPlant P&ID allows access to P&ID data via a simple Web interface. Filtering/reporting can be done on all engineering and process properties. Reports can then be created in Excel to document the findings. Approximate savings is 70%.

70% of 50 hours per month = 35 hours saved. Savings:

35 hours saved per month x 12 months x $50/hour = $21,000.

Process Design

A change in production may require a change in process design, and must be correlated with the physical plant specification as defined on the P&ID. A significant design change requires an estimated 1,000 hours to complete.

Same as above. SmartPlant P&ID can save 50% of the time typically spent on accessing engineering data and documentation.

2 significant process design changes/year x 500 hours saved per design change x

$50/hour = $50,000.

Quality Incident

Quality incidents are costly and can result in disastrous effects for plant production and revenue.

The interface from AspenTech to SmartPlant P&ID enables verification and management of plant configuration and process design. Eliminating just a single quality incident with SmartPlant P&ID gives you enormous benefits. Improve on-time shipments and help reduce non-optimal product quality.

The association of the plant configuration and plant items with the process data helps to prevent a quality incident

from occurring. Costs of these incidents can be significant.

Reprocessing a single product can significantly

impact productivity, costing hundreds of thousands of

dollars per incident.




Services – Value-added Implementation Take advantage of

SmartPlant P&ID Most plant P&IDs were created in a traditional CAD format such as AutoCAD or MicroStation. To take advantage of the new technology and financial benefits that SmartPlant P&ID provides, such as those described in the various workflows and ROI examples in this resume, the legacy data needs to be converted to SmartPlant P&ID.

Obviously, this is an important and critical step that requires: • Accuracy – All data must be converted with the highest quality • Speed – A quick conversion minimizes the disruption of operations

and reduces the overall conversion cost

Intergraph provides services and software utilities for fast, efficient, and affordable P&ID conversion. Migrate your AutoCAD, MicroStation, or AutoPLANT P&IDs to take advantage of all the benefits that SmartPlant P&ID offers. The intelligent, data-centric P&IDs enable efficient plant operations and interface with complementary solutions such as HAZOP analysis from HAZID or other solutions.

Budget Understanding that you want to plan your budget to avoid surprises, Intergraph offers a fixed conversion price per P&ID. This fixed price ranges from $200 to $300 US per P&ID, depending on the quality of your P&IDs. The exact cost can be determined after evaluating a sample set of the P&IDs. The cost is dependent on the structure and format of the P&ID. Very structured P&IDs with all layers/levels, colors, and line weights, for example, consistently convert with a very high percentage initial success rate and minimal manual work. Unstructured P&IDs have a lower automatic conversion rate and require more manual cleanup, resulting in a higher cost. Still, this price range is a very acceptable investment in comparison to the considerable savings projected.

Options Intergraph offers several options for your legacy P&ID data conversion to SmartPlant P&ID, offering maximum flexibility to meet your business requirements:

• Intergraph’s services department – Consultants are located around the world, including conversion centers in Poland and China, to provide conversion services.

• Intergraph partners – Take advantage of partners’ expertise. For example, Rolta is the preferred partner for conversion services in North America.

• Local service providers – Intergraph’s regional offices maintain local agreements with various service providers.

• EPCs – Major engineering companies such as Fluor make use of Intergraph’s SmartPlant Import Assistant (SPIA) tool for conversion work.

• In-house – Use the SPIA tool to perform the conversion work yourself. An Intergraph on-site consultant provides assistance as needed.

Services – Value-added Implementation Data quality An important part of the conversion services is the quality check

to ensure that the input is equal to the output. SmartPlant P&ID offers better functionality than traditional CAD in the sense that inconsistencies will be flagged. The conversion process will not correct engineering inconsistencies automatically, but once flagged, they can be resolved by your own group. Once all of your P&IDs have been converted, the P&IDs will have increased data quality because of SmartPlant P&ID’s engineering rules and consistency checks.

Add the value of SmartPlant P&ID

SmartPlant P&ID enables you to consolidate a number of your engineering plant databases, such as equipment data, valve lists, and line lists, into a single environment for maximum business advantage. You can add data either by consolidating databases or by enriching the P&ID over time through manual input into the SmartPlant P&ID environment. For instance, you may have a Microsoft Access database that contains equipment information. This database can be imported, because SmartPlant P&ID can manage the equipment data inside the P&ID, which ensures consistency and lowers costs by maintaining only one environment.



SmartPlant P&ID in Use Many companies have chosen SmartPlant P&ID, including: Who Has Chosen

SmartPlant P&ID and Conversion

Services?

• ABB Lummus • Aker Offshore Partner • ALSTOM Power Sp. z o.o. • BASF • BP p.l.c. • Chiyoda • Degussa • Fluor Daniel • Foster Wheeler • Jacobs Engineering • Lyondell Chemical Company • Mitsubishi Heavy Industries

• Murray & Roberts Engineering Solutions

• Rayong Olefins Company • Saudi Aramco • Siemens Axiva • Snamprogetti • Technip • Técnicas Reunidas • Tecnoconsult • Uhde GmbH • Westinghouse • Washington Group International

Some of the customers who have chosen Intergraph’s conversion services include Lyondell, Saudi Aramco, and Westinghouse.

References Degussa Corporation

Designers, engineers, and plant engineers at Degussa Corporation use SmartPlant P&ID during capital project engineering. "The product helps us reduce the cost of engineering thanks to its reporting and highlighting capabilities," said John Little, Piping Design, Systems and Drafting Manager.

SmartPlant P&ID is also used in Degussa plants to support compliance with regulatory programs such as OSHA Process Safety Management (PSM) and EPA Leak Detection and Repair. Little says, "SmartPlant P&ID helps us comply with regulations because we can highlight relevant systems on the P&IDs and then assign the extra data we need to help manage them."

BP p.l.c.

"When the Fluid Catalytic Cracker Unit (FCCU) revamp project was sanctioned, it was only natural that we should choose a system which would integrate with PDS, since we already had an existing PDS model of the majority of the plot area," stated Thomas Vaughan, engineering manager for the BP Grangemouth FCCU project. Grangemouth is currently undergoing a major transformation with the aim of ensuring a sustainable future as a major Scottish manufacturing site.

"A brief review of the other onsite systems, Rebis & Plant 4D, showed that they did not meet our requirements. Plus, the refinery chemical forum had requested that any new projects consider utilizing intelligent P&IDs."

The group previously used AutoCAD 14 for its P&IDs. "Data migration gave us the opportunity to re-work all of the P&IDs to the standard we required for a large project like this. The as-built exercise proved just how out-of-date our existing drawings had become," said Vaughan.

SmartPlant P&ID is used by BP's engineers, designers, maintenance, operators, and design companies. They plan to later integrate SmartPlant P&ID with CREDO and possibly MAXIMO.


Additional Information Resources We invite you to learn more about SmartPlant P&ID by visiting

ppm.intergraph.com/more for additional materials, including:

Product Information • SmartPlant P&ID: Maximizing plant productivity and reducing

project risks • SmartPlant P&ID Workshare Capability Promotes Global Engineering • What’s New in SmartPlant P&ID • Migration of Legacy P&IDs to SmartPlant P&ID • SmartPlant P&ID Integration with HAZID • P&ID Evaluation Project – SmartPlant P&ID versus Plant 4D P&ID • SmartPlant P&ID Modules

Article • Best Practices: Effective equipment data management important

to industry

Technology Partner Web Links • Meridium by Meridium Inc. • Aspen Zyqad by AspenTech (Aspen Technology Inc.) • HAZID by Hazid Technologies Ltd.

Glossary Following is an explanation of some of the abbreviations used in this document.

• CAPEX – capital expenditure

• FEED – front-end engineering design

• Intergraph PPM – Intergraph Process, Power & Marine

• PFD – process flow diagram

• P&ID – piping and instrumentation diagram

• RBI – risk-based inspection

• ROI – return on investment

• SPIA – SmartPlant Import Assistant

• TEF – The Engineering Framework

• TIC – total installed cost

Return on Investment Calculation Worksheet

Explanation

SmartPlant P&ID is a powerful product that pays for itself in one year through savings in maintenance funding. Now that you have seen how SmartPlant P&ID has helped other owner/operators, discover how it can help you. Determine the Return on Investment that SmartPlant P&ID offers with the worksheet on page 25. Complete the form and then return to your salesperson for a customized analysis.


Page intentionally left blank

SmartPlant P&ID

Return on Investment Calculation Worksheet To receive a customized ROI calculation, simply complete this worksheet and return to your salesperson, or see the back cover for contact information. Type of plant (chemical, process, etc.): ___________________

Number of engineering resources employed: ______________

P&ID format: MicroStation AutoCAD PDS Rebis Other:_________________________

P&ID structure:

Unstructured (no symbols or application used)

Structured (all symbols and applications used)

Please list the average number for each of the following departmental questions:

Inspection/Environmental Risk-based Inspections checked per month ______ Project Management Systems checked per month _________________________________________ HAZOP analyses each year __________________ Others – please describe type and frequency ________________________________________ Maintenance/Construction Preventative maintenance worksheets completed per month_________________________________ P&ID walk-downs per month __________________ Others – please describe type and frequency _________________________________________ Engineering Engineering projects each year ________________

• P&IDs per project ____________________ Turnarounds each year ______________________

• P&IDs per turnaround__________________ Others – please describe type and frequency _________________________________________ Technical Services Production changes each year_________________ Process updates for quality improvements each year_____________________________________ Others – please describe type and frequency __________________________________________

Training Training classes your staff attends each year _________________________________________ Reliability Equipment analysis items per month____________ Instrument analysis items per month____________ Static equipment analysis items per month_______ Others – please describe type and frequency ________________________________________ Operations/Process Product optimization major cases per month _________________________________________ Others – please describe type and frequency _________________________________________

Utilities System upgrades each year__________________ P&IDs per system upgrade ___________________ Others – please describe type and frequency _________________________________________

Research/Development New process/product designs or expansions performedeach year _________________________

• P&IDs involved per process/ product design ___________________________________

Others – please describe type and frequency __________________________________________




Why Choose SmartPlant P&ID? SmartPlant P&ID will add value to your company’s work process and

bottom line by providing an efficient way to manage P&IDs throughout the plant life cycle. Created for the process, power, and offshore industries and constantly improved through customer input, SmartPlant P&ID has an excellent fit in all industry segments. A component of Intergraph’s SmartPlant design and data management solutions, it is integrated with complementary tasks such as instrumentation, electrical, piping, data management, and Web browsing for engineering data. The customer references provided show clearly that SmartPlant P&ID is a proven solution with a solid track record and measurable benefits in terms of saving work hours, and construction and operating costs.




Headquarters Process, Power & Marine Intergraph Corporation 300 Intergraph Way Madison, AL 35758 1-800-260-0246 or 1-256-730-3707

For Process, Power & Marine International Locations Americas Canada 1-800-661-8134 Mexico 52-55-5525-5594 Venezuela 58-212-959-5344

Asia-Pacific 61-2-9929-2888

Europe Central 49-89-96106-0 Eastern 48-22-5658-800 Southern 39-02-57545-1 Western & Africa 44-1793-492500 Middle East 971-4-3367555

For more information about Intergraph Process, Power & Marine solutions, visit our Web site at ppm.intergraph.com.

Documents

SmartPlant® P&ID Benefits for Owner Operators - A Resume