Excellence in All Plant Life Cycle Phases

1
Excellence in All Plant Life Cycle Phases

• 11th April 2005 PELC Conference The Hague
• Lyn Fernie, Director, Aker Kvaerner Engineering
  Services

2
Contents

• Introduction
• The challenges facing plant operators
• Integrity of plant data
• AK Plant Asset Lifecycle
• Engineering Change Efficiency
• Case Study Nuclear Application
• Conclusions

3
AK Engineering Services

• Leading provider of engineering solutions across
  the full asset lifecycle.
• Our focus is upon creation of mutual prosperity
  through long-term relationships with customers by
  applying our skills, technology and creativity.
• Our experience is in chemical, refinery,
  petrochemical, nuclear, pharmaceutical, water,
  non-ferrous and power.

4
AK Engineering Services - Life Cycle Capability
Adding Value through Innovation and
Technology Project Management Project Services
Systems Procurement Asset
ManagementInspection Alliances CDM EHS
Consultancy Risk Management Change Management
Commissioning, Testing and Inspection
Concept Studies Business Case
Engineeringand Design
Fabricateand Construct
Operate, Maintainand Overhaul
Debottleneck/Deconstruct

• Conceptual Design
• Imaging
• Business Studies
• Licence Expertise
• Safety Cases
• Development
• FEEP
• EHS Risk

• Process Design
• Front End Engineering
• Multi Discipline Engineering
• PED Module H
• Operating Models
• 2D/3D CAD
• CFD
• EHS Risk

• Workshops
• Subcontract Management
• Construction
• Installation
• Project Controls
• Constructability
• Safe Systems of Work
• EHS Risk

• Overhaul Management
• Asset Integrity
• Performance Alignment
• Reliability Productivity
• Project Prize
• Safety Reviews
• Planning Expertise
• EHS Risk

• UKAS
• Process Technology
• Technology Department
• In House Testing and Inspection
• Operator Training
• Plant Start Up
• EHS Risk

• Process Engineering
• Retrofit
• Decommission/Deconstruct Management
• Plant Operating Data Analysis
• Optimisation
• Troubleshooting
• EHS Risk

5
Classic Complex Plant Challenge
6
The Cost of Poor Quality Plant Data
Engineering Changes
CorrectiveAction
Confusing
IntermittentFailures
Schedule, Costand TechnicalOUTPUTS
Process
ICM
7
Continuous Improvement through Quality Data
Engineering Changes
Schedule, Costand TechnicalOUTPUTS
Process
ICM
8
The Benefits of Improved Information Quality
Based on 8 data sets used in series and each data
set at an integrity level varying from 75 to
100
ICM
9
AK Plant Asset Life-cycle

• In many industries the level of engineering
  information integrity is actually around 75 -
  this relates to resource effectiveness of only
  11 of its potential
• An increase of information integrity from 75 to
  83 improving resource effectiveness by 63, with
  consequent reductions of cost and shortening of
  project timescales.

10
AK Plant Asset Life-cycle

• AKES use Spescom eB as part of its ability to
  Manage the whole Engineering Lifecycle giving
  seamless transfer of information and knowledge
  from Phase to Phase.
• Initial Bid Response right through Design
  Build, through Handover, into Operations and
  Maintenance, even into Decommissioning.

11
AK Plant Asset Life-cycle
Constant EngineeringChange
12
Linking Silos of Information Around the Plant
13
A Typical Plant Change Management System
14
AKeB Engineering Change Efficiency
Client Activity
eB
Operations Maintenance
15
eB Engineering Asset Life-cycle

• So when a Change or Modification is required to
  the Plant a formal Change Request is raised
• We assess the Full Impact of the Change through
  eBs Change Effect Analysis capability, showing
  the Ripple Effect on all relevant connected
  items
• Change Approval cycles can be reduced by up to
  94 (actual experience at AmerenUE, SA Telkom,
  Nissan)

16
Handling a Plant Modification Under Change
Control

17
Calculating Change Effect Analysis Complex
document
18
Calculating Change Effect Analysis Complex
document
19
Case Study Nuclear Application

• AK Engineering Services are working with the
  British Nuclear Group on a Design Build project
  for Control Surveillance
• Creating and storing c2,000 drawings and
  associated diagrams and documents
• Linking these together and to the related
  physical items
• Transmittals function enables accurate and
  auditable distribution of drawings and documents.

20
Case Study Nuclear Application

• Investment is already positive
• Milestones consistently reached early (c20)
• Typical problems have been identified and
  resolved early in the Design phase, rather than
  expensively in the later Build stages
• As Changes are requested, re-work time is
  minimised as team can see the connections
• High Productivity (144), with Costs under
  control (94)
• Reduced project risk, simple user environment.

21
Conclusions

• Summary - AK Engineering Services have
  established a successful Plant Lifecycle Model
• It has formed an Alliance partnership with
  Spescom, and are jointly delivering projects
  which have a shared risk reward business model
• AK Engineering Services are planning that further
  implementation of eB should involve integration
  with other systems and applications