Synergy Planr Presentation

1. DNV GL © 2016 04 April 2016 SAFER, SMARTER, GREENER
DNV GL © 2016
SOFTWARE
Synergi Plant
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A holistic plant integrity and reliability management platform
Tommy Tang
Plant Integrity Software product architect
DNV GL Software

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Question:
How do you
predict and monitor
potential damages, impacts and financial losses
for your assets in the plant,
and
make sure the risk is reduced continuously?
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Did you know …
 A proper implementation of asset integrity/reliability software solution
can help you to prevent more than USD 100M potential financial loss
every year?
 You may waste 90% effort doing unnecessary inspections and
maintenances, while the most critical 10% are missed?
 You can plan the plant inspection and maintenance based on
quantitative risk, predict and monitor the risk change in the coming
years on a management dashboard?
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What if you can …
 Get help to know about the available software in the market, and assess the
level of depth you need to implement an asset integrity/reliability software
with a prototype or pilot study
 Save more than 50% of your inspection cost and prevent more than 50% risk,
and at the same time measure and justify your return on investment for the
asset integrity/reliability solution in a dashboard
 Manage future asset risk quantitatively, plan your inspection and maintenance
efficiently, and change the software configuration easily, all by open your
browser anytime, anywhere
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Before doing it, do you know how to measure your success?
Financial Return$
Reduce 1 unplanned shutdown
x 1 day production
x 150,000 bpd
x 50 USD
= 7,500,000 USD
Risk reduction (Potential risk cost)
Extend 1 year production
x 365 days
x 150,000 bpd
x 50 USD
= 2,737,500,000 USD
Life and inspection extension (Potential revenue)
- Reduce inspection cost
- Reduce maintenance cost
- Improve efficiency
Operational cost (Current cost)
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Asset integrity and reliability overview

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Did you know this is possible?
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Do you know where you are, and where you want to go?
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Are you doing everything risk-based on your way?
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Synergi Plant – Managing risk in your plant continuously
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Asset Data
RBI Scope RBI Analysis
Regulation Scope Regulation Schedule
Insp. &
Maint. Packages
Insp.
Recording &
Integrity
Assessment
Anomaly &
Notification
Maint.
Work order
（SAP，EAM）
Dashboard
and KPI
RCM / SIL
Analysis
RCM / SIL
Scope
Maint.
Recording

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You may want to know and focus on your goals beforehand
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No. Driver Count
1 Work planning - Risk based 33
2 Managing information verification and traceability 18
3 Work planning - Regular/Time based 14
4 Managing plant inspection and maintenance work process 13
5 Reliability based 10
6 Change in integrity best practice 9
7 Reports: Technical compliance management reports 9
8 Introduce new system to get higher position in the organization 6
9 Managing aging assets 6
10 Alleviate manpower or skill shortage 5

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Synergi Plant
- A holistic software platform from DNV GL
for integrity and reliability management

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What we can offer for asset integrity and reliability
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SYNERGI PLANT
• Facility management
• RBI, RCM and SIL
• Inspection and maintenance plan
• Work packaging and execution
• Integrity assessment and anomaly
• KPI, traffic light, and report
• Integration interface
SYNERGI STRUCTURE
• Structure data and model
• Structure RBI
• Inspection planning and recording
• 3D viewer
• KPI, traffic light, and report
• Integration interface
SYNERGI PIPELINE
• Pipeline data management
• Pipeline risk assessment
• Inspection data management
• Integrity and anomaly
• GIS and spatial
• KPI, traffic light, and report
• Integration interface
SYNERGI DASHBOARD
• Management overview
• Risk summary and trend
• Geographical risk view
• Integration and drilldown

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If you are one of these operators, Synergi Plant is for you
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Exploration
and Gathering
• Platform Topside
• FPSO, FSO, FLNG Topside
• Onshore Gathering Unit
• Terminal
• Storage Tank Farm
• Process Unit & Station
along the pipelines
• Refinery
• Chemical Plant
• LNG Plant
• Power and Utility Plant
Transportation
and Storage
Refine
and Production

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Synergi Plant today
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• Fully web-based and cross
browser, can be hosted on
cloud
• 48 customers in 20+
countries, use IDMS and
other modules like RCM or
MMS, with 100+
customers using the
standard RBI module.
• 4 major types of SAP
integration
• 1 system supporting
various configurations for
all customers
• Link from expert tools to
management dashboard
• Migrated modules from
GL’s Galiom AIMS
software

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We respect and learn from our customers
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CPC
USI
KOC
SAMIR
INEOS ABS
CNPC
GS CALTAX
DONG
ENERGY
STAATSOLIE
GNPOC
CAIRN
ENERGY
SALALAH SMC
SCG
(REPCO)
ADMA OPCO
BW OFFSHORE
PCS
STATOIL
BP NCSP &
GUPCO
SINOPEC
INEOS
PTT
MURPHY OIL CARIGALI HESS VICO PEMEX QAPCO
PREMIER OIL
BANGCHAK
INDIAN OIL
TIGF
SAMARA
NAFTA
GDC ADGAS CENTRICA
EMAS
OFFSHORE

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Dashboard
Fit for purpose – Select the modules you need
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Hierarchy and
Asset Model
Technical
Detail
Document
and Drawing
Onshore RBI
(API 581)
Offshore RBI
(DNV G 101)
Tank RBI
(AST RBI)
Bespoke RBI
Regulation &
Scheduling
Package
Report
Inspection
Detail Scope
RCM
SIL
PM & TPM
Scheduling
Maintenance
Packaging
Inspection
Job and Task
Inspection
Recording
Inspection
Attachment
Maintenance
Job and Task
Maintenance
Recording
Security and
Admin
Integration
Data Loading
Formula and
Rules
Reference
Data
UOM and
Currency
Asset Report
Anomaly
Management
Layout Design
Workflow
Engine
KPI and
Traffic Light
Inspection
Report SAP
Interface
Maximo
Interface
Data Logger
Interface
Scada / MES
Interface
Asset Data
Management
Integrity
Assessment
Inspection
Work
Management
Reporting
Supporting
Functions
Inspection
Planning
Safety Critical
Reliability
Assessment
Maintenance
Planning
Maintenance
Work
PSV
Management
Integrity OP.
Window
Formatted
Key
Management
of Change
Power Plant
RBI
Maintenance
Detail Scope
Maintenance
Attachment
To Do List
Dashboard
Interface
Safety Critical
Element
Inspection
Packaging

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Usability – Use your browser anytime, anywhere
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- User definable themes
- Toolbar and buttons
- Matrix layout - Combination of function driven and data driven usages
- Cloud enabled

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Usability – The comprehensive offline RBI tools
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- Convenient data population and editing
- Easy calculation
- Aggregated output reports
- Integrated with Synergi Plant web modules

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Flexibility – Define the practices and libraries for your needs
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Reference codes
RBI Configuration
RCM and SIL Configuration
Property and datasheets
Security and Admin

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Visible success - Build your own KPI dashboard
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Asset conditions
Assessment Results
Inspection and Maintenance Status

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Industry 4.0 – “Cyber-physical” digital asset eco-system
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Harvesting
environment data
(weather, population …)
Harvesting
inspection data
Harvesting
sensor data
Harvesting
Production data,
Reliability data, …
RAM analysis Risk analysis
Risk-Based Inspection
Reliability Centred
Maintenance
Analytics
Digital
Asset
Custodian

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Plant Ecosystem
- Core Processes & Analytics
Analytics
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QRA RAM SIL
RBI
RCM
Support for key
work processes
• HSEQ
• Asset
Integrity
Interfaces to
external systems
• SAP/CMMS
• SCADA/PCS
• CAD
Asset Centric
Digital Twin
Shared data
utilised by all
analyses
Results passed
back to digital
twin

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The Power of the Cloud
 Utilise the power of industrial cloud
investment in cyber security
– With thousands of companies using the
cloud, investment in security is many
times more and takes a holistic approach
 Only pay for what you use
– Scalable storage
– Scalable processing power
 Reduce overall costs of IT infrastructure
and software deployment
– Reduced hardware costs
– Reduced IT function costs
– Faster deployment to the business
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Synergi Plant RBI, RCM, SIL
and Inspection & Maintenance Management

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Fully quantitative RBI (risk-based inspection)
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Synergi Plant
RBI data and process
Configuration on Web
RBI standalong
Applications on PC
1. RBI Onshore (API 581)
2. RBI Offshore (RP G101)
3. RBI Power Plant

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Risk Based Inspection “Driving Factor”
Version
Slide
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% of Total Risk Vs % of Equipment Items
Plant Unit, ~500 Total Items
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
% of Equipment
%
of
Total
Risk
•Risk is not equally distributed among the individual pieces of
equipment.
•A large percent of the total unit risk is concentrated in a small
percent of the equipment.

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Risk Target and Inspection Planning
Slide
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Inspection
Target
Risk
/
Damage
Factor
(DF)
Predicted Risk
Increase
Now
Time to next
inspection
Highly Effective
Risk / DF
1st
Turnaround
Fairly Effective
2nd
Turnaround
Time

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Quantitative Risk-Based Inspection (RBI)
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Equipment Data and Inspection/Measurement History
(Pressured Vessel, Piping, Heater, Heat Exchanger, Tank, Compressor, PRV)
Risk Risk Risk Risk Risk
Inspection
Plan
Inspection
Plan
Inspection
Plan
Inspection
Plan
Inspection
Plan
Thinning SCC
External
Damage
HTHA,
Liner, etc
PRV
PoF CoF PoF CoF PoF CoF PoF CoF PoF CoF
Overall
Total
PoF
Total
CoF
Overall Risk
Overall
Insp. Plan

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Semi-quantitative and qualitative RBI (Bespoke RBI)
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1. Create RBI assessment 2. Select method and scope 3. Damage allocation
and pre-POF formula
4. PoF assessment 5. CoF assessment 6. Task selection
and approval

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RCM (reliability-centered maintenance)
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1. Assessment and scope 2. RCM screening 3. FMEA/FMECA/Risk
4. Logic tree analysis 5. Task selection
roadmap
6. Task selection
and approval

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CSS (critical safety system)
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1. Critical safety systems 2. PM cond. assessment 3. CM cond. assessment
4. Technical diagnostics 5. Assurance tasks 6. Work orders & records

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Inspection and maintenance planning
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Scheduling
Packaging

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Consolidate time-based and risk-based schedules
with packaging and re-grouping
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Schedule
Ad-hoc Job
Tag01-V3Y
Next 2010-08-01
Tag02-P1Y
Next 2010-09-02
Tag20-V3Y
Next 2010-08-15
EleX-Thinning
Next 2010-10-30
EleY-SCC
Next 2010-11-25
Execution Plan
TeamA-INSP-Q34
TeamB-INSP-Q34
VT-601
MUT-602
FollowUp-1
FollowUp-2
Master Plan
PlantA-INSP-Q34
Job-0001-Tag01
2010-08-01
Job-0002-Tag02
2010-09-02
PlantB-INSP-Q34
Job-0003-Tag20
2010-08-15
Job-0004-TagX
2010-10-30
Job-0005-TagY
2010-11-25
Job-0006-Tag30
2010-11-16
Generating Jobs

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Inspection and maintenance job execution
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Work recording
Anomaly and follow-up

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Configurable Workflow
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Inspection Job
Inspection Task
(UT, RT, etc.)
Follow-up
Task Selection
(Insp. Planner)
History Reporting
(Insp. Reporter)
Task Accepting
(Insp. Accepter)
Follow-up Request
(Insp. Reporter)
Follow-up Progress
(Insp. Reporter)
Follow-up Closure
(Insp. Reviewer)
End
End End
Task-out Task-out
Done
Approve
Re-do
Close
Redo
Done
Done
Task Review
(Insp. Reviewer)
Re-do Reject
Reject
Execution Plan
(Package)
Create
Execution Plan
Plan
Execution Plan
Approve
Execution Plan
Confirm
Execution Plan
End
Done
Done
Approve
Close Close
Complete
Create
Scheduled Job
Create
Ad-hoc Job
Add
Existing Job
Optional Optional
Optional

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Using Excel Templates for Offline Recording
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User-designable Task Reports
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Integrity and condition assessment
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Metal Loss and Remaining Life Corrosion Trending
Follow-up and Maintenance Notification
Risk re-calculation
New Risk and Inspection Plan

40. DNV GL © 2016 04 April 2016
Synergi Plant – Managing risk continuously
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Asset Data
RBI Scope RBI Analysis
Regulation Scope Regulation Schedule
Insp. &
Maint. Packages
Insp.
Recording &
Integrity
Assessment
Anomaly &
Notification
Maint.
Work order
（SAP，EAM）
Dashboard
and KPI
RCM / SIL
Analysis
RCM / SIL
Scope
Maint.
Recording

41. DNV GL © 2016 04 April 2016
SAFER, SMARTER, GREENER
www.dnvgl.com
Thank you !
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Tommy Tang
Tommy.Tang@dnvgl.com
+65-8699-5620