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TRANSCRIPT
By: AJAY Mathur
Managing Physical Assets to deliver business
outcomes cost effectively – Mumbai 12/10/17
Slide1
ENGINEERING SERVICES SOLUTIONS
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
AGENDA
1. Background
2. Cx Requirement
3. How Cx helps in AM
4. Challenges and opportunities
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
OUR 21ST CENTURY WORLD
• We live in complex , 24x7 world
• Critical infrastructure include:
➢FPSO/RIGS/Refineries
➢Rail/Airports/Ports
➢Power Generation
➢Data Centre/Telecom
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
OUR WORLD
– Any failure or Downtime is not acceptable!
• Fukushima’13/Chernoby’86
• Piper Alpha’88/GOM Deepwater Horizon’10
• BHN (Bombay High North) Platform Fire;05
• Texas City Refinery’05/Union Carbide ‘77
• US Northeast power blackout ‘03
• Mumbai Flooding during monsoons
– This means asset should be in managed well through its life cycle
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Cx and ISO 55000
• ISO 55001 AMS also covers the design, construction, commissioning, O&M and decommissioning / replacement of plant, equipment, facilities, as well as fixed assets and digital / IT assets
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ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
IS0 55500 and Cx
• The standard spells out the general principles for good management and governance of the AMS and processes.
• However, it leaves it up to the owner operator to decide how and at which level of detail to implement the standard.
• So Cx gets limited attention in AMS
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Managing Risk with Assets and make them Profitable
• Commissioning is a Key Element of AMS which impacts an assets ROI
4 O
& M
3 Test &
Comm
issioning
2 Plan and
Construct
1 Design
&
Procu
re
5 Retire/Decommission
ASSET MANAGEMENT
AND
COMMISSIONING
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Why Commissioning makes Sense!
Lif
e C
ycle
Co
st %
100%
50%
20%
2YEARS 3Month 20 Years1
Year
Design and ConstructAcquire
CO
MM
ISS
ION
ING
O&M
Re
tire
an
d
recy
cle
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Commissioning : Not a New Field
ClientCommissioning
Engineer
Construction
Team
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
12
Project Development: Typical Project Framework
Project Planning Project Implementation
Evaluation &
Definition
FEED
Contracts
PEP
Estimate
Engineering and Procurement
Fabrication
Construction
Commissioning
Operations
Startup
Concept
Project Approval
Plan the
Work
Work the
Plan
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Commissioning Process
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CONTRACT REQUIREMENTS
DRAWINGS
PROCESS/SYSTEM
DESCRIPTION
FUNCTIONAL SPECS
O&M MANUALS
SIMULATIONS
FMCEA/RELIABILITY
APPOINT CX MANAGER
PREPARE CX PLAN & SCHEDULE
PREPARE MOS & SOP
PREPARE CHECKLIST
ALIGN CX & CONSTR. SCHDL.
PRE COMMISSIONING PHASE 1
MECHANICAL COMPLETION AS BUILT
DRAWINGS
INSPECTION RECORDS
PERFORMACE GUARNTEE INFO
PUNCH LIST
WISH LIST/NICE TO HAVE
PERFORMANCE OPTIMIZATION
TEST RECORDS
OPERATE COMMISSIONING
PHASE 2(DRY)
INTEGRATION/RELIABILITY/ACCEPTANCE TEST
COMMISSIONING PHASE 3 (WET/ERFORMACE)
INPUTS OUTPUTSCOMMISSIONING PROCESS
FORM CX TEAM
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Cx examples
• EHV Power Cable Tunnel- Integrated Cx
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Cx examples
Metro train
–Interference Performance
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Cx examples
• Semi Sub Rig
-Thruster String
VFD
Make- SIEMENS , 4160V,
3 Phase,60Hz 4000kw,
Star, 680A, pf-0.84,
Duty –Single Quadrant Vector Drive,
11 KV,3ph, 60 Hz.
MV
SWITCHBOARD
FLEXIBLE
CT
HIOKI
LOGGER
M
THRUSTER 6
Make- LOHER, 4160V, 3
Phase,60Hz
4000kW, Star, 680A,
pf-0.84, Duty -S1,
2x 3core,
3 phase
cable
THRUSTER TRANSFORMER
Make- TRANSFOR, 4800kVA, 3 Phase ,60Hz
V1-11kV (225A)/2200V(638A), Dd0.25
V2-11kV (225A)/2200V(638A), Dd11.25
DC
FLUKE
LOGGER
FLEXIBLE
CT
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Cx examples
• BSL Lab
- Energy Performance
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Cx Examples
• LNG Plant
- Gas Metering Validation
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Some AM Challenges
–Teething Problems
–Premature failures and breakdowns
–Energy inefficiency
–High Opex
These issues are linked to Cx!
Proper Cx can go long way to reduce impact on above issues
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Challenges in Infra CX
• Project never gets 100% complete
• Start up loads/output • Optimization challenge• Long infra life 60-100 years• High Cost of Decommissioning
( Nuclear/offshore > OPEX)
• Continuous upgrade• Needs continuous Cx
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Future Opportunities
• AM plans must align with Cx standards that guide investment and mesh with overall strategy.
• AM Strategies that have adopted Cx and Continuous Cx report strong
benefits and satisfaction.
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Conclusions
• The current state of both Cx and AM is far from ideal, leaving companies/govt exposed to greater costs and risks than necessary.
• India as fast developing infrastructure economy has is in right moment to embrace AM and Cx
• EPC and BOT contracts could benefit by incorporating AM and Cx process as part of project delivery
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Queries?: Mr. Ajay Mathur, B. Eng, M.Tech., M.Sc.Hp: ++ (65) [email protected]
Your Partner for Engineering
Services & Solutions
www.PowerQTech.com [email protected]: (65) 67790225 Fax: (65) 67790155
21 Bukit Batok Crescent #07-73WCEGA Tower, Singapore 658065
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
Speaker Profile
• Technical Director in PowerQ technology Pte Ltd Since 2000
➢ B.E. , M.Tech. degree –India
➢ M.Sc., NUS
➢ BOSIET Certified for Offshore
➢ NEBB USA Certified for Cx Professional
➢ BCA - CSCPM
• Involved in Cx of following projects :
➢ Pharma (GSK, Novartis, Abbott,Pfizer, Roche)
➢ Biosafety labs (GSK, MSD)
➢ Tunnels ( 400kV Tx Tunnel, MCE Tunnel)
➢ Semiconductor plants (Micron, Samsung Siltonics, Seagate)
➢ Oil and Gas ( P81 Platform, Neste Oil refinery)
➢ Buildings (MBS, SSH, Terminal 4)
➢ Metro (MS-RTS/Jakarta LRT), Metro CD shelter
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ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
About PowerQ
▪ Inc. in 2000 as Pte Ltd Co in Singapore.
▪ Co. Reg. No. 200003680R
▪ ISO 9001, OSHAS1801and NEBB USA Cx certified
▪ Active in Projects in Asia
▪ Equipped with Software, Instruments and trained design and engineering staff
▪ Professionally audited Company
▪ Company, Staff and Third Parties insured
▪ Investment in own office, vehicles etc.
▪ Proven track record
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
About PowerQ
▪ Inc. in 2000 as Pte Ltd Co in Singapore.
▪ ISO 9001, OSHAS1801, Biz Safe Star and NEBB USA Cx certified
▪ Active in Projects in Asia
▪ Equipped with Software, Instruments and trained design and engineering staff
▪ Professionally audited Company
▪ Company, Staff and Third Parties insured
▪ In house Clean room, Labs etc.
▪ Proven track record
ENGINEERING SERVICES SOLUTIONSENGINEERING SERVICES SOLUTIONS
PowerQ Services
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PowerQ technology Pte Ltd operating through Singapore
Since 2000
Services
Projects and Commissioning Management
Specialized Engineering Consultancy.
SKM/ETAP/EDSA Power System Design and Analysis.
Electrical Power Quality EMF/EMC Quality Solutions
SAFOP, System Assurance and Reliablity Solutions
NEBB Certified Commissioning of Mechanical, Environmental ,
HVAC & Plant Utilities System.
Control System Integrated Testing.
Plant Operation & Maintainenece Audits, Validation
Troubleshooting & Optimization
www.powerqtech.com