topsides4.0 optimizing o&g production

© Siemens Energy, 2020

1

July 2020 Siemens Energy is a registered trademark licensed by Siemens AG.

Topsides4.0 – Optimizing O&G Production

More efficient | More reliable | Safer


2

July 2020 © Siemens Energy, 2020

2

July 2020

Agenda

1 Digitalization landscape 10

2 Topsides 4.0 OverviewHow does Topsides 4.0 compare to your digital

vision?

30

3 Topsides 4.0 Differentiators

- Low risk project delivery

- Digital out of the box

- Ready for low manned operations

10

10

10

4 Discussion & Next steps 20


3

July 2020

The Digital Maturity Journey

Remote

Commissioning

& Support

Remote

ControlWork process

Changes/

Improvements

Low manned

Operations

Normally

Unmanned

Operations

Virtual

OperationsHigher level of

Automation/

Control

DecisionSupport

What-if Simulations

Fast, reliable, secure Connectivity

Predictive Diagnostics

AI-AidedDecision Making

Fully Digital Plant

Leve

ls o

f D

em

an

nin

g

Autonomous

Operations

Design for Digital Readiness

Connected Worker, Virtual Testing

De

plo

ym

ent P

hase

s Digital Asset Management

Digital Workflows

Asset Optimization

Enterprise Optimization

• Data persistence • Inventory & Obsolescence Management• Management of change

• Better Visualization • Digitalization of work processes

• Integrated optimization of maintenance and operations

• Improved Capacity & Distribution Planning


4

July 2020

The Challenges Facing Adoption of Digitalization in O&G

• Culture Change

• Today’s best practices will not be tomorrow’s

• Opportunity lies between the silos

• Failing is good – start small, learn, correct fast

• The risk is not in failing, it is in doing nothing

• Cyber Security

• Yes, but like HSE it can be managed

• Data Privacy

• What data can't you share

• …..rather than what data can you share

• Customer-Supplier Business Model

• Transition from procurement to performance

based partnerships


5

July 2020

Enabling the Digital TransformationCulture change must lead Technology change

People are at the core of

digital transformation

Seed the organization with change

agents

Communicate a clear

change story, why & how

Learn through PoCs and pilots before

full implementation

Adapt to process changes and

empower people with new skills

Set up an integrated project &

transformation office

Create clarity on implementation

roadmap and business cases

https://intranet.for.siemens.com/cms/059/en/processes/publications/Pages/compliance_anti-corruption.aspx


6


6

July 2020

Topsides 4.0 discussion, 20 Oct 2020Table of contents



vision?

30





10

10

10

4 Discussions & Next steps 20


7


Topsides 4.0 is Siemens integrated digital approach to O&G Production

Automation, safety,

control and telecom

Power generation

(gas turbine, generator)

Cyber Secure Digital

SolutionsCompression

Thrusters

motors and

drives

Power

distribution

Motors & Drives

for multiple

services

Topsides 4.0 is our secure digital approach to rotating equipmentand electrical, instrumentation & control (EIC) systems through the entire life cycle of the asset.

Client Value

Reduced CAPEX

• Shorter project

delivery

• Reduced project risk

• Flawless start-up

Reduced OPEX

• Operational efficiency

• De-manned

operations

• Higher availability

• Sustainability

http://www.lcm.no/Siemens/Siemens%20Pictures/Components/Thruster%20And%20Propulsion%20Drives/Thruster_System.jpg


8


Topsides 4.0 Data persistence and collaboration - from concept

Detailed design data

Digital fabrication,

virtual commissioning

& support

Analytics for process

optimization

Service and maintenance

data for asset management

Real time and historical

asset generated dataAnalytics for equipment

optimization

Cyber Secure Cyber Secure

Digital Twin starts

Concept & FEEDDigital Twin expands

Design & Build

Digital Twin matures

Operate & Maintain

• P&IDs

• 3D drawings

• Isometrics

• Equipment data sheets

• Time series data

• ICSS

• Electrical Load Lists

• Single Line Diagrams

• Life Cycle data

• etc.

Data Backbone

Cyber Secure

Design tools for fast,

best practice designs

Process simulation

for concept selection

EICT with class 1 package

integration


9


Topsides 4.0 Value added applications at edge or in cloud

Detailed design data

Digital fabrication,

virtual commissioning

& support

Analytics for process

optimization

Service and maintenance

data for asset management

Real time and historical

asset generated dataAnalytics for equipment

optimization

Cyber Secure Cyber Secure

Digital Twin starts

Concept & FEEDDigital Twin expands

Design & Build

Digital Twin matures

Operate & Maintain

Data Backbone

Cyber Secure

Design tools for fast,

best practice designs

Process simulation

for concept selection

EICT with class 1 package

integration

OEM

Services

Predictive diagnostics,

advisories & asset

optimization

Performance

Twin

Analytics and

alerts for process

& equipment

monitoring

Process

Twin

Dynamic process

model for

automation

testing, ops

training, what-if

scenarios

Equipment &

Plant Twin

Smart 3D view

for construction

planning, field

training, etc


10

July 2020

Challenge

• Operating offshore production platform in a harsh environment

and remote location

• Minimum offshore operational team

• Leverage onshore key expertise

• Condition monitoring to ensure asset uptime and efficient

maintenance campaigns

Solution• Fully integrated Electrical, Automation and Digital solution

• Onshore operations center for seamless remote operations

• Advanced condition monitoring of equipment

• Expert support based on big data and analytics

• Process Twin simulation and training software

Case Study:

North Sea Field

Lower

OPEX

Fewer

people on

the platform

Stable

operations

in 1 week


11

July 2020

How does

Topsides 4.0 compare to your

digital vision?


12


12

July 2020

Topsides 4.0 discussion, 20 Oct 2020Table of contents



vision?

30





10

10

10

4 Discussions & Next steps 20


13

July 2020

Author | Department

Restricted © Siemens Energy, 2020

13

YYYY-MM-DD

Why Topsides 4.0

and not traditional

Digitalization?


14

July 2020

The difference

lies in project

execution

and in

integration by

design

1 Single point of responsibility for Siemens scope,

with synergies in control hardware & engineering

2

3

Interoperable digital content out of the box

YYYY-MM-DD

Lower OPEX, ready for low manned operations


15

July 2020

Author | Department


15

YYYY-MM-DD

How will we deliver

these benefits?

Single point of responsibility

for full Siemens scope


16

July 2020

Single point of responsibility for full Siemens scope

Joint Siemens project management

Integrated scope delivery

Control Class 1 Integration

• Scope and schedule coordination managed internally

• Single point of contact for customer

• Aligned commercial contracts

• Full responsibility for managing the interface between

the ICSS and rotating equipment

• Internal change orders between rotating equipment

and ICSS has no impact on the customer

• Lower CAPEX for control hardware and engineering

• No integration testing at yard

• Auxiliaries automatically rolled into digital solution

• Automated workflows for maintenance


17


Control class 1: Package control is

fully integrated into the ICSS and

implemented utilising standard ICSS

software and hardware

Control class 2: Packages use their

own controller hardware and software,

with an interface to the ICSS with a

subset of control signals. Control class 2

needs a “translator” in one of the ICSS

nodes to display package data and

alarms in the ICSS HMI


18


Control Class 1 Integration allows partial automation of digital solution development and maintenance

Control Room

Contextualized

Data

Analytics/Applications

ICSS

Process

instrumentation

IP21, PI,

etc

Gateway

Automated configuration Tool (ACT)

3rd Party

Measurement Point

Measurement

Measured Value, Quality, Time stamp

Measurement descriptionService Description

Range Min, Max values

Alarm Limits

Equipment Type

Function Block (Measurement)

Instrument with meta data

ALL, AL, AH, AHH

Siemens O&G ICSS Data Model

Measurement Point

Measurement




Alarm Limits

Equipment Type



ALL, AL, AH, AHH


Measurement Point

Measurement




Alarm Limits

Equipment Type



ALL, AL, AH, AHH


Tool: HTML5

Siemens Scope of delivery

Measurement Point

Measurement




Alarm Limits

Equipment Type



ALL, AL, AH, AHH


Siemens SOGO Data Structure – Free to be used for 3rd party

Siemens

Engineering

Data

Siemens COMOS

Other non time series

data

Class 1

Packages

Onshore Control Center

Simulator

Engineering

Data

Siemens

COMOS

Control Class 1 Integration


23

July 2020

Author | Department


23

YYYY-MM-DD

How will we deliver

these benefits?

Interoperable digital content out of

the box


24

July 2020

Digital Content out of the box

Built on data quality and designed for

cyber security

Templated solutions for predictive

analytics

Prescriptive maintenance with prebuilt

O&G libraries

• By design, ICSS and IoT data is pushed on change,

not polled on defined frequency

• TUV cyber secure certified since 2018

• Data analytic templates for 50 asset types

• Auto data mapping from ICSS into templates

• Machine learning to refine site specific operating

envelope

• Framework for implementation of Risk Based

Maintenance

• 3,300 unique failure modes & best practise responses

• 1,000 years of O&G operational experience


25

July 2020

Siemens follows a holistic and comprehensive approach

to secure solutions and services based on IEC 62443

• Siemens is the first in the world to achieve

IEC 62443 2-4 / 3-3 certifications for:

˗ Project Management and processes

˗ Offshore greenfield solution blueprint

• Siemens security expertise

˗ was key in the certification process

˗ will enable implementation in project and service

• Cyber security being a pre-requisite for digitalization

˗ Certificates provide unique value proposition

and differentiation

Security certification by TÜV achieved

Hand-Over Ceremony @ SPS 2018

https://newscenter.siemens.com/siemens-news/index.php?webcode=50082452&lang=no

Digital Content out of the box – cyber security

https://newscenter.siemens.com/siemens-news/index.php?webcode=50082452&lang=no


28

July 2020

Siemens implementation of OPC UA Server based on NAMUR Open Architecture

Data Collector (“Edge Box)

Application Platform

Analytics, e.g. valve monitoring, field

device management, process

equipment monitoring, etc


29

July 2020

How do Siemens analytic solutions work together?

REMOTE DIAGNOSTIC

SERVICES

Deep OEM expertise - OEM analytics

combined with many man years of

service experience on rotating

equipment, to reduce downtime and

maximize equipment performance.

SOGO DIGITAL

Prebuilt, broad analytics on balance

of plant to identify performance

degradation early, forecast time to

failure and enable condition based

maintenance campaigns.

ASSET PERFORMANCE

MANAGEMENT

Prebuilt root cause analysis for

O&G equipment to accelerate client

responses to abnormal situations.

Embedded Failure Modes and Effect

Analysis informs maintenance strategy

and failure indicators trigger the right

maintenance tasks.


30

July 2020

3rd

pa

rty O

EM

How do Siemens analytic solutions work together?

Va

lve

s (

ex

. C

ho

ke

)

PID

co

ntr

oll

ers

Hea

t e

xc

ha

ng

er

Future

Condition based

maintenance

Predictive

maintenance

Prescriptive

maintenance

Filte

rs

HV

AC

/ C

hil

lers

Tra

ns

form

ers

UP

S

Pu

mp

s

Su

bse

a v

alv

es

, P

ow

er

Gri

d

Subsea

systems Main topsides process & auxiliary systems

Electrical supply &

distributionICSS systems

& security

Integration &

Visualization layer

Co

mp

res

so

rs &

Tu

rbin

es

Netw

ork

sw

itc

he

s, S

ine

ma

for

ne

two

rk

mo

nit

ori

ng

HV

& L

V S

wit

ch

gea

r

Sim

oc

od

e(m

oto

r s

tart

er)

, P

ow

er

Qu

ali

ty

An

aly

sis

Sie

me

ns

Cyb

er

se

cu

rity

se

rvic

es

Filte

rs

Se

rve

rs

SOGO

Digital

……

Asset Performance Management

Equipment failure models for > 1,400 O&G equipment types

3rd

pa

rty O

EM

Sie

me

ns

Dri

ve

Tra

in A

na

lyti

cs

Mo

tors

3rd

pa

rty O

EM

Sie

me

ns

RD

S


31

July 2020

Predictive data analytics feed APM or run standalone

SOGO Digital is a predictive data

analytics solution with prebuilt templates

for > 50 different asset types

• Built on high quality data from PCS7

• Auto generated with ACT tool

• Object oriented definition and templating for

ease of deployment and maintenance

• Analytics, machine learning and advanced

visualisation of condition elements, based

on domain expertise

• Triage and improved situational awareness

and alerts on exception

Digital Content out of the box – predictive analytics


32

July 2020

SOGO Digital's contextualized data analytics provide transparency and decision support

Examples of dashboards tailored to user roles with aggregated information and alerting

Alarm Management &

Maintenance dashboard

Other discipline and 3rd

party dashboards

Network communication

dashboardPMS dashboard

Standard

Equipment

dashboardsAuto generated standard dashboards from templates

Configured role based custom dashboards

Motors Protection devices Transformers Heat exchangers ValvesVFDs

Digital Content out of the box – predictive analytics


35

July 2020

Asset Performance Management (APM) manages the RCM process

1Assets

2Strategy

Development

3Indicators

4Task, jobs

5Checklist

Plant asset

hierarchy

introduced in APM

from master asset

register

Based on built in

Asset analysis

methodology,

embedded Failure

Modes and Effect

Analysis are linked

to assets

Predefined eng.

indicators assess

the condition of an

asset based on

what usually

causes it to fail and

when

Indicators trigger

predefined tasks

in the APM

inspection

management

module

Completion of tasks

is tracked, with

input from

the mobile

inspection app

These are all the elements of an APM "Asset Model"

Digital Content out of the box – prescriptive analytics


37

July 2020

Author | Department


37

YYYY-MM-DD

How will we deliver

these benefits?

Lower OPEX, ready for low manned

operations


39


The journey to unmanned operations requires a x-functional approach to technology, people & processes

Data & Digitalization

Automation & Electrification

Process

Physical Assets

(e.g. SGT A35 package, compressor, etc)

Secure

IT

& C

onnectivity

Tru

ste

d f

ailu

re p

redic

tions

Sim

plif

ied b

ut

relia

ble

desig

n

Safe

rem

ote

contr

ol

Bro

wn

field

–ve

nd

or

ag

no

stic

Gre

en

field

Transformation

Low

touch m

ain

tenance &

inspections

Eq

uip

men

t →

Facil

ity

New

Tech

no

log

ies


40

July 2020

Less

downtime

Operations

Maintenance

Manning ModernizedFewer People | Safer Operations | Better Business

Value delivered….. ……as a result of:

Lower

EmissionsSupporting Net Zero

• More efficient operations

• Fewer helicopter trips

• Fewer shutdowns = less flaring

Optimized:

Production

Energy usage

Emissions

Risk and

condition based

maintenance

campaigns

Extended

MTBO,

lower tool

time

Connected

Worker for

fewer expert

mobilizations

No manual

operations and

routine

maintenance

ICSS

designed for

remote control

40

Prim

ary

va

lue

dri

ve

rsC

on

se

qu

en

tia

l va

lue

Higher UptimeHigher availability

• Reduced unplanned downtime

• Extended MTBO

• Faster, better response to

deviations

Improved

Safety Zero Harm

• Fewer people exposed to high risk

environments

• Fewer mobilizations of experts

• Lower human error

Lower OPEXResilience against

volatile market

• Cyber secure IT-OT

• No on site control room operators

• Fewer permanent on site

maintenance technicians

Data

Management

Cyber

security

Shutdown

Start-up

MTBO: Mean time between Overhauls


41

July 2020

Less

downtime

Operations

Maintenance

Manning Modernized translated into deliverables

Optimized

Production

Energy usage

Emissions

Risk and

condition based

maintenance

campaigns

Extended

MTBO,

lower tool

time

Connected

Worker for

fewer expert

mobilizations

No manual

operations and

routine

maintenance

ICSS

designed for

remote control

Data

Management

Cyber

security

Shutdown

Start-up

• Cyber Secure ICSS with

PCS7 / PCS Neo

• Control class 1 Integration

for packages

• Engineering data

handover

• ATEX cert. collaboration

environment

• Design for longer MTBO,

ease of access, modular

replacements, etc.

• Design, control and digi

solutions to remove

manual tasks

• Requirements definition

tbd

• Integration of SOGO

Digital, RDS and APM

• Analytics enhancements

as required

• Transformation &

Change Management

RDS: Remote Diagnostic Services APM: Asset Performance Management

© Siemens Energy, 2020Siemens Energy is a registered trademark licensed by Siemens AG.

Demanning Concepts for production facilityBased on integration of SOGO Digital and APM

Facility wide

predictive analytics

See Equipment list*

Auto Safety Valve

testing & reporting

1-Button start-up

As for Tyra Future

FPSO

Auto earth fault

monitoring

Demanning Roadmaps

Solutions to address other common site activities & failure modes -

Customer sit-downs to discuss tailored solutions

Auto electric motor

starter testing

To be productized

Available now

*Equipment list – available predictive monitoring templates:

Extended Instr.

calibration intervals

From 12 to 36 months

Auto UPS Battery

Health Monitoring

Process▪ Filter

▪ Heat Exchanger

▪ Oil in Water meter

▪ On/Off Valve

▪ Generator

▪ Centrifugal Compressor

▪ Fixed & Variable Speed Pumps

▪ Control Valves

Electrical▪ UPS

▪ Transformer

▪ Variable Speed Drive

▪ Breakers

▪ Switchboard

▪ Switchgear

▪ Motor

IT/OT▪ Virtual and physical servers

▪ network switches

▪ Control loops

▪ Instrument calibration

Available WIPProposed developments

APM Risk Based

Maintenance

Integrate / expand existing solutions

© Siemens Energy, 2020Siemens Energy is a registered trademark licensed by Siemens AG.

Extended MTBO

• Annual Inspections

• GT Overhaul Intervals (Dynamic

Lifing)

Lower Emissions

• Bleed Off Valve Optimization

• Predictive Emissions to optimize

Operating Profile

• Real-time GT Power Margin

Reduce Unplanned Downtime

• Alarm and trip rationalization

• MyFleetRisk: Adaptive Spares holding

to reflect age and failure paretos

• Time-to-outage: Failure prediction of

major components

• Package Reliability upgrades

Fewer Expert Mobilizations

• HMI Maintenance Screen

• Smart IO Modules

• Pre-Post-Trip Data Logging

• Fuel Dew Point Monitors

• Extended Instrumentation calibration

intervals

• Fire & Gas Data into ICSS

• Connected Worker to support

service engineers / customer

resources

Automate Inspections(6 monthly inspection intervals)

• Oil Quality Sampling, incl. viscosity

and acidity

• Pump switch tests

• Enhanced vibration analysis incl.

debris monitoring to replace

boroscoping

• Start-up analysis (edge analytics)

• GT Compressor efficiency (air intake

filter degradation and online water

wash efficiency)

• Camera leak detection (thermo)

• Junction boxes

• Drainpipe blockages

• Valve position

• Automated safety valve testing &

reporting

Demanning Concepts for turbine package (compressor packages are WIP)


46

July 2020

How can we contribute

our experience to

maximise your digital ROI

and prepare you for a

future of autonomy?

topsides4.0 optimizing o&g production

Documents