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How Smart P&IDs will Reduce Compliance Risk and Operating Costs

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Shane Kling

on 29 January 2015

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Transcript of How Smart P&IDs will Reduce Compliance Risk and Operating Costs

How Smart P&IDs will Reduce Compliance Risk and Operating Costs
Presented by: Shane Kling, Environmental intellect
Moderated by: Thomas Canter, GuideWare Systems
Wednesday, March 26th
Presentation Agenda
History of CAD
Anatomy of a Smart P&ID
Usage of P&IDs Among Different Disciplines
Reducing Operating Costs
Real Time Compliance Through Data Bridging
Technology Integration Opportunities
Technology Demonstration
Integrating Maintenance Management Systems with Smart P&IDs
PI ProcessBook Integration
with AutoCAD P&ID
Document Management
Consider the following annual budget for large-sized refinery client:
CAD Budget = $1,000,000
Environmental Budget = $3,000,000 (LDAR = $1,000,000)
Safety Budget = $3,000,000 (PSM and Mechanical Integrity = $1,000,000
Engineering, Maintenance and Operations = $5,000,000

AutoCAD P&ID™ studies have shown CAD cost reductions of 40%
Result: $400,000 cost savings
Ei’s
LDAR Intelligence
projected to reduce LDAR costs by 25%
Result: $250,000 cost savings
PSM Intelligence
projected to reduce PSM costs by 25%
Result: $250,000 cost savings
10% efficiency gain projected for Operations, Maintenance, and Engineering tasks
Result: $500,000 cost savings

*And how much does non-compliance cost?
ROI
Annual cost reduction of approximately 25% of these budget line items projects of approximately $1,400,000

Leveraging Capital Projects
Operating Expense Budget Reduction
Studies show up to 40% CAD budget savings
LDAR Projects
Semi-automate inventory/retagging process
Evergreen LDAR P&ID markups
PSM/Mechanical Integrity Projects
Data Integration Projects
Workflow efficiency gains between Engineering, Operations and Maintenance, Safety and Environmental teams
Data Quality Control and Assurance
Data exchange with programs, such as SAP, Maximo, PI ProcessBook, GuideWare, etc.
Compliance Improvement Projects


Opportunities for Management Buy-in
Recap
Traditional CAD programs were not designed to meet the present needs of industry
(e.g., compliance, information management, data sharing).
Long-term costs will continue to grow over time for managing industry standard P&IDs
, but "smart P&IDs" can flip this trend.
In the absence of smart P&IDs,
compliance risk will continue to increase over time
: MOC, in combination with capital projects and regulatory changes will soon render industry standard P&IDs to be obsolete.
"Smart P&IDs" provide the technology platform to
improve workflow
for Engineering, Operations, Maintenance, Environmental and Safety disciplines thereby reducing operating costs.

Questions?
Thank You For Your Time
Operating Costs Associated with P&IDs
Many operating facilities spend millions of dollars each year in activities that directly/indirectly involve P&IDs:
Engineering/CAD
MOC Updates and Redlines, Troubleshooting
CAD Updates
Safety
PHA Revalidation
Process Safety Information (PSI) Updates
Mechanical Integrity
System Identification
Inspections
Operations and Maintenance
Identification of equipment
Environmental
Applicability determinations, P&ID-based compliance reviews (e.g., LDAR, BWON, NSPS Ja), MOC updates

Introductory Questions
P&IDs vs. Smart P&IDs
Benefits of Implementing Smart P&IDs
Technology Demonstration
Return on Investment
Question and Answer

1) Stream Identification
2) Design Specifications
4) Piping ID and Specification
5) Valve Types
6) Equipment Identification
8) Directional Flow
9) Off Page Connectors (From/To)
10) Equipment Inventory
Overview of Smart P&IDs

A data driven drawing (i.e., "smart" or “intelligent" P&ID) is a CAD drawing but with a back-end database.
Contains a powerful database which can be then bridged with other applications and compliance software solutions.
Smart P&ID platforms include Intergraph (SmartPlant P&ID), Autodesk™ (AutoCAD P&ID), Bentley™ (AutoPLANT P&ID).
There are other "smart P&ID" platforms used by industry, but many of these are add-ons to traditional CAD.
Drawings are populated from the data; and data can be extracted from the drawings.
…all you AutoCAD™ users: think AutoCAD™ (but with a hidden database to capture data and to improve CAD workflow
Anatomy of a P&ID
Import/Export P&ID Data
What is the Purpose
to this Discussion?
Traditional CAD Programs are Inadequate for the Needs of Industry
CAD programs were not designed to meet the needs of all plant disciplines
Purpose was to provide an "electronic drawing board" to draftpersons
In fact, the first commercial version of AutoCAD was released
10 YEARS
prior to the promulgation of the Process Safety Management standards in 1992
Requires P&ID updates every 5 years as part of PHA revalidation
What is the solution?

(A more elegant CAD program with the ability to input and extract data)
Have You Ever Considered These Questions?
1. What is a "smart P&ID?" How is it different from standard P&IDs? And how do I know if my plant has them?

2. Why should I be a voice for changing to "smart P&IDs," if our CAD Department says our current CAD software works just fine?

3. We struggle to maintain current P&IDs, let alone having the resources to implement "smart P&IDs" - are there other benefits for non-Environmental or Safety personnel that justify the time and expense to upgrade our P&IDs?

4. Our process P&IDs are always changing - can "smart P&IDs" really offer a better way to keep track of regulatory changes?

5. What other compliance improvements can be gained from "smart P&IDs?"


Be sure to mark your calendars for Ei's next
e-Training event on
Wednesday, June 25th
at 1PM CDT
entitled:

"Automating the LDAR Inventory Process:

How Your LDAR Contractor Can Use Smart P&IDs
to Lower Costs While Improving Quality and

Execution

3) Title Block
7)PI Tag References
0000000000000
000000000000
8888
77777
Program Release Date
CAD Jul-1950
AutoCAD Dec-1982
Microstation 1 1987
Microstation2.0 Feb-87
Bentley AutoPlant
AutoCAD P&ID 2008
Concluding Thoughts
1.
Shift from Analog to Digital
: The need exists to begin process of converting your facility P&IDs into "smart P&IDs" that can fulfill the company's needs.
There are multiple applications that can accomplish this, but "path to least resistance" is one your CAD Department is familiar with
2.
Technology Integration Reduces Operational Costs
: Automating redundant processes allows professionals to focus on solving problems computers cannot
Ei's tools extend the benefits of smart P&IDs to Operations, Engineering, Maintenance and other disciplines to improve workflow
3.
Management Buy-in
: There are several opportunities to gain Management buy-in, such as capital projects, P&ID revalidation, LDAR inventory/retag, etc.
There is a conversion step to get from your current P&IDs to a "smart" P&ID state, but long-term cost savings will balance these costs.
4.
Leading the Effort
: As professionals, your knowledge is more valuable to the company than repetitive job tasks
P&ID management, updating, and reviews continue to present one of the largest challenges to operating facilities - there is a solution; will you pursue it?
5. Ask Questions, Learn More: The information presented today should provide a good introductory conversation with CAD, engineering and your Management.
Feel free to contact us at Ei to answer any follow-up questions, as well as to facilitate conversations amongst various stakeholders at your facility.


Hypothetical Situation:
LDAR identifies a leak. What happens next?

Current Paradigm:
A series of manual reporting, tracking and communication processes takes place.
Hypothetical Situation:
A unit upset occurs and process engineers begin troubleshooting and analyzing root cause. How are these tasks carried out?

Current Paradigm:
The engineer accesses data from a process data historian, as well as navigates between several applications, such as the P&ID, design specifications, and inspection history to determine root cause.
Hypothetical Situation:
An MOC is executed by engineering to upgrade process equipment. Several documents are generated from start-to-finish: purchasing documents, engineering design specifications, preventative maintenance requirements, etc. How are these documents managed?

Current Paradigm:
Many facilities have centralized, document management systems (e.g., Documentum, while some rely on file storage on network servers.
Computer-Aided Design (CAD) software was initially developed in the mid
1950s
and was first released for commercial use in the 1960s
Various CAD programs are used across a range of industries, including manufacturing, construction, architectural, etc.
AutoCAD (.dwg format) is the predominant CAD platform used by operating facilities for piping and instrumentation diagrams (P&IDs)
First released in
December 1982
[1]
Other CAD programs include but are not limited to Bentley Microstation, Microsoft Visio, QCAD, etc.










[1] "Autodesk, Inc". FundingUniverse. Lendio. 2012. Retrieved 29 March 2012


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