connectivity & industry 4 - firjan

Connectivity & Industry 4.0Claudio Makarovsky – Siemens Oil &Gas

siemens.comUnrestricted © Siemens AG 2016

Unrestricted © Siemens AG 2016

Carlos Fernando Albuquerque, PD PA AE VSS Brazil



Digitalization @ Process IndustriesHow to survive a disruptive technology wave

Digitalization winner candidates Doomed to disappear candidates ?

OTC-28669-MS• Digital Lifecycle for Offshore Oil and Gas Production • E. La Grange

Drivers for Explosion in Digitalization Across Industries

Applicability to O&G

Predictive Maintenance

Mass Transit IndustryBarcelona – Madrid

99.9% availability of trains

Only 1 of 2,300 trips is late

Remote diagnosis facilitates

predictive maintenance


Improved Cycle Time

Automotive IndustryMaserati, Turin

30% less development time

Digital production optimizes

plant design and enables

manufacturing flexibility


Image Analytics

Health IndustryMultiple Locations Worldwide

Enables more patients to be

treated in less time

50% reduction in doctor’s

time for bone reading

Automated image processing

enables faster diagnosis

10% higher accuracy rate

and detection of fractures


Remote Monitoring

Marine IndustryHamburg (Service Center)

3x more cars producedReduced cost for operation

and commissioning

Increased availability and

avoidance of unplanned

downtimes

Enables shorter time

to market

Increased availability and

avoidance of unplanned

downtimes

Remote monitoring facilitates

expert center support

40% of all critical systems

monitored in real-time with

expert technical support

Sensor explosion Secure Connectivity Integrated PLM Advanced Analytics

• Cyber SecurityYes, but like HSE it can be managed

• Data PrivacyWhat data can't you share, rather than what data can you

share

• Customer-Supplier Business ModelTransition from procurement to partnership

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

Opportunity lies between the silos

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

The risk does not lie in failing, it lies in doing nothing


The Challenges Facing Adoption of Digitalization in O&G


The Digital Maturity Journey

Evolution and Revolution

Digital Asset Management

Digital Maturity & Intelligence

Le

ve

ls o

f D

igita

liza

tio

n

Process & Plant

Digital Twins

Predictive

Diagnostics

Asset

Optimization

Intelligent

Monitoring

AI-Aided Decision

Making

Autonomous

Operations

Digital Workflows

Asset Optimization

Enterprise OptimizationImp

lem

en

tation

Ph

ase

s

• Data persistence • Inventory & Obsolescence Management• Improved Plant Maintenance

• Better Visualization • Efficient Data & Workflows

• Integrated optimization of maintenance and operations

• Improved Capacity & Distribution Planning

Remote

Operations

Topsides 4.0 is the secure digital approach to rotating equipment,

electrical and automation systems through the entire life cycle of the

asset.

Designed for reduced

CAPEX and OPEX

• Shorter project cycle

time

• Shorter time to stable

operation with

training, virtual

commissioning on

the digital twin

• Reduced interfacing

risk with integrated

automation and

safety systems

• Lower OPEX with

reduced manning

and predictive

analytics

Power distribution Power generation

(gas turbine,

generator)

Compression Cyber Secure

Digital Solutions

Motors and

drivesAutomation, safety,

control and telecom


Topsides 4.0 – Integrated Life Cycle Solution for O&G

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

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


Topsides 4.0 – Data Persistence

Operate & Maintain

Concept & FEEDConfigurators for fast,

best practice designs

Analytics for process

optimization

Service and maintenance

data for asset management

Detailed design data Design & Build

Digital fabrication,

virtual commissioning

Real time and historical

asset generated data

Process simulation

for concept selection

Integrated EICT, designed

for remote operations

Analytics for equipment

optimization

Data Backbone

Cyber Secure

Cyber SecureCyber Secure

• P&IDs

• 3D drawings

• Isometrics

• Equipment data sheets

• Time series data

• ICSS

• Electrical Load Lists

• Single Line Diagrams

• Life Cycle data

• etc.

Predictive

diagnostics &

asset

optimization

OEM

Services


Topsides 4.0 – The Intelligent Digital Twin

Operate & Maintain

Concept & FEEDConfigurators for fast,

best practice designs

Service and maintenance

data for asset management

Detailed design data Design & Build

Digital fabrication,

virtual commissioning

Real time and historical

asset generated data

Process simulation

for concept selection

Integrated EICT, designed

for remote operations

Data BackboneCyber Secure

Cyber SecureCyber Secure

Analytics and alerts

for process &

equipment

monitoring

Automated

MonitoringSmart 3D view

for construction

planning, field

training, etc

Plant

TwinDynamic model

for automation

testing, ops

training, what-ifs

Process

Twin Role Based

Portal

(Cloud)

Analytics for equipment

optimization

Analytics for process

optimization

Asset performance

and maintenance

reporting/ KPIs

Static reference data

(product,

engineering, project

data)

Dynamic, simulated

data

Visualization and

navigation (client

view)

Intelligent

Digital

Twin

Real time asset

generated data

(time series and

events)

Individually engineered solutions, significant duplication of data and effort

Creating the Digital Twin Without the Topsides 4.0 Approach

Notifications &

Alerts

3D walk through

plus operations,

engineering &

maintenance

data

Reports,

dashboards,

drill downs

Asset wide

Analytics

(vendor agnostic

OEM predictive

diagnostics &

optimization

Dynamic Process

Simulation

On premise /

cloud historian

Asset wide EIC

for remote

operations

Process Design

FEED/Detailed

Engineering

EIC emulation

Digital fabrication

and testing

Process Twin

Intelligent Monitoring

OEM Services Plant Twin

Inte

gra

ted

Op

era

tio

ns &

Asset

Op

tim

izati

on

Asset performance

and maintenance

reporting/ KPIs

Static reference data

(product,

engineering, project

data)

Dynamic, simulated

data

Visualization and

navigation (client

view)

Intelligent

Digital

Twin

Real time asset

generated data

(time series and

events)

Create the Intelligent Digital Twin as you execute the Project

Creating the Digital Twin With the Topsides 4.0 Approach

Notifications &

Alerts

3D walk through

plus operations,

engineering &

maintenance

data

Reports,

dashboards,

drill downs

Asset wide

Analytics

(vendor agnostic

OEM predictive

diagnostics &

optimization

Dynamic Process

Simulation

On premise /

cloud historian

Asset wide EIC

for remote

operations

Process Design

FEED/Detailed

Engineering

EIC emulation

Digital fabrication

and testing

Inte

gra

ted

Op

era

tio

ns &

Asset

Op

tim

izati

on

12 weeks saving on detailed design with vendor templates

8 weeks shorter engineering phase with configurators

4 weeks faster to first oil with virtual testing, training

Reduce cycle time

3 – 9 months

Reduced offshore manning

Shorter and safer turnaround times

Early warning of performance degradation

Reduce OPEX

>$ 100 mover 10 yrs

Reduced engineering for digital twin

Reduced accommodation for offshore staffing

Reduced risk from integrated control

Reduce CAPEX

$ 10 – 15 m


Example Savings For A Mid Size FPSO (100 k bpd)



Solution

• Fully integrated Electrical, Automation and Digital solution

• Onshore operations center for seamless remote operations

• Advanced condition monitoring of critical equipment

• Expert support based on real time big data and analytics

• Process Twin simulation and training software

Increased

recovery

Fewer

people on

the platform

Lower

OPEX

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

Example: Remote Operations of the Ivar Aasen Field




Incubate through Evolution

• Digitalize inside the firewall while developing a cyber policy

• Start small but do so quickly

• Pick your data backbone for longevity

• … but plan for 2 year obsolescence of applications

Leapfrog through Revolution

• Accept that the past should not dictate the future

• Pick long term partners for OEM & digital expertise

• Choose a secure, scalable platform for stakeholders to

collaborate

• Include digitalization right from concept development

• Select technologies on Life Cycle Cost


Steps to Starting your Digitalization Journey

Claudio Makarovsky

+5521 995980289

connectivity & industry 4 - firjan

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