Unasys are changing the boundaries for completions management
By using *digital twin technology we are able to optimise and augment the lifecycle process from engineering to start-up
Completions and Start-up is a complex, progressive and phased process which requires early detailed definition and planning in order to facilitate efficient and seamless project execution and control. This in turn allows for timely client approvals and final acceptance, thus enabling early project technical and commercial close out, and thereby minimising the risk of contractual penalties.
The Unasys business function is to identify and manage such complexities in order to optimise project turnover, handover and close out. Unasys provides integration of Completions using the expertise of specialist managers and engineers, together with an effective software.
This unique combination enables projects to deliver structured Certification Management, which enables documentation packages to be delivered concurrent with completion of the physical works. The waiting period for final documentation, a common feature of so many projects, is eliminated.
This proposal will show how Unasys can assist Vølund to deliver structured completions in accordance with approved procedures and plans. The intent is to safely deliver facilities that will be in a state of readiness for operation. It also puts forward the case for using an electronic completions system (ePM) to support this operation.
* our ‘digital twin’ technology provides a navigable 3D model of your asset, linked to all your Documents, Drawings and Data.
Can we have smart tools?
Visible project scope and the latest information give smarter teams the tools to find their way
Keep it simple
Allows us to maximise efficiency through a smaller project workforce where everyone can use this tool
A simple, predefined scope gives you the information you need at the precise moment you need it. That streamlining of lifecycle processes allows for a smaller project workforce…..keeping it SIMPLE
I want powerful navigation with clear visibility of my project scope.
Move from the highest level right down to the smallest component
A navigable 3D model of your asset, linked to all your documents, drawings and data
I want to get to information quickly and I want to know it’s accurate
Locating information on a project is a challenge. Our Intelligent search feature uses key words to quickly scan the system for relevant documents.
Managing supplier documentation is a project on its own. The Unasys ePM system eliminates the waiting periods for final delivery - a common problem on many projects.
Smart Documents including Smart Document Importer
Documents now imported to ePM, either as a physical document or a link, will automatically have their contents scanned to enable smart searching. ePM utilises OCR (Optical Character Recognition) to enable deeper smart searching within these files. We’ve created a drag and drop feature to enable bulk document upload.
Digital tracking ensures the latest revision is always available.
Third party integration
Unasys have experience with integrating data flow from 3rd party applications like Autodesk Navisworks, Oracle Primavera P6, and OpenText Documentum.
Existing import / export features can be customised to support virtually any modern web based system.
I want to know where my system or piece of equipment sits at any time within its lifecycle.
Better life cycle management of project information leads to time and cost savings, enhanced productivity and safer more efficient project execution and start-up. This demands that for all projects one should ‘begin with the end in mind’. Unasys are raising the standard for Completions and e-PM is the unique result of deploying this approach in an integrated solution with standardised models firmly founded on best practice.
Lifecycle process of Systems & Equipment gives us better product control
Life Cycle Management identifies two main phases — Definition and Execution. Definition begins in FEED and comprises evaluation/planning through the beginning of fabrication/construction. The Execution Phase starts with Factory Acceptance Testing (FATs) and ends with stable operation and acceptance of the facility by Operations. Systems completion definition and execution activities overlap at detailed engineering and procurement and fabrication/construction. Life Cycle Management, like Systems Completions Management, will have the distinct levels that match each project phase. Each level is sub-divided into a series of actions; and each level will be validated, through offer and acceptance.
Tag equipment identified
Systems / Subsystems
Areas / Construction Areas
Data sheet complete
Relationships / Mapping
AFD – Data good to share
Bid documents received
Review supplier data
Supplier data approved
Engineering design data complete – AFC
Inspect and Test
Inspection and Test Plan
Vendor data agreed and in e-PM
Factory acceptance test
Inspection release note
Packing list / manifest
Call out schedule
Fabricate & Assemble
Inspections complete (internal)
Vendor punch list closed
Calibration / PSVs
Mechanical Completion Certificate
Line walk / inspection (Turnover)
Consents and approvals
SCE / System Performance (Testing)
Site Acceptance Testing (Testing)
System Commissioning (Testing)
Tech Queries Closed
Test Preparation (Testing)
Start up and readiness review
Cause and effects
Operational interface / compliant
Interface with SAP
The Systems Completions Process
Whatever the project type, all of the equipment, whether static or dynamic, is generally encapsulated within a specific ‘System’. How we manage that Equipment from Engineering to Operation we refer to as Life Cycle Management. How we control Life Cycle Management we refer to as Systems Completions Management. There are a series of very specific levels or gates to be passed which require actions and tests to be carried out and supported by certification and documentation. These gates are categorised by phase and the progress of each phase shall be constantly monitored and reported in detail, providing for thorough feedback and close control of all project activities. Life Cycle Management is defined as the sequential activities within a project that verify and prove that the construction, installation, integration and testing of systems, including all of their component parts, have been completed properly and thus the facility is ready for start-up and operation. The Systems Completions process is designed to help manage the transfer of care, custody, and control of facilities through appropriate certification and documentation. Systems Completions Management is defined as the sequential activities, the management team must undertake to ensure a seamless process.
Reduce Risk & Costs
One week delay for a 50MW plant = £110,oo0 loss in revenue
Any delay not only removes revenue, but it’s loss is compounded by the additional costs of:
Continued labour costs
Continued Insurance costs
Continued on-hire costs of equipment & plant
And Penalty charges & liquidated damages dependant on contract.
Together these can amount to £150,000 - £350,000+ per week’s delay to handover
Engaging the life cycle early, identifying the risks and committing to the process will reduce or even reverse potential overrun at a fraction of the latent cost penalty.
Management of punch lists
Snagging and Technical Queries
Electronic change control and versioning are at the centre of the process for securing data reinforced by a full audit log.
Is my data secure?
How information is secured and electronically backed up
Information is primarily secured within e-PM by limiting uncontrolled changes, confining access to the project data to only those users who need it, while at the same time making data available to all project staff in a read only manner.
The e-PM data load process accepts project data from a variety of sources and is able to quickly secure data into the system. Data is tagged with its source document details for reference and logged in the audit history.
Unasys and the e-PM software ensure both the quality and security of the project data by following recommended industry best practices for data storage and access control. Populating e-PM with project data is achieved via several unique and time saving technologies developed by Unasys.
Training (offices & site)
Training is primarily offered to fit with the workforce and project to maximise system acceptance and result output.
Unasys have seen the best results with hands on instructor supported project work for individuals and small teams. Other good options include toolbox talks for manual workers with kiosk access and lunch and learn sessions for corporate users, allowing a compact overview of system capabilities with 1-1 follow-ups as needed.
Classroom sessions and manuals to read are historically known to Unasys to be of limited value, poorly attended and of poor value to a project in terms of money, time and user acceptance of systems.
All training is customisable and long lasting via refreshers and on going support from any onsite Unasys team present.
Questions frequently asked…
Can I see which activities are incomplete?
Can we have any easy way of seeing what documentation is missing?
Can I see materials associated with punch lists?
Can I monitor shutdowns and outages?
…with ePM you can
Proposal for Vølund
July 2019, Michael Flynn, Unasys
Since its conception almost 20 years ago, Unasys has supported clients, both large and small, to overcome complex problems on facilities around the world.
Historically working with Oil and Gas majors, including current clients Equinor (Statoil), Technip, Neptune (GDF), Worley Parsons, TAQA and Premier Oil, the organisation has diversified to support projects within the Renewables sector, with a number of recent projects on Waste to Energy plants.
When Unasys has been involved in projects from the outset, it has a strong track record of finishing on time and within 10% of budget.
Example – Castor Underground Gas Storage (onshore/offshore GoM/Spain) - €1bn project
This project for Enagas and ACS Cobra featured two bridge linked platforms, subsea pipelines and an onshore processing plant.
Unasys were involved from the outset and saved the client a significant amount of budget through solid project and scope definition together with a realistic workable schedule for both phases onshore in Spain and the Gulf of Mexico and offshore Spain.
By utilising Unasys’s ePM software during definition, it meant that the Hook Up interfaces could also be included and managed within the project negating the need for the client to bring in a Hook Up and Commissioning Contractor. The Unasys Completion schedule showed a Ready for start-up date of 30th Jun.
On 30th June the entire project was ready for start-up, including; project certification, supplier documentation and system handover packages.
(Planning for supplier documentation is critical. Months can be wasted trying to handover systems because of the lack of supplier documentation)
Whilst working with Premier Oil to help improve the late life management process of their offshore assets, Unasys developed a digital twin of their Balmoral and Huntington facilities.
After discussing the principles of this approach and the benefits to energy companies, government and the wider environment, Unasys were approached by the Oil & Gas Technology Centre (OGTC). The OGTC, who are funded by both the Scottish and UK Governments to support innovation in the sector, wanted to expand and develop this technology further to create a digital copy of the North Sea.
The Digital North Sea is now becoming a reality and work continues with a minimum viable product expected for release around the end of September 2019. This solution is based upon and driven by the Unasys ePM Completions software.
This means that the existing version of ePM will be benefit from this investment in functionality and will see it improve substantially.
The new and improved version of ePM will reduce risk by;
Better visibility of project scope
Improved information flow
Enhanced means for measuring and monitoring progress
Easier access to supporting documentation
An improved framework for managing issues
Creating a standard for information management
Keeping things simple
Much improved Digital Handover
Setting the standard
Technology processes and standards are constantly evolving meaning there will always be a smarter way to do things. Unasys are able to support the improvement of processes rather than superseding them and making systems obsolete. The optimum path to flawless start up is improved delivery.
We will help Vølund to deliver their projects.
Timeframe & Costs
Unasys will be in a position to accept data into the newly released and tested version of ePM mid-August 2019, with the minimum viable product ready around the end of September 2019.
Costs per annum
The newly updated version of ePM will be available without any development cost, which means Vølund will benefit from a significantly improved product.
Vølund may also see benefit in recommending the Unasys services to their supply chain. In this instance, Unasys would be happy to come to a commercial arrangement with Vølund for any referred business.