Where unified engineering meets digital twins A data-centred approach to solving the huge complexities of EPC projects and optimizing asset performanc
Software technology for Engineering Procurement and Construction (EPC) projects within the oil and gas sector has been steadily developing for years; seemingly marked at each stage by the continual introduction of an increasing number of now well-known industry anacronyms. From the introduction of CAD (computer aided design) systems for drafting and designing exploration and drilling equipment in the 1970s, GIS (geographical information systems) in the 80’s, ERP (Enterprise Resource Planning) technology that integrated all back-office business processes in the 90s, through to iOps (integrated operations) that drove real-time, data-driven decision making in the noughties. More recently, IoT (Internet of Things) has driven a swathe of digitalization that has enabled the move towards the use of AI, machine learning, as well as blockchain technology.
Evolution of EPC software technologies
At the heart of these developments has been the desire to simplify the huge complexities of executing any EPC project and drive efficiencies and collaboration, while also reducing project lag time.?
Despite this, many large EPC projects still come in over budget by circa 10% and are also delayed, with three out of four projects at least 40% behind schedule, accumulatively costing billions of dollars in lost revenue.?
There are several reasons why this happens, not least the conservative nature of the industry, and a culture of unwillingness to embrace digitalization and the readily available technologies and software that currently exist.
Within this digital world, Unified Engineering and Digital Twins have also heralded much attention in attempting to solve the problems of this massive complexity and managing the vast multiple workflows involved in delivering EPC projects. Both have been in development over the past few years (indeed Cadmatic began the process of developing its own UE and DT technology over 15 years ago), but it is only now that we are seeing companies starting to properly utilize it.?
Fundamentally, the hype has now gone; replaced by a level of pragmatism in how it can be practically implemented and successfully used in a real world way to solve real world issues. This is supported by a recent report from GlobalData , the analytics and consulting company, which estimated that the global digital twin market will be worth $150 billion by 2030.
Global digital twins revenue, 2019 to 2030
And it really is needed, because today’s major projects are becoming increasingly complex. Indeed, there may be over three EPCs involved in a large oil and gas construction project ; from one that specialises in auxiliary processes, one that specialises in buildings, and one in infrastructure and so forth. Within this, there are multiple engineering disciplines from process and electrical to civil and environmental, all of whom are working with a myriad of different external vendors and stakeholders.
While they work within their silos, they must send and share a vast quantity of documents, information, drawings and updates on developments that are constantly evolving and changing; a lesson in inefficiency. On top of this, they may all work in very different ways and with different systems; many still use email and/or Microsoft Excel, they’ll have physical meetings, and other outdated methods of communicating and collaborating. However, any change, however small and at whatever level, can set in force a significant reaction that can affect the whole chain.
The role of unified engineering in streamlining EPC projects
Unified Engineering solves this problem by taking an integrated, holistic approach that goes beyond just tools and practices; rather it combines and integrates all the multiple engineering disciplines, and all phases and processes of a project within one unified system and platform. Fundamentally, it moves from a position where the backbone of a project is document-based, to one that its centred on data.?
Where communications is one of the greatest challenges, and where the leading cause of time consuming reworking in construction is design and engineering errors, Unified Engineering enables seamless collaboration among all stakeholders involved, facilitates better and faster decision making, and improves efficiency and co-ordination at all stages of a project. Ultimately, having data in a single environment inherently increases quality and timeliness of deliverables through accuracy and consistency of data, but even more importantly it allows teams to assess and manage the impact of design changes in real time, mitigating risks and optimizing performance.
Digital Twins: Bridging the physical and digital worlds
If Unified Engineering is the creator of data within an EPC project, the Digital Twin is the consumer; taking the data to create a virtual replica and up-to-date representation and model of the asset, systems, people as well as processes; it is, in effect, a bridge between the physical and digital world.
The real power however is when the two are combined, not just for the initial construction phase of a project, but throughout the ongoing operation and entire lifecycle of the asset. For example, an oil refinery’s operational lifetime might be around 50 years, where over the course of that period, it may be rebuilt two or three times. This will constitute massive projects, from the initial construction and build through to major technical revamps and significant changes and modifications to processes and automation. In the oil and gas market, an owner might need to add a new $200 million hydrocracker, which requires the creation of new plans that are flawlessly connected to existing systems. However, the Unified Engineering data platform integrated with the Digital Twin ensures that all the technical data that is required to start and deliver the project is correct and easily available for everyone.
Essentially, the Digital Twin sits as a platform above the Unified Engineering system, consuming information and trusted data from multiple sources, becoming the common platform for all stakeholders involved in the project. Importantly, the best Digital Twins can receive the information from any source or from whatever system a person or an organisation is using; it’s effectively agnostic, which creates a significantly high level of interoperability.
Much development work is going into ensuring that Digital Twins can monitor the current performance of an asset. Within the next 5-10 years, Digital Twins will start using real time data, machine learning, artificial intelligence and software analytics to create a dynamic digital model that can simulate the future performance of the asset and forecast potential scenarios, such as when to increase or decrease production, providing profound insights to influence decision making. It will enable owners and operators to streamline processes, pre-empt potential breakdowns and schedule maintenance to minimize unplanned downtime, bolster and improve safety measures, and, ultimately, improve operational performance and profitability.
Cadmatic’s comprehensive solutions for EPC projects
Cadmatic has been at the forefront of this software technology development for many years, working with owners and operators, EPCs, engineering and construction companies, as well as contractors to develop Unified Engineering and Digital Twin systems and platforms to drive progression and change within the industries that it serves.
At the core of Cadmatic’s Unified Engineering offering is a comprehensive, data-driven, and fully integrated suite of software solutions for process and plant design; from P&ID and 3D plant design to EIA design. Cadmatic’s data-driven approach enables close collaboration between all disciplines, integrates processes and assures end-to-end continuity by sharing the same source of real-time information:
Cadmatic’s Digital Twin solution, CADMATIC eShare , acts as a project collaboration and information sharing portal, including engineering data, scheduling and construction site management.
For EPCs, eShare enables access to all project data, which can be integrated and visualized; monitoring key metrics in real time using the data from project management systems, materials management, fabrication and construction analysis, as well as ERP systems. Fundamentally, it provides that level of transparency and oversight to ensure that projects can be finished on time and to budget. For owners and operators, eShare provides a single window to all asset and facility-related data. It integrates the 3D model, engineering data and 3D captured data from laser scans and the plant’s operational and maintenance data for maximum project insight. Ultimately, it provides the latest real time information on the status of the asset, how it is performing, as well as predictive simulation on future performance. This reduces operational costs by streamlining maintenance and operations processes.
Unified Engineering and Digital Twins were largely viewed as aspirational technology by an, arguably, traditional industry not adept to change or doing things differently, or just apprehensive by the potential sheer complexity of using technology. But change is happening, and these technologies are both proven and viable for all, be it EPCs or owners and operators.
Not only that, with experience and the advanced, interoperable nature of the technology, the building and scaling of these platforms, and the integration of Unified Engineering with Digital Twins is actually not a hugely difficult process, or overtly costly or indeed time consuming. Ultimately, when they are integrated and joined together the impact on EPC projects and the ongoing operation of the asset are significant; driving efficiencies, delivering huge cost savings by working on time and to budget, as well as optimizing asset performance and production now and into the future to maximize profitability. Put simply, it is an investment worth making.