Achieving Environmental and Safety Excellence at
Operating Plants by Using AutoCAD® P&ID
Jess Askey
Shale Robison
Aditya Kumaran
CTO, Environmental intellect
CEO, AllCADNorthwest
VP Engineering, Environmental intellect
© 2012 Autodesk
Class Summary
In this class, we will present the need for a change in how environmental and safety
compliance issues are tackled in various industries regulated by the Occupational
Safety Health Administration (OSHA) and Environmental Protection Agency (EPA).
The limitations and inefficiencies of industry-standard work practices and data
systems will be examined for cost and non-compliance implications. We will do
case studies and demonstrations for how petroleum refineries have implemented
AutoCAD® P&ID software as part of environmental and safety compliance projects
to achieve a reduction in actual and reported VOC and HAP emissions. We will
cover a stepwise workflow process for owner-operators and engineering,
procurement, and construction firms to follow, engaging various plant disciplines,
including CAD, engineering, and environmental and safety that are favorably
affected by this workflow. Specifically, the case study will share a process for using
data-driven drawings to achieve improved compliance with environmental and
safety regulations.
© 2012 Autodesk
What is the problem?

Facilities in a wide variety of markets are under Environmental and
Safety regulatory compliance mandates…. Food Processing, Chemical
Processing, Refining, Oil & Gas, Pharmaceuticals, Biofuels, Power
Generation and more.
 Compliance can be complicated and exasperated by paper-based data
tracking
 Regulatory non-compliance represents a high risk and very high cost
both monetarily and perceptually
© 2012 Autodesk
What is the solution?

A formalized approach or workflow that is tested and repeatable

A basis in data-sharing which utilizes current best-in-technology
solutions

An approach that increases data quality and expands data accessibility

A solution which can adapt to future changes in the regulatory
landscape
© 2012 Autodesk
Learning Objectives

Attain an awareness of the regulatory compliance standards required at
facilities from the Environmental Protection Agency (EPA) and the
Occupational Safety and Health Administration (OSHA).
 Acquire knowledge of what the new generation of Smart, Data-Driven
P&IDs are, as opposed to the older drawing functions.
 Obtain a step flow understanding of how to convert .dwg files into Smart
P&IDs.
 Achieve an understanding of how an compliance plugin works in
conjunction with AutoCAD P&ID to expose environmental data.
 Examine case-studies to see the short and long term benefits of a Data
Driven compliance program.
© 2012 Autodesk
© 2012 Autodesk
Environmental and Safety Compliance in
Operating Plants
© 2012 Autodesk
(Show of Hands)
Who has worked on a project where you
had to consider environmental and
safety compliance?
© 2012 Autodesk
What is Compliance?
•
All industries are facing increasingly stringent compliance standards
•
Federal EPA and OSHA, as well as State and local standards need to be
met
•
Severe financial and/or criminal penalties
•
Huge market for new technology solutions to ease this process
© 2012 Autodesk
EPA’s and OSHA’s Mission

Taking Action on Climate Change and Improving Air Quality

Protecting America’s Waters

Cleaning Up Communities and Advancing Sustainable Development

Ensuring the Safety of Chemicals and Preventing Pollution

Providing training, outreach, education and assistance

Enforcing Environmental and Safety Laws
© 2012 Autodesk
EPA and OSHA Hot Topics

Process Safety Management (PSM)

Leak Detection and Repair (LDAR)

Greenhouse Gases (GHG)


GHG Mandatory Reporting Rule
Benzene Waste Operations NESHAP (BWON)
© 2012 Autodesk
Regulatory Drivers

Process Safety Management – analytical tool to prevent releases of any
substance defined as a "highly hazardous chemical" EPA or OSHA

Management of Change (MOC)
 Process Hazard Analysis (PHA)
 Process Safety Information (PSI)

Clean Air Act - includes several Federal, State, Local, and Consent
Decree regulations

Initial and ongoing applicability assessments
 Ongoing compliance monitoring
 Recurrent compliance reporting and recordkeeping
© 2012 Autodesk
Let’s Focus on Leak Detection and Repair (LDAR)

LDAR is a program that requires monitoring of regulated components
and sensory inspections of:

Volatile Organic Compound (VOC) service, or
 Hazardous Air Pollutant (HAP) service

Timeframes for equipment leaks
© 2012 Autodesk
Regulated Components

Pumps
 Valves
 Compressors
 Agitators
 Connectors/Flanges (in some
areas)
 Sampling Connections

Pressure Relief Devices
 Capped/Plugged lines
 Instrumentation Systems
 Process Drains(in some
areas)
© 2012 Autodesk
Who Is Responsible?

Plant Management – allocates resources

Environmental – interprets regulations and applicability

Engineering – stream composition data

LDAR Group – monitoring, first attempts, recordkeeping, and draft report
materials

Operations and Maintenance – repairs, DOR, keeping OELs controlled,
sampling properly, helping keep tags in place
© 2012 Autodesk
LDAR Compliance

What is needed to comply with Leak Detection and Repair (LDAR)?
1.
Firm understanding of regulations
2.
Operations/engineering knowledge to define applicability
3.
Resources to manage equipment inventory and compliance inspections
4.
Data systems to produce required records and reports
5. Structured Management of Change (MOC) process to identify compliance
impacts
© 2012 Autodesk
Non-Compliance Costs

LDAR penalties range from > $10MIL to < $10K
 Since 2000, USEPA has negotiated 28 Consent Decree (CD) settlements
covering 90% of U.S. refining capacity
 Settling companies have paid more than $6 billion in control technologies, civil
penalties, and supplemental environmental projects

Stipulated penalty example

10 missed valves in LL/GV service:
$100/valve/day
$10,000/mo./process unit max
$10,000/mo. x 24 mos. (2 years)
$240,000 for 10 missed valves!!!
© 2012 Autodesk
Using AutoCAD® P&ID
© 2012 Autodesk
(Show of Hands)
Who has used AutoCAD® P&ID or
Plant3D?
© 2012 Autodesk
What is AutoCAD® P&ID Used For?

Piping and Instrumentation Design Software

Easy to use, standard AutoCAD® based functionality

Millions of users in industries worldwide (Oil & Gas, Petrochemical, etc)

Transition into “Smart P&IDs” features
© 2012 Autodesk
Current Approach to Compliance Using
AutoCAD® P&ID

Existing, “dumb” Piping and Instrumentation Design drawing limitations

Drawings independent of one another, hence compliance issues are
tackled independent of one another

Inefficiencies with paper-based P&IDs with respect to generating reports,
routine inspections and recordkeeping

Engineering staff and plant managers do not have access to real-time
compliance records

Compliance industry outdated in a world of Data-Driven software
© 2012 Autodesk
Q: What is a “Smart” P&ID?
A: A P&ID with underlying data
© 2012 Autodesk
Features Demonstration: Shale Robison
© 2012 Autodesk
AutoCAD® P&ID Functionality
Quick P&ID Creation
Quick Editing
• Easy-to-learn interface
• Industry standard P&ID symbols
• Dynamic components
• Easy symbol creation and substitution
Simple Data Handling
Export / Import
• Tag generation and uniqueness
• Spreadsheet interface
• Generate reports via MS Excel
• Import / export to MS Excel
© 2012 Autodesk
10 Reasons to switch to P&ID or Plant 3D

Full listing in handout

Enables faster, more efficient creation, manipulation of P&ID drawings

Lets discuss but a few of these reasons…

Industry standard P&ID symbols

Dynamic process and signal lines
© 2012 Autodesk
Intelligent P&IDs can Reduce Owner-Operator
Costs

Integration with intelligent P&IDs enables increased efficiency and
compliance processes
 CAD Management – implementing AutoCAD P&ID can reduce costs of
day-to-day CAD operations
 Environmental Compliance – includes several Federal, State, Local
regulations, which requires:
•
•
•

Initial and ongoing applicability assessment
Ongoing compliance monitoring
Recurrent compliance reporting and recordkeeping
Process Safety Management (PSM) Compliance – involves compliance
with safety requirements for several industries
© 2012 Autodesk
Intelligent P&ID Cost Savings
 Integrated with tools that users are familiar with
•
•
•
•
Engineering / Drafting: AutoCAD P&ID, etc.
Management: Web-based interfaces / reporting engines
Technicians – software products that use regulatory determinations to
define their daily tasks (e.g., LDAR databases)
Other data systems (e.g., SAP, e-MOC, IP 21, etc.)
 More efficient data processing
 Streamlined EH&S compliance activities during MOC
 Automated compliance assessments, recordkeeping, and reporting
lowers labor costs for similar tasks
 More reliable compliance systems mitigates compliance risk (as well as
compliance penalties)
© 2012 Autodesk
CAD Management
 Day-to-day CAD operations include the following types of tasks:
•
•
•
•
Design of as-built CAD drawings
Management of change (MOC) updates
Field review, redlining and updating of outdated CAD drawings
Others?
 Traditional AutoCAD lacks the sophisticated tools of the intelligent P&ID
platform AutoCAD P&ID
 AutoCAD P&ID can effectively improve day-to-day tasks by almost 50%
(see Autodesk/Cambashi study)
© 2012 Autodesk
Improved Productivity
 In June 2008, Autodesk contracted with Cambashi to conduct an
AutoCAD P&ID Productivity Study
 Overview of Methodology: the test comprised a set of activities to be
completed under a timed test environment. All users were provided with
the materials needed to complete the test, including the complete P&ID
and an extract for each of the tasks to be executed.
 Ease of Transition: the results from the graphical tasks demonstrate that
experienced AutoCAD users will experience little difficulty in upgrading.
© 2012 Autodesk
Improved Productivity
“The ‘headline’ productivity gain was
found to be in the region of 40% -- and
this outcome was based on a rigorous
and wide-ranging test of AutoCAD P&ID
capability.
- Tony Christian
Cambashi Limited
© 2012 Autodesk
Productivity Specifics
Quick Editing
Export/Import Data
• Automatic equipment nozzle placement
• Update P&ID data from MS Excel
• Automatic valve alignment & insertion
• Review and approve data edits
• Annotation updates
• Ensure data consistency
• Dynamic lines & components
• Consistent data across sheets
• Off-page connectors
• Approve data during import
© 2012 Autodesk
What has your experience been?
© 2012 Autodesk
Using Data-Driven Drawings in
AutoCAD® P&ID to reduce owneroperator costs as well as actual and
reported emissions at facilities
© 2012 Autodesk
Case Study #1:

Wyoming Refinery

250 Drawings

15,000 components
in LDAR database

50,000 annual
LDAR monitoring events
© 2012 Autodesk
Case Study Goals

Convert to Smart P&ID drawings

Successfully integrate into site LDAR database

Educate engineers, managers, technicians on workings of AutoCAD®
P&ID
© 2012 Autodesk
Case Study #1: Project Tasks
1.
Convert Drawings to AutoCAD® P&ID
2.
Successfully integrate into site LDAR Database
3.
Import facility stream speciation data into compliance plugin (DEMO)
4.
Review LDAR drawings for accuracy
5.
Establish SOP for integrating with site LDAR database
6.
Educate engineering personnel on workings of AutoCAD® P&ID
© 2012 Autodesk
Case Study #1 Demo

Stream import

Dashboard of facility overview

LDAR database export functionality
© 2012 Autodesk
Case Study #2:

Texas Refinery

372,000+ components
in LDAR database

About 350,000 annual
LDAR monitoring events
© 2012 Autodesk
Case Study #2: Project Tasks

Create Smart P&ID’s for new process unit

Apply LDAR speciation data

Verify accuracy of LDAR drawings

Export new components into LDAR database
© 2012 Autodesk
Case Study #2: Demo
© 2012 Autodesk
Case Study Outcomes
Benefits

Improved data flow

Faster updates to LDAR database after process changes

Lower risk for environmental non-compliance

Higher satisfaction in data quality

Better transparency across departments
© 2012 Autodesk
Case Study Outcomes
Challenges

Slow conversion rate (Over 250 .dwg files)

Some drawings not upto standard, difficult conversion process

Small losses in metadata

AutoCAD® functionality difficult to apply in template format
© 2012 Autodesk
Future Case Studies

Participated in very small fraction of total facility markup

Capacity to explore other areas of compliance besides LDAR (GHG,
PSM, BWON, etc.)

Host webinars for engineering personnel at facilities

Update compliance plug-in to suit the needs of individual facilities
© 2012 Autodesk
Standard Implementation Workflow
© 2012 Autodesk
Implementation – How To Get Started

Piping & Equipment Intelligence
using AutoCAD P&ID

Add Compliance plug-in validation
tool(s)
1 – Convert P&ID’s
© 2012 Autodesk
Implementation – How To Get Started

Facility Specific




Stream Constituents
Streams
Equipment
Regulatory Requirements
2 – Data Mapping
1 – Convert P&ID’s
© 2012 Autodesk
Implementation – How To Get Started

Create Baseline Fingerprint
3 – Compliance Calculations
2 – Data Mapping
1 – Convert P&ID’s
© 2012 Autodesk
Implementation – How To Get Started

Environmental Data Integration
4 – Systems Integration
3 – Compliance Calculations
2 – Data Mapping
1 – Convert P&ID’s
© 2012 Autodesk
Implementation – How To Get Started

Ongoing



Update to CAD Standards
Transparent
Leverage Additional Data Systems
Data Organization

5 – Operations & Maintenance
4 – Systems Integration
3 – Compliance Calculations
2 – Data Mapping
1 – Convert P&ID’s

Audit Management
© 2012 Autodesk
Implementation Questions?

What other complications do you foresee?

With your facility exposure and knowledge, are there any concerns that
you wish to raise at this point?

Handout caters to all engineering staff and plant managers at facilities
© 2012 Autodesk
Handout Review

Procedures for conversion

Development of SOPs

Additional details available if you contact us!
© 2012 Autodesk
Wrap-up: Tools demonstrated

AutoCAD® P&ID

Regulatory Compliance Plugin

LDAR Database
© 2012 Autodesk
Rehash Solution to Problem

Compliance issues cannot be solved overnight

Short-term solutions, long-term gains!

Intelligent P&IDs are part of a paradigm shift in today’s world of DataDriven technologies

Huge financial incentives for companies to gain competitive advantage
and cut-costs
© 2012 Autodesk
General Questions and Discussion


FAQs

Where can I get more information on intelligent P&IDs and their uses?

How can I get help converting P&IDs?

Can intelligent P&IDs be developed in other CAD software platforms?
Discussion
© 2012 Autodesk
Contact Information

Jess Askey
jess@env-int.com
(307)760-5270

Shale Robison

srobison@allcadnw.com
(208)546-9893

Aditya Kumaran
aditya@env-int.com
(630)995-1557
© 2012 Autodesk
Autodesk, AutoCAD* [*if/when mentioned in the pertinent material, followed by an alphabetical list of all other trademarks mentioned in the material] are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and
services offerings, and specifications and pricing at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. © 2012 Autodesk, Inc. All rights reserved.
© 2012 Autodesk