Proceedings of COBEM 2011 21st Brazilian Congress of Mechanical Engineering Copyright © 2011 by ABCM October 24-28, 2011, Natal, RN, Brazil INTEROPERABILITY AMONG ENGINEERING SYSTEMS AND THEIR RELEVANCE TO THE EFFECTIVENESS OF THE ENGINEERING PROJECTS’ LIFE CYCLE – REGULATION, WELL SUCCEEDED EXAMPLES AND PROPOSED ACTIONS Carlos Augusto Pereira, [email protected] Alexandre Carlos Casalechi Dias Correa, [email protected] Petroleo Brasileiro SA – Petrobras, Rio de Janeiro, RJ, Brazil Ricardo Yogui, [email protected] RYO Consulting, Rio de Janeiro, RJ, Brazil Carlos Magno de Lima, [email protected] Universidade Federal do Rio Grande do Norte Departamento de Engenharia Mecânica Natal, RN, Brazil Abstract. This study reflects the need to standardize the format of files and data allowing information to be sovereign over the technology, and legacy data to be less vulnerable to technological advances and improvements, keeping up their usefulness and efficiency to the detriment of the market interests. It is presented as the open innovation has contributed to the development of the interoperability standard, and are also presented some examples of initiatives in an effort to implement the regulation ISO – 15926 – Industrial Automation Systems and Integration – life cycle data integration for process plants units including oil and gas production plants, and actions are proposed to accelerate its adoption by the national engineering community. Keywords: ISO-15926, Computer-aided-design (CAD), Interoperability, Data integration, Oil and Gas. 1. THE CURRENT SCENARY: CHALLENGES FOR IMPROVING THE EFFICIENCY THROUGHOUT THE ENGINEERING PROJECTS’ LIFE CYCLE The recent finding of the pre-salt on the Brazilian coast and the technological challenges for its exploitation, as well as to improve the production of the actual national petrochemical and refining park has a new challenging component which is the goal of nationalization on global competitive levels which was presented to the production chain for the equipment and service supply for these engineering projects. According to the document: “Network Improvement of National Chain Management of Goods and Service Suppliers”, produced jointly by Petrobras and the Industrial Engineering community to Productive Development Policy – PDP, coordinated by the Ministry of Development, Industry and Foreign Trade – MDIC, and supported by an Executive Secretariat, formed by ABDI (Industrial Development Brazilian Agency), BNDES (National Bank of Social and Economic Development) and the Ministry of Finance, assumes that the present moment of the Brazilian economy demands firm and wide support to capital formation and innovation to sustain the long-term growth of the nation. To meet these demands, the Plant Design Automation stands as an important strategic tool to leverage the solutions of the challenges of competitiveness that the domestic industry faces new engineering projects and their nationalization index in terms of global competitiveness The Plant Design Automation enables the resources optimization, productivity improvement and better information quality of ENGINEERING PROJECTS and assets throughout the life cycle, allowing managers a better decision making in the operational and strategic issues in managing these assets. Globally, the theme Plant Design Automation becomes relevant with discussion forums on best practices and specially to address the issue of interoperability, key point to greater effectiveness and scale of benefits brought by the Plant Design Automation and so important to meet the challenges of the national chain suppliers in oil and gas segment. 2. INTEROPERABILITY 2.1. Definition According to the description given by SAYÃO (2008), the Interoperability is the ability of a system (computerized or not) to communicate transparently (or close enough) with another system (similar or not). To be considered an Proceedings of COBEM 2011 21st Brazilian Congress of Mechanical Engineering Copyright © 2011 by ABCM October 24-28, 2011, Natal, RN, Brazil interoperable system, it is very important that it works with open standards or ontologies. Either a portal system, or an educational system or an electronic commerce system, or e-commerce, nowadays we are more and more likely to the creation of standard systems. There are several types of interoperability; below we highlight the most relevant ones for this article: • Technical Interoperability – It is the continuous development of communication standards, transportation, storage and representation of information through the involvement of a number of organizations. It is up to information technology facilitate the convergence of standards, wherever is possible to have a set of standards in the system to benefit the community. • Semantic Interoperability – Is the meaning or semantics of information from different sources, it is solved through common tools of information representation such as classification and ontologies • Legal Interoperability – They are legal requirements and implications of making information items. 2.2. Problems caused by the lack of Interoperability In the environment of engineering projects, with the increasing adoption of computational tools, the strategic integration with business systems and greater collaboration with stakeholders systems, it creates an environment of great challenge for convergence in interoperability. One of the main aspects that are mentioned in the discussion of the lack of interoperability is certainly the cost dimension of engineering projects that can be impacted by lack of interoperability and therefore for redoing works, inefficiency and delays caused by the lack of interoperability among engineering systems. Due to its strategic relevance, and in order to quantify the cost of lack of interoperability, NIST – National Institute of Standards and Technology, which is the U.S. National Institute of Standards and Technology, linked to the federal department of Commerce – created a study in 2005 – the NIST GCR 04-867, to identify and estimate the loss in the Engineering Enterprises due to the lack of an appropriated interoperability in the United States. For this study, NIST held an inadequate estimated cost of interoperability, quantifying and comparing the current state of interoperability with a hypothetical scenery against a factual in which the availability and exchange of electronic data is fluid and seamless. The difference between the current sceneries and against factual represents the total estimate economic losses associated with inadequate interoperability. The cost was calculated at the social level. In other words, this analysis quantifies the loss of efficiency by society due to inadequate interoperability. Among the found cost, we can highlight: • The cost avoidance - They are related to the activities of concerned parts to compromise in order to avoid or minimize the impact of problems of technical interoperability before they occur. • The cost of acquisition, maintenance and training to redundant CAD/CAE systems; the maintenance cost of redundant paper systems to exchange information. • Outsourcing of translation services to third parties. • Investments in domestic programs, such as translators from point to point, and translators from a neutral file format to solve interoperability problems. • Mitigation Costs – arising from activities in response to interoperability problems. There is often the most part of interoperability cost (Martin, 1999) (Gallaher, 2002). Most of them results from mitigation cost of electronic files or paper files which must be inserted manually into multiple systems. In this analysis, mitigation cost may also result from redundant construction activities, including scrap materials. • The cost of redoing the work of conception and construction due to interoperability problems. • The cost of manually re-enter data when exchange electronic data is not available or when mistakes were made during the exchange • The cost of checking information when original sources cannot be accessed. Proceedings of COBEM 2011 21st Brazilian Congress of Mechanical Engineering Copyright © 2011 by ABCM October 24-28, 2011, Natal, RN, Brazil • The cost of delay – resulting in interoperability problems such as, delay the conclusion of a project or increase the time when a facility is not in normal conditions of operating. These costs are the most difficult ones to quantify. • Idle resources for the delay of construction activities. • Profit loss due to delay of revenues (discounted values of future profits). • Losses for customers and consumers due to delay on availability of products and services. • Lost on productivity when a resource is not in a normal operation. This study identified U$15.8 billion in inadequate interoperability costs and were quantified for the capital installations and supply chain in the U.S. in 2002. This estimated annual cost corresponds from 0.86 to 1.24 percent of annual revenues for architects and engineers, specialist contractors and manufactures and suppliers. When compared to the annual value of construction of capital facilities’ in 2002, 2.84% are the losses attributed to lack or interoperability in the projects representing U$15.8 billion and of this total, 70% are funded by owner operators. This can be considered a conservative estimate because it does not include in those cost categories, items such as opportunity cost and decommissioning costs. In addition, costs were not quantified for all components. Collaborating with these