Operational
Excellence
Service
Service forOperational ExcellenceLong-term Partnering for Our Clients’ Business SuccessClients’ Expectations
For many years,
JGC has provided solutions
to meet the various
expectations ofplant owners.

Conserve the Environment
Reduction of GHG emission

Clients’
Expectations
for

O&M

Optimize O&M Cost$

Improve operations strategy
and system reliability

Shift to Smart O&M

Digital Tool application for O&M

Secure Plant Safety

Assessment and management ofrisksManage Turnaround Activities
Minimize downtime and loss of profit

Empower Employees

Training local engineers and techniciansOur Approach
JGC offers the most excellent services
for your plant operations
optimization to solve difficult
problems and technicalissues you confront.

Commissioning & Startup

Decarbonization

Approach to
Excellent

O&M

•
•
•

Energy Saving in Operation
Manage Life Cycle CO2
Quantify & Reduce GHG

HSE
•
•

Manage Operational HSE
Risk
Optimize Fire Protection
SystemEnsure Emergency
Preparedness••

Smooth & Safe Startup
Perfect Operations Readiness•••Maximize Profit
Optimize OPEX
Visualize Operations

Reliability & MaintenanceFurther efficiency throughour digital technology•

Operation

Smart O&M Solutions
•

•

•
•

Maximum Plant Availability
Flawless and Smooth
Turnaround
Extended Plant Life

Our Operational
Excellence
Services Map
Commissioning & Startup
 Predictable Start up Program Operations Readiness &Assurance Program

Operation
 Profitability Improvement
ProgramDecarbonization
 Decarbonization Program

HSE

Operational
Excellence
Service Operational HSE Risk
Management Program Fire Protection Improvement
Program
 HSE Improvement Program

Reliability & Maintenance Mechanical Integrity
Program Turnaround Assistance
Program Maintenance Improvement
ProgramSmart O&M Solutions

Technical Assistance & Training Plant Smartification Program Maintenance and inspection
digital twins Program Technical Assistance Service
 Training Service

DecarbonizationJGC Group provide a large variety of Decarbonization Program which is the
proprietary GHGs assessment solution and optimized operation service
based on our successful experiences in countless EPC & O&M fields.

Service Menu

Return to
OE Service menu Decarbonization Program
GHG Quantification Service (HiGHGuard™)
Life Cycle CO2/Management
CO2 Removal Solutions
Energy Optimization
Fired Heater Improvement

Pinch Analysis

CO2 footprint of Plant Lifecycle/Life Cycle Management

DDR Membrane - High Performance Separation Technology

Operation

Return to
OE Service menu

Service Menu1

Our engineers have a wealth of experience, knowledge and enthusiasm

 Profitability Improvement Programfor all aspects of plant engineering, and channel their expertiseLNG Cube (Engineering Consultation Service)

Improvement service of the highest quality without major CAPEX.

HAR (Hot Air Recirculation) Digital

through cutting-edge engineering tools to provide Profitability

AIRLIZE LNG

Weather
Simulation

LNG Cube Technical Service Menu

Site
Survey

CFD Simulation

Plant Layout
Optimization

Airlize LNG Coverage Services

HAR Analysis&
Mitigation

Noise Analysis&
Mitigation

Reliability & MaintenanceIn addition to highly developed engineering technologies and theapplication of its safety management skills, JGC O&M service improves
plant reliability, availability, and quality by collaborating with global
affiliates companies and local maintenance companies.

Service Menu

Return to
OE Service menu Mechanical Integrity Program
Risk Based Inspection (RBI)
Asset Integrity Management (A-MIS)
Plant Life Extension Program
Plant Diagnosis and Lifetime Improvement
Service Turnaround Assistance Program
Turnaround Scope Optimization & Planning
Turnaround Execution Management
Finite Element Analysis (FEA)

Maintenance Planning

Inspection & Diagnosis

 Maintenance Improvement Program
Reliability, Availability, Maintainability (RAM)
Reliability Centered Maintenance (RCM)
Prescriptive Maintenance

JGC Maintenance Team at LNG Plant

Inspection Data Management System (A-MIS)

HSEService Menu

HSE service focuses on systematic identification and evaluation of plant risks

based on our long experience in on-site HSE and our own excellent evaluation
methods, and on proposing systems that can ensure safe plant operation
without major CAPEX.

Return to
OE Service menu Operational HSE Risk Management Program
HSE Risk Management- Formal Safety Assessment- Hazard Identification (HAZID)- HAZOP/SIL/LOPA/Bow-tie Analysis- Operational Hazard Reduction- Management System Review- Process Safety Management

 Fire Protection Improvement Program
Active Fire Protection Assessment
Fire Proofing Assessment
Fire and Gas Assessment
Fire Hazard Simulation

Fire and Gas Mapping Study Technology

 HSE Improvement Program​
Escape Simulation and Assessment
Hazardous Area Classification (HAC)
Optimization
Noise Assessment​

QRA

Commissioning & Startup
Our commissioning engineers are passionate about risk in commissioning
and start-up management, and work closely with the client to create theoptimized plan taking into account lessons learned and our knowledge
from our many previous projects, aiming always to deliver the best
commissioning and startup service

Service Menu

Return to
OE Service menu Predictable Start up Program
See the Detail of Predictable Start up

CASTOR®
(Commissioning & Startup Transient
Operability Review)
Commissioning Safety
Commissioning & Start-up for
FLNG/FPSO/Module
Decarbonized Commissioning and Start up(Under Construction)
Recommissioning service (Restart)(Under Construction)- Plant Condition Assessment- Preservation planning Operations Readiness & Assurance Program
High-quality Planning Based on a Wealth of Experience

Operations Readiness & Assurance (OR&A)

Technical Assistance & Training

Service Menu

Over the past several decades, JGC Group has conducted various engineer training programsand technical assistance programs at plant site and remote locations. Many of our clients
have achieved considerable improvements in their employee skills and plant operations
which significantly contribute to the profitability and efficiency of their business.

Return to
OE Service menuTechnical Assistance Service
Onsite Assistance (Residential/On-call)
Asset & Operation Due Diligence
OPEX Assessment
Strategic Operational Improvement
AssistanceTraining Service
Training and Competency
Management Services
Maintenance Optimization Road Map
Asset & Operation Management Framework

Onsite AssistanceTraining Class and Technical Seminars

Smart O&M Solution
JGC has developed its own process and unit operation technologies whichhave been adapted to a wide range of energy and industrial plants.

Service Menu

Return to
OE Service menu Plant Smartification Program
Remote Monitoring and Assistance
Plant Smartification with AI Technology

 Maintenance and Inspection Digital
Twins Program
Integnance VR
MODS - Reality
AI analysis for clogging causing

Integnance VR

MODS Solution

MODS - Connect

Remote Operations Visualization

Operational Excellence Services

Decarbonization

GHG Quantification Service

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceGHG Quantification Service
Do you have any of these issues?
Difficulty in quantifying GHG (including CH4)
Need to quantify emissions in actual operation
Identifying baseline for decarbonization project

Actual measurement

Top Down

Bottom Up

GHG Quantification••••

Quantify GHG (CO2, CH4, N2O) by actual measurement
and engineering calculation.
Conduct actual measurement with drone, satellite,
handheld sensor, IR camera
Provide optimized MRV(*) methodology
Reporting the GHG emission to the authorities.
(*) Measurement, Reporting and Verification© 2023 JGC GROUP

Emission Calculation
GHG emissions = Emission Factor * Activity Factor

Factors in
regulation/guidelines
Operational Data
​Enhancing planetary healthGHG Quantification Service
Workflow ＆ Results

Our Strengths
Conduct sitemeasurements

Data andinformationcollection

Identification of
calculation points
and measurement
pointsConduct
calculations with
operational data

GHG
emission
reporting

Steps
•
•
•

•

Professional HSE, Process, Mechanical Engineer•

Dispatched technical experts to participate inTeamsvarious international discussions on GHG

Measurement, Reporting and Verification (MRV).
•

Experience in EPC and O&M of many types of•Collaboration between oversea group companies

Identify measuring points and calculation points from design documents.

facilities in many locations around the world.
and local companies.

Conduct engineering calculations / Actual measurements

Report to client or government agency with preset format

JGC is••able to select the most appropriate MRV methodology from those

Our Background•proposed by international organizations and standards/guidelines

familiar with a variety of plants and can provide the best combination ofdrones, satellites, and handheld sensors© 2023 JGC GROUP

JGC has been commissioned by Japan Oil, Gas andMetals National Corporation (JOGMEC) to develop
their guidelines.

•

The Institute of Energy Economics, Japan (IEEJ) has

contracted JGC as a technical adviser for GHG MRV​Enhancing planetary healthReturn toDecarbonization
menu

Case Study : Quantification of Methane Emission in Ammonia Plant(*) PAU: PT Panca Amara Utama

Project in Actual plant• JOGMEC/JGC completed direct measurement to quantify Methane emission in PAU(*) Ammonia Plant. (Dec-2022)• Satellite / Drone / Handheld Sensor / Camera have been used in the project• CO2 calculation has been conducted using operating data.

Google Map

Satellite

Drone

Project Formation
SupportHandheld
OGI
Sensor Camera

Image of on-site measurement© 2023 JGC GROUP

Operating
Data

Measurement
Reporting

Data

Coordination &Discussion​Enhancing planetary healthOperational Excellence Services

Decarbonization

Life Cycle Assessment/
Management (CO2 Footprint)

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceLife Cycle Assessment/Management (CO2 Footprint)
What is the Life Cycle Assessment (LCA)?
LCA is a method of assessing the environmental impact of your product orservice throughout its life cycle (resource extraction, raw materials, productproduction, distribution, consumption, disposal, recycling) or at a specificstage. LCA can objectively and quantitatively evaluate whether a product is“good” or “friendly” for the environment, human body, and society.

Advanced Application of LCA (LCM) to ….

Concept of LCA

High Client Concern on Environment Impact, Optimized Plant Life
Cycle (Engineering, Procurement, Construction, Commissioning, Start
up, Maintenance, Manning, Turnaround, Demolition) , GHG Protocol(Scope 1/2/3)© 2023 JGC GROUP​Enhancing planetary healthLife Cycle Assessment/Management (CO2 Footprint)

Return to
Decarbonization
menu

Case Study, Experiences and expectations
LCA of your product or service (e.g. Polyester Chemical Recycling)

•
•
•
•

Numerical result of CO2 emissions
Higher CO2 reductions are expected compared with conventional process
Visual presentation of hot spots
The scope of evaluation, methods, and assumptions that greatly affect the results, it
depends on the implementers and companies•••© 2023 JGC GROUP

LCA case studies for new decarbonized technologies
and made presentation in the International
Conference (EcoBalance 2022)

Calculate CO2 footprint (Scope 1/2/3) for CDP Report
2021 and 2022, JGC Holdings got Score B.
Attend the 8th S-LCA Conference 2022 – Leave No
One Behind -CO2 footprint of Plant Lifecycle/Life Cycle Management

•
•
•
•

Numerical approach for plant life cycle (GHG Protocol Scope 1/2/3)
With Data-centric (DX), environmental impact as well as the operation data,
can be monitored in real time, and identify the hotspots.
Present data visualizations of high CO2 emission hot spots during
maintenance periods
Trade off between CAPEX/OPEX and CO2 emission rate for optimization​Enhancing planetary healthOperational Excellence Services

Decarbonization

CO2 Removal Solutions

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceCO2 Removal Solutions
Challenges for CO2 Capture in Operating Assets

HiPACT® - an Innovative CO2 Capture Process

Management of Increased CO2 in Feed Gas

CO2

 Natural gas/associated gas quality varies over thelife of oil/gas fields.

 Unexpected increases of CO2 in the feed gas
requires additional CO2 capture

units/enhancement of the CO2 capture

performance.

Limited Space and Utilities

Commercial HiPACTTM plant (NIS, Serbia)∗1

DDR Membrane - High Performance Separation
Technology

 Limitation in the available space to accommodate
the new unit/expansion of the unit.

 Limitation in the available utilities to operate theCO2 removal unit

© 2023 JGC GROUP​Enhancing planetary healthCO2 Removal Solutions – DDR Zeolite Membrane
DDR Zeolite MembraneTechnology• Technology jointly developed by JGC and NGKApplication• Natural Gas Processing (CO2 removal in CO2 rich gas fields)• CO2 recovery from associated gas for CO2-EOR(*) projects(*) EOR: Enhanced Oil Recovery• World’s largest zeolite membrane element

Advantages• Enhanced separation performance= minimal hydrocarbon loss

• Tough under high pressure, high CO2 concentration= longer membrane life

• Significant lifecycle cost saving (20-30%)

Technology Development Status• Field tested at U.S. oil field (2017, completed)• Commercial scale field test at U.S. oil field (from 2020)
Details of the technology can be found at:https://www.jgc.com/en/business/tech-innovation/environment/ddrmembrane.html© 2023 JGC GROUP​Enhancing planetary healthReturn toDecarbonization
menu

CO2 Removal Solutions - HiPACT®
HiPACT® - CO2 Capture Process

•


•
•
•

Technology

Chemical absorption process, using newly developed
absorption solvent (jointly developed with BASF)

Advantages

Highly stable against thermal degradation

Enables high pressure CO2 stripping, leading tosignificant energy and cost saving (25 to 35% reduction)

Reducing the number of compression stages, optimizing
the space

Reduction of initial investment andreduction of operating costs

by high pressure CO2 stripping process
Product Natural Gas
without CO2

Absorber#1

Regenerator

Conventional

1

Natural Gas
with CO2#2

Acid Gas Removal Unit

HiPACTTM

110

5Compression Ratio

Conventional HiPACTTM

40

HiPACTTM
160

Regeneration bottom
temperature [°C]

Details of the technology can be found at:https://www.jgc.com/en/business/tech-innovation/environment/hipact.html

Commercial HiPACTTM plant (NIS, Serbia)∗1© 2023 JGC GROUP#4

HiPACTTM

Regenerator Pressure[bar-A] 200
Conventional#3​Enhancing planetary health

200

barA

CCS/CO2-EOR(CCUS)

Operational Excellence Services

Decarbonization
Energy Optimization

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceEnergy Optimization
Do you have any of these issues?
How to reduce energy consumption?
How to eliminate equipment bottlenecks?
What kind of equipment should be updated
to improve efficiency?
What is our service ?

Our Approach
Pinch Technology
 Diagnosis of energy/watersaving potential andtargeting Study on modification ideas

of equipment to be modified.

• Pinch Analysis: Identify heat recovery target and create Optimization on production
units and utility facilities
operation

Advanced Technologies
Equipment Effectiveness Binary power generation

 Efficiency diagnosis of rotary
machine and combustion
equipment

 High-efficiency heat pumps

 Energy storage system
 Chemical heat pumps

 Studies on equipment renewal• Equipment Effectiveness: Diagnosis to identify the efficiencyof existing facilities to be improved and suggestions for types

Operation Improvement

Optimization: Unit to Plant-Wide Level

What is Pinch Analysis?

Systematic and Visualization Methods to Identify the Target

solutions such as heat recovery networks that balance thetrade-off between investment costs and energy savings.

• Operation Improvement: Studies on unit operation and utility
facilities modifications to improve energy efficiency.

• Advanced Technology: Studies and proposals on the

introduction of high-efficiency equipment and new heatrecovery technologies.

© 2023 JGC GROUP

Energy Utilization and
Optimization of Heat
Recovery System

Optimization of Site-Wide
Energy Usage

Optimization of PowerSteam Supply System​Enhancing planetary healthReturn toDecarbonization
menu

Energy Optimization
Workflow ＆ Result
Data
Collection

Our Strengths

Analysis &Diagnosis
Targeting

Solutions

Modeling

•
•
•
•
•

Plant Data collection(Operating Data, Climate Data)
Analysis and diagnosis

Modeling for Pinch Analysis, and Targeting

Prioritization of solutions into tree categories as Phase-I

As Phase-II, detailed study to materialize the investment
solutions proposed in Phase-I
No-costsolutions
Experience

Phase-I
BenefitTargetingExpertise
Systematic
Approach© 2023 JGC GROUP

Low-cost
solutions

Investment
solutions

Screening

Phase-II
Detailed
Study•

The proven and successful experiences in executing similar•

Extensive technical knowledge and know-how for energy and•Qualified professionals.

•

consultancy services.
water conservation.

Collaboration between oversea EPC-capable group companies
and out-sourcing for consultancy services.

Our Experiences

50+

Projects

IndustryJapan

Overseas

Petroleum Refinery

26

11

Petrochemical

6

4

Chemical

5

Steel

1

-

Total

38

15

-

• Contributed to over 50 projects in various phases (FS, Pre-FEED, FEED,
EPC, Revamps) for Petroleum Refinery, Petrochemical, Chemicals, etc.
• We are certified by a national oil company as an energy consultant.
​Enhancing planetary healthOperational Excellence Services

Decarbonization

Fired Heater Improvement

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceFired Heater Improvement
Do you have any of these issues?
Poor performance and unreliable operation
Reducing maintenance interval due to severematerial degradation
Need for engineering consulting partner for heater
modification

Examples of combustion and heat transfer
analysis of Furnace (CFD)

Radiant coils

Fired Heater Improvement Solution
•
•
•
•

•

Utilized Computational Fluid Dynamics (CFD) to simulate Combustionand Heat Transfer
Assessed as-installed Heater Performance based on operation data and
CFD Results
Identified O&M Issues and their Root Causes
Proposed and Evaluated Performance and Reliability Improvement Plan•
Burner Layout Optimization for Replacement•
Windbox Modification for Uniform Air Flow Distribution to eachburner
Provided the Technical Guidance for the Implementation of the
proposed solutions© 2023 JGC GROUP

BurnerWall-side

As-installed

CenterLowered coil skin temperature
Wall-side

As-Improved
Analysis of Radiant Coils​Enhancing planetary healthReturn toDecarbonization
menu

Fired Heater Improvement
Workflow ＆ Result

Our Strengths•

Gathering Information

CFD Planning/Simulation(Design Evaluation)

Improvement Ideas© 2023 JGC GROUP•

Extensive experience in Combustion and Heat Transfer modeling•

Collaboration with Material Engineering experts•

and evaluating heater designs

Customer-Focused Global Engineering Service Provider

Our Experiences

CFD Simulation(Design Verification)

Solution Implementation

performance improvement of fired heaters utilizing the advanced
CFD simulation

Analyzing Issues /Developing Hypothesis

Final Improved Design

Years of experience in serving domestic customers for






Shorter Flame length
More Uniform Air Distribution
Lower Coil Skin Temperature
Sufficient Heat Flux on Coils

Reliable Operation
Higher Performance
Extended Life

50+

15+

Fired heater design evaluationand improvement studies withthe advance CFD simulations

Simulation-based engineering
service for plant diagnosis
and lifetime improvement

PlantsYears​Enhancing planetary healthOperational Excellence Services

Operation
LNG CubeContact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
Service(Engineering Consultation Service)
Do you have any needs in your operating plants?
• Sudden shutdown of the plant with unknown root-causes• Frequent malfunction of equipment• Unachieved production corrective planning• Flare minimizing• Smooth startup operation and flawless maintenance

What is?

•LNG Cube is a comprehensive technical service•

LNG Cube starts from Workshop and Consulting by•Analysis and Consulting leveraged on lessons learnt

package related to LNG plants

the world’s leading LNG specialists

and operational database from past engineering,
construction and operational experiences•

LNG Cube technical services are not limited to

LNG Cube Technical Service Menu

existing plants but can be applicable to grassroots
plants© 2023 JGC GROUP​Enhancing planetary health(Engineering Consultation Service)
Workflow ＆ Results

Our Strengths•

Send Survey Form
Send Operational Data and Register for LNG
Cube Analysis
LNG Cube Analysis
Develop Improvement Plan or General Concept(2~3 weeks)

ClientAbundant experience in commissioning and startup•

Speedy solutions leveraged on millions of Lessons Learned from•

Consulting by Project Manager and Study Manager withpast commissioning and startup experienceextensive site experience and EPC execution experience

Our Experiences
ClientYear

RegionA Company

2017 2019

South
East
Asia

-

2018 2019-

B Company

South
East
Asia

C Company

2018 2019

South
East
Asia

D Company

2018 2019

EuropeLNG Cube Workshop with Client
Share Improvement Ideas, Execute Consultation
Implementation of the Plan, Seamless Executionof EPC© 2023 JGC GROUP

Return to
Operation menu

Activity---

LNG Cube Workshop (Development of New Digital Solutions)
Feasibility Study for the implementation of the Digital
Solution
Implementation of the Digital Solution
LNG Cube Workshop (Development of Efficiency
Improvement Ideas)
Proposal for Advanced Control System Installation
Feasibility Study of the Advanced Control System Installation(Planned)
LNG Cube Workshop (Development of Production
Enhancement Ideas)
Business Case Study for LNG Production Enhancement
LNG Cube Pre-Workshop (Development of New LNG
Technology)
LNG Cube Workshop​Enhancing planetary healthOperational Excellence Services

Operation

Hot Air Recirculation(HAR) Digital

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceHot Air Recirculation (HAR) Digital
HAR causes loss of LNG Production

LNG

Sudden HAR to the air-cooled heat exchangers could cause an

GTMain Cryogenic
Heat Exchanger

under-speed trip of the gas turbines when the power usage of theHelper Motor (HM) exceeds its limit. Many operators, therefore, set
to cope with any unexpected HAR. This prevents the plant fromGT

realizing the full benefit of the motor power for maximum
production.

•

HAR Digital is an auto control system powered by Artificial•

The feed-forward process control powered by the HARIntelligence (AI) to mitigate HAR.

HAR

MR Refrigerant
Cycle

the software limit to the HM power well below its designed capacity

What is HAR Digital ?

HM

HM

HAR

C3 Refrigerant Cycle

HAR on C3 Condenser
Data
Cleansing

Data Analysis
z2

Predictive Model allows you to realize the full benefit of the

motor power which will enhance your LNG throughput by atleast 2~3% without any major modification to your facility.

F2
F1

Modeling=y σ (Wx + b)
∆R
R0

z1

AI Modeling© 2023 JGC GROUP​Enhancing planetary health

Test RunHot Air Recirculation (HAR) Digital
Workflow ＆ Results
FEEDBACK FOR DATAIMPROVEMENT

Weather Measurement(Actual)•

REAL-TIME DATACOLLECTION•LNG PREDICTIVEANALYTICS SERVER

Plant Historical Data

•
•
•
•

Our Strengths

Rigorous Process
Simulation

Plant Layout

Weather Simulation(Forecast/Sudden Change)

DCS
APC SERVERCFD Simulation

Operators takeaction in advancefor higher LNG
production

Plant Data correction (Weather Data, Operating Data)
Data Analysis by Data Scientist
AI Modeling
System Deployment© 2023 JGC GROUP

Return to
Operation menu•

Introduction of the Real-time Weather
Monitoring System
Process Big Data Analysis, CFD Simulation, andRigorous Process Simulation
JGC’s extensive experience in LNG processes and
Hot Air Recirculation Analysis

Our Experiences•••

HAR Digital is jointly developed with
PETRONAS
HAR Digital is deployed in Malaysia LNG
and is in operation.
This technology can be applied to various
types of plants, not limited to LNG plants.

​Enhancing planetary healthOperational Excellence Services

Operation
AIRLIZE LNG

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceDo you have HAR (Hot Air Recirculation) issues?
Process performance degradation due to HAR
HAR visualization and identification
HAR mitigation plan
What is Airlize ?
•Airlize LNG is JGC’s Comprehensive Life Cycle Engineering•

Airlize LNG helps to identify root and cause of HAR by•

Airlize LNG gives Plant Layout Optimization, HAR Mitigation

Support Services for Air-Cooled LNG Plants

HAR Mechanism
Weather
Simulation

Site
Survey

CFD Simulation

Plant Layout
Optimization

HAR Analysis&
Mitigation

Weather Simulation, Site Survey, CFD Simulation

Plan leading to minimization of loss of production

Airlize LNG Coverage Services© 2023 JGC GROUP​Enhancing planetary health

Noise Analysis&
Mitigation

Return toOperation menu

Workflow ＆ Result

Our Strengths•••

Data andinformationcollection

•
•
•
•
•

Data Analysis

Simulation
Study

•

Solution
Implementation

Plant Data correction (Weather Data, Operating Data)
Site Survey
Data Analysis by data scientists
Weather Simulation, CFD Study
Solution Recommendation and Implementation
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Professional Process Engineers, CFD Engineers & LNG Specialists
Accumulated Know-How on HAR mechanism

One Stop Service for Weather Simulation to CFD Simulation

Utilization of big data that integrates customer plant operating
data and JGC design data to identify best solution

Our Experiences

1.5
0.5
0.3
0.2
0.1
0.1
0.1
0.3
0.6
1.0
1.3
1.2
0.8
0.5
0.3
0.4
0.6
1.6
3.0
3.7
2.8
2.0
1.5
1.0
0.7
0.5
0.4
0.2
0.1
0.1
0.1
0.1
0.2
0.6
1.9
4.6

3.2
1.2
0.7
0.3
0.1
0.1
0.1
0.3
0.6
1.2
1.7
1.9
1.8
1.3
1.0
0.9
1.4
2.5
3.9
4.7
4.8
4.2
3.2
2.1
1.2
0.8
0.6
0.4
0.2
0.2
0.1
0.1
0.3
1.0
2.6

1.1

4

0

1.0

0.9

1.0

1.1

1.0

0.8

1.5
2.1
3.1
4.4
6.0
7.4
7.9
8.0
7.8
7.4
6.9
6.6
6.2
5.6
4.8
4.3
4.2
4.2
4.2
3.9
3.5
2.9
2.3
1.7
1.2
1.1

1.3
1.9
2.7
4.0
5.6
6.7
7.4
7.6
7.5
6.9
6.1
5.9
5.7
5.1
4.2
3.9
3.8
3.9
3.8
3.5
3.1
2.5
1.9
1.4
1.1
1.2

1.1
1.6
2.5
3.8
4.9
5.6
6.6
7.3
7.1
6.1
4.6
4.4
5.1
4.8
3.9
3.6
3.6
3.6
3.5
3.2
2.7
2.1
1.5
1.1
1.0
1.4

1.4

1.0
0.8
0.7
0.6
0.6
0.8
1.0
1.5
2.1
2.9
2.8
2.3
3.0
5.1
6.2
5.6
4.3
3.3
3.2
3.5
3.8
3.7
3.5
3.4
3.5
3.4
3.3
2.9
2.5
2.1
1.6
1.2
0.9
0.9
1.2

1.1
0.8
0.6
0.6
0.5
0.6
0.8
1.1
1.6
2.1
1.9
1.5
1.9
3.2
3.9
3.9
3.5
3.3
3.3
3.2
2.9
3.1
3.1
3.2
3.3
3.2
3.0
2.6
2.2
1.7
1.4
1.1
1.0
1.0
1.2
1.8

1.1
0.9
0.7
0.6
0.6
0.5
0.6
0.7
0.9
1.2
1.3
1.5
1.9
2.7
3.2
3.4
3.5
3.6
3.7
3.6
3.0
2.7
2.8
2.8
2.9
2.8
2.5
2.1
1.8
1.5
1.3
1.3
1.4
1.5
1.5

20+

Project
0

Contributed to over 20 projects invarious phases of Project/Plant Life
Cycle (FS, Pre-FEED, FEED, EPC,
Revamps)

Airlize LNG Service Image© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services

Reliability & MaintenanceRisk-Based Inspection (RBI)

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Operational
Excellence
ServiceRisk-Based Inspection(RBI)
Do you have any of these issues?
Many Reliability IncidentHigh Maintenance and Inspection Cost
High Insurance Fee
RBI Solution•••

Corrosion Loop Marking

Determined Risk with probability and consequence of failure
Prioritized and effective inspection based on risk assessment
to static equipment, piping
Improved reliability whilst reduced maintenance &inspections cost and insurance fee

Risk Matrix Assessment© 2023 JGC GROUP​Enhancing planetary healthReturn toReliability &Maintenance menu

Risk-Based Inspection(RBI)
Workflow ＆ Result

Our Strengths•

Consequenceof Probability

Data andinformationcollection

Likelihood ofProbability

Risk Ranking
in Risk Matrix

Inspection
Planning

・Evaluation of the Potential Risks

・Development of Inspection Task Plan

・Development of Computerized Maintenance and Inspection System
・Development of Integrity Operating Window

Reduced inspections and cost cuts with RBI© 2023 JGC GROUP

Professional Process and Material Engineer Teams•

Global experiences and performances on risk assessment,•

Integrating JGC’s many years of inspection and plant design•

Collaboration between overseas EPC-capable group companies

inspection planning, on-site Inspection.

experience to achieve lower inspection costs and longer plant lifeand local maintenance companies.

Our Experiences

Worldwide
Achievement
RBI Experience in Far East,
Middle East, Southeast Asia,
Africa, North America

15+

Project
Refinery, GTL, Gas Processing,
Gas Oil Separation, FLNG,
LNG, LNG Terminal​Enhancing planetary healthOperational Excellence Services

Reliability & Maintenance
Asset Integrity Management

Introduction of“Advanced Maintenance Inspection Support System(A-MIS)”
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Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceAsset Integrity Management (A-MIS)
A-MIS Share90%

Selected in Japan

A-MIS features and Benefits
Management of Engineering Data for Equipment & Piping
Better asset data management !
Thickness Inspection & Non-Destructive Inspection Planning
Effective work planning !

12Visual/Non-Destructive Inspection Recordings
Easy inspection data management and generates report !

Countries

Historical Thickness Inspection Data Management

128
Plants© 2023 JGC GROUP

Automatic corrosion rate calculation & remaining life assessment !
Trending graph and effective visualization !
Web Version
Web based and connectable with CMMS (SAP, etc.) !
Site Work Assistance by mobile tool !
Quality data source for further improvement(RBI, etc.) !
​Enhancing planetary healthAsset Integrity Management (A-MIS)
A-MIS will solve your problem!
Voice of A-MIS Users

Do you have any of these issues?
Many asset integrity issues (e.g., leaks)
Missing asset information, docs, inspection records
Unsure how to utilize inspection data
Unsure of asset condition (e.g., remaining life)
Leave inspection matters to contractors

Implementation Steps and Our Strength＊Maintenance Business Analysis＊Engineering Data Collection

STUDY

Experts of asset integrity

management, unlike an IT vendor.

© 2023 JGC GROUP＊Cleansing Data
＊Develop initial data plan
＊Insp. Plan & procedure

DEVELOP Full range of Asset Integrity Management Risk
Assessment, Inspection Planning, Corrosion
Management, Shutdown Inspection Support, etc.

Able to reduce more than 50% MH and expenses and increased
efficiency. I will highly recommend this system.
How useful! A-MIS can visualize equipment, piping condition directly
on drawing. I wanted to know A-MIS system earlier.
A-MIS makes us find suspicious inspection point easily. Reliable data
made it possible to plan next inspection more accurately. Now I cancut out excessive cost for maintenance inspection work.
A-MIS developed with our experience and users’ feedback!

＊A-MIS Set-up＊Initial data input＊Data migration

SET UP

DELIVER Digitalized historical data stored in
A-MIS for better asset management.
​Enhancing planetary healthReturn toReliability &Maintenance menu

Case Study : Asset Integrity Management (A-MIS)
Effective Case

BEFORE
It took time to gather past inspection reports in years from every
place which will be the base material for planning maintenanceand inspection work.
Hand-writing reports were in different formats in years and theinspection points were not fixed which were difficult to catch the
thickness reduction trends and their causes.
It was indispensable to consume a lot of man-hours andexpenses for planning the maintenance and inspection work.

© 2023 JGC GROUP

AFTERWith the introduction of A-MIS, the necessary design data can beaccessed instantly, and by inputting measurement results, thethickness reduction trend, corrosion rate, and remaining life could
be instantly determined.
In particular, the thickness trend graphs brought up questionable
results. Comparing trend graphs, measurement tables, anddesign data exposed that inspection points had not been fixedand led to setting the fixed annual measurement points after that.
This enabled more accurate inspection results to be obtained,leading to more appropriate and efficient work planning.

​Enhancing planetary healthOperational Excellence Services

Reliability & Maintenance
Plant Life Extension Program(PLEP)

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https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServicePlant Life Extension Program (PLEP)
Do you have any issues about plant materials ?
Plant Aging

Approaching the life, material degradation is accelerating…

Operating Condition Changing

Conditions becoming more severe, deviating the design range…

Competitiveness Stagnating

O&M cost increasing, maintenance intervals shortening…

PLEP Solutions•••

Identification of facility and locations having
materials and inspection concerns
Suggestion of practical and economical solutions
to solve the concerns
Projection of revamp work, inspection andmaintenance work, etc., to extend plant life

Example of issue:

Furnace tube bowing
Cause

Bowing on the specific location
 Main cause: coking

Photo: Bowing

Countermeasures•••

Periodical IR Monitoring (Hot Spot Monitoring)
Periodical Pigging

Visual, DPT, UTTM, Creep/PI.Tape, PMI, Hardness, etc.
Recommendation for Life Extension•

To measure circumference length on bowed andsound tube periodically in order to assess the
creep in every shutdown.

•

CFD modeling and consultation may be an
option for detailed assessment.

CFD Analysis© 2023 JGC GROUP​Enhancing planetary healthPlant Life Extension Program (PLEP)
PLEP for preventing troubles in advance…

Our Strengths
 One-stop service of engineering, construction andmaintenance services to make convenient for client Practical and efficient approaches including workshops
and site observations will provide best solutions

Workflow ＆ Result

 Easy methods without special software will avoid client

1st Step - Plant Integrity Assessment (PIA) : Finding / Screening

Assessment of materials selection, inspection program, etc.
Site visit and discussion with client.

2nd Step - Integrity Improvement Initiative (III) : Detail Study
3rd Step - Life Extension Project (LEP) : Project Development and Execution
Result of PLEP

To extend plant life
and to improvereliability.

burden Flexible program will run along with client’s demands to
the goal.

Our Experience CDU/VDU, Asia
83 findings / 22 recommendations
 Gas Processing Unit, Middle East
116 findings / 34 recommendations
 GOSP, Middle East
88 findings / 7 key recommendations© 2023 JGC GROUP​Enhancing planetary healthReturn toReliability &Maintenance menu

Plant Life Extension Program (PLEP)
 Hot insulation setting<Finding>
Due to inadequate length of
hot insulation, corrosive water
condense, and it induce
severe corrosion.

 TML setting at RV manifold<Finding>
Severe condition is expected becauseof stagnant condition.
<Recommendation>
To set thickness measurement
locations (TMLs) around the
manifold.

Inhibitor
NH3

 Flow-meter trouble<Finding>
Flow-meter malfunctioned, andflow rate could not bemeasured<Recommendation>
To fix the flow-meter and to adjust proper
injection rate.

© 2023 JGC GROUP<Recommendation>
To apply hot insulation.

Water

Water

 Assessment of flow distribution<Finding>
The actual corrosion rate issignificantly different between old andnew bays (condensers), and it suggests
uneven flow distribution.

 TML setting at condenser downstream<Finding>
Corrosion monitoring device is installed, butthickness measurement location was not set.

<Recommendation>
To conduct flow
distribution analysis.

Old Bay

New Bay<Recommendation>
To add thickness measurement locations to monitor actual corrosion rate. This canalso check the efficiency of corrosion inhibitor and NH3 injection at upstream.

​Enhancing planetary healthOperational Excellence Services

Reliability & Maintenance
Plant Diagnosis and Lifetime
Improvement Service

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Operational
Excellence
ServicePlant Diagnosis and Lifetime Improvement Service
Do you have any of these issues?

Examples of Finite Element Analysis (FEA)

Mechanical damage occurred!
Can we continue operation? Should we replace?
What is the root cause?
Which improvement plan is the most efficient?

Temp
High

PLANT PLUSSM Solution
•
•
•

•

JGC’s simulation-based engineering service
Investigate the root cause of the mechanical damage
Diagnose whether a damaged equipment can continue
operation or should be reinforced, revamped partially,
replaced totally Leads to reduced cost of repair/revamp
Propose effective improvement/reinforcement planLow(1) External Corrosion
Analysis Model by Laser Scanning(2) Flange Deformation
due to Temperature Distribution(3) Creep Deformation of Vessel during PWHT

© 2023 JGC GROUP​Enhancing planetary healthPlant Diagnosis and Lifetime Improvement Service
Workflow ＆ Result
Step-1

Step-2

Step-3

Step-4

Data and Information Collection

Our Strengths
Example: Large opening
discovered during Turnaround•

Plan Mitigation against Risks•

Provided quantitative and easy-to-understand study

results and countermeasures using structural analysis
techniques such as finite element analysis (FEA)

Assessed buckling risk
for vessel with large hole

Our Experiences

1000

50+

Structural analysis technology,
computational fluid dynamics
technology and noiseassessment/control technology
for 1,000+ diagnoses

Simulation-based engineering
service for plant diagnosis
and lifetime improvement

Plant Diagnoses• High Possibility Root Cause• Effective Solutions

Proposed reinforcement plan
© 2023 JGC GROUP

international design codes, fitness-for-service codes,
plant industry, and JGC own company standards

Assessment Results
Step-5

Diagnosed from various perspectives such as

post construction codes, guidelines often used in the

Site Survey (if necessary)
Scenario Planning:• Root Cause, Damage Mechanism• Improvement/Reinforcement
Plan

Return to
Reliability &Maintenance menu

Years

​Enhancing planetary healthOperational Excellence Services

Reliability & Maintenance
Turnaround Scope Optimization& Planning

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Operational
Excellence
ServiceTurnaround Scope Optimization & PlanningDo you have any of these issues?

Scope Optimization Process

Many reliability incidents during operation
High turnaround maintenance cost
Fail to achieve Solomon First Quartile Target
Turnaround Solution
•
•
•

•

Setting of turnaround leadership and steering team
Risk based process of maintenance and inspection
work scope definition by multi-disciplined teamComprehensive review process for high cost/long
duration items to find lower cost/shorter duration
alternatives
Setting milestone based on turnaround complexity© 2023 JGC GROUP​Enhancing planetary healthTurnaround Scope Optimization & Planning
Turnaround Planning Process

Our Strengths

Turnaround (TA) planning starts 12 months prior
to turnaround (for Medium / High Complexity TA)- 12 to - 10 months- 9 to - 7 months- 6 to - 2 months

Basic Maintenance& Inspection
Planning

Procurement andContract
Preparation

DetailImplementation
Planning• Develop TA
execution plan
based on turnaroundstrategy and finalized
work scope• Procurement plan
• Preparation of job
package for service
contract• Develop detail work
steps and resource
requirement
to finalize timelinechart• Develop inspection
plan
based on inspection
strategy• Specification
preparation formaterial procurement• Issue TA Schedulewith Critical Path
works

• Contracting for
major services• Detail cost forecast
to be provided• Bidding for longlead item• Provide cost
information
for budget© 2023 JGC GROUP• Ensuring availabilityof specialty service
e.g., refractory
specialist

•
•
•
•
•

Professional Maintenance Engineer Teams
Global resources
Practical application of Risk Based Work Selection
process such as RCM and RBI
Rigorous turnround readiness review methodology
So many experience of turnaround planning

Our Experiences

Executed
Project

40+ Cases
54​Enhancing planetary healthReturn toReliability &Maintenance menu

Case Study ~ Turnaround Scope Optimization & Planning
Background:

A Refinery in Southeast Asia have encountered some difficulties
for managing hot spots in several portions and some damages at
air lift pipe and air rings in regenerators of RFCC unit after theircompletion of the second Turnaround & Inspection (T&I).

Sample Deliverables

Objective:

The third turnaround maintenance work is itemized properly for 4
years continuous operation after turnaround.

Achievement:

JGC provided the mechanical and refractory assessment for the
major maintenance work itemization for the third turnaround, andthe engineering for modification of air lift pipe and air rings
including root cause analysis.

Key Deliverables :1. Root Cause Analysis of Hot Spots
2. Maintenance Planning Worksheet (Mechanical/Refractory)
3. Location Map of Major Work (Mechanical/Refractory)
4. List of Major Spare Parts
5. Method Statement of Critical Work
6. Preliminary Scaffolding Assembling Plan
© 2023 JGC GROUP

Reference Services
FCC Unit in a Refinery Complex in Middle East 2010 - 2011
: T&I Planning and Execution Support at site
 2015: T&I Execution Support at site
 2018: T&I Planning
RFCC Unit in a Refinery Complex in Southeast Asia
 2016 - 2017
: T&I Planning
Gas Processing Plant in Middle East 2022 – Present: T&I Planning​Enhancing planetary healthOperational Excellence Services

Reliability & Maintenance
Turnaround Execution
Management

Contact Us
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Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceTurnaround Execution Management
Do you have any of these issues?
Fail to achieve turnaround targets
 Safety, Schedule and Cost
Lack of experienced execution workforce
Shortage of frontend supervisors
Turnaround Solution••••

Management and planning approach using provenmethodology
Detailed work procedures which include description ofpotential hazard of the work
Involvement of frontline supervisors in detailed
planning of the critical works
Dedicated coordinators for high-risk works(e.g., inert entry work, critical lifting, etc.)© 2023 JGC GROUP

Turnaround Execution

Turnaround Work Progress Management System​Enhancing planetary healthReturn toReliability &Maintenance menu

Turnaround Execution Management
Turnaround Safety Management

Our Strengths

 Drastic cultural change in behavior-based safety

•
•
•
•
•

Abundant experience in turnaround project execution
Professional maintenance management teams
Global resources
Incident & Injury Free (IIF) culture (Behavior-based
safety)Advanced work progress management system

Our Experiences
Adaptive Challenge
・Attitude
・Belief・Intention
・Culture・Commitment
・Responsibility
・Behavior
・Clarity
・Understanding© 2023 JGC GROUP

Executed
Project

40+ Cases​Enhancing planetary healthOperational Excellence Services

Reliability & MaintenanceInspection & Diagnosis

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https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceInspection & Diagnosis
Do you have any of these issues?
Need to enhance mechanical integrity of processequipment and piping system
Lack of experienced inspection and diagnosis engineers
Need engineering support during turnaround
Turnaround Inspection Solutions••••

Prioritized inspection planning, reliable inspection execution
and practical repair engineering
Cutting edge simulation technologies and experienced
specialist for complex process degradations evaluation
Utilization of advanced NDT technologies to fit for purpose“Fitness for Service” assessment by experienced engineers.

© 2023 JGC GROUP​Enhancing planetary healthReturn toReliability &Maintenance menu

Inspection & Diagnosis
Turnaround Inspection

Our Strengths

 Develop inspection plan
based on type ofdegradations before
turnaround•• Inspection related
preparation work
arrangement

Scaffolding and ladders

Surface preparation for NDT

 Preparation of NDT service
package for contract
 Inspection Record
Management System© 2023 JGC GROUP••

Abundant experience in turnaround inspections
Experienced and qualified inspectors(API 510, API 570, API 936 etc.)
Simulation with Computational Fluid Dynamic (CFD)
Fitness for Service assessment by experienced engineers

Our Experiences

Executed
Project

40+ Cases

Data
Analysis100+ Facilities​Enhancing planetary healthOperational Excellence Services

Reliability & MaintenanceReliability, Availability,
Maintainability (RAM)Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

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Operational
Excellence
ServiceReliability, Availability, Maintainability (RAM)Do you have any of these issues?

RAM Concept

No appropriate answer to the conflicting demandsof "maintaining the reliability of equipment" and"reducing maintenance costs“
Unable to see opportunities for improvement inreliability from data accumulated in CMMS/EAM

RAM Solution•••

Evaluate the current reliability of facilities based on
valuable historical data, which are accumulated at
EAM/CMMS.
Select optimal maintenance measures while balancing
the reliability of equipment and maintenance costs.
Establish a strategic PDCA cycle in the operation andmaintenance organization© 2023 JGC GROUP

Weibull Analysis

RBD
Availability Analysis​Enhancing planetary healthReturn toReliability &Maintenance menu

Reliability, Availability, Maintainability (RAM)Workflow ＆ Results

Our Strengths

JGC’s RAM Study Steps

1

Reliability
Block
Diagram2

Maintenance
Data Check3

RAM
Analysis1

DesignOptimization2

Maintenance
Optimization

Building an appropriate RAM analysis model based•

Collection of the appropriate reliability data andSpare parts
Optimization

1 Weibull Distribution
2 MTBF Estimation
3 Production Efficiency

Optimization Phase (Cost Based)
1 Optimized Equipment Configurations
and Redundancy
2 Optimized Maintenance Method andFrequency
3 Optimized Spare Parts List

2-3 months for Unit (e.g., CDU, FCC)
Critical Equipment : Approx. 70 sets

on process engineering knowledge

optimization proposals based on the knowledge of
operations and maintenance experts•
Analysis phase© 2023 JGC GROUP

3•

Best method approach by combining internal andexternal resources to meet clients needs andobjectives

Our Experiences

20+

VariousType of
Facilities

Cases

Not Only O&M phase, but also
FEED and EPC phases.

Refinery
Gas Processing
LNG
FLNG,
LNG Terminal, etc.

​Enhancing planetary healthOperational Excellence Services

Reliability & MaintenanceReliability Centered
Maintenance (RCM)

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Operational
Excellence
ServiceEnhancing planetary health​Reliability Centered Maintenance (RCM)
Do you have any of these issues?
Many unreliability events
Constant unrequired maintenance work
High maintenance cost

Risk Matrix Assessment​Analise detailed failure pattern

RCM Solution
 Determine the optimal failure management strategies
for all equipment including risk base approach.
 Provide sustainable Predictive and Preventive
Maintenance tasks
 Prevent Functional Failure for Required Function ofequipment Mitigate Safety, Environment, Production and Assetdamage risks

Consider Condition Monitoring​Decision Diagram
Consider Maintenance Tasks

Delivered appropriate Maintenance Tasks© 2023 JGC GROUP​Enhancing planetary healthReturn toReliability &Maintenance menu

Reliability Centered Maintenance (RCM)
Workflow ＆ Result

Our Strengths•

Professional Process & Material Engineer Teams•

Global experiences and performances on Risk assessment,•

Integrating JGC many years of inspection and plant design•

Collaboration between oversea EPC-capable group companies

Inspection planning, On-site Inspection.

experience to achieve lower inspection costs and longer plant lifeand local maintenance companies.

Our Experiences
•
•
•
•
•
•

Analyze Equipment Criticality to prioritize RCM study level
Organize cross-functional RCM study teamDefine Operating Context including desired performance, legal
requirement, integrated operating window, safety hazard, etc.
Start RCM study depend on RCM work steps
Identify Function, Functional Failure, Failure Mode, Failure Effect,
Consequence and Risk ranking
Identify Failure Management Tasks to prevent required Functional Failure© 2023 JGC GROUP

15+

Project​RCM Study serviced
for over 10 projects

Worldwide
Achievement
RCM Experience in Far East,
Middle East, Southeast Asia,
Africa, North America​Enhancing planetary healthOperational Excellence Services

Reliability & Maintenance
Prescriptive MaintenanceContact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServicePrescriptive Maintenance
Machine Learning
Detect Failure Signature

Damage has already progressed when you can find out thatthe equipment is failing.

Lack of the experienced engineer and resources for RCM
study and development of maintenance tasks.

Our Solution•

JGC introduce prescriptive maintenance tool to your critical•

Provide early and accurate warning of when an asset failure will•

The tool can be installed without experienced engineers.

•machines in collaboration with software company.

Equipment Condition

Do you have any of these issues?

P

Production Opportunity Loss
Current Solution

Much Earlier
Detection

Potential Failure

Maintenance Cost

P

F

Functional Failure

Time

Early detection of Anomalies avoids damage onset

Operational Data
From Plant Historianoccur, how the failure will occur and what to do about it.
Data sources for machine learning are:1.

2.

Plant Historian to collect time-series data from thesensors on and around equipment

EAM/CMMS System to collect maintenance data on

Maintenance Data
From CMMS

Machine Learning(Normal & Failure Patterns)

equipment.

Data sources for machine learning© 2023 JGC GROUP​Enhancing planetary healthReturn toReliability &Maintenance menu

Prescriptive Maintenance
Prescriptive Maintenance Process
Data
Gathering

Connect Plant Historian and
CMMS to tool

Model
Development
Modification ofModels

Maintenance
RequestEvaluate
Alarm

Deployment of Models
for Live Monitoring

Sustainment Cycle

MonitorLive Equipment

Our Strengths
 JGC engineers identify the root cause of the failure and recommend maintenance tasks toeliminate bad actor equipment.
 JGC engineers create reliable and explainable models in a short time based on extensive
knowledge of a wide variety of equipment and maintenance engineering such as RCM/FMEA.
© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services

Health・Safety・Environment(HSE)

HSE Risk Management

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Operational
Excellence
ServiceHSE Risk Management
Do you have any of these issues?
Formalizing facility safety
Process and operational safety concerns
High insurance fees
HSE Risk Management Solutions•

Justify safety using a prescribed process, which includes:• Formal Safety Assessment• Quantitative Risk Analysis (QRA)• Hazard Identification (HAZID)• Hazard and Operability Studies (HAZOP)• Layer of Protection Analysis (LOPA)• Bow-tie Analysis• Operational Hazard Assessment/Reduction Study• HSE Management System Review© 2023 JGC CORPORATION

Combination of Desk-top Study and Workshop​Enhancing planetary health72

HSE Risk Management
Workflow ＆ Results
Safety Philosophy

Concept of Safety in
DesignHAZID
HAZOP
Hazard Register

Hazardidentification

Fire Risk Analysis
Explosion Risk Analysis
QRA

Risk Analysis•

Professional Safety, Process, Control, Mechanical, Operation and•

Top global experience of EPC execution

Maintenance Teams

Plant types - Refinery, Gas Processing, LNG, Chemical
Plant locations – Onshore, Offshore
Clients – IOC, NOC

ALARP Study

ALARP Demonstration

Bow-tie Analysis

Visualization of Threat,
Consequence andBarriers and Recovery
Measures

SCE&PS

Define Safety Critical
Element andPerformance Standard

HSE Risk Management System /Safety Case
© 2023 JGC CORPORATIONOur Strengths

Hazard Identification in P&ID•

Huge record of HAZOP and Operational Hazard Reduction

Our Experiences
QRA

Bow-tie Diagram

10+

500+

10+ HAZOP revalidation and OHR
for operating plant

500+ Process safety plant design

Cases

Cases

​Enhancing planetary health73

Return to
HSE menu

Wide Range of HSE Risk Management Support Services (Last 10 years)
Year

Country

2012

Saudi Arabia

Oil Stabilization, NGL Recovery, Storage

Fire Safety Review

2012

Algeria

Oil Production

Fire Safety Review

2013

Japan

LNG Receiving Terminal

HAZID, HRA, SIL, Fire Safety Review, QRA, Bow-tie, ALARP, SCE&PS, SIMOPS/MOPO, Noise Study, PSSR, Safety Case

2014

Japan

Gas Processing

HAZID, HAZOP, SIL, Consequence Analysis, Bow-tie, SIMOPS, ALARP, SCE, Safety Case2014

RussiaOffshore Gas Field

FEED Design HSE Assessment

2014

Japan

Pipeline (including valve station)

HAZID, SCE&PS

2014

Brunei

Methanol Plant

PSM Assessment

2014

Japan

Drilling

HAZID, ENVID, HRA, SIMOPS, QRA, Bow-tie, MOPO, Safety Case

2015

Japan

Gas Booster Station

HAZID, SIL, Fire Safety Review, QRA, Bow-tie, ALARP, SCE&PS, MOPO, Safety Case

2016

Japan

Offshore Gas Field

HAZID, HAZOP, FERA

2016

Japan

LNG Receiving Terminal

QRA (Support)

2016

KuwaitGOSP

Operational Safety Design Review

2016

Japan

Valve Station

QRA

2017

Japan

Gas Processing

Design Review, HAZID, HAZOP

2017

Japan

Refinery

SIL/LOPA Education and Implementation Support

2019

Japan

Refinery

HAZOP, SIL/LOPA Education and Implementation Support

2021

Japan

Refinery

HAZOP Training, HAZOP Validation

2021

Japan

Distillery

HAZID, HAZOP/LOPA Training & Implementation Support, Consequence Analysis

2021

Japan

Ethylene

RBPS Implementation, HAZID, HAZOP/LOPA Training and Implementation Support, Consequence Analysis

2022

Japan

Pipeline (including valve station)

HAZID, HAZOP, SIL, QRA, Bow-tie, ALARP, SCE&PS, SIMOPS, MOPO, Noise Study, Safety Case

© 2023 JGC CORPORATION

Facility Type

Consultation Category​Enhancing planetary health74

Operational Excellence Services

Health・Safety・Environment(HSE)

Active Fire Protection Assessment

Contact Us
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Access to Our Homepage

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Operational
Excellence
ServiceActive Fire Protection Assessment
Do you have any of these issues?
Fire and explosion incidents
High maintenance and inspection cost
High insurance fees
Active Fire Protection Assessment Solution•••

Foam Extinguisher System Monitor Protection

Water Spray Protection

Evaluation for facilities based on credible fire scenario
and codes & standards
Fire scenario simulation based on identified fire scenario
Fire fighting system evaluation by• Hydraulic calculation• Fire water monitor coverage assessment
Example of Jet Fire Risk Contour© 2021 JGC GROUP​Enhancing planetary healthActive Fire Protection Assessment
Workflow ＆ Result

Fire Hazard
Scenario
Identification

Site
Survey+Gap
Analysis

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HSE menu

Our Strengths
Fire Fighting System
Assessment- Fire Water
MonitorCoverage- Hydrauliccalculation••
Cost-Effective
Improvement

Fire Hazard Scenario +Fire Water Monitor Coverage Assessment••

Professional Fire Protection and Analysis Teams
Top global experiences of active fire protection design and application from EPC
execution
Plant type - Refinery, Gas Processing, LNG, Chemical
Plant location – Onshore, Offshore
Client – IOCs, NOCs
Code and Standards – NFPA, API, BS, etc.
Strong relationships with global firefighting equipment suppliers
Analysis software – Phast (DNV), in-house simulation

Our Experiment

20+
Study

Fire Hazard Simulation© 2021 JGC GROUP

Visualizing Monitor Coverage in 3D model

Fire water monitor coverageassessment 20+ studies.

500+
Cases

500+ Active Fire Protection
Design​Enhancing planetary healthOperational Excellence Services

Health・Safety・Environment(HSE)

Fireproofing Assessment

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Access to Our Homepage

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Operational
Excellence
ServiceFireproofing Assessment
Do you have any of these issues?
Is Our Plant Really Safe from Fire Hazard?
High Maintenance Cost for Fireproofing
Compliance with Latest Standard?
Fireproofing Assessment Solution••••

Evaluation of existing fire proofing based on identified
fire hazard and latest standard.
Identification of critical fireproofing improvement
points.
Optimization of fireproofing by fire risk assessment andstructural redundancy analysis.
Recommendations of cost-effective improvement
solutions.

© 2023 JGC CORPORATION

Evaluation of existing Fire Proofing

Deterministic method>International Code and Standard>Local regulation>Fireproofing Application
Conventional Method

Fire Risk
Analysis

X

Redundancy
Analysis=

Cost-Effective
Improvement

Latest Method​Enhancing planetary health79

Fireproofing Assessment

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HSE menu

Workflow ＆ Result
Fire Hazard
Scenario
Identification

Site Survey&
Gap Analysis

Our Strengths
Structural
Redundancy
Analysis

Cost-Effective
Improvement

Structural Redundancy Analysis
 JGC original method to optimize fireproofing
Conventional Approach

New Approach

•
•

•
•

Professional Fire Protection, Structure, Material and Analysis Teams
Top global experiences of fireproofing design and application from
EPC execution
Plant type - Refinery, Gas Processing, LNG, Chemical
Plant location – Onshore, Offshore
Client – IOCs, NOCs
Code and Standards – NFPA, API, BS, etc.
Strong relationships with global fireproofing material suppliers
Analysis software – Phast, FLACS, Abagus, etc.

Our Experiences

3+

500+

Fireproofing assessment service for3+ plants.

500+ Fireproofing Design

PlantsFireproofing on Red Structure(All load bearing structure)

Fireproofing on Red Structure Only
(Only critical structure for integrity)

Cases

Significant Reduction of Fireproofing© 2023 JGC CORPORATION​Enhancing planetary health80

Operational Excellence Services

Health・Safety・Environment(HSE)

Fire and Gas Assessment

Contact Us
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Access to Our Homepage

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Operational
Excellence
ServiceFire and Gas Assessment
Do you have any of these issues?
Insufficient Fire and Gas detector coverageHigh Maintenance Cost of fire and gas detector
High Insurance Fee
Fire and Gas Assessment Solution••••

Gas Detector

Plant are covered by Fireand Gas Detectors

Flame Detector

Evaluation of facility and gap analysis
Identification of credible fire and gas leak hazard
Conduct fire and gas mapping study to ensure theeffectiveness
Safety improvement by appropriate fire and gas
detector placement
Evaluation of facility© 2023 JGC GROUP

Fire and Gas Mapping Study Technology​Enhancing planetary healthFire and Gas Assessment

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HSE menu

Workflow ＆ Result
Fire and Gas
Leak Hazard
Scenario
Identification

Site
Survey+Gap
AnalysisOur Strengths
Fire and Gas
Mapping
Study

Cost-Effective
Improvement

Mapping study

One of the method to analyze the effectiveness of fire and gas
detector, and optimize detector location

•
•

•
•

Professional Safety, Instrument, Process and Analysis Team.
Top global experiences of fire and gas system design and application from EPC
execution
Plant type - Refinery, Gas Processing, LNG, Chemical
Plant location – Onshore, Offshore
Client – IOCs, NOCs
Code and Standards – NFPA, API, BS, etc.
Relationship with global fire and gas detector suppliers
Analysis software – Detect 3D(Insight numerics), Phast (DNV),Our Experiment

20+

Mapping Study
Fire and Gas Mapping Study
Experience 20+ Study

500+
Cases

500+ Fire and Gas Design

Same quantity of gas detectors --> Better coverage (wider green area)© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services

Health・Safety・Environment(HSE)

Escape Simulation & Assessment

Contact Us
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Access to Our Homepage

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Operational
Excellence
ServiceEscape Simulation and Assessment
Do you have any of these issues?
Insufficient escape and evacuation plans
Maintenance plan without safety consideration
Many modification in the facility
Human Escape Model

Escape Simulation and Assessment Solutions
•
•
•
•
•

Evaluation of current escape route by specialized
escape route simulation program.
Identification of critical point (bottle-neck) in escaperoute plan
Provide improvement plan of escape route
Escape simulation in accidental scenario
Provide safe maintenance plan (location ofmaintenance, number of maintenance person,
barricade plan in maintenance period)© 2023 JGC GROUP+Characteristics of Plant Facility

Specialized Plant Escape Route Simulation Program(developed with the University of Tokyo)​Enhancing planetary healthEscape Simulation and Assessment
Workflow ＆ Result
Plant Layout

Accident
Scenario
Definition

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HSE menu

Our Strengths
EscapeSimulation

1) Improvement Plan
2) Maintenance Plan••

Professional Safety, Operation and Maintenance Teams
Top global experiences of escape route design andevacuation planning from EPC execution

Plant type - Refinery, Gas Processing, LNG, Chemical
Plant location – Onshore, Offshore
Client – IOCs, NOCs•

Specialized escape simulation program developed with
the University of Tokyo. Research Article is available in“Chemical Engineering Transactions (CET) Journal Vol

OUTPUTS

1) Improvement Plan

Modification plan of escape route to enhance safety for
operators in normal situation and accidental situation

2) Maintenance Plan considering safe operator escape© 2023 JGC GROUP

Maintenance activities in same location
Number of maintenance person

90(2022)”

Our Experiment
Plant and Escape Route
Design Cases

500+ Cases

Barricade plan

​Enhancing planetary healthOperational Excellence Services
Health・Safety・Environment(HSE)

Hazardous Area Classification
Optimization

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Operational
Excellence
ServiceHazardous Area Classification (HAC) Optimization
Do you have any of these issues?
Cannot use unclassified electrical devises at site
Many manual works for inspections and recording
Increase cost for inspections and recording
HAC Optimization Solution•••

Unclassified electrical devices can not be used in hazardous area

Optimize the hazardous area for unclassified electricaldevice with International Standards (IEC 60079-10)
Based on the detail analysis, the classified area can be
reduced/optimized
Propose a plan to use unclassified electrical devices tominimize the accident risk
HAC for permanent items

HAC for portable items

Hazardous Area Optimization for temporary use of unclassified electrical devices© 2021 JGC GROUP​Enhancing planetary healthHazardous Area Classification (HAC) Optimization
Workflow ＆ Result

•
•
•
•

Evaluation of potential hazards’ magnitude

Optimization hazardous area classification considering not
only hazardous area classification requirements but also
potential impact in case of ignition•

Our Strengths•

Professional safety and electrical engineers for not only•

Top global experience of hazardous area classification design

Preparation of plan for use of unclassified electrical devices© 2021 JGC GROUP

hazardous area classification but also risk assessment
Plant type - Refinery, Gas Processing, LNG, Chemical
Plant location – Onshore, Offshore

Collection of facilities information

Evaluation of existing hazardous area classification

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HSE menu

Clients – IOCs, NOCs•

Wide knowledge for international standard such as, IEC, IP, EI,
API, NFPA, JIS, etc.

Our ExperimentHazardous Area
Classification Design
Experiences

500+ Cases​Enhancing planetary healthOperational Excellence Services

Health・Safety・Environment(HSE)

Noise Assessment

Contact Us
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Access to Our Homepage

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Operational
Excellence
ServiceNoise Assessment
Do you have any of these issue?

Noise contour map
High

Noisy work environment
High costs noise mitigation for noise emitters
Need for consulting partner for noiseassessment

Sound
Pressure
Level

Noise Assessment Solution•••

Through noise survey;
 identified noise sources produced noise contour maps before and after
noise mitigation plans
Proposed most effective and cost-minimum noise
mitigation plans based on result of noise simulation
Verified the effectiveness of noise mitigation plans

Low

Example of noise mitigation plan (Acoustic insulation)

Before© 2023 JGC GROUP

After​Enhancing planetary healthNoise Assessment
Workflow ＆ Result
Assessment

Our Strengths•

Goal setting
Noise survey & Analysis
Identification of noise sources
Mitigation Planning
Proposal of practical noise mitigation plans
Implementation
Implementation of noise mitigation plans
Verification of effectiveness© 2023 JGC GROUP

Experienced for noise assessment/control technologies todomestic and overseas customers for many years, and solved
various noise problems•

Provided services for noise survey, evaluation, planning ofcountermeasures, and confirmation of effectiveness after
implementation of countermeasures

Our Experiences

600+
Cases

Noise assessment/control
technology for 600+ cases.

50+
Years

We have been accumulating
noise assessment/control
technologies for more than 50
years through EPC businesses
and consulting services.

​Enhancing planetary healthNoise Assessment
Regulatory Inspections
We provide prompt and accurate measurements and analysis
of site boundaries and neighborhood measurements forregulatory inspections, as well as equipment, piping, andindoor measurements within the plant site.

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HSE menu

Noise Measurement and analysis

 All Inclusive (Noise maps & Proposal)

Measurement results are shown as noise maps, andproposal of variety of noise mitigation measures areincluded.

Conventional measurement

Noise monitoring

Tablet measurement system

Noise analysis

 Latest Measurement Technology

In addition to the conventional noise levelmeasurement using a sound level meter, we offer thebest measurement method such as measurement
system using a tablet, cell phone or unmanned noisemonitoring measurement with the latest technology.
We will propose the most suitable measurement
method for each client.

© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services

Commissioning & Start-up
Predictable Start up

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Operational
Excellence
ServicePredictable Start up
Do you have any of these issues?
Reliability of current Commissioning Plan
Lack of experience in planning
Unfamiliar equipment/unit
Resource for unfamiliar countries© 2023 JGC GROUP

Our Solution
Provide consultation, recommendations and/or improvements for thefollowing items on the following plans/topics:•

Commissioning HSE Plan•

Commissioning Execution Plan•

Plan and/or procedure with CASTOR®

•

Completion Plan includes Systemization and/or RFSU Blocks•

Commissioning & Start-up for FLNG/FPSO/Module•

Design/Engineering Considerations•

Benchmark Schedule and/or manning against projects completed•

Contractor Strategy (SOW, Technical evaluation, Selection)•

Identifying Commissioning Risks and Mitigation​Enhancing planetary healthPredictable Start up

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Our Strengths andExperiences
Extensive experiencein commissioningof refinery, LNG, Gas

and petrochemical plants

for a variety of clientsaround the world.

© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services

Commissioning & Start-up
CASTOR

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Operational
Excellence
ServiceCASTOR®(Commissioning and Start-up Transient Operability Review)
Do you have any of these issues?

Upset Scenarios

Failure Scenarios

Catalytic modes

Other issues

Special modes

Non routine/Temporary
Modes

Main process trips

Cat activation

Thermalexpansion/contract

Specific Production
Modes

Weather Scenarios

Embrittlement/Low
temperature

Recycle modes

Product Load mode

Recycle modes

Heavy rain/snow

Over temperature

Main compr trips

Cat re-juvination

Controls on manual

Product hold mode

Dryout mode (static)

Cat regenHeavy rain/snow

Other feed flow Modes

Dryout mode / min firing
mode

Reactor switch

Tidal/Waves/Move

Oxidation mode

Other feed quality Modes

Steam out mode

Cold winter /Winterization

Meggar test

Cat/ Chem load
Cat Start Up / Activation

Cat Circulation

Cyclone/dust storm

Drying & reduction mode

Equipment bypass /cripple mode

Firing modes

Day-Night swing

Energize

Inerting
External Tightness at
NOP
Compartimentalizedinternal tightness test at
NOP

Overfill
Over pressure
Back flow

Concerns on Commissioning and Start-up Plan
Lack of (or No) Experience in Plant Start-up
Introduction of Unfamiliar Equipment/Unit

CASTOR® Solution
•
•
•
•
•

Loss of containm. Leaks
small/large)
Internal leaks/fail. (e.g.
tube rupture)
Fired equipment failure(overfiring/tube
ruptures/leaks)

Wax removal gas-oilflush
Wax removal - Hot H2
stripping

Precommission. Tests /Modes
Equipment internal(instal/insp.)

Commissioning Tests/
Modes

Tidal/Waves

ESD/TSO valve leak test

Solo (motor)runs

CycloneInstrument Loop test

Chemical clean run

Vapour breakthroughInstrument failure

Coking/Decoking

Cold winter /Winterization

Molecular sieve heating& cooling

Batch operation

Depress/blow downmode

Floods (land slide)

Lube oil flush cleaning(Compr. Pack.)

Vacuum fillng/emptying

Internal failure

Stripping

Day-Night swing

Catalyst drying

Regen. Mode

Offspec modes

Lightning strike

Airblow (per system)

Flaring/emission

Failing RVs/valves

Cat make up/spent

Human error

Steam out mode

Pigging mode

Haze/Smoke/Dust storm

Impurity/Solids
issues/Break throughCracking (caustic
thermal, stress, etc.)

Water flush (forpipes/systems)

Competence

Depress/blowdown mode

Vacuum unload.

Natural disasters

Offspec productFatique

PIF's

Offspec (modes)

Specific Maint. Modes

Test modes e.g.
IPF/ESD/PRV test

High humidity

Composition different

Loss of N2

Different Reactor modes(K-modes)RHA (Exothermic
reaction / run away / prepost ign.)
Cat/Feed ratio

Online flushing / clean
modesHigh Inventory

T/A maintenanceHydrates/freez-out/up

Loss of heating

Coke Fire/Ignition

1st year maint.

Manual modes
Acoustically Induced
Vibration

Start up Tests/ Modes
Untested joints tightness
test
Surge tests oncompressor
Pumps tests not able totest on benign fluid
Turbo expander tests
Compressor tests notable to test on benign
fluid
Equipment test not able
to test on benign fluid
QMI tests

Min. firing

Metering tests

Drains cleaning

Refractory Dryout

ESD trip tests

Special cleaning (Jap.
Black removal)

Static Dryout

Other tests not able test
on benign fluid

Valve Stroke test

N2 / Air run

Final tuning

Dry function test

Water run

Turndown test

Water explosion

Loss of cooling

Cat/O2 issues (e.g.
deposits/breakthrough)Online routine mainten.
Modes

Cat loading

Chemicals run

Performance test

O2 ingress(e.g. vacuum,
back flow)

Loss of steam

Backflow issues

Cat changeout

Preservation

Special circulation run

Other tests

pH issues

Loss of FG

Incompatible
comp/impurities

Chemical changeout

Low pressure Leak test

Electrical test

LNG Liquid/MR Turbine
Start up

Loss of water

Cat plugging

Preservation mode

PSV test

Wet funct. Test

Loss of chemicals

Cat Regen issues

Special Inspections

Other tests

Complex loop text

Unexpected side
reactions
Reaction conv. Loss
Cat deactiv.
Attrition/erosion
O2 mixing issues
RV design for upset
cases
Catalyst within tested
window
Hot spots
Cat resid time issues
Particle distribution
issuesPolymer foulingSpecial cleaning / decom
steps

Large bore pipe cleaning(strainer)
Solid/Polymer/Plugging/di
rtigress
Thermaldegrad.Decomposit
Vacuum during start up
e.g. below dew point
Fouling

Loss of HVACElectrostaic spark

Loss of product(s)Passing RV
Amine issues (degrad,conc,)

Loss of feed(s)Foaming

Loss of Air

Liquid carry overCondensation
Vibration: noise/flow/puls.
Fatique
Auto ignition / FeS
Thermalexpans./contract.

Loss of tracing
Loss of Unit
Insufficient safetyzone/area/distance
Sabotage
Tanker/truck/train
incident

Loss of oil(s)Loss of Power

Legal tests
QMI tests
F& G tests
Passivation chem dosing
Preservation
ESD trip tests
Other tests

Phase separation issues

CASTOR Guideword Template (General)

Reveal risks during transient state operation atcommissioning and initial start-up phase
Plan mitigation actions against risks
Increase likelihood of successful commissioning andplant start-up
Minimize downtime due to trouble
Eliminate risks of schedule delay
CASTOR Database© 2023 JGC GROUP

Steam blow

​Enhancing planetary healthCASTOR®(Commissioning and Start-up Transient Operability Review)
Workflow ＆ Results

Our Strengths

Workflow of CASTOR®

•

Step-1
Step-2
Step-3
Step-4••Develop CSU Plan and Diagram
Review Plan with Experienced Engineers
Reveal Risks using Guidewords
Plan Mitigation against Risks

Develop Commissioning and Start-up (CSU) Plan and Diagram

Review CSU Plan and Diagram with highly experienced engineers•

Reveal risks related to transient operation during Commissioning•

Plan mitigation actions against revealed risks•

and Start-up using Guidewords and experiences of engineers

Improvement of Operation Manuals, Procedures (SOP), Training
Programs and updating of procedures for existing plants© 2023 JGC GROUP

Return toCommissioning &Startup menu

Professional Process & Commissioning Engineer Teams•

World-class experiences and expertise in Plant Commissioning•

A wealth of Lessons Learned about Commissioning and Start-up•

and Start-up as an EPC Contractor

Experiences in various types of plant like LNG, Refinery, NGL,GOSP, Floating LNG, Chemical, etc.

Our Experiences•••

CASTOR® for LNG, NGL, GOSP, Floating LNG, Ethylene, etc.
Not only for EPC but also for FEED projects

Long history of start-up review as the predecessors of
CASTOR® == > CASTOR Database

CASTOR®
Since 2015

7

​Enhancing planetary health

Cases

Operational Excellence Services

Commissioning & Start-up
Commissioning Safety

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Operational
Excellence
ServiceCommissioning Safety
SIMOPS Study

Do you have any of these issues?
Introduction of hazardous material in areas
where construction is still in progress Electricity
 Chemicals
 Steam Hydrocarbon

Our Solution
Provide consultation on the following plans/topics:• Completion Plan
• Systemization• Identify Safety Risks and Prepare Risk Mitigation (SIMOPS Study)• Design/Engineering Considerations (Additional Isolations)•

QRA Study with Technical HSE Engineering：Construction：Commissioning[Utility Commissioning]
Inlet Facilities

Process Train1

Process Train2

Utility
Utility

ChemicalConstruction

Storage

Flare

BuildinWWT
SteamElectricityg[Gas-In]

Inlet
InletFacility
Facilities

Utility
Utility

Process Train1

Hydrocarbon

Process Train2

Construction
Construction

Chemical

Flare

Storage

BuildinWWT
SteamElectricity
g

Flare

Construction
Construction[Process Commissioning]

Inlet
InletFacility
Facilities

Process-1
Process Train1

Hydrocarbon

ChemicalHydrocarbon

Process-2Train2
Process

Hydrocarbon

Utility
Utility

Buildin
WWT
Electricity
Steamg© 2023 JGC GROUP：SIMOPS

Storage

Construction
Construction
Flare

Storage

Flare

Hydrocarbon

Hydrocarbon​Enhancing planetary healthReturn toCommissioning &Startup menu

Commissioning Safety
Workflow ＆ Result

Our Strengths•[Hazardous Zone]

SIMOPS
Construction

Schedule Merit with
Safety Control

SIMOPS

PreCommissioning

Commissioning•

Top global results and performances on Degradation•

Utilization of big data that integrates customer plant operating•

Collaboration between oversea EPC-capable group companies

Schedule Reduction[Approach]

Professional Process & Material Engineer Teams

Minimize SIMOPS

Assessment, Inspection Planning, On-site Inspection.

data and JGC design data to forecast future plants’ needs
and local maintenance companies.

Optimize Area
Control of Risk
[Results]

Achievement of Safety SIMOPS

Our Experiment••x

Construction© 2023 JGC GROUP•
Commissioning

CSU planning using system definitions since early 1990s

SIMOPS study since early 2000s

Continued to ensure commissioning safety in recent larger

and more complex projects.

​Enhancing planetary healthOperational Excellence Services

Commissioning & Start-up
Commissioning & Start-up
for FLNG/FPSO/Module

Contact Us
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Operational
Excellence
ServiceCommissioning & Start-up for FLNG/FPSO/Module
Do you have any of these issues?
What shall be conducted at each location??

 At Module Fabrication Yard
 At Shipyard / Onshore At Offshore (both Pre-RFSU and Post-RFSU)

What shall be prepared at each phase??

 Manning (POB Plan/ Flotel)

 Spare Parts/Special Tools/ Temporaries/Consumables
 Logistics/Onshore Base/Storage Area
 Start-up Procedure/Training, etc.

Shipyard/ Onshore

Solution based on actual FLNG EPCIC experiences
Provide consultation on the following topics:






© 2021 JGC GROUP

Project Completion Plan​
Design/Engineering Considerations​
Commissioning Execution Plan
Start-up Plan, Procedure and Operator Training
Manning​ including Offshore Training

Logistics Strategy and/or Material Arrangement​ etc.

Modules

FLNG/ Offshore​Enhancing planetary healthReturn toCommissioning &Startup menu

Commissioning & Start-up for FLNG/FPSO/Module
Workflow ＆ Result- Establish Project Completion Plan
- Establish Commissioning Execution Plan
- Pre-commissioning (Clean & Tight)- Preservation- Maximize Commissioning (Minimize Offshore Works)- Preparation for Offshore (Materials/Manning etc.)- Hull & Marine Operation- Preservation

Our Strengths
We are one of leading companies for Modularized Project &FLNG and have several experiences of actual project execution.
•

Executed several Modularized Projects for both Onshore and•Accumulated know-how to work with Module Fab Yard and•Executed two (2) FLNG EPCIC Project (see below photos)•

Offshore

Shipyard

Executed Construction Management and Completion
Support Service for Prelude FLNG Project

Our Experiment- Offshore Installation- Reverification of Onshore Works & PSSR
- Smooth Start-up as per SOP- Rump up & Performance Test

Successful Project Completion© 2021 JGC GROUP

Petronas FLNG-2 EPCICENI Coral FLNG-2 EPCIC​Enhancing planetary healthOperational Excellence Services

Commissioning & Start-up
Operations Readiness &Assurance (OR&A)

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceOperations Readiness & Assurance (OR&A) Program
Do you have any of these issues?
Concern of safe and smooth start-up of O&M
High total cost of ownership
Potential areas of concerns and its mitigations in OR*

OR&A Solution•

Execute OR&A program for all OR key components of•Assess OR plan and progress and reporting with findings and•Follow up prioritized mitigation actions to reduce OR risk andfacilities** by expert team
mitigations

to minimize the facility total cost of ownership

Operations Readiness & Assurance (OR&A) Program*OR : Operations Readiness**facilities : Onshore and offshore O&G plant, chemical plant etc.

© 2022 JGC GROUP​Enhancing planetary healthOperations Readiness & Assurance (OR&A) Program
Workflow ＆ Result

Our Strengths

A) OR&A Planning Phase
1. Verification of overall OR schedule
2. Define OR elements
3. Establish OR progress and KPI tracking system••

HeadcountB) Assurance Phase
1. Monitor OR activities
2. Assess the progress and risk for OR activities (Health Check)
3. Report and follow up mitigation actions

Project Month

Recruiting Progress Tracking•

Return toCommissioning &Startup menu

Standardized OR&A program based on FLNG project
Expert O&M engineers with experiences inoperating companies
Utilization of global project management
experiences from over 20,000 FEED and EPC projects

Our Experiences•••

OR&A program execution for FLNG O&M
Operations audit for FPSO in West Africa
O&M and Training readiness planning andexecution for various EPC projects

Business Process Progress Tracking

Sample Progress and KPI tracking system© 2022 JGC GROUP​Enhancing planetary healthOperational Excellence Services
Technical Assistance &Training
Onsite Assistance(Residential/On-call)Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceOnsite Assistance (Residential/On-call)
Do you have any of these issues?
Lack of experienced engineers and technicians
Need specific expertise
Need technical problem-solving teams when in trouble
Our Solutions•••

Dispatch customized teams, experts, and operation andmaintenance staff to the operation site to meet theclient’s needs.
Select the most suitable resources from JGC network
for client's situation over a long period of time or even
within a short period of time.
The dispatched teams and crew will work as anintegrated resource with client's operating organization,
or work as an independent task force team.

© 2023 JGC GROUP​Enhancing planetary healthReturn toTechnical Assistance& Training menu

Onsite Assistance (Residential/On-call)
Our Approach
Understand Client
Needs or Issues

Our Strengths
Propose Best
Teams andCandidates• Shortage of• Job Description
Engineers and• Role andTechnicians
Responsibility
Analysis phase• Reinforcement• Duration (longNeeds
tern/short-term)• Specific Technicalissues•Service
Agreement

Mobilize Team or
Personnel

Options:
1. Combination with Operational
Excellence services
2. Troubleshooting by Experts in
Global Operating Center••

A wide variety of global human resources
networks allow flexible use of experienced andknowledgeable experts
Cooperation with specialized teams at
headquarters with expertise from various EPC
and Operational Excellence services
Standby by various experts who can solve
problems quickly

Our Experiences

30+

VariousType of
Facilities

Middle East
North Africa
West Africa
Southeast Asia

Gas Processing
Oil Producing
FPSO
Integrated Water, Steam,Power Plant, etc.

Years in Global Market© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services
Technical Assistance &Training

Asset & Operation Due Diligence

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceAsset & Operation Due Diligence
Do you have any of these issues?
Considering investment for operating assets
Audit for operation and maintenance of
operating assets
Focus Areas•••

Facility design and construction in accordance withrecognized and generally accepted engineering practices
Implementation of Process Hazard Analysis
Established Operation Manual




•
•
•
•

Startup and Shutdown
Normal operations
Emergency Operations

Deployment of safe work practices
Written procedures for maintenance, inspections and testing
Rigorous quality assurance systems
Training and competency management system© 2023 JGC GROUP

Asset & Operation Management Framework
1. Management Leadership
2. Risk Assessment
4. Facility Design and Construction
5. Information & Documentation

Maintenance

Emergency
Response

Operation

3. Management of Change
7. MechanicalIntegrity

6. Operation
Procedure

8. Contractors

10. Training

11.Incident
Investigation
12. Emergency
Planning andResponse

9. Occupation Health and Safety

14. Assessment & Improvement​Enhancing planetary healthReturn toTechnical Assistance& Training menu

Asset & Operation Due Diligence
Example of JGC’s PSM Assessment Checklist

5.0

Our Strengths•

Extensive, worldwide EPC project and maintenance•Experience in investment for operating assets•

5.1

experiences

Professional Operation & Maintenance Engineer Teams•

Asset & Operation Management (AOM) system based on•Experience in Due Diligence (DD) and audits for

OSHA PSM

operating plants.

Our Experiences

5.2

Element 5: Information & Documentation© 2023 JGC GROUP

O&M Due
Diligence

3+ CasesAudit forO&M

5+ Cases​Enhancing planetary healthOperational Excellence Services
Technical Assistance &Training
OPEX Assessment

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceOPEX Assessment
Do you have any of these issues?
Estimating OPEX to assess the feasibility atbusiness planning phase
Verifying future OPEX in operation phase
Identifying improvement opportunities on
operation and maintenance costs

Historical Data and Event Analysis

Production PlanOPEX Estimation

Our Solution•••

Estimate or Assess OPEX by experts who understand theprocesses and regions at business planning phase
Analyze historical OPEX data from the operation phase
Conduct a case study to identify the optimized OPEX ineither of the above cases

OPEX Estimation based on Production Plan
OnshoreSupply Base

Head
Quarter

LNG Plant Manager

Headquarter
Manager
Adm Section
Finance/Account-ing Section

O&M Strategy Development as
the basis of OPEX
(e.g., Organization Chart)

Floating LNG FPSO

Logistics
Section••

Human Resources
SectionTechnical Services
Section

Supply & Marine
Operation Section•

HSE Section
Manager
Production
Section Manager•••

Deputy LNG Plant
Manager

Logistics
Management
Warehouse
Control

Production
Planning
Turnaround
Planning
Reliability
Management
Corrosion
Management

Maintenance
Section Manager

•
•
•

•

© 2023 JGC GROUP

Purchasing​Enhancing planetary health

LNG Process
Utility
Marine Shipping

•
•
•
•

IT System Operation
Camp Management
Cafeteria
Visa / Travel•••

Fire Fighting
Safety / Security
Environment & Hygiene

Logistics
Section•••

Helicopter
Workboat
Warehouse

HSE
SectionMaitenance
SectionTechnical
Service Section•

Logistics Section

Adm
SectionOperation
Section•Process
Coordination
Laboratory
Operation

•
•
•
•
•

Static / Tank
Rotating Machine
Instrument
Electrical
WorkShopReturn toTechnical Assistance& Training menu

OPEX Assessment
Workflow ＆ Results

Our Strengths

Business Planning Phase•

Business Caseand Plant
Concept Check

OPEX Item
Definition• County• Personnel• Plant Type• Maintenance• Production Plan
• Chemical• Schedule• Fuels• Local Conditions
Analysis• Insurancephase• etc.
• Training• etc.

O&M Strategy
Definition

OPEX Item
Estimation

Case Study for
Optimization• Organization andWorking System• Operation Strategy• Maintenance
Strategy• Logistics Strategy• Training Strategy• etc.

• Estimation by
O&M Experts andCost Engineers• Case Studies with
optional O&M
Strategy• County• Plant Type• Production Plan
• Schedule• Local Conditions• etc.

© 2023 JGC GROUP

Historical Data
Check

OPEX Item
Estimation• Past OPEX Review• Past Operation
Result Review• Past Maintenance
Event review• Future OPEX plan
review (if available)• Estimation by
O&M Experts andCost Engineers••

Our Experiences

Operation Phase
Business Caseand Plant
Concept Check•

Assess using the latest cost information
accumulated through plant EPC projects
worldwide
Estimate by experts with plant process,operation and maintenance knowledge
Provide output tailored to client needs andbusiness phases
Advise improvement opportunities byexperts

GAP Analysis• Identification of
GAP between JGC
estimated OPEX
and Client given
future OPEX

Case Study for
Optimization• Case Studies with
optional O&M
Strategy

10+

Projects in 10 years

VariousType of
Facilities
Gas Processing
LNG Terminal
Onshore LNG
FLNG
FPSO, etc.

​Enhancing planetary healthOperational Excellence Services
Technical Assistance &Training
Strategic Operational
Improvement AssistanceContact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceStrategic Operational Improvement AssistanceDo you have any of these issues?
Increasing Unplanned Plant Outages

Strategic Operational Improvement – Transformation Roadmap

Increasing Maintenance Costs along with Age
Lack of Experienced Maintenance Staff
Representing Improvements Visually

Solution•••••

SWOT Analysis of operation and maintenanceorganization
Middle and long-term operation and maintenanceplan including turnaround plan
Setting Key Performance Indicators (KPI)
Root Cause Analysis (RCA) for equipment failureand countermeasure development
Training focusing on younger staff andskill/knowledge transfer from experienced staff© 2023 JGC GROUP​Enhancing planetary healthReturn toTechnical Assistance& Training menu

Strategic Operational Improvement AssistanceLong-Term Strategic Operational Improvement Assistance ProgramFirst Year

Second Year

Third Year

Fourth Year

Analysis &Assessment

Turnaround Planning
Assistance

Turnaround Execution
AssistanceLong-term Turnaround
Plan

Analysis Items• Plant Availability• Risk Assessment
Implementation• Turnaround Performance• Resource Training

Training at JGC Yokohama

Implementation of Training
System

Optimization of
Maintenance Organization

RCA for Major Plant
OutageCountermeasure
Implementation

Elimination of Unplanned
Outages

Improvement Activities for Identified Opportunities

Our Strengths••

Professional Operation and Maintenance Engineer Teams
Global resources•

Practical application of Risk Based Work Selection process such as RCM•

Rigorous turnround readiness review methodology••

Our Experiences Chemical Plant Case in Indonesia
Number of Unplanned Outages
33

and RBI

Many experiences in turnaround planning

Engineering tools and experienced analytical staff for RCA© 2023 JGC GROUP

12First Year

Second Year

1

Third Year

​Enhancing planetary healthOperational Excellence Services
Technical Assistance &Training
Training and Competency
Management Services
Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceTraining and Competency Management Services
Do you have any of these issues?
Catch up to the latest technical trends
Refresh knowledge on essential technical matters
Specific training linked to technical issues(e.g., troubleshooting, performance improvement)

Struggling to fill gap between actual and required skill set

Training Services
•

•
•
•

Organize a tailor-made training program(e.g., Asset Management, Process Safety Management,
TA Management, Plant Life Extension, etc.)
Deliver training courses and seminars (at site or on-line)
Implement competency management program
Dispatch experts to site; for hands-on training
 for troubleshooting and performance evaluation withfollow-up technical sessions© 2023 JGC GROUP​Enhancing planetary healthTraining and Competency Management Services
Key Categories / Themes for Technical Training
Engineering & Project
P&ID
Hydraulic Design
Process Engineering
Dynamic Simulation Technology
Plant Safety Design and Risk Management
HAZOP
Material Selection
Piping Engineering
Pressure Vessel, Exchangers and Tanks
Energy Efficiency Improvement
Pump and Compressor
Instrument Engineering
Safety Instrumented Systems
Electrical Engineering
Civil Engineering
Welding Technology
Paint Technology
Corrosion under Insulation
Latest Non-Destructive Testing Technology
Vibration Control
Mechanical Handling
Commissioning
Operations Readiness & Assurance© 2023 JGC GROUP

Operation & Maintenance
Process Safety Management
Reliability, Availability, Maintainability (RAM)
Reliability-Centered MaintenanceRisk-Based Inspection
Plant Life Extension Program
Fitness for Service
Simulation Technology for Plant
Troubleshooting (CFD)
Turnaround Management
Computerized Maintenance Management
SystemComputerized Inspection Management System

Our Strengths•

Professional Engineering Experts run our Training Services.

•

Training programs are updated in line with latest technical•

In association with and funded by Japanese governmental•

Continuous follow-up and support are provided by ourtrends and are applicable to actual implementation.

support, such as JCCP (Japan Cooperation Center, Petroleum).
overseas affiliates and local partners.

Our Experiences

Technical
seminars

20+ in past 5 years

Trainees

500+ in past 5 years​Enhancing planetary healthReturn toTechnical Assistance& Training menu

Case Study : Customized Training for FCC Unit Reliability Improvement
Background:A refinery in Southeast Asia was struggling with stable operation of RFCC unit
from the start after EPC project

Attendees:
Maintenance and inspection departments and technical service departments at
the plant site and headquarters

Objective:
To share information on various problems that occur in RFCC, analysis methods
to solve them, and technical advice from refractory vendors.
Workshops are also held to share examples of problems encountered in their
RFCC and to discuss how to plan the next turnaround maintenance.

Examples of customized training programs
Material Degradation and Remaining Life Assessment (Day 1)
1.

FCC Unit Process Overview

2.

Material Selection and Degradation

3.

Remaining Life Assessment Methodologies

4.

Experience of Material Degradation and Current Issue (by Client)Corrosion Management and Inspection Data Management (Day 2)
1.

Corrosion Management Program

2.

Corrosion Under Insulation

3.

Inspection Data Management System

4.

Corrosion Management Program and Improvement Plan (by Client)

5.

Workshop - Corrosion Management Program (All members)

Fitness for Service and Major Replacement Work (Day 3)

Reference Services

1.

Fitness for Service Technology

Process Safety Management Seminar - JGC Headquarter 2016 for E&P Company in Japan

2.

Major Replacement Work

3.

Advanced Repair Technology

Plant Life Cycle Management Seminar - JGC Headquarter 2017 for E&P Company in Japan

4.

Past Experiences and Future Plans (by Client)

Process Safety Management Seminar - Online 2021 for E&P Company in Japan

5.

Workshop – Major Replacement and Repair Planning and Execution (All members)

FCC Unit Integrity & Reliability Improvement Seminar– Online 2022 for Refinery in Middle East
FCC Unit Integrity & Reliability Improvement Seminar– Online 2023 for a Refinery in Southeast Asia
O&M Engineering Training – JGC Headquarter 2023 for a Petrochemical Plant in Middle East

© 2023 JGC GROUP

Reliability of Critical Mechanical Components (Day 4)
1.

Refractory (Vendor)

2.

Expansion Joint (Vendor)

3.

GRP Piping

4.

Future Actions and Wrap Up (All members)​Enhancing planetary healthOperational Excellence Services

Smart O&M Solution
Remote Monitoring andAssistanceContact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceEnhancing planetary health​Remote Monitoring and AssistanceDo you have any of these issues?

Example of KPI Dashboards for remote operations monitoring

Restricted number of persons for site access
Understand operational status of remotely located plants
Identify improvement opportunities in operations
Problem-solving teams in technical troubles
Lack of experienced engineers & technicians

Our Solutions•

Remotely visualize the operations data or share theoperations information with the remotely located plantsite and our Global Operating Center and solve theproblem with Clients as “one team”.

•

Without dispatching experts to the site, our expert teamat Global Operating Center will support clients withtroubleshooting.

© 2023 JGC GROUP​Enhancing planetary healthReturn toTechnical Assistance& Training menu

Remote Monitoring and Assistance
Use Case

Bringing scattered information to your fingertips

Significantly reduced time to spend for searching necessary information
for managers for right decision at right time

Our Strengths•••

Data Visualization System to enable monitoring
and analyzing the trouble with clients
Specialized teams at Global Operating Centerwith expertise from various EPC andOperational Excellence services
Availability of various experts who can solve
problems quickly

Our Experiences

30+

Years in Global Market
Middle East, North Africa
Southeast Asia…etc© 2023 JGC GROUP

VariousType of
Facilities
Gas Processing
Oil Producing
FPSO
Integrated Water, Steam,Power Plant, etc.

​Enhancing planetary healthOperational Excellence Services

Smart O&M Solution
Plant Smartification withAI Technology

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceEnhancing planetary health​Plant Smartification with AI Technology
Do you have any of these issues?
Lack of specific expertise for O&M improvement
Decline in productivity due to plant aging
Accumulated large amount of data but not being utilized
Knowledge gained through the experience of senior O&M

personnel is not shared well with other members of the team.

Why choice AI Solution with JGC
Excellent
AI experts

Extensive successful experience inproviding AI solutions and welldeveloped implementation methodology.

Our team have wide knowledge andexperience in O&M service

30+ Cases

Prediction of catalyst degradation, Digitalsystemization of O&M, Equipment Failure
Prediction System…etc.

Our engineers can propose AI solution withmultiple fields including process, pressure
vessels, rotating equipment, static equipment,
electrical, instrumentation, HSE, etc.

Various Typesof Facilities

Oil Producing, Power Plant, LNG Plant,
Chemical plant, Space station, Waste
treatment plant…etc.

Know yourProcess Design

Extensive achievement in processengineering for various types of EPC projectLongstanding
O&M Service
Multi-field
Engineers© 2023 JGC GROUP​Enhancing planetary healthPlant Smartification with AI Technology
Our Solution

Our Approach

Operation
Visualization

Visualize plant operation data tointuitively determine operating conditions

Anomaly
Detection

Quickly detect abnormalities andanalyze causes to prevent any
unforeseen events and trouble

Prediction ofage-related
deterioration.

Predicts age-related deterioration of
catalysts, solvents, etc., and suggests
optimal replacement times.

Productivity
Improvement

Incorporating external factor such as
climate data into operational data
analysis to improve productivity

Trace the process determine the cause Time-dependent catalyst deterioration© 2023 JGC GROUP

Workshop

ProposalContract

Mobilize
Team andEngineer

Discussions between client and JGC data
analysis engineers (1.5-2 hours/workshop x 1 ormore times as required).
• Identification of customer recognized andpotential issues• Planning of problem-solving measures• Confirmation of quantity and quality of datarequired for data analysis
Offer the best methods such as:• Report on cause investigation, etc.
• AI software (GUI of customer's choice)• Automation system• Image identification equipment• Consultant for customer's AI construction
and useAI Digital Solution​Enhancing planetary healthCase Study: Analysis equipment clogging factors in Chemical plant

Return to
Smart O&M Solutionmenu(1) Issue
Equipment clogging occurred frequently

Operation condition
caused Clogging

To clean the clogging, the plant had to be shutdown and resulting in asignificant loss of production.

Difficult to analyze the large number of operating conditions underwhich clogging occurs.

(2) Our Solution

Normal Operation
condition

Step-1 Developed AI model based on algorithms for LightGBM Classifiermodel to investigate operating conditions during clogging for the
past 10 years

Step-2 Use the model calculates clogging in real time during operation andextracted operational factors (e.g., sensor values) related to blockages
sequentially.

Step-3 Approximately 20 factors representing operating conditions that
contribute to blockage were found. The top three factors werevisualized as a three-dimensional plot. (Fig. 1)

Step-4 The results allowed engineers to properly analyze the elements

Fig.1 3D visualization of elements causing clogging(3) Client’s Benefit
Improved productivity was achieved by operating toprevent clogging

causing the clogging and develop an efficient solution.

© 2023 JGC GROUP​Enhancing planetary healthOperational Excellence Services

Smart O&M Solution
INTEGNANCE VR

Contact Us
Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Operational
Excellence
ServiceINTEGNANCE VR
Do you have any of these issues?
••

Wasting time on Site Visit for repair work
planning, inspection planning, and daily
maintenance work planning
Struggling with promoting DX

Our Services
Easy to carry out maintenance management
using web-based 3D viewer
•
•
•
•
•
© 2023 JGC GROUP

Spatial Simulation
Desktop surveying
Piping Navigation
3D position Coordinate Management
Quick Search for Facility Information​Enhancing planetary healthReturn to
Smart O&M Solution
menu

INTEGNANCE VR
Use Case•

3D Simulation / Measurement

Meetings with subcontractors can be holdremotely. Construction study will be

improved (e.g. Scaffolding Planning).

•

Corrosion Inspection Target
By showing the inspection targets on the VR,
the inspection planning and conducting canbe performed efficiently. No need paper
drawings for inspection record.

Our Strengths•••

Delivers 3D models quickly at low cost by capturing reality of plants.
Easy to use for efficient maintenance planning and execution.

Improve workability and safety at sites located in remote area.

© 2023 JGC GROUP•

3D position Coordinate Management
Visualizes attribute data and analysis
results on the appearance of the plant.

Our Experiences

Over 10 Sites

INTEGNANCE VR have been
adopted to over 10 sites.
​Enhancing planetary healthOperational Excellence Services

Smart O&M Solution

MODS REALITY
Digital Twin for MaintenanceContact Us

Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Access to MODS Reality

Asset Visualization Software | MODS Reality | MODS

Operational
Excellence
ServiceEnhancing planetary health​View more detail on https://www.mods.solutions/mods-reality/

FunctionsTools• 3D twin of your Plant and Data (Design & As Built)• Live Project Construction Visualization• 4D Scaffold management tools• Permit linking and tracking in 4D•••• Compare As-Built vs Design• Auto mapping of Lidar and 360’s in GPS• Mobile device with 3D Model and 360 for capturing data on site•

• Integrate Existing maintenance packages such as SAP and Maximo•• 3D Dashboard insights•• View Inspection status in 2D, 3D and 360 images••• Point Cloud Management of Change

Intuitive Interface withcustomisable layout•
Bookmark 3D navigation
3D Model, Point Cloud and 360 •overlay with compare slider and •transparency fader
Document viewer and mark up•
tool
User Display settings which•
include visibility range of tags•
Share screen view with•organisation•
Screenshot and Mark-Up tool•
Create a variety of Tag types, from•
Equipment and inspection to•

Scaffold and Permit
Extensive Editing and Measuring
Tools
Intelligent Drawing tags
Create 3D objects for Scaffold,
Permits and Containers
Live Review for mobile and web
collaboration
Link to Connect Activity Manager
Notification’s system
Project Model Overlay
Integrate Connect Construction
Mobile Connectivity
Tag Harvester
Bespoke Inspection filters

4DVi
Visual Inspection Module
Visualize the integrity of your Asset• 3D twin of your Plant and Data (Design & As Built)• Excel Import to quickly digitize your asset• View Inspection status in 2D, 3D and 360 images• Filter the status by Corrosion Rate, Thickness andRemaining Life & Planned Inspection• Automated Tag Harvester and inspection tag creation• 3D Dashboard insights

Use Case Examples

Scaffolding Management
Build, Visualize and plan your Scaffolding in 4D• Build 3D tagged shapes for scaffold volumes• Link to an activity to better manage existing and project related scaffolding• Quickly understand Scaffold status by colour, In use or harness required• Identify Scaffold owners by vendor, easily• QR code updating of status in the field• Create Material matrix for 3D volumes

Tagging, Data & documentation
Tags and attributes for the item/equipment that canbe correlated to documents Drawings and Data
• Create tags under different categories – Equipment, Inspection, General,
Containers, Permits and Scaffold• Attach searchable documents & engineering drawings to tagged items,
create intelligent links for P & ID’s, Work scopes, also mark-up drawings &Screenshots• Review Drawings and documents• Show all tagged items in 2D plan, 3D and 360 images

Use Case Examples

Container and Lifting Management
Build, Visualize and plan your lifting operations in 4D• Build 3D tagged shapes for container volumes• Link to an activity to better manage timelines for container movements• Identify containers location and vendor identity easily• Add comments to items with our date stamped chat feature• Identify container locations in 2D as well as 3D

Paperless approvals
Our digital Mobile connectivity suits a variety of use
cases so you can track progress, manage queries
and sign-off in real-time, streamlining workflows for•fabrication,•

operations•

maintenanceand more …….

: Customisable mobile connectivity to track, Query and sign-Off Digitally

Operational Excellence Services

Smart O&M Solution
MODS Connect
Turnaround Execution

Contact Us

Technology Inquiries | Contact Us | JGC HOLDINGS CORPORATION

Access to Our Homepage

https://www.jgc.com/en/business/epc/operation-maintanance/service/

Access to MODS Connect

Industrial Construction Management Software | MODS Connect | MODS

Operational
Excellence
ServiceEnhancing planetary health​2Work Pack
Completions
Materials Manager
Reality• 4DVi

Activity Manager• SIMOPS• Fabrication

Reporter Module
Document Hub
NEW!!
Knowledge centre for raisingtickets, viewing user guides andwatching training videos.

View more detail on https://www.mods.solutions/mods-connect/

Paperless Systems
Completion
QR driven Bolted
Connection
management

Digital Fabrication Tracking &Dossier Creation

Project & Inventory
management

Advanced / DigitalWork Pack creation

Activity & workflow Management forEngineering, Construction, Operations &MaintenanceDigital Twin
UnifiedProcess
Visualisation

BridgeUse Stand Alone &Seamlessly Link to yourOrganisations Digital
Solutions using ourdocumented API
Dashboards &ReportingBusiness insight andanalytics in 2D & 3D

Turnaround Workflow - Example

GOOD PREPARATION
Collaboration withall stakeholders

Benjamin Franklin

Plan imported for optimization
MODS receives
integrated base line plan

Creating a Work Pack auto populates:

Create work packs

Dimensional
Control Assurance
Scope Definition

Execute Project using
Mobile technology
Use Hand Held device
to record data for:Materials Manager
Completions
Joint Integrity
Activity Manager

Phased handoverStable operations“By failing to prepare,you are preparing to fail.”

Materials Manager
Completions
Joint Integrity
Fabrication

EFFICIENT EXECUTION