NEXTPLANT:

FUTURE-PROOF
INDUSTRIAL PLANTS
 HOW THE DIGITAL TRANSFORMATION
CAN CONTRIBUTE TO
THE ENERGY TRANSITION
What do we do?
We are a leading technology-driven multinational group and we
help our clients to reach their goals in energy transition leveraging
on digital technologies, to be competitive and unlock value for our
clients both during the EPC phase as well during plants operation,
through our NextPlant platform, which enables them to be fully
future-proof.

Why choose NextPlant?

What's in it for you?
Next Plant platform is a portfolio of digital
solutions and services that enables to design All this also allows for a significant
“natively digital” plants starting from the CAPEX and OPEX saving, as plants
become increasingly “greener”
engineering phase thus to unlock value during
and lighter:
plants operation.
Maire Tecnimont has a 50-year track record as a • Less energy consumption
leading EPC contractor with a highly • Less CO2 emissions
technological DNA to create digital
• More efficiency
transformation solutions.
We design industrial plants with a "cyber • More connected and
security design driven" approach thus to avoid collaborative (OT & IT are
any threat with an end-to-end approach. converging)

Yes, we said more margins

One of the top priorities for plant owners to adapt to this
new business environment is investing in digital
technology, which can increase the cost of investment
(CAPEX) for new industrial blocks but meanwhile is an
enabler to reduce their cost of operation (OPEX) by up to
30% as medium-term market target being effective to
minimize the Total Cost of Ownership (TCO).
Plant owners have high expectations from digital Enabler for reducing the
technology but 70% of these digital transformations fall Plant OPEX
short of their goals.
So, what might make digital transformation succeeding?
up to 30% within
2030
 The Maire Tecnimont approach to succeed
on digital transformation
• Our proposition shall firstly fit with the plant owners’ business model, and not
the other way around.
• Instead of inventing new solutions or creating a revolution, we aim to
streamline the most relevant processes, with the goal of making it simple to
make it happen.
• Our aim is to scale up solutions and adopt them by avoiding over piloting.
• We adopt an open innovation approach to what is available on the market and
in adjacent industries, to learn from the ecosystem.
 How can we help you become future-proof?
Through Project Control Tower for excellent EPC
execution
Project Control tower is a central hub that provides enhanced visibility for short and long-
term decision-making and risk-control aligned with strategic objectives, through end-to-end
EPC data management.
The main areas of control are :
⚬ Engineering activities status
⚬ Materials management
⚬ Construction activities workfront
⚬ Site Quality & HSE aspect

How can you use IoT and AI?

The Internet of Things (IoT) and AI are opening new possibilities for industrial plants, in a push that has so far
been led by the other sectors (bank, insurance, retail, etc.). Now the energy transformation sector is stepping its
digital investment at a moment when several factors besides operational cost savings are combining to make it
the right time to shift to digital operations. Evolutions in cloud storage, edge computing, security and enhanced
plant connectivity means interconnected plants are much more achievable than ever. The basic requisite to safely
adopt such evolution is the “cybersecurity by design” approach.

Plant connectivity through 5G

To be future-proof, you need to have tremendous capacity in data collection, storage,
integration and analytics.
You need to improve interoperability and coordination among different industrial
plants, strengthening their ability to operate in harsh, remote environments.
How do you do this? Through 5G, which allows you to have:
• Faster speed
• Lower latency
• Massive connections density
• Less CAPEX by reducing conventional cables application

Blockchain technology and process digital twin

The application of blockchain technology to energy transformation plant is a unique value
proposition in the market.
The blockchain combined with Maire Tecnimont process optimization can be used to
certify the carbon footprint of the feedstock (to ensure access to incentive and to
demonstrate the contribution to decarbonization process for scope 2-3 emissions),
meanwhile it can be used to certify output products (to obtain green premium incentives).
The process digital twin can be used to optimize yield of plant and reduce emissions (to
demonstrate contribution to decarbonization process for scope 1 emissions).
 BEYOND DIGITAL…
THE NEW NORMALITY

After the oil price crash in late 2014, companies had to learn how to cope with the “new normal”:
though budget cuts helped, they are not enough to cope with the energy transition.

Plant owners now need to take a new approach focusing on two main goals. The first is to reduce
investment and operating costs. Fortunately, digital technology is a powerful tool helping plant
owners achieve the cost reductions demanded by the new business environment. The second is to
improve environmental performance to respond proactively and intentionally to pressure from
public opinion, investors and governments about climate change. Digital technology can help on
this front with advanced analytics and Artificial Intelligence (AI) tools that can run a plant more
efficiently, saving energy, and thereby reducing emissions making it easier to achieve
sustainability targets.

Energy transformation and petrochemical plants have fallen behind the digitalization seen in
other industries like retail, banking, entertainment and manufacturing for three main reasons:

legacy platforms generate fragmented sets of data in pieces that are hard to assemble into
one overview;
faraway and site-specific plants make it hard to standardize across geographies;
conventional wisdom and operating models of “what has always worked” is creating inertia,
frequently increased by safety concerns on plant operation.
The benefits of digitalization are maximized
DIGITAL SOLUTIONS
when executed by an EPC contractor with fully TO SUPPORT ESG ISSUES
digitalized work processes.

75%
Companies that seize the opportunity to OF SOLUTIONS SUPPORT
TRANSPARENCY AND
reinvent entire process from start to finish, INCLUSIVENESS
investing in digitalization for the long term,
leveraging on key aspects like Artificial
Intelligence, are the ones that will end up 70%
OF SOLUTIONS SUPPORT
being the market leaders.
HSE AND CO2 REDUCTION

Maire Tecnimont aims to act as the single

orchestrator of a digital transformation by 25%
coordinating with the plant owner and OF SOLUTIONS SUPPORT
ICV/KNOW-HOW TRANSFER
suppliers of the overall ecosystem thus to find
solutions aimed at generating significant
value for plant owners and to make industrial
complexes more and more sustainable for
health, safety and environmental impact
perspectives.
 THE DIGITAL SUITE FOR
EPC EXECUTION

To harness the power of digitalization to make costs and environmental impact more sustainable,
plant owners need EPC contractors that have already made the leap to redesigning their own
work processes by adopting digital solutions internally.

Maire Tecnimont has transformed its own capacity to attain more efficient performance as an EPC
contractor, thereby increasing its ability to offer its clients a wider and deeper data set and more
reliable scheduling that make a measurable difference in project execution and cost of
investment.

The digital transformation offers a series of opportunities that are process-driven, in an industry
where there is space for improvement, becoming the “enabler” of NextPlant digital portfolio.

DIGITAL TRANSFORMATION OF
MAIRE TECNIMONT CORE EPC
PROCESSES HAS BEEN FOCUSED ON
INITIATIVES REQUIRED TO ACHIEVE
AND SATISFY CONTRACT
REQUIREMENTS WITH LOWER
MANHOURS CONSUMPTION AND
EXCELLENT EXECUTION. THE RESULT
IS A “DIGITAL ADVANTAGE” DERIVED
FROM MORE ACCURATE SCHEDULING
AND FULL TRANSPARENCY, SHIFTING
FROM A “DELIVERABLE” WORKFLOW
TO “DATA” WORKFLOW MEANS
GAINING THE ABILITY TO CARRY OUT
PROJECT MANAGEMENT ANALYSIS
WITHOUT REPEATING STEPS OR
WASTING TIME.
By using digital tools across the overall EPC Some of the key digital technologies that
phases, Maire Tecnimont can achieve up to: optimize EPC processes are:

20% reduction in time spent for Robotization of routine working

tendering process (Market & tendering processes;
intelligence); Outsourcing of services to improve time
25% reduction in time spent from and cost control of the activities;
documents first revision to their issue for Use of advance analytics and Artificial
construction (Collaborative advanced Intelligence to support cost-driven
engineering); decisions;
50% reduction in cost of documents and Use of design collaboration solution
deliverables management; based on the 3D modelling;
40% reduction in cost for vendors Development of 4D (i.e., 3D model linked
qualification (Optimized Sourcing & to time schedule for constructability
Supply Chain orchestration); analysis) and 5D (i.e., 3D model linked to
25% reduction in cost for inspection of materials costs and quantities);
manufactured materials; Use of remote collaboration solution to
10% reduction of time/cost needed for reduce response time for tasks closure;
executing field welds during piping Digitalization of construction working
erection works (Digital connected plant & processes to reduce the overall
Construction site 2.0). construction site supervision and to
increase the safety of building phase as
well as the control of quality on executed
work.
Maire Tecnimont’s leveraging on Advanced
Work Package has made a significant impact
on worksite efficiency, in some cases cutting
erection hourly overruns by 30%.
 CYBERSECURITY
BY DESIGN

Legislators are responding with new regulations. In Europe, the ongoing discussion about NIS2
Directive (i.e. the Directive on Security of Network and Information Systems) is updating the
existing cybersecurity framework and it is extending cyber security standards to new industrial
segments with the consequential duties for plant owners. “Security by design” means the plant
is protected from security breaches through a full architectural design based on components
provided by a selected supply chain and assembled properly from the IT perspective.

A deep understanding and long experience with plant design, construction and operational
management allows Maire Tecnimont to take a holistic and technology agnostic approach to
cybersecurity over the full life of the plant with an end-to-end mindset. The choice is driven by a
comprehensive analysis of the client’s needs. To leverage on the most advanced state of the art of
technologies, Maire Tecnimont forms partnerships with top class technology providers thus to
convert client needs into self-standing services.

DIGITALIZATION BRINGS HUGE ADVANTAGES FOR The natural consequences are the main
INDUSTRY, BUSINESSES AND CONSUMERS. THE protocols for cyber security that Maire
CONVERGENGE BETWEEN INFORMATION Tecnimont adopts for protecting its
TECHNOLOGY (IT) AND OPERATION TECHNOLOGY own core processes and that can be
(OT) IMPOSES A PARAMOUNT FOCUS ON extended by designing an industrial
CYBERSECURITY. digital plant.
Identity security in and outside of plant
based on a “zero trust” digital signature. This
approach calls for a user to be checked with
every login and has become the industry
standard with the spread of remote working.

Plant security using Endpoint Detection and

Response software (EDR) that records and
stores endpoint-system-level behaviours. This
software uses various data analytics
techniques to detect suspicious system
behaviour, provide contextual information and
block malicious activity.

Behaviour-based security is a proactive

approach in which all relevant activities are
monitored so that deviations from normal user
behaviour patterns (such as long-on times or
places) can be identified and dealt with
quickly.

NIS NIS2

Healthcare Transport Providers of public Digital services such as

electronic social networking services
communications platforms and data center
networks or service services

Banking and financial Digital infrastructure Wastewater and waste Space

market infrastructure management

Water supply Energy Manufacturing or Postal and courier services

certain critical products
(pharmaceuticals,
medical devices,
chemicals)

Digital service Food Public administration

providers
 THE DIGITAL SUITE FOR
PLANT OPERATION AND
MAINTENANCE

Maire Tecnimont engages top class THIS “OPEN INNOVATION APPROACH”

technological partners to deliver digital LEVERAGES ON TECHNOLOGICAL NEUTRALITY
advantages that create real value for clients, TO FIND THE BEST SOLUTIONS FOR A PLANT
becoming the single point of responsibility for OWNER’S PARTICULAR NEEDS OR BUSINESS
plant owners. ENVIRONMENT.

The results are tangible benefits such as improved production efficiency, more effective maintenance,
a safer work environment, easier emissions control and more effective training.

A digital approach can leverage on the following pillars.

ASSET DIGITAL TWIN

The Asset Digital Twin (ADT) is the core of digitalization. It consists of a 3D model as a single repository of
asset information, based on CHFIOS standard, starting with the technical documents produced during EPC
phases. The ADT grows along with the plant lifecycle, to include maintenance plans developed by vendors, and
is continuously updated with maintenance and inspection reports, becoming a fundamental backbone for
future solutions for plant and people productivity, and connected field operations.
Overall, the ADT has three main benefits:
1. it decreases the level of human errors in planning and execution of field operations;
2. it reduces major turnaround time;
3. it reduces maintenance personnel costs by increasing productivity of day-to-day activities.

The concept of Digital Twin using an open 3D model application as repository of all engineering data
and information starts from the first stages of plant design and continues during the overall
engineering lifecycle. This approach guarantees that both the EPC contractor and plant owner can
have a complete and accurate view of the project at each phase of the detail engineering,
construction, commissioning and operations.

The ADT when used during plant operation, keeping

MAIN AREAS OF DIGITAL
TRANSFORMATION FOR IMPROVING it enriched and updated with asset data relevant to
PLANT OPERATION & MAINTENANCE maintenance activities, makes operations and
maintenance smarter and more efficient.
PLANT PRODUCTIVITY After the project completion and plant handover by
EPC contractor, the plant owner has a useful and
PROCESS OPTIMIZATION ENGINE
- Maire Tecnimont Licensed units powerful tool that enables external suites to access
- Other Licensed units all available data, giving a wide range of
opportunities of integration also to existing
PRESCRIPTIVE MAIN. SUITE
- CMMS integrated with 3D model applications (e.g. tools for scheduling maintenance
activities).
ASSET DIGITAL TWIN

PREDICTIVE MAIN. SUITE

The major advantages resulting from an ADT when
- static
- rotating integrated with other solutions are:

COMPETENCES' IMPROVEMENT
1. access to documentation through a solid 3D
OTS + VR DIGITAL TRAINING model interface

CONNECTED FIELD OPERATIONS 2. simulation of field interventions,

HSSE PLATFORM
DIGITAL FIELD FORCE
3. clash tests during high-impact field interventions
such as turnarounds and revamping.

4. day-to-day maintenance management,

5. it can help during work orders generation, spare

parts management and monitoring and
workload tracking.
SQUEEZE MORE EFFICIENCY OUT OF A PLANT WITH A PROCESS
OPTIMIZATION ENGINE (POE).

A POE enables plant owners to capture processed data and feed it to a digital replica of plant processes. It
leverages not only on thermodynamics but also machine learning models, simulating the process and
optimizing its operations as precisely as possible, integrating production programs and economics. As a result,
the plant consumes less energy and therefore also reduces its carbon footprint. Our target is to enrich the
portfolio of companies belonging to Maire Tecnimont group of POE for licensed units for conventional
hydrocarbon processes as well for green chemistry applications.

A Prescriptive and Predictive Maintenance Suite (PMS) helps with maintenance planning, spare parts
management, workload tracking, work orders management and planning improvements. The improvement to
the traditional maintenance suite comes from merging the database typically used to plan maintenance
activities with a 3D model of the plant. Moreover, process, machine & environmental parameters can be
monitored and analyzed through statistical and machine learning algorithms, to identify abnormal operating
conditions and predict failures in advance.
This more sophisticated approach to maintenance (unlocked by a predictive approach) has a beneficial impact
on OPEX:

1. It reduces the cost of unplanned maintenance activities

2. It avoids the loss of production due to unexpected shutdowns

3. It also may increase plant safety reducing the risk of unexpected assets failures with consequential risks for
human beings and environment.

Training based on Operator Training Simulators (OTS)

combined with Virtual Reality (VR) environment allows plant
owners to maximize the effectiveness and efficiency from the
very start of plant operation. These tools are the equivalent of
a flight simulator and allow staff to be trained in advance to
handle plant start-up and operations in a fully immersive 3D
environment. The combination of the VR platform with the OTS
model and system creates a unique and advanced training
environment introducing a more realistic interaction between
control room and field operators:

1. This creates new job opportunities and may facilitate and

speed up the transfer of competences in case of
retirements of expert crews.

2. It delivers real safety benefits by creating a scenario for safe

test conditions for any potentially dangerous plant upset
status without creating any real risk for human beings and
environment.
CONNECTED FIELD OPERATION

A Smart HSSE platform can remotely monitor possible Health, Safety, Security and Environment risks in the
field. By connecting smart devices to a central control room (via Wi-Fi, beacons etc.) it is possible to prevent
dangerous conditions while maintaining an operator's "regulatory privacy". With this approach the workers are
geolocalized and their healthy parameters may be remotely controlled to limit any potential risk of injuries or
access to unhealthy or restricted areas without the proper training and authorization, thus reducing the risk of
fatalities.

By using a Digital Field Force (DFF):

1. Field operators are supported by mobile applications during daily operations in a fully connected plant.

2. All equipment is uniquely tagged, all plant data is saved on a central repository and experts are connected
to field force to provide technical support remotely.

3. On a single app, operators can access a range of functionalities to improve the productivity of their day-to-
day activities.

4. Maintenance and operation activities of the field team are facilitated because any needed information is
available at their fingertips by having an easy access to structured database also leveraging on Augmented
Reality (AR) approach, and remote assistance can be easily granted by limiting the circulation of experts
across various countries but providing support almost on real time.

The backbone to unlock any digital field service is the plant connectivity characterized by a very wide
band and very low latency time. Therefore, new communications paradigms (like 5G technology) are
crucial within the plant.
 TAKE AWAYS

Digital transformation is a powerful tool helping plant owners achieve business sustainability during the
energy transition. Maire Tecnimont provides technological solutions that can help plant owners save on
operating expenses, reduce emissions, and make the plant more economically manageable.
At Maire Tecnimont, digital transformation starts from core EPC processes, reducing hourly overruns and
cutting plant delivery times.

BEING A TECHNOLOGY-DRIVEN
CONTRACTOR MAKES MAIRE TECNIMONT
THE SINGLE ORCHESTRATOR OF THE EPC
VALUE CHAIN TO ENVISION A DIGITAL
PLANT THAT WILL MEET PLANT OWNER
BUSINESS NEEDS TO GENERATE
SIGNIFICANT POSITIVE IMPACTS ON PLANT
CAPEX AND OPEX. MAIRE TECNIMONT IS
INDUSTRIALIZING CUTTING-EDGE
TECHNOLOGICAL CONCEPTS LIKE WIRELESS
PLANT BASED ON 5G, BLOCK CHAINS
APPLICATION TO INDUSTRIAL COMPLEX, TO
BE THE DIGITAL LIGHTHOUSE.
THE RESULT IS A PLANT THAT IS MORE
SUSTAINABLE, BOTH IN TERMS OF TOTAL
COST OF OWNERSHIP, AND FOR ITS HUMAN
SAFETY AND ENVIRONMENTAL IMPACT.
CONTACTS

To find out more, please contact:

Ezio Pasqualon
Digital Transformation Services Head of Department
Via Gaetano De Castillia, 6/A, 20124 Milan, Italy
[email protected]

www.mairetecnimont.com