OXAL122_IntelligentEngineeringV0.1 - Invensys OpsManage'11

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opr
ietary marks of Invensys or its subsidiaries. All third party
trademarks and service marks are the proprietary marks of their respective owners.

© Invensys
2011

Invensys proprietary & confidential

Slide
2

OXAL121
-

Intelligent Engineering

A Practical Way to Reduce Project
Risk and Deliver Faster with Better Quality


Joe Lindley

Keith Perkins

Global Engineering Management

November 2011

Slide
3

Invensys Enterprise Control Offerings

Manufacturing / Production Operations

Corporate


Integration and

Collaboration Platform

Automation

Invensys and Third Party


Software Applications

Invensys and Third Party


Enterprise Control System


IT

Platform

Corporate Systems

Industry
Solutions


Services:

Consulting,
Project

Execution,

Learning,

Operational
Improvement,
Maintenance &
Support


Partner
Ecosystem



Slide
4

Integration &
Collaboration

Platform

Enterprise

Integration

Workflow

Open Device

Integration

Web
Portal

Application

Toolkit

Historian

Third
-
Party Offerings

Software Applications

Execution

Manufacturing Execution


Systems

Batch

Enterprise Asset
Management

Mobile Workforce
Management

Performance

Enterprise Manufacturing
Intelligence

Performance Measurement

and Reporting

Visualization

Quality

Asset
Performance

Optimization

Operator Training

Design

Advanced Process
Control

Simulation /
Optimization

Control

DCS

PAC

SCADA

HMI

Safety

Safety Instrumented Systems

General
Purpose

Safety

Turbomachinery Control


Measurement &


Instrumentation

Instrumentation

Controllers

Recorders

Automation

Software Applications

Where The Offerings We Will Discuss Fit Within The

InFusion Enterprise Control System

Slide
5

Pillars of Operational Excellence and
Focus of This Discussion

Level 3

(Multi
-
plant/Multi
-
site)

Level 2

(Plant Floor/Area)

Level 1

(Resource/Asset)

Operational

Excellence

Environment

And Safety

Control

People

Asset

Slide
6

Intelligent Engineering


The Problem





The Invensys Approach





To Project Execution

Slide
7

What clients have been telling us


Time to market


need to be online faster
with reduced risk and
minimum cost


Automation system
requirements mature late
in the project
lifecycle


Design validation occurs too late
in the project lifecycle


Managing
change

is an issue


Global engineering workforce
is required with local content


Systems have become
more inter
-
dependant and complex
to
integrate


Multiple groups
are required; internal, vendor, external


We have a
shrinking resource
pool


Need to mitigate
human errors



† Supplier Provided
Automation Services
Worldwide Outlook, 2009

Slide
8

The Engineering Problem

Engineering

Manual Translation

‘Bottom
drawer’ tools

Slide
9

Invensys Response


Reduce risk of schedule extension due to changes by
capturing
knowledge and using automation


Drive consistent global execution using
automated workflow
and
global standards


Integrate Client Design tools including
SmartPlant

Instrumentation & P&IDs

into process


Provide tools to help clients and EPCs
capture requirements


Minimize manual activities by
auto
-
generation of automation
system configuration


Provide capability to validate process design earlier by providing
auto
-
generation of plant model and instrument validation


Provide operator familiarization early by
auto
-
generating plant
models


Slide
10

Our Approach


Define Global Standards


Integrate Plant Engineering Tools


Provide tools to:


Manage Workflow


Capture Knowledge and Requirements


Automate Workflow


Test

early and often


Divide project into separate ‘Unit’ projects


Use Plant Simulation from the start

Consistent use of best
practice

Make better use of
existing data

Reduce manual errors

Find problems early

Experience whole
process early

More robust testing

Slide
11

Bridging the Gap

Intelligent

Engineering Tools

Invensys Product

Configurators

Plant

Design Tools

Slide
12

Project Activities


Let’s consider an Integrated Control and
Safety System with an Operator Training
Simulator


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
13

The Project Framework


Consistent process
execution


Enable
collaboration
between
engineering teams


Efficient delivery
and deployment of
standards, tools
and templates

Ensure consistent use of best practice


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
14

Define Project Standards

SmartPlant
P&ID

SmartPlant
Instrumentation


Receive sample instrument
data (all loop types)


Build templates for each
loop type


Build rules for each
template


Build tie
-
back simulation for
each template


Build sample plant model


FAT templates, rules and
simulation


Ensure consistent use of best practice


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
15

Define System Architecture


Define physical locations and
networks connecting locations


Define equipment at each
location



Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
16

Define Cabinet and Console
Designs


Select from a range of
standard system and
marshalling cabinets


Select from a library of
signal wiring loop typicals



Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
17

For each Unit

Define Equipment Layout


Define cabinet and console
locations


Calculate heat generation and
power requirements



Receive preliminary unit
instrument data (all loops)



Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
18

Build Initial Unit Model


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
19


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Build Initial Unit Model

Validate plant model to provide a sound basis for testing

Slide
20

Build Unit Control and Safety
Modules

Preliminary Instrument Data

Eliminate manual errors


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
21


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Build Unit Tie
-
back Simulation

Reduce manual errors

Slide
22

Develop Unit Displays and
Control and Safety Applications

Cause & Effects Editor


Import Instrument Index


Drag & drop Causes and Effects


Define device types and allowed parameters


Define function blocks


Logic emulation


Change tracking


Report package

Find problems early and reduce manual errors


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
23

Develop Unit Displays and
Control and Safety Applications

Reduce manual errors


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
24


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Engineer Unit Marshalling and
System Cabinets

Ensure consistent use of best practice

Slide
25

Update Unit with ‘Released for
Construction’ Data


Receive RFC instrument data
including all parameters


Assess impact of
added/deleted/changed loops


Regenerate control/safety
module layer


Update applications and plant
model

Gives client more time to mature data


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
26

Unit Verification Tests


Perform acceptance tests on unit hardware


Perform acceptance test on control/safety
functionality


Deliver cabinets to site for field wiring
connections and loop tests


More robust testing


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
27

Integrated Acceptance Tests

Unit A

Unit B

Unit C

More robust testing


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
28

Pre
-
Commissioning

Unit start
-
up

Equipment control

Unit shutdown

Tanker loading/unloading

Material movements

….

Find problems early and at less cost


Project
Framework


Project Standards


System
Architecture


Cabinet Design


Equipment Layout


Unit Model


C&S Modules


Tie
-
back
Simulation


Displays &
Applications


Engineer Cabinets


Update with RFC
Data


Unit Tests


Integrated Tests


Pre
-
Commissioning

Slide
29

Projects using Engineering Workbench

Project Name

Region


Size

Status

Total
K5CU

EURA

S

Complete

Total
France

EURA

S
Complete

Valero Complex 6B

East & West

NA


S

Complete

Hunstman

NA

M

Complete

Georgia Power

NA

M

Complete

USAN FPSO

APAC

M

Complete

France SONATRACH

EURA

M

Complete

PHRC Jetty Rehabilitation

EURA


S

Complete

Falah B/Dubai

MENA

M

Complete

LCRA
(Fox Mass)

NA

M

Complete

City of Atlanta (IEE)

NA

S

Complete

Exxon Mobile Thailand

APAC


S

Complete

Project Name

Region


Size

Status

Helpe

EURA


M


Complete

Kashagan

EURA


M


Complete

Shell/Motiva
Webster

NA

S

Complete

Suncor VRU (Calgary
)

NA

S

Complete

NTPC

APAC

L

In Progress

Kapstone Montreal

NA

S

In Progress

Skidka

APAC

M


In Progress

Enagas

EURA

M


In Progress

Manifa

MENA

L

In Progress

RN 2012

EURA

M

In Progress

Shell Tranmere

EURA

S

In Progress

KOC
-
BS171

EURA


TBA

In Progress

RNEST

LAO

L


In Progress

Slide
30

On Time, On Budget

Slide
31

Intelligent Engineering



Slide
32

Question Time