Reduce Risks and Increase Flexibility by maintaining project quality and accommodating late freezing of project data

Transcription

1 Reduce Risks and Increase Flexibility by maintaining project quality and accommodating late freezing of project data Invensys Engineering Workbench Intelligent Engineering

2 Executive Summary Frequent, rapid changes in the marketplace and more aggressive ROI demands are resulting in shorter and shorter project execution schedules. Automation is always on the critical path, being a prerequisite for plant start-up and operation, yet relying on the output of other disciplines. To help mitigate the variety of issues that arise in trying to obtain needed data while maintaining project schedules, Invensys has developed the Invensys Engineering Workbench (IEW). Part of the Engineering Excellence program, IEW is an integrated toolset which automates and tracks many of the tasks performed by engineers on a project, including as-built reporting. The Invensys Engineering Workbench employs Invensys knowledge, standards and processes, and integrates them with data coming from plant engineering environments, such as Intergraph and others databases or spreadsheets. This integration streamlines the project engineering effort and helps ensure its reliability and final documentation. Using this approach, the project team achieves: Better quality Late design Simulation Virtualization Cross check between multiple sources of data and almost automatic creation of critical documents like loop wiring and other reports. Errors are found early in the engineering process. Late changes are easily accommodated in existing rules, templates and documentation. Cubicles and marshalling are redefined with acceptable effort. Accommodating late freezing of data results in increased project execution flexibility. To automatically generate plant/processes models. Validate and verify a customer s control and safety design early in the project lifecycle, reducing rework considerably. Working in a common, formal and virtualized environment enables distributed teams to adopt common best practices and guidelines. Thus, minimizing human influences and reducing overall project risk. Local teams can be trained more efficiently and effectively. One target in mind: to give you more time The Invensys Engineering Workbench enables maximum schedule flexibility by giving more time to the EPCs and Package Suppliers to freeze their data. By allowing more time to deliver data, Invensys can deliver automatic and consistent high quality automation detailed design and reduce overall project risk. Plant Design Tools Invensys Product Confiigurators Intelligent Engineering Tools

3 Features The features included within the Intelligent Engineering Workbench are: Defines users workspace to restrict write access to templates, rules, client data and sections of the plant Provides versioning for each change Produces a hierarchy of system architecture drawings Assigns control database compounds to controllers, following wiring constraints Captures company site data such as number of locations, networks and distances between them Imports field wiring data (Instrument Index, including Plant Breakdown Structure) from Instrumentation (SPI), Excel or Access Imports Piping and Instrumentation Diagrams from P&ID for simulation models Imports a Bill of Materials from the Invensys materials ordering system Generates and assists the design of the control and safety system at three levels, fostering re-use for templates and rules: Operator workstations, servers and control network Controllers and I/O modules Control and marshalling cabinets Loads controllers and I/O modules in system cabinets Lands field cables on terminal blocks in marshalling cabinets Identifies the appropriate wiring typical for each field tag Mounts termination assemblies in marshalling cabinets Creates signal cross-wiring for each loop Generates manufacturing data for cabinet production, such as wiring schedules and drawings using Cabinet profile templates Generates heat and power data for HVAC and UPS sizing Creates Invensys hardware and signal wiring in the EPC s SPI database. Supports the generation of quality and detailed checks during the system testing phase. This is accomplished by leveraging Tie Back simulation rules for FSIM/ TRISIM/DYNSIM or a medium-fidelity plant model Instrument Database Invensys Engineering Workbench P&ID Foxboro InTouch Application Foxboro Configuration Tools Tristation DYNSIM

4 Workflow The workflow is the primary automation function of the IEW. This function enables the engineering team to standardize and automate parts of the engineering-build process. In the IEW, the workflow requires the following external data inputs to generate control strategies and safety logic: Instrument Index and Field Wiring Index data (from the Client or EPC) divided in WorkSpaces assigned to a specific project engineer Invensys Project Information Database (aka. PIDB, Buy Automation Basket) (newly created in IEE or from Invensys Knowledge Base or previous phases for the project) There are separate workflows for control and safety. Each workflow contains a fixed set of workgroups made up by worklets. To perform the required actions, each worklet has the corresponding sets of rules to be applied to Instruments Index data according to the relevant template. These rules govern the flow of execution for the worklet and generate the required data for the final output file or report. These rules can be modified to address project-specific requirements as defined by the client. Rules are responsible for the automation in the IEW. They embed artificial intelligence which automate tasks traditionally performed by an engineer. They are adaptable to meet client specification. Rules in the IEW are required to generate: Safety logic for a TriStation controller Taglist for Foxboro Evo TM Engineering Environment and the Control Database for InFusion Engineering Environment (IEE) Invensys Engineering Workbench is centred around data availability. The proper use of quality information provides the flexibility to freeze data later in the project. Versioning and compare eliminate the risk of inconsistences, rework and project overrun. Extensive use of templates and rules enables reuse and consistency. Early Data P&IDs, instrument index, specification, meeting reports, process description in natural language are used to setup project standard based on existing templates, rules, typical and graphic symbols. Project team goal is to define an instance for each device on the project. The advantage here is that we are able to do the bulk of the design very early in the project lifecycle with a moderate amount of data. Client Invensys Control Module Specifications Define Project Safety Module Cabinet Dialogue Wiring Typicals Rules Naming Rules Early Database Define Project Rule Set C&S Module Building Rules Early P&ID Database Simulation Define Project Equipment Cabinet Design Rules Simulation Equipment

5 Later Data Further into the project later data will be made available containing all the devices but not all the necessary information (descriptions, trip sets). Client Invensys Auto-validate I/O Tag Data Auto-validate Wiring Data Validation Reports The advantage here is that we are able to begin the cabinet and marshalling design and the control and safety application build knowing inevitable rework iterations will be automated hence fast, consistent and error free. Database Interlock Definition Safety Logic Definition Auto-build Control & Safety Auto-design System & Marshalling Cabinets Auto-build Display Symbols Build Process Interlock Logic Build Safety Logic C&S Cabinet Design Display Symbols Validation Reports Later P&ID Database Build Plant Simulation Plant Model Release for Construction Data The RFC data will contain all the required information. Often RFC data cannot be made available at a single time and may come as several issues of data associated with different plant areas or units.this is accommodated by IEW features that allow stabilized data to be locked and then new data merged with that existing locked data. Re-generation of the application can be completed in a controlled and safe way. The advantage here is that project engineers can backdocument the application into the IEW and keep complete control on how RFC data are used in the development and loops. Client RFC Process Interlock Definition RFC Safety Logic Definition RFC Database Invensys Build Process Interlock Logic Build Safety Logic Auto-validate I/O Tag Data Auto-validate Wiring Data Auto-build Control & Safety Auto-design System & Marshalling Cabinets Auto-build Display Symbols Auto-test of Control & Safety Validation Reports Control & Safety Cabinet Design Display Symbols Test Reports Client Cabinet & Wiring Data RFC P&ID Database Build Plant Simulation Plant Model

6 Benefits Automating many of the manual steps that an engineer makes during a project results in improved quality and a reduction of the risks associated with project implementation. Every engineering company uses process maps to describe the standard flow for project execution Design system architecture (based on integration with systems at site if applicable) Lead Engineer Generate architecture drawings Application Engineer Define Module allocation based upon I/O segregation Application Engineer These process maps are good. Every activity needs to be done, but they make assumptions about the availability of data and information; and it is well known that those assumptions are rarely met Define Servers, Workstations, Networks and other Ancillary Equipment Application Engineer Calculate System Loading, Power and Heat Dissipation Application Engineer rd Party hardware review Lead Engineer; Safety Authority Instruments data from the client is specified at three points, but the data supplied at these milestones by clients, particularly adopting a new process, are usually subject to considerable change, shortening time for testing and resulting in project delays. Good Engineering Practices mandate segmenting a project into units. Two examples include: reusing engineering in an LNG train or dividing the plant in smaller trunks which are easier to be engineered. This is also common when a project is spread across different locations or takes advantage of the contribution from multiple EPCs. Using IEW on a project partitioned in units secures consistency and minimizes re-work not only on copy/paste like applications, but when a project evolves in steps spanning over a period of time. Integration phase is reduced to a minimum and misalignments are avoided even if developments are geographically distributed. Invensys Engineering Workbench uses early data to start building application modules, architecture and cabinet mechanicals. Thanks to the workflow, versioning and compare features embedded in IEW, as soon as data are made available they are used to refine the project. The client and the EPCs are given much more time to mature data. A single global database and check-out mechanisms are applied such that even distributed team are confident they are working on trustable data. The result is no risks of inconsistencies during the testing phase. Project knowledge is embedded in rules and templates and are readily available to the project team and client, not laying down in the bottom drawer of a project engineer. Project Execution Plan TASK Week Original Schedule Project Startup Draft FDS Review FDS Final FDS HW Client Review and approve FDS Hardware freeze Purchase/build/wire/test/stage cabinets 90% Config. Software minor freeze 90% Configuration Data Software freeze Database generation Human Interface Database modification for final data Pre-test FAT Intelligent Engineering Schedule Project Startup Define project standards Draft FDS Review FDS Final FDS Client Review and approve FDS Develop device templates from library Develop wiring loop typicals from library Receive sample instrument data from client FAT device templates Deliver sample cabinet wiring data to client Hardware freeze for cabinet mechanicals Build Unit A: LNG REGASIFICATION Receive preliminary instrument data from client Validate instrument data Build control and safety device logic Build device tie-back Define system and marshalling cabinets Load system cabinets & wire marshalling cabinets Build process interloc logics Build safety interlock logic Build displays Build start-up/shutdown sequences Internal tests for unit Receive final instrument data from client Validate instrument data Rebuild device logic and tie-back Modify and test applications Modify and test cabinets FAT unit cabinets and applications Build Unit B: DEHYDRATATION Receive preliminary instrument data from client Build and test unit (as per Unit A) Receive final instrument data from client Modify and test unit (as per Unit A) FAT unit cabinets and applications Build Unit C: SULPHUR RECOVERY Receive preliminary instrument data from client Build and test unit (as per Unit A) Receive final instrument data from client Modify and test unit (as per Unit A) FAT unit cabinets and applications Integration tests and FAT Example Instrument Cabinet Mechanical Freeze Unit A Instrument Unit A Final Instrument SW Final Integration Tests and FAT completed 3 weeks in advance even if Unit C Final Instrument Data received 12 Unit B Instrument Unit B Final Instrument Unit C Instrument Unit C Final Instr.

7 Helping Clients Across the Globe Succeed CLOV Skikda An EPC The CLOV Floating Production Storage and Offloading (FPSO) project scope includes the implementation of safety systems within tight project schedules as well as overall project completion within a stipulated time frame. The Client was in search of an innovative solution to reduce project risk, cut implementation costs, leverage critical plant information and meet project deadlines. In line with the Intelligent Engineering approach, IEW utilizes innovative technology, engineering experience and project execution methodology to bridge the gap between plant design and control & safety system implementation. Accordingly, IEW proved to be the obvious choice in meeting Client s objectives while improving scheduling integrity, reducing human errors and ensuring consistency in software development. The CLOV FPSO Project was managed by the Invensys Singapore office with the engineering carried out in Singapore and Cairo, Egypt. The project, which included a total of 8 systems, was split into two phases: 1. HULLSide - Frame or body of a ship, exclusive of engines. More than 3500 I/O. 2. TOPSide - Surface of a ship s hull above the water line. Close to 4000 I/O. Focused on the total cost of ownership and promoting overall project delivery excellence, Invensys IEW offering helped the Client by reducing risks, improving global collaboration and strengthening its ability to respond to changes in a timely manner during the life of the project. Skikda is a city in the north eastern Algeria. Natural gas, oil refining, and petrochemical industries were developed in the 1970s and pipelines have been built for their transportation. A Client, the largest oil and gas company in Algeria and Africa, awarded Invensys for a project to be executed in three phases. It was a natural choice to adopt IEW to ensure that configuration done for the first step can be easily reused in the following ones. All of the design and development work was done in Cairo, Egypt. The project was managed from the business unit in Singapore. The primary benefit that the project team obtained by using the Invensys Engineering Workbench has been the re-use of the work done on subsequent phases and the quality and the consistency of the output produced. Additionally, the ability to respond to client changes by modifying the rules has been very useful. IEW being a corporate tool was well supported by the technical members within Global Engineering Management (GEM). This is evidenced by how well the Invensys Engineering Workbench evolved through the three phases on the project. The project team commented: We were very impressed by how the IEW improved and evolved over the three phases on our project. To start off we have a lot of challenges, however, by the time we got to the second and third phase of the project, we were making significant savings on engineering hours. We have had a good experience using the tool and intend to use it on future projects. Invensys is proud to be among the few process automation companies able to deliver complex control and safety systems for Oil and Gas, Upstream, and Power. What does it mean to execute a large project often spanning over years? The secret is to apply a rigorous process consisting of many steps to be followed. This process sets out the steps to successfully interact with the Client to obtain the necessary data and develop the required solution. Instruments data, templates, rules, networks, cubicles, junction boxes, cubicles, operator stations, reports, mimics, documentation, backup and versioning are some of the items required to be developed as if an orchestra is executing an opera. The Project Director has to be sure that project data is made available in a timely manner and here is where Invensys Engineering Workbench comes into play. An example is Algiers Refinery Rehabilitation and Adaptation project awarded by the End User to the Client EPC. Invensys was chosen as the vendor for all the ESD, FGS and DCS systems. Invensys scope covers up to 200+ Cabinets and IO points. The project is ongoing but both the Client and Invensys are in agreement that Invensys Engineering Workbench is a unique tool with terrific potential because: errors are discovered in the early stages no errors are present during data transfer allows for fully detailed data which is required later in the process versioning helps traceability and rollback as required

8 Consistency Knowledge PEOPLE End Users Management PROCESS Execution EPCs TOOLS Later Data Reduced Risk Invensys Equity Drive, Houston, TX USA Tel: (713) Fax: (713) iom.invensys.com Copyright All rights reserved. Invensys, the Invensys logo is a trademark of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners. IN-0270 AP/MKT/OP/COLL/139