1 ebook Agile Project Execution The future of Industrial Process Automation projects v1.4 EMK(VDS)-TR-EB-01 APEX ebook
2 Table of Contents Intro Agile Project Execution Page 2. Chapter 1 Conventional Project Execution Page 4. Chapter 2 Agile Project Execution as a Solution Page 10. Chapter 3 How can we do things better? Page 21. 1
3 Evolving Automation Technology & Changing Project Execution Process automation is undergoing major changes, driven by customers desire for technological advances from the main automation system integrators in the industry. Representatives from different industries are driving vendors like Yokogawa to re-evaluate how large-scale automation projects are implemented. The customer message is clear: projects take too long; they are too engineering-intensive; and the automation systems frequently become the critical path in the final stages, often causing the project to fall behind schedule. Individually and collectively, they are applying their knowledge of best practices and lessons learned to answer the question, How can we do things better? As a result, Yokogawa is being guided by the industries it serves to develop and improve solutions that provide the reliability, operability and safety expected from control system platforms. Yokogawa is also being asked to improve methodologies for assembling, executing and deploying a complex process solution with improved efficiency, lower installation cost and greater adherence to schedule. With several hundred major automation projects executed globally each year, the industry system integrators can draw on several decades of experience working in various industries and with a range of technologies. 2
4 Agile Project Execution Most innovations tend to advance two main categories: 1) project management and 2) technical improvements. These two categories are deeply intertwined on multiple levels and, as such, can work together to improve projects. This ebook will address Yokogawa s vision on Project Execution. We know that the challenge for automation providers is, to develop technologies combined with project execution processes designed to create the greatest possible value. The key to achieve this is, is to reduce or remove the dependency of application engineering on the hardware implementation, eliminate the constraints of marshalling and termination, and allow system independent commissioning of IO loops (no DCS database required). The software side of automation can be engineered and tested in a similar modular fashion, independent of the actual target hardware which can be assigned flexibly at any stage in the project. Yokogawa calls this: This approach to automation utilizes key Yokogawa technologies to achieve smart, decoupled software and hardware engineering, using a modular design approach with flexible project implementation. In order to better understand the evolving automation landscape and the way automation projects are being executed is changing, we will define what we call the conventional project execution methodology in chapter 1. We will also address the main challenges that arise with this conventional approach. In chapter 2 we dive deeper into the technical aspects of these challenges and we will describe how Yokogawa deals with them according to our Agile Project Execution vision for automation projects. In chapter 3 we will answer the main question: how can we do things better? For now, we hope that you will enjoy reading this ebook. Agile Project Execution (APEX). 3.
5 CHAPTER 1 4.
6 From Serial to Parallel For the last few decades, most projects have followed the same basic path. Each phase of this conventional path takes place in a serial fashion and builds on the previous effort, shown in figure 1: Fig. 1 - Conventional Project Execution Project Start Definitions, Standards, Detailed Functional Specifications Control Logic, Graphics, Alarms, Procedures Software to Hardware Binding Project Delivery + Start Up Design Application Hardware Field Installation Loop Check High Application Dependency on Hardware and Field Wiring Hardware, Cabinets Marshalling, Ship to Site Hardware Installation, Wiring, Device Configuration, Signal Termination Project Risk Mitigation 5.
7 5 Basic Project Phases For the past few decades, most projects have followed the same basic path shown in figure 1. Each phase takes place in a serial fashion, as each builds on the previous efforts: 1. The design phase typically includes development of the functional, detailed specifications, and agreement on project engineering standards, schema and, sometimes, resources. Control logic, graphics, alarm configuration, tuning parameters and so forth can be applicationengineered in this 2 nd phase by a software team in a single or in multiple locations. At the same time, controllers, I/O cabinets, marshalling boxes and enclosures can be manufactured, wired and tested by another specialized team. Definitions, Standards, Detailed Functional Specifications Design Control Logic, Graphics, Alarms, Procedures Application 2. This leads to the 2 nd phase, the main engineering work, which can be grouped into hardware-related and software-related activities. During this phase it is desirable to have as much parallel engineering as possible with these activities, and the conventional model achieves this up to a certain point. Hardware Hardware, Cabinets Marshalling, Ship to Site 6.
8 3. The significant dependence of application engineering on the design hardware is a challenge. An automation application must be configured to fit the very specific controller, I/O module, marshalling, termination and wiring plan for which it is designed. Software to Hardware Binding 4. Upon site delivery, the application piece is bound to the hardware loop by loop. The conventional model refers to this as binding. Late binding allows enough time in the schedule for project design changes to be implemented in both hardware and software before final binding. Flexible binding, as we will show later on in this ebook, allows for these changes, as well as reconfiguration, at any point in the project. Hardware Installation, Wiring, Device Configuration, Signal Termination Field Installation 5. Either after or during loop commissioning, the owner signs off on the automation project, and the plant starts up. Depending on the business environment, schedule flexibility in start-up may be acceptable, but late is never desired. Loop Check 7.
9 Impact of Design Changes If events unfold as planned, the project can stay on schedule, although the schedule might be longer than the company considers desirable. However, most projects do not run exactly as planned because process engineers may realize a vessel is not in an ideal location, the distillation tower is not large enough, or another pump needs to be added at some point to maintain sufficient flow. Any of these process equipment changes will create process automation system changes by moving or adding hardware and related instrumentation. As figure 2 shows, such changes can extend the time necessary for one or more project phases due to re-work, ultimately stretching out the schedule and eventually pushing the project past the start-up deadline. The automation system now becomes the critical path item holding up the schedule. Fig. 2 - Conventional Project Execution: impact of design changes Project Start Design Application Hardware Field Installation Loop Check Project Delivery + Start Up High Application Dependency on Hardware and Field Wiring Changes Re-work Late data changes can impact all project pieces and require engineering re-work Project Risk Mitigation 8.
10 Summary As we have seen, any of the process equipment changes will create process automation system changes as well by moving or adding hardware and related instrumentation. The impact of such changes becomes all the greater as the project moves farther along. Once it has moved into the loop commissioning phase, late arriving changes are expensive. The conventional project model therefore, with its high interdependency of the hardware and software, cannot not respond well to late-arriving changes. In the next chapter we will show how Yokogawa s Agile Project Execution approach offers a solution to this challenge. Such changes can extend the time necessary for one or more project phases, ultimately stretching out the schedule and eventually pushing the project past the start-up deadline. The automation system often becomes the critical path item, delaying start-up and the realization of revenue from the new installation. 9.
11 CHAPTER 2 10.
12 The Agile Project Execution Approach As described earlier, the challenge for many automation providers is to develop and implement new technologies combined with project execution processes designed to create the greatest possible value. In order to achieve this, the key is to reduce or remove the dependency of application engineering on the hardware implementation. Yokogawa calls this Agile Project Execution (APEX). This approach to automation utilizes key Yokogawa technologies to achieve smart, decoupled software and hardware engineering, using a modular design approach with flexible project implementation. By effectively separating the project into hardwareindependent and system-independent layers, it is possible to advance the hardware project further toward completion, with less consideration of the application project status. Utilizing System-Independent Loop Commissioning, project activities normally requiring a completed system, such as I/O-to-device loop commissioning, may be accomplished with a mobile device before the main controller is operating. With the Agile Project Execution, application and hardware can be equalized at any time, and final binding can occur at any flexible time in the schedule to ensure an airtight schedule as the project advances toward final delivery. In this chapter we will first outline the technical aspects of the problem and then dive deeper into our solution called Agile Project Execution. 11.
13 Technical Aspects of the Problem and Solution Compressing a project schedule by including more parallel, instead of serial, activities depends on the ability to decouple many elements of the process and mechanical design from the automation system details. To be effective, this requires a method of maintaining overall project management and information for automation software and hardware layers, equalizing engineering documentation, and facilitating final binding. One reason why traditional automation projects make such decoupling difficult is the highly customized nature of the hardware, particularly I/O and field wiring. These designs cannot be finalized and built until the process and mechanical portions of the plant are completed. A typical example is as follows: A vessel in the process needs a level sensor to ensure that the amount of liquid is beyond a given point. For the sake of simplicity and economy, a level switch is specified with a digital on/off output and an appropriate I/O channel created in the control system to receive the signal. However, the process designer later decides that it is critical to know the actual level, and requests a modification. A level transmitter must now be deployed in place of a level switch alone, so it is necessary to change from a digital signal to a 4-20 ma (HART) signal. Such a change might not seems substantial, but in the real world it can involve a whole series of steps, from hardware implementation to documentation updates. Multiply this process by a few (or even dozens of) such changes, and construction begins to fall behind schedule. Fortunately, there is a solution to this problem, and it lies with more flexible I/O systems. 12.
14 N-IO: Smart, Configurable N-IO (Network I/O) is a key technology for Agile Project Execution. It simplifies the whole process of wiring field devices and supports flexible binding. Several industrial automaton vendors have developed smart, configurable I/O technology capable of supporting multiple signal types on a perchannel basis, and this development is arguably the most critical for the parallel execution of process/mechanical and automation system design. So when changes comes late in the project, such as the shift from a point level sensor to a level transmitter, as mentioned previously, it is a simple matter to reconfigure the connection point in the cabinet. It can support multiple signal types on a per-channel basis, and this development is arguably the most critical for parallel execution of process/mechanical and automation system design (Fig. 3). Increase in I/O count over the project duration can be accommodated with a standard cabinet mounted with N-IO, which can then be assigned after termination earlier or later in the project. Fig. 3. Configurable N-IO cabinets are a key element of new project management techniques. 13.
15 N-IO: Smart, Configurable The capability for changing configurations, as described on the previous page, along with the flexible binding of the automation hardware layer to the software layer, support a seamless transition to the final phase of project completion, without gaps in the schedule. This is because much of the hardware loop validation is accomplished during system-independent loop commissioning. When the I/O cabinet is in place and the field devices are installed, the performance of the field device and its interaction with the relevant final control element can usually be verified, even before the control system is installed. When changes come late in the project, such as with the point level sensor to a level transmitter example, it is a simple matter to reconfigure the connection point in the cabinet. This capability for changing configurations, and flexible binding of the automation hardware layer to the software layer, supports a seamless transition to the final phases of project completion without gaps in the schedule. This is because much of the hardware loop validation is accomplished during system-independent loop commissioning using a Field Asset Validation and Diagnostics tool, as we will show later on. N-IO increases the independence of the automation system from the process/mechanical design since it supports system-independent loop commissioning. Utilizing N-IO as part of Agile Project Execution can result in very significant reduction in complexity, hardware and total installation cost for the engineering firm, or end users. The new CENTUM VP DCS 14.
16 1) It supports multiple signal types on a per-channel basis 2) Once a transmitter is replaced and all hardware tasks are finished, the necessary application change can be done centrally. All data and documents are consistent at any time. 3) Spare hardware channels are 100% available at any time without delay or physical adjustment 4) Application functions can be assigned to any available hardware channel at any time during flexible binding, enabling more independence in application engineering and reducing project risk. No rewiring or exchange of signals is required. 5) I/O cabinets can be ordered, shipped and wired as a standard item, since they require no project specific engineering (except size and layout), marshalling cabinets or field terminations. 6) Changes in any section (Hardware, Software) do not affect the other due to Flexible binding. Flexible binding of the hardware layer to the software layer is achieved to seamlessly transition to project completion without gaps in the schedule, as much of the hardware loop validation is accomplished during System-Independent Loop Commissioning. 7) Marshalling cabinets are eliminated along with most termination points. The number of wiring terminations from each device to the control system is reduced from 20 or even more, to perhaps
17 Field Asset Validation and Diagnostics Another common element of the configurable N-IO system is their ability to use latest digital communication protocols for communication with smart field devices, typically instruments and analyzers. With natively supported communication in place, the diagnostic information form these smart field devices can be gathered and used in a sophisticated assetmanagement program. When the I/O cabinet is in place and the field devices are installed, a field asset validation and diagnostics tool can be used to verify performance of the field device and its interaction with the relevant final control element, even before the control system is installed. System-Independent Loop Commissioning The field asset validation and diagnostics tool takes advantage of PCs and the software configurability of N-IO to allow not just the activation and configuration of the I/O modules, but also the device-to-field loop check and validation. This can happen if the devices are available in the field, or as part of modular skid building. A screenshot of Yokogawa s field asset validation and diagnostics tool FieldMate TM Validator 16.
18 The Workflow for System-Independent Loop Commissioning & Flexible Binding The workflow for system-independent loop commissioning & flexible binding is very simple: 1. While the application development work is being done, I/O tags and information can be exported and imported into the field asset validation and diagnostics tool. 2. With that information, I/O tags can be assigned to the real physical I/O, allowing field loop check and validation much earlier than conventionally possible. 3. With the field site instruments connected to the I/O, accuracy and function checks can also be carried out. 4. Reports can be generated after all the fieldwork is completed. 5. Updated I/O information can be transferred to the master database for central application access. Transferred to the master database Generate reports Export & import information Accuracy and function checks Assign I/O tags 17.
19 Flexible Binding: Convenience to Avoid Rework Late Binding vs Flexible Binding One of the most important parts of systemindependent loop commissioning is flexible binding. The concept is simple, but results in huge improvements. Flexible binding allows assigning or re-assigning any field I/O item to application control functions at any convenient phase in the project. Traditional conventional models make this practical only during final site delivery of the complete system, and then as costly rework. Late binding is useful, allowing the hardware and software pieces of a project to be developed in parallel and then brought together, validated and tested late in a project; however if there is any re-work beyond this phase, the cost is high. Additionally, it means loop testing must wait until final binding. Flexible binding using a field asset validation and diagnostics tool supports an even higher degree of separation, allowing field loop checking to be carried out even earlier. 18.
20 The Software Story: Modular Control Engineering Software Class based modular control engineering with modular control engineering software is the unifying element in the Agile Project Execution approach. Modular control engineering software is, or should be, the central engineering application and database for all aspects of an automation project, making it a major element of the larger Agile Project Execution program. Modular control engineering software condenses operating and procedural information into class modules able containing: Standardized engineering graphics Control logic Process-related intellectual property Alarms Loop tuning tools and parameters Configurations for single pieces of equipment These design patterns can be accessed from a central repository managed by end users, integrators and engineering firms. The design patterns can utilize global and industry-based class module libraries available for project engineering to greatly reduce overall engineering effort for unique applications by using defined project rules. Modular control engineering software functions handle bulk engineering, change management and auto documentation reducing overall application engineering time while adhering closely to company or project standards. Class modules provide a very useful way to capture and institutionalize industry automation knowledge and best practices, which is a critical activity as a wave of experienced people move into retirement in the automation field. Most process automation vendors also maintain an extensive library of class modules for various industry applications. End users, integrators, engineering firms and technology licensors can also maintain their intellectual property in local class module repositories, taking advantage of modular control engineering software and bulk engineering to deploy standardized, tested applications. 19.
21 Modular Control Engineering Software Automation Design Suite: Yokogawa s smart engineering environment The Automation Design Suite, Yokogawa's new engineering environment, retains the entire engineering history of your plant from design phase, through commissioning and live operation; which ensures up-to-date plant knowledge with every expansion, or hardware and software change throughout your lifecycle. 20.
22 CHAPTER 3 21.
23 Putting Technical Advances to Work When N-IO, system-independent loop checking with a field asset validation and diagnostics tool and flexible binding are used together with modular control engineering software, different functions can now overlap to shorten project execution time and reduce required engineering resources. With this project methodology, there is significant risk reduction as a result of parallel engineering, reduced automation hardware-tosoftware dependence, flexible binding, and reusing engineering modules and best practices. There is also additional reduction in total project installed cost due to much less wiring, marshalling and field terminations. Additionally, project software changes are accommodated independent of field hardware installation. Automation System Changes 22.
24 Reducing Project Execution Time Using these products and techniques, it is possible to envision both parts of the automation effort, hardware and software, as independent pieces assembled from reusable modules. This allows each to follow its own schedule in parallel rather than in serial, greatly reducing project execution time. More equipment is purchased off-the-shelf, already engineered and tested to relevant standards, then shipped and assembled in modular fashion, with flexible binding applied at the appropriate time. This approach allows design changes and problems related to late data to be contained within a particular execution piece, reducing overall project impact. In fact, it becomes possible to construct an entire process unit or skid, offsite, with its associated devices, wiring, piping, equipment and so forth, and mount N-IO cabinets as part of completed unit. 23.
25 A Flexible Approach Process skid and unit device and I/O loops can be checked and commissioned offsite, independent of the plant s automation system design specifics. The construction and hardware piece can be factory accepted, and then the entire unit can be shipped to site for assembly and connection with the rest of the plant, or adjacent units, all independent of the actual application engineering or system platform at the site. Process control system OEMs and user companies are increasingly using engineering resources scattered around the world. These resources can work with growing class module libraries to avoid the need for writing code from scratch specifically for a single project. Customers, integrators and suppliers alike are looking for ways to use intellectual property repeatedly, reducing time and cost and class modules address these needs. New technologies from Yokogawa are making these engineering approaches possible and more practical. They provide a great benefit to EPCs and technology licensors, who can now protect their own technology as well as execute projects utilizing these methodologies to provide greater value. 24.
26 Thanks for reading this ebook! Agile Project Execution The future of automation projects For more detailed information about Yokogawa & Agile Project Execution Yokogawa offers a Free Consultation CLICK HERE Author: Eugene Spiropoulos Business Consultant for Process Management & Manufacturing Solutions For a Free Consultation About Yokogawa Yokogawa's global network of 88 companies spans 56 countries. Founded in 1915, the US$3,5 billion conducts cutting-edge research and innovation. Yokogawa is engaged in the industrial automation and control (IA), test and measurement, other business segments. The IA segment plays a vital role in a wide range of industries including oil, chemicals, natural gas, power, iron and steel, pulp and paper, pharmaceuticals, and food. More information: EMK(VDS)-TR-EB-01 APEX ebook
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