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Reduce Risks and
Increase Flexibility
… by maintaining project quality and accommodating
late freezing of project data
Invensys Engineering Workbench
Intelligent Engineering
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 SmartPlant 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 D
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Product Configur
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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
•
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 SmartPlant
Instrumentation (SPI) , Excel or Access
•
Imports Piping and Instrumentation Diagrams from
SmartPlant 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
•
•
Produces a hierarchy of system architecture drawings
•
Assigns control database compounds to controllers,
following wiring constraints
•
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
Invensys Engineering Workbench
Instrument Database
Foxboro InTouch Application
SmartPlant P&ID
Foxboro Configuration Tools
Tristation
DYNSIM
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)
•
Templates (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 EvoTM 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
Templates
Templates
Specifications
Safety Module
Templates
Define Project
Templates
Wiring Typicals
Dialogue
Naming Rules
Rules
Early
SmartPlant
Database
Early
SmartPlant
P&ID Database
Cabinet
Templates
Define Project
Rule Set
C&S Module
Building Rules
Cabinet Design
Rules
Simulation
Modules
Define Project
Equipment
Simulation
Equipment
Modules
Later Data
Client
Invensys
Further into the project
‘later data’ will be made
available containing all
the devices but not all
the necessary information
(descriptions, trip sets).
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.
Auto - validate
I/O Tag Data
Validation
Reports
Auto - validate
Wiring Data
Preliminary
SmartPlant
Database
Auto - build Control
& Safety Modules
Preliminary C&S
Modules
Auto - design System
& Marshalling Cabinets
Preliminary
Cabinet Design
Auto - build
Display Symbols
Preliminary
Display Symbols
Preliminary
Interlock
Definition
Build Preliminary
Process Interlock Logic
Preliminary Safety
Logic Definition
Build Preliminary
Safety Logic
Later SmartPlant
P&ID Database
Build Plant Simulation
Validation
Reports
Preliminary
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.
Client
Invensys
RFC Process
Interlock
Definition
Build Process
Interlock Logic
RFC
Safety Logic
Definition
Build
Safety Logic
Client
Validation
Reports
Auto- validate
I/O Tag Data
Auto- validate
Wiring Data
RFC
SmartPlant
Database
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.
Auto- build
Control & Safety
Modules
Auto- design System
& Marshalling
Cabinets
Cabinet Design
Auto- build
Display Symbols
Display Symbols
Auto- test of
Control & Safety
Modules
RFC
SmartPlant
P&ID Database
Control & Safety
Modules
Build Plant
Simulation
Test Reports
Plant Model
Cabinet & Wiring
Data
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.
4.1.1.1
Design system architecture
(based on integration
with systems at site if
applicable)
4.1.1.2
Generate architecture
drawings
4.1.1.3
Define Module allocation
based upon I/O
segregation
Lead Engineer
Application Engineer
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.
4.1.1.4
Define Servers,
Workstations, Networks and
other Ancillary Equipment
4.1.1.5
Calculate System Loading,
Power and Heat
Dissipation
4.1.1.6
3rd Party hardware
review
Application Engineer
Application Engineer
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.
TASK
Week
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73
Original Schedule
Project Startup
Draft FDS
Review FDS
Final FDS
Client Review and approve FDS
Hardware freeze
Purchase/build/wire/test/stage cabinets
Software minor freeze
90% Configuration Data
Software freeze
Database generation
Human Interface
Database modification for final data
Pre-test
FAT
HW
90% Config.
SW
Intelligent Engineering Schedule
Project Execution Plan
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
Final Integration Tests and
FAT completed 3 weeks in
advance even if Unit C Final
Instrument Data received 12
Unit A Preliminary Instrument
Unit A Final Instrument
Unit B Preliminary Instrument
Unit B Final Instrument
Unit C Preliminary Instrument
Unit C Final Instr.
Helping Clients Across the Globe Succeed
CLOV
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
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”.
An EPC
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 10000+ 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
End Users
Execution
PEO
P
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en
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OC
PR
Consistency
Ma
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EPCs
La
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Invensys • 10900 Equity Drive, Houston, TX 77041 USA • Tel: (713) 329-1600 • Fax: (713) 329-1600 • iom.invensys.com
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