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Execution of a project using Foundation Fieldbus as the preferred communication protocol is challenging, whatever the size of the project. Implementation of very large or World Class Mega Projects also requires the involvement of multiple EPC offices in different continents or even multiple EPC contractors. A key factor in identifying the sometimes overlooked details that can cause problems and delays, drawn from Bechtel's global experience.
Execution of a project using Foundation Fieldbus as the preferred communication protocol is challenging, whatever the size of the project. Implementation of very large or World Class Mega Projects also requires the involvement of multiple EPC offices in different continents or even multiple EPC contractors. A key factor in identifying the sometimes overlooked details that can cause problems and delays, drawn from Bechtel's global experience.
Execution of a project using Foundation Fieldbus as the preferred communication protocol is challenging, whatever the size of the project. Implementation of very large or World Class Mega Projects also requires the involvement of multiple EPC offices in different continents or even multiple EPC contractors. A key factor in identifying the sometimes overlooked details that can cause problems and delays, drawn from Bechtel's global experience.
Execution of World Class Petrochemical Projects, using Foundation Fieldbus Technology David S. Lancaster, P.E. Control Systems Chief Engineer Houston ---------------------------- Richard Mills Control Systems Supervising Engineer London Bechtel Oil, Gas & Chemical Inc. 2 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Execution of World Class Projects Execution of a project using Foundation Fieldbus as the preferred communication protocol is challenging enough, whatever the size of the project. Implementation of very large or World Class Mega Projects also requires the involvement of multiple EPC offices in different continents or even multiple EPC contractors. In addition, system suppliers will use their international resources; there will be multiple packaged equipment vendors, and many hundreds or even thousands of skilled and semi- skilled workers at jobsites and off-site fabricators such as module yards. What are the differentiators that ensure project success? 3 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Close cooperation between the End User, EPCs and Suppliers is a key factor in identifying the sometimes overlooked details that can come to light at the end of a project, causing problems and delays. Among the issues we will consider are: ! Evaluation and selection of devices, wiring components, wire/cable make up and characteristics ! Development of tools and standards to support the design ! Implementation of Foundation Fieldbus on the selected Host ! Installation, testing and commissioning tools and procedures ! Training for design, implementation, installation, testing, commissioning, start-up, and maintenance for Engineering, Construction and Maintenance personnel This presentation will address these issues, showing where they were encountered and how they were resolved, on recent Mega- Projects, drawn from Bechtels global experience. Execution of World Class Projects 4 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Execution of World Class Projects TBD Emerson Honeywell ABB Yokogawa Honeywell Honeywell Invensys Host 420 Houston Brass LNG 505 New Delhi, Shanghai Houston LNG Projects 682 Richland, Washington U.S. Dept of Energy - WTP 2800 Houston, New Delhi, Beijing, KL, Shanghai, Milan, Madrid, Yokohama, Taipei Reading (BSF JV) Shell/CNOOC - CSPC Nanhai 10185 TOTAL 1600 New Delhi, Shanghai, JVs with other EPCs Houston Motiva CEP 678 Calgary, New Delhi, Toronto, Edmonton, Montreal, Shanghai Houston Shell - Scotford Upgrader Expansion Unit 1 3500 Houston, Frederick, Shanghai, New Delhi, Toronto, Portsmouth, Mumbai, Jamnagar, Paris London Reliance - JERP Segs Secondary Offices Primary Office Project EXPERIENCE BASE: 5 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Background: 5 years ago ! Early adopters. Novel technology ! End User / Manufacturer lead the way ! Small Projects ! Involved Customer specialist teams ! Customer "pull" Today ! Routine technology ! Customers look to contactors for expertise ! Mega Projects ! General engineering teams. Customer may have no experience ! Industry norm Execution of World Class Projects 6 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation What Does It Take To Do a Mega Project? !Multiple offices & Time zones !Multiple countries and continents !Training, training, training !Multiple Technical Evaluations (how does it all fit together?) !Multiple suppliers, supplier offices !Standardization - Clear, concise instructions !Coordination !Follow-through Execution of World Class Projects 7 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation What are the extras at each stage of a project that ensure Certainty of Outcome? Execution of World Class Projects 1. EARLY IN THE PROJECT (Front End Design) 2. DURING PROJECT DESIGN (Detailed Design) 3. IMPLEMENTATION 8 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation "#EARLY IN THE PROJECT: ! Overall vision expectations (realistic? achievable?) ! Brainstorm Installation savings (schedule and cost) Engineering (tools, schedule and cost) Diagnostic tools (will they be useful & used during the project lifecycle) Maintenance (how to use FF to its greatest advantage) ! Installation ! Maintenance ! Operations ! Enterprise Execution of World Class Projects 9 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation "#EARLY IN THE PROJECT: ! FFB evaluation is it right for the project? ! What benefits are expected ! Are they realistic based on experience ! Can they be realized by the Project ! Can they be realized on schedule ! What problems are expected, Can they be resolved ! Should we use a different FB ! Should we use conventional technologies Execution of World Class Projects 10 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Execution of World Class Projects "#EARLY IN THE PROJECT: ! Training ! Plan for all phases (design, system implementation, installation, commissioning, operations) ! Implement appropriate early training (include O&M, management etc) 11 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation "#EARLY IN THE PROJECT: ! Implementation Basis: ! Prepare sound, clear design basis ! Follow that basis ! Keep current with the technology Execution of World Class Projects BECHTEL Oil, Gas & Chemical Inc. ENGINEERING CONTROL SYSTEMS ENGINEERING DESIGN GUIDE IMPLEMENTING FOUNDATION TM FIELDBUS TECHNOLOGY 3DG-J41D-00009, Revision 001, 31 Jan, 2008 Prepared by: A. D. Boquiren Checked by: R. D. Mills Approved by: D. S. Lancaster Reason for Issue: Issued for Use 12 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation "#EARLY IN THE PROJECT: ! Host Selection: ! FF Capability ! FF Experience ! Ease of use ! Integration of Asset Management System ! Diagnostics available ! Simulation capability for design and FAT ! Local support capability ! How easy to change to new DD revision? ! Other? Execution of World Class Projects 13 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation "#EARLY IN THE PROJECT: ! Component Selection: ! Meets area class requirements? ! How does it work individually? ! How does it work with other devices? ! How easy to configure? ! Experience, does it perform as published? ! Proven track record? ! Many others Execution of World Class Projects 14 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation "#EARLY IN THE PROJECT: ! Interoperability Testing: ! At the EPCs facility ! At the Host Supplier ! Project Office or Centre Of Excellence ! Integration Tools between Offices ! Integration with suppliers ! Work Processes Execution of World Class Projects 15 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation $#DURING PROJECT DESIGN: ! TRAINING (MORE, DETAILED) ! Engineering ! Construction ! Owner/End User Execution of World Class Projects 16 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation $#DURING PROJECT DESIGN: ! RISK ASSESSMENT RULES AND REVIEW ! Basis for Risk Assessment ! FF Final Control Element Process Severity Ranking Matrix ! FF Final Control Element Risk Assessment Philosophy ! Single Failure of Final Control Element ! Normal Failure mode of Final Control Element ! Number of Devices per Segment ! Diversity and redundancy ! Client expectation, perception of risk ! Balance between availability and reliability Execution of World Class Projects 17 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation $#DURING PROJECT DESIGN: ! SEGMENT LOADING RULES AND REVIEW Execution of World Class Projects Segment B Segment A Discretionary Utilities should be separate from process A and B services should be separate 18 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation $#DURING PROJECT DESIGN: ! SEGMENT LOADING RULES AND REVIEW ! LAS / Control Philosophy ! Resource availability (VCR, time) ! Audit Execution of World Class Projects 19 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation $#DURING PROJECT DESIGN: ! SHIELDING / GROUNDING (EARTH) DESIGN ! Determine shield termination design for Conventional and Foundation Fieldbus installations they may be different ! How are unused (spare) conductors for Trunks and Spurs terminated ! Which ground (earth) is used Instrument (clean), Power, AC? ! Are Surge Protection Devices used? To which system are they grounded? Execution of World Class Projects 20 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation $#DURING PROJECT DESIGN: ! SURGE PROTECTION DESIGN ! Different philosophies on surge protection (end users / EPC vs manufacturer) is it really needed? ! What you are really trying to protect? ! What is the risk? ! Is the process area properly bonded and grounded? ! Are the FF signal lines physically isolated from the plant and process ground system? ! Is the FF Segment shielding properly grounded? ! Are the FF devices and support devices CE compliant (EMC requirement provides a 2kv surge test)? ! Is the cost for surge devices justified? ! Will implementation of surge protection impact availability? ! How does FF protection integrate with other system protection? Execution of World Class Projects 21 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Execution of World Class Projects 2. DURING PROJECT DESIGN: ! METHODS (TEMPLATES) ! Do they work with the devices selected? ! How easy or difficult are they to configure (drag and drop vs. keyboard entry) ! Are there any quirks or special considerations ! Review all options and defaults for selected devices ! What are the unknowns before Commissioning and Startup? 22 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Training ! Construction ! Commissioning / Startup ! Owner/End User Execution of World Class Projects 23 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Review Field Changes ! Was a Risk Assessment Review done? ! Were segment design guidelines followed? ! Were installation practices adhered to? ! What effect will downloading the new device have on the existing segment? ! When is the appropriate time to implement the change (can Operations be affected)? Execution of World Class Projects 24 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Host System Performance ! Are execution times as published? ! Does the HOST slow down or have any other adverse effects due to loading? ! How useful are the system diagnostics? ! Are any new DD revisions required available? ! Any unanticipated problems? ! If planned software revisions contain significant changes, is there a plan for implementation? Execution of World Class Projects 25 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Diagnostics Training ! What is displayed and what does it mean? ! What needs to be done if.? ! How can we do....? Execution of World Class Projects 26 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Maintenance Methods ! What are the tools and equipment required? ! How is a device disconnected and reconnected correctly? ! What happens in a download? ! How to use remote diagnostics ! What is a valve signature and what does it mean? Execution of World Class Projects 27 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Operations how to optimize the use of FF ! What parameters are available? ! What do they mean? ! How can combinations of parameter values be used to indicate how the process is behaving?? ! How to best used advanced diagnostic tools now available? ! How can valve diagnostics be used to verify or enhance performance ! Development and use of diagnostic reports Execution of World Class Projects 28 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation %#IMPLEMENTATION: ! Review installation ! Maintenance of shields ! Bending radius of cable ! Grounding ! Are all devices supplied with expected DD revision? Execution of World Class Projects 29 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Summary ! Todays need for Mega Projects requires an extra effort to ensure Certainty of Outcome ! Owners / End Users, Contractors and the Suppliers must be willing to provide that effort ! Traditional design methods and execution are not enough ! Thinking out of the box is required to ensure success but must stick to the rules once set Execution of World Class Projects 30 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Summary ! Product Maturity ! End Users and Contractors have developed "Standard" solutions ! Need for manufactures to update Spec Sheets/guidelines to work with new products ! Still developing installation standards / assemblies, use new products on project ! Not yet fully mature as a technology ! Products evolve over Project lifecycle ! Similar requirements for all projects, Mega Project makes best practice and early application essential Execution of World Class Projects 31 General Assembly, Antwerp, 27-28 Feb 08 2008 Fieldbus Foundation Questions