Fieldbus Foundation General Assembly 2008 Project Planning and Execution Mike Downey Jacobs Engineering

Fieldbus Foundation General Assembly 2008 HSE First Jacobs have HSE as a Core Value We have a behavioural based approach to achieve an Incident and Injury Free Workplace

Fieldbus Foundation General Assembly 2008 Safety Moment – Hotel Fires Know The Fire Alarm Know The Exit Route Count The Doors Keep Low Use Fire Escapes

Fieldbus Foundation General Assembly 2008 Agenda The presentation covers the early stages of establishing a Project Strategy through to Factory Acceptance Testing. Focus on the following : System Strategy FF Component Compatibility Design and Engineering F.A.T. The presentation will not deal with any DCS or FF technical issues but focus on the project delivery cycle.

Fieldbus Foundation General Assembly 2008 System Strategy FEEP (Front End Engineering Phase) System Architecture System Component Instrument Selection

Fieldbus Foundation General Assembly 2008 System Strategy – Front End Engineering Phase Jacobs strategy is to engage all the stakeholders early in the project cycle, to achieve a team approach and to facilitate early information flow. During the FEEP, Jacobs employ an alliance strategy where: Client Contractor work together over a 6 to 8 week period to develop the DCS and FF system architecture. DCS Vendor FF System Vendor Jacobs always employ one of our Value Enhancing Practices (J-VEPs) called "Interactive Planning". (a practice that develops an agreed project schedule with all major stakeholders participating under the guidance of a trained facilitator).

Fieldbus Foundation General Assembly 2008 System Strategy – System Architecture A successful system architecture is developed by meeting, discussing and agreeing the operational split of the plant with the clients: Process Engineers Technical Engineers Plant Operation Managers The plant is split into operational modules that are aligned with how the client operates his plant Process Flow Diagrams are used to identify plant breakdown

Fieldbus Foundation General Assembly 2008 System Strategy – System Architecture …cont'd Agree the control and redundancy requirements for:  DCS network  FF Instrument Network  Motor Communications  Non-FF Instrumentation  On/Off Valve Control  Control Valves Agree the Quantity of:  Sever Cabinets  DCS Controller Cabinets  Field I/O Cabinets

Fieldbus Foundation General Assembly 2008 System Strategy – System Component Selection It is beneficial to the long term success of the project if you can agree all the system components at a very early stage of the FEEP. The Client / Contractor / DCS Vendor should meet, discuss and agree the following: DCS comms interface to the DCS Controllers FF Power Hub Manufacture and Model FF Field Barrier Manufacture and Model Package Unit Communication Interface Motor Communication Interface Local I/O and Valve Control Interface With all these components selected the DCS Vendor can draw up the communication network as early as Week 6 of the project schedule of the FEEP.

Fieldbus Foundation General Assembly 2008 System Strategy – System Instrument Selection Meet and agree the Preferred Vendors list for Instrumentation with the Client. Agree the FF / None FF split for: Flow (all techniques) Pressure Temperature Level (all techniques) Analytical (all techniques) Control Valves Try and agree a single vendor for each technique, this will improve: The multi-discipline design process by providing early information to the design team Control of Package Vendor Supply

Fieldbus Foundation General Assembly 2008 FF Component Compatibility FF Power Hubs and Field Barrier Field Instruments

Fieldbus Foundation General Assembly 2008 FF Component Compatibility – FF Power Hub and Field Barrier Jacobs Project Strategy is to select a single vendor for both the FF Power Hub and Field Barrier. This selection is agreed with the Client. Work with the selected vendors to ensure full compatibility.

Fieldbus Foundation General Assembly 2008 FF Component Compatibility – Field Instruments It is vital that when the preferred FF Instrument manufacturer and model is selected, discuss and agree the required FF asset information for the technique. Confirm with the DCS FF specialist that the instrument can provide the asset information required, to the DCS for long term use by the client. Although the Instrument is certified for use in an FF Environment, always check with the DCS FF Specialist.

Fieldbus Foundation General Assembly 2008 Design and Engineering FF Network Control System Panels Package Units

Fieldbus Foundation General Assembly 2008 Design and Engineering – FF Network When developing system architecture, operational breakdown of the plant will have been agreed To develop the FF network for each operational unit, consider the following: Instrument physical location on plant Work with the design team to agree instrument locations Identify Specific Process requirements  A column with a series of temperature measurements providing a profile - consider splitting over 2 hubs Identify Similar Processing Vessels  Again consider splitting over 2 hubs Discuss with the client any Specific Project Concerns

Fieldbus Foundation General Assembly 2008 Design and Engineering – Control System Cubicles Complete and issue a detailed control cubicle specification to the Vendor Issue Equipment Preferred list of suppliers Agree Manufacture and model of specific control equipment – early! Work closely with Vendor for Electrical cubicle design Ensure client's Engineers and Technicians are part of the layout review cycle One strategy Jacobs have used successfully, is to have the DCS vendor provide all the cabinets – less interface management.

Fieldbus Foundation General Assembly 2008 Design and Engineering – Package Units Discuss and agree with the client the Control Strategy for each package unit or the project.  Package unit stand alone control  Package Unit control with DCS supervisory interface  Full DCS control – opportunity for FF instrumentation Provide Preferred Vendor list to Package Vendors (single source vendor where possible) Issue clients URS to Vendor Work very closely with the Vendors :  Ensure compliance with URSs  Ensure DCS/packages interface is controlled  Control cabinet design is compliant with legislation  Instrument installations are compliant with legislation  Package instrumentation cabling is controlled

Fieldbus Foundation General Assembly 2008 Factory Acceptance Testing System Control Cubicles FF network

Fieldbus Foundation General Assembly 2008 Factory Acceptance Testing – System Control Panels During the 'Interactive Planning' session at the start of the FEEP, agree planned arrangement for the full Factory Acceptance Testing. Arrange for F.A.T. at DCS vendors works Include all panels  DCS server cabinets  DCS controller cabinets  Field I/O cabinets  MCC  Package unit control panels (or PLC for interface handshake)

Fieldbus Foundation General Assembly 2008 Factory Acceptance Testing – System Control Panels …cont'd Fully test all communication between all panels Appoint a F.A.T. Manager from the contractor. Rigorously follow the approved F.A.T. test documentation Do not allow "nice to have" changes or control of the F.A.T. is jeopardised. Use a Formal F.A.T. change control process for issues raised during the F.A.T.

Fieldbus Foundation General Assembly 2008 Factory Acceptance Testing – FF Network Conduct a specific FF F.A.T. Arrange for one of each of the following to be available at the FF F.A.T:  DCS Control Panel (FF power hub)  Field Barrier (may need 2 or 3)  Each type of Instrument Measurement »Flow »Pressure »Level »Temp »Analytical »Control Valves Connect them up as a working network Confirm communication to the DCS for each instrument

Fieldbus Foundation General Assembly 2008 Finally – Top 10 Hits Develop Relationships with the vendors to achieve improved schedules and interfaces. Complete a Front End Engineering Phase Engage the DCS Vendor for the FEEP – Pay for his time Agree operational breakdown of plant Agree redundancy requirements Agree DCS and FF Equipment – early Agree Single Source for Instrument technique – ( ideally). Develop the FF Network with consideration to client requirements and physical plant layout Put a high level of effort in dealing with Package Vendors Complete a rigorous F.A.T. for FF and DCS systems at the DCS vendor factory.

Fieldbus Foundation General Assembly 2008 Questions / Answers