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Advanced Digitalization for Agile Project Execution

(in lingua inglese)

Agile Project EXecution
APEX Smart Engineering
APEX –Technology
Shorter project execution
Tangible APEX Benefits

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Atti di convegni o presentazioni contenenti case history
SAVE ottobre 2017 Misure e controlli di impianto per l’Industria 4.0

Pubblicato
da Benedetta Rampini
SAVE 2017Segui aziendaSegui




Estratto del testo
Veronafiere 18-19 ottobre 2017 Gli atti dei convegni e pi di 8.000 contenuti su www.verticale.net Cogenerazione Termotecnica Industriale Pompe di Calore 27 ottobre Cogenerazione Termotecnica Industriale Pompe di Calore Alimentare Alimentare Petrolchimico Alimentare 28 ottobre Alimentare Petrolchimico Alimentare Alimentare Petrolchimico Visione e Tracciabilit 28 ottobre Luce Energia Domotica LED Luce Energia Domotica LED Advanced Digitalization for
Agile Project Execution
Massimiliano Veronesi, PhD
Product Marketing Manager
Process Control and Safety Systems
Yokogawa Italy Agile Project EXecution Scenario ' Products and Projects ' Product developments according to technological improvements and marketing strategies ' Project execution according to best engineering practices
' Not enough any more: ' Technological developments to favorite efficient/flexible project execution and minimize risk ' Make use of IIoT technologies (Cloud Enabled Execution, Virtual Testing, Flexible Binding, Bulk Engineering, ') yesterday today | EBD-EMK-TRM-12 | June 14, 2017 | Yokogawa Electric Corporation APEX in a nutshell 4 ' Why change the current Execution Model' ' Drive from Industry : Get automation off the critical path
' Customers Reduce CAPEX budget : Focus on Capital Efficiency
' Apply Enabling Technologies : Smart IO & Virtualization ' Design standardization & modularization to save cost
' Reduce project schedule risks by removing hardware and software inter-dependencies (decoupling) ' Improve Commissioning workflow with remote support
' Execution Flexibility and Lifecycle Management
Customer expectations for Industry specific issues ICSS Technology Delivery Excellence Smart Engineering ' Re-usable Applications
' Secure Remote Testing
' Smart JB designs
' Virtualization Approaches ' Predictable and modular Engineering ' Optimized Engineering and Space Utilization ' Minimize Travel (Reviews, Testing, Validation) Generic Benefits Reduce unnecessary work Minimize customization Validate software without HW FAT
Prevent design recycle and HW/SW rework
Minimize unnecessary HW Simplify 3rd party package I/F configuration Eliminate / minimize physical, data & schedule dependencies Reduce effort of Documentation Less effort in Alarm management & Cyber Security Challenge traditional approaches Accommodate change easily & less impact ' Optimized project execution
' No Engineering Surprises
' Validated & proven Integration ' Consistent Risk Mitigation
' Knowledge Management
' LEAN execution
' Basic Design Toolkit ' Early Plant Startup
' Easy Modification
' Reduced Footprint ' Networking
' Modularity/Standards based Design
' Independent (parallel) phases
' Flexible Binding at site
' Built-in Management of Change Challenges AGILE PROJECT EXECUTION
Benefits: Removing waste and Reducing cost
What is our approach Agile Project EXecution Next Generation Platform Delivery Excellence Smart Engineering APEX, Removing waste and Reducing cost in all Projects Customer Benefits Our Approach APEX Smart Engineering Delivery Excellence ICSS technology CONVERGENCE Agile Project EXecution Removing Waste and Minimize Customization Flexible Binding and Late Changes Lowest Cost, Consistent Quality APEX Smart Engineering Customer Benefits Our Approach ' Predictable Engineering, No Engineering Surprises
' Optimize Space Utilization (Power, Weight, Cooling)
' Minimize Travel (Reviews, Testing, Validation)
' SEPARATING LOGICAL FROM PHYSICAL ' Module (class) based engineering
' Re-usable Applications
' Standard Panels
' Global PC
' Preconfigured switches
' Virtual (remote) test Delivery Excellence ICSS tehnology Smart Engineering APEX Smart Engineering Delivery Excellence ICSS tehnology Smart Engineering APEX Smart Engineering Delivery Excellence ICSS tehnology Smart Engineering APEX Smart Engineering Delivery Excellence ICSS tehnology Smart Engineering APEX ' Technology Customer Benefits Our Approach ' Early Plant Startup
' Easy Modification
' Reduced Footprint ' Network-IO
' System Independent Loop Check (without FCS CPU) ' Flexible Binding at site
' Built-in Management of Change Universal I/O Module
' 16 Channels IO
' Signal: AI/AO/DI/DO
' Software Configurable
' HART 7 Support
' Full Redundancy Signal Conditioner (Optional)
' Wide range of I/O
' Pulse, Relay, DO, etc. Termination Block I/O Backplane Smart Engineering Delivery Excellence ICSS technology No need for Marshalling Cabinets ! Terminal Boa rd Terminal Boa rd Field Cables (Multicore) Duct Terminals Marshalling ' FIO Field Cables (Multicore) Duct Sm art IO Sma rt IO Marshalling ' N-IO | EBD-EMK-TRM-12 | June 14, 2017 | Yokogawa Electric Corporation 16 Field Wiring Reduction by Smart JB Smart I O Smart I O Smart JB ' N-IO FO Cable T ermi na l Bo ard T ermi na l Bo ard Duct Terminals Marshalling - FIO Prefabricated
System Cable Instrument JB Homerun
Cable Field Field LCR LCR 4500 series IS base plate IS base plate H-System Non-IS Intrinsic safety MTL P+F N-IO Yokogawa N-IO for Hazardous Applications APEX Delivery Excellence Customer Benefits Our Approach ' Minimize Waste
' Robust time management
' Validated & Optimized Integration ' Consistent Risk Mitigation ' Standard Panels
' Global PC
' Preconfigured switches ' Functional Safety Management
' LEAN execution based on 3R
' Basic Design Toolkit LEAN: reduce waste through innovation 3R: Right people, Right location, Right timing Smart Engineering ICSS technology Delivery Excellence Shorter project execution 20 HFAT: Hardware FAT AFAT: Application FAT SAT SAT SAT Solution platform
that exceeds the capabilities of
conventional production control systems
Conventional
Execution Increasing quality and Reduce waste Reducing risks of handover slippage Design Configuration Application & HW FAT Field wiring Agile
Project
EXecution
The class module effect Design Configu- ration SAT Application AFAT Site Activity Possible Early Startup Ship & Install Site Activity (incl. Loop check) N-IO Solution effects Manufacturing & HFAT Ship & Wire Loop Vali- dation FieldMate Validator effects Tolerate delays in project execution 21 HFAT: Hardware FAT AFAT: Application FAT SAT SAT SAT Solution platform
that exceeds the capabilities of
conventional production control systems
Conventional
Execution Increasing quality and Reduce waste Reducing risks of handover slippage Design Configuration Application & HW FAT Field wiring Site Activity (incl. Loop check) SAT Application AFAT Site Activity Ship & Install Agile
Project
EXecution
The class module effect Design Configu - ration Later Start N-IO Solution effects Manufacturing & HFAT Ship & Wire Loop Vali- dation FieldMate Validator effects Tangible APEX Benefits APEX and how we deliver DIFFERENTIATING value APEX: Competitive Project Execution model applicable to all projects Apex Generation Platform: ADSuite Automation Design Suite Master Database Network-IO Universal I/O and signal conditioner Validator FieldMate Validator N-IO loop commissioning software Integration DCS-ESD, DCS-subsystems Agile Project EXecution CENTUM VP R6 ADSuite
New Engineering Environment Benefits | EBD-EMK-TRM-12 | June 14, 2017 | Yokogawa Electric Corporation Technologies and tools used in APEX Architectural Design Application Software Development and Testing Hardware Manufacturing Total System Verification Start-up SAT & Loop Check Site Installation & IO Check Library Repository Automation Design Suite Module Engineering Bulk Engineering Change Management A Auto Doc Generation Flexible Binding FieldMate Validator Yokogawa Standard Cabinets & N-I/O JB's Yokogawa Standard Industry Libraries iDefine for SIS/FGS Engineering Yokogawa Standard Design Documents Cloud Enabled Environment PRM Commissioning Support Package 27 Class, Instantiation, Module binding Class module Class-based Application module Drawing module Module binding Instantiation Classless Application module DR0001 DR0002 DR0010 Instance List Module Binding Window ADSuite: Modular Engineering ''. Anywhere PT001 PCV001 PID PIC001 Modular Application Logic ADSuite Automation Design Master Database XY001 XI001 SEQ Library Repository Yokogawa Standard Industry Libraries Yokogawa Standard Design Documents ADSuite + N-IO = Flexible Binding Flexible Binding HIS (OWS)/ENG Project Database FCU( CPU) NIU NIO N-ESB Bus Vnet/IP PT001 AI: PT001 NIO1 Ch.1 PCV001 AO: PCV001 NIO1 Ch.2 PID PIC001 Modular Application Logic ADSuite N-IO Software Configuration Table Ch.1 Ch.2 ADSuite Automation Design Master Database R Ch.3 Ch.4 R DO: XY001 NIO1 Ch.3 DI: XI001 NIO1 Ch.4 XY001 XI001 SEQ faceplate PT001 PCV001 XY001 XI001 SILC: System Independent Loop Commissioning AD Suite Master Database I/O Binding N-IO HMI Site work without HMI and Controller - Install and wiring - Devices parameter setting - I/O check Controller Factory work without I/O - Application coding by using labels - Application FAT I/O' Concurrent work Return fixed I/O information Get I/O Tags & information STEP 1 I/O' Device parameter setting & loop check STEP 2 STEP 4 App STEP 1-4 shows SILC workflow. Generate reports automatically STEP 3 Reduce delays and be assured of starting production on schedule Avoiding Project Delays Smart Configurable IO Designed & constructed on site Virtual I/O wiring Application validation during FAT Last minute software marshaling 45 Integration Different Field Digital Communication Protocols ALP121
PROFIBUS-DP Module ALF111 FOUNDATION
fieldbus Module HART I/O Module A2EN402/404
N-ESB Bus Coupler Module ALE111
Ethernet Communication Module 46 UGS Unified Gateway Station Modbus RTU Modbus TCP OPC DA/A&E Ethernet/IP STARDOM Sub-systems Vnet/IP Operate and monitor your sub-systems in CENTUM, like
CENTUM. Alarms Graphic Trend Tuning Alarms ' and more IEC 61850 Unified Gateway Station ' Seamless Operation UGS Redundant communication ' Simple Architecture ' Just add one more UGS2 with same configuration (such as Vnet/IP address) for redundant communication. ' No extra software license is necessary for redundant configuration
' No FT(Fault Tolerant) Server, no extra L2 switches, no shared disk as HA cluster are necessary HIS FCSs (Active) (Stand-by) 1-sec switch-over RTU network 'Optimal' integration with subsystems ' Sub-system communications ' Data for HMI: OPC Client (redundant) workstation can manage up to 100,000 TAGs ' Data for control logic: put (redundant) link module in one rack of the related CPU ' Integrated Control+Safety system provides optimization + performance at the same
time RTU network UGS Modbus / Profibus ' Redundant Configuration is
available. DCS network UGS Distr. communication modules Benefits - Lower Controller CPU load
- High throughput
- Multiple protocols
- A&E by OPC A&E - Simple reliable industrial solution
- Subsystem data directly available in DCS controller for control/logic functions Drawbacks - Unreliable IT technology
- Subsystem data NOT directly available in DCS controller for control/logic functions - Affecting Controller CPU load (to be distributed among
the DCS controllers)
- Not supporting A&E with timestamps
Integration with Safety System Field Control Stations Vnet Router Safety Control Stations Plant Asset
Management Plant Information
management Vnet System 3rd party system
Subsystems Real Time
Control Network Unified
Gateway
Station Vnet/IP Engineering
Station Human Interface
Station Safety System Integration ' DCS and SIS are 'truly integrated' ' SIS and DCS data are within the same window
' SIS data can be used in the FCS
' Sequence of Event (SOE) data from the SIS and DCS
are integrated Integrated Monitoring
- Faceplate
- Trend
- Graphic
- System status
- Alarm
- SOE FCS and SCS information integrated SOE Viewer SCS FCS System status SCS FCS SCS and FCS Faceplates CENTUM VP HIS Time shared on the same
network CENTUM VP FCS ProSafe-RS SCS SIS data can be
used in FCS Cause & Effect (C&E) User can directly implement C&E diagram which is automatically converted into FBD by just clicking
'Graphic View' tab. FBD generated from C&E Module Logic can be added in auto-converted FBD ' shown as 'F(x)' in C&E Auto-converted FBD Exported to excel
spreadsheet Summary From Waterfall to Agile Source: laSalle Almere yi-MAC Innovative MAC Conclusion: APEX Value by phase FEED Testing / Commissioning Operations o Single Point of Responsibility o Optimize Total Automation Investment o Improve Project economics o Flawless Start-up & Commissioning o Flexible binding o Reduce Total Cost of Ownership o Maximize Lifecycle value o Standard Design of Cabinets, reduced Rack-
room space
o Standard Functional Design of Application
o Standard Design of smart JB's, optimized cable
routing
o Reduce Execution dependencies o Getting ICSS off from Project critical path
o Optimize project execution in terms of timelines and effort
o Reduce engineering complexities and improved quality
o Simplify documentation o Reduced footprint and cabling related work
o Reduce travel o More time for Application software and System ( CPU )
cabinets shipments
o Reduce construction and Commissioning effort
o Ease of Bulk changes , Management of change ,Auto
documentation etc.
o Shorter loop checks and standard commissioning
procedures o Reduce maintenance effort o Maintain latest documentation APEX Agile Project Execution ' ICSS technology
' Smart Engineering
' Delivery Excellence Execution Project Lifecycle ICSS for APEX: Overview ' N-IO, AD-Suite, FM-Validator ' Flexible Binding
' SILC: System Independent Loop Commissioning
' Smart Junction Box ' AD Suite ' Module based engineering
' Separation between logical and physical
' Bulk Generation
' Auto Documentation with Module
' Industry Library (DCS/SIS) ' Standardization ' Standard Cabinet / Hardware Design
' Global PC
' Preconfigured network Switches ' Integration ' Smart and flexible integration with subsystems (UGS)
' Complete DCS-SIS integration (CentumVP+ProsafeRS)
' Easy configuration from C&E diagrams (iDefine)
' Structured Systematic Approach for FSM requirements (Yokogawa) 3rd party system
Subsystems Unified
Gateway
Station Instantiation Thank you Any question ' 72 Proprietary info goes here'


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