AutomAtion integrAtor Technology

How to Develop a Project Execution Plan

Designing and implementing advanced engineering projects, such as an advanced operator training simulator, requires meticulous planning and communications. Here’s a template for success.
Example operator training simulator interfaces
OTS provider Specifications, design change, approvals Process & equipment data Study feedback Schedules, engineering data Requirements, design changes, approvals Equipment specifications study results schedule Client

A

trend in major upstream oil & gas projects is the addition of an advanced operator training simulator (OTS). To fully realize the benefits from this technology, the OTS should be developed early enough to complete operator training before facility startup and to support process and operability studies. But there are challenges to early development, particularly when designing and implementing such advanced engineering projects. A detailed project execution plan is essential. A high fidelity OTS is typically integrated with the same process automation system (PAS) hardware and software used to control the new facility. PAS implementation must therefore be completed sooner, often significantly sooner, than what is required to meet facility engineering and construction schedules. Consequently, the OTS schedule may drive the PAS development schedule with its cascading impact on EPC (engineering procurement construction) schedules. Project success is therefore dependent on the EPC and main automation contractor (MAC) as key stakeholders. Understanding the elements of a project execution plan from the EPC and MAC perspectives can lessen project challenges and help clearly define

PAS software Control narratives, punchlist logic drawings, PAS equipment & software supply & support

PAS design changes, approvals PAS design data schedule support

EPC

MAC

P&IDs, engineering data, schedules Engineering data schedules Source: Control Engineering with information from Mustang Engineering

Acronym help for engineering project management
AFD: approved for design EPC: engineering procurement construction FAT: factory acceptance test FEED: front end engineering design HMI: human-machine interface IEC: International Electrotechnical Commission MAC: main automation contractor OTS: operator training simulator P&ID: process and instrumentation diagram PAS: process automation system SOP: standard operating procedures

the role of the client. Elements include: n Statement of goals; n Scope of work; n Roles and responsibility matrix; n Technical specifications; n Contracting plan; n Organization chart; and n Integrated schedule. Here we’ll go into each of these in detail.
OTS project goals Statement of goals should define the training and engineering study requirements, which may include: n Pre-startup training and familiarization for new or experienced operators; n Long-term training or formal re-certification of operators as may be required in some regions; n Process design validation and throughput optimization studies (new facility and changes); n Validate basic process controls and safety interlocks (new facility and changes); n Validate standard operating procedures (SOP)

Roles and risks associated with OTS stakeholder interactions should be addressed early in the project.

at a GLaNCE

• Plan ahead • Develop

concensus early upon points in the process

• Validate at agreed-

www.controleng.com/integrators  •  CONTROL ENGINEERING SUPPLEMENT DECEMBER 2009  •  9

identifies the source of project and long-term support funding and the OTS location. The contracting strategy should recognize the unique challenges of the project. the client defines the equipment and processes to be modeled and the model fidelity requirements. A – Approve. and study requirements. owner and system manager at each phase. The life-cycle plan. A long-term support and software management plan also should be included. verify SOPs Long term OTS management & support R/A R C/R R I R A A R A R A/R R R A C Phase 4 – Detailed design. modeled areas typically include all major oil. Specifications define technical. C – Consult. This software is also interfaced to OTS models. improve support. PAS HMI and controls software is commonly interfaced to these models. R/C C C C C C R R C Table 1. reduce schedule risk. well injection and export systems. Studies may include validating facility throughput. MAC support may be needed to complete the PAS-OTS interface. The cumulative costs from all contractors should be considered when selecting the strategy. I – Inform Scope definition During scope definition. Vendors and contractors should be OTS MAC limited to those with proven provider technical and execution track records. OTS-PAS Integration & Testing Implement OTS study-initiated & approve changes to facility and PAS designs Train OTS trainers Train operators.Roles and responsibility matrix Index Activity Owner EPC Phase 2 – Concept phase 1 Define OTS statement of goals R Phase 3 – Front end engineering design (FEED) phase 2 3 4 5 6 7 Develop OTS specification Define engineering study requirements Develop initial OTS execution plan & schedule Define OTS Scope in EPC & MAC Contracts Develop OTS cost estimate for OTS equipment and provider services Develop cost Estimate for PAS Equipment and Support Services (EPC. procurement & implementation 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 R R R A I I A C C C C C I C R R R C I C R I I R I C C C C R C I C R I I C R I R I R I R C C C C Phase 5 – Operations & maintenance phase R. Model fidelity is typically high (±2% accuracy from the steady state design) to achieve accurate process responses and dynamics. covering pre. For oil & gas applications. This support can be a challenge. Early OTS development may be required to support process and design validation studies.Responsible. subsea. and n Validate PAS alarm system performance (alarm floods. and standardize on OTS software.and post-facility startup.AutomAtion integrAtor Technology and changes. identify key schedule milestones and provide an initial OTS lifecycle plan. Upstream projects also commonly employ skidmounted packaged equipment supplied with local embedded control systems provided for compression. since peak OTS support often occurs during peak PAS activity periods. 10  •  DECEMBER 2009 CONTROL ENGINEERING SUPPLEMENT  •  www. equipment. The statement should define the modeled facilities (new or existing facility or process units). The OTS execution plan must to be prepared early to make it available when the client’s project team is ready to issue proposal requests and contracts to the EPC(s) and MAC.controleng. alarm masking). MAC) OTS procurement / contracting OTS kickoff meeting Develop integrated schedule Update in-house execution plans with agreed OTS milestone dates Provide facility engineering & process data Provide packaged equipment control system software & data Provide PAS equipment & software to OTS provider Model development Develop facility standard operating procedures (SOPs) Conduct OTS studies Assess/authorize OTS study-initiated changes impacting EPC and MAC. gas and subsea production and utility systems.com/integrators . A single OTS provider should be employed to reduce interfaces. Risks associated with stakeholder interfaces and accelerated schedules should be addressed early in the projR C ect through the process of risk C C minimization.

Then. Common acceleration software or algorithms. The OTS support plan. OTS boundaries should be clearly delineated and stakeholder responsibilities clearly defined. The client is typically at the cendevelop new HMI and control software templates ter of this challenging. an understanding of interface and schedule and construction schedule can trigger significant management.scope during the detailed design phase. MAC Provide PAS equipment As needed and third-party deliverables is listed and applications support in Table 2. testing and OTS integration. process & equipment data Safety logic drawings and control narratives Vendor data from long lead 3rd party package & equipment vendors Preliminary Approved for design (AFD) AFD 3-10 6-12 * 6-10 * Up to 22 months if dependant on packaged equipment data AFD **13-22 ** Earlier dates may be required to meet OTS schedule Schedule development Developing an integrated schedule Fully tested/approved begins with the client defining when Issue PAS configured I/O. Adding n Project adds new work processes or design this and the associated new scope to the EPC and requirements (for example. ing front-end engineering design (FEED). Example timing for OTS deliverables are listed in Table 3. interface development.and post-delivery. Months from start of detailed design phase Defined in FEED PAS hardware & base software selected P&ID.decisions. and of project success. Employing the right people in and standards. n Unplanned custom emulations are needed. OTS schedule requirements must be included in n Significant changes in the PAS design basis or the main facility project schedule developed dur. Example timing for EPC. attend interface meetings and requirements.tion skills and sufficient technical knowledge and lenge for all parties. authority to respond to queries and make timely Project realities that can impact the OTS sched. multi-organization. the OTS provider. coordinate schedules and activities within their n Late access to vendor software needed for PAS respective organizations. 9) shows n Client requirements trigger a major effort to some possibilities.com/integrators  •  CONTROL ENGINEERING SUPPLEMENT DECEMBER 2009  •  11 . RecomDelivering the PAS design six months sooner than mended skills include basic contract manageis needed to meet the general facility engineering ment. and starting OTS and PAS development work before Organizational considerations design documents are available. The client Integration to control system software FAT works with all parties to facilitate a from long lead. the client project manager role is critical. good organization and communicaacceleration costs. Controlling these costs is a chal. Table 1 is an example of a roles and responsibilities matrix. if applicable. “Example interfaces” illustration (on p. pre. Spot test base HMI and tor training and. increasing staffing decisions. The contractor interfaces. Selecting the right person for the EPC’s and MAC’s scope and therefore cost. software templates the OTS must be ready to start operabasic controls and HMI. 3rd party vendors mutually agreed schedule. EPC and MAC each identiIssue PAS complex Full factory acceptance fies when required information and controls & software update tested (FAT) equipment is needed and when deliverables can be provided. 15-18 16-22 16-24 22-28 Duration www.Table 2 – Example timing for EPC and MAC deliverables EPC & MAC deliverables Deliverable status operability and PAS display and controls performance. The EPC and MAC should provide an ule and completion include: OTS interface coordinator to manage information n Late supply of vendor data and interface exchange requests. IEC 61511 adds steps MAC schedules after contracts are signed becomes that can lengthen the safety system design and increasingly difficult. Schedule acceleration is typically required to such as when vendors will not provide proprietary meet agreed delivery dates. approaches include working tasks in parallel. to controls software support OTS studies.controleng. and decreases the likelihood software development duration). Both approaches Project success requires sound organizational and result in varying degrees of rework. Risks associated with OTS stakeholder intern Effectiveness and timeliness of contractor-tofaces should be addressed early in the project. is fully developed here so costs can be assessed and resources and responsibilities defined. process & equipment data P&ID. Schedule Issue PAS balance of plant software FAT risks are shared among parties. interface-intensive effort.

com Table 3 – Example OTS timeline Event or EPC and MAC supplied engineering data OTS award P&ID. specifications Model build Model validation. acceptance tests EPC OTS provider MAC Feedback from OTS studies will generinterface project interface ate PAS and facility design changes to coordinator manager coordinator consider. Opportunities to simplify or streamline an interface also should be considered to reduce project risk. realities.Plan.AutomAtion integrAtor Technology key roles provides a means to improve the timeliness and effectiveness of an interface. The change process must Project managers for the client and provider inter. CAP. to the extent possible. A challenge when designing safety systems to IEC 61511 is acquiring process response times for a new facility. The client will need a process to manage this work and its potential impact on cost and schedule. and document work status as it tion (EPC) interface coordinator and with the main Early supply of a high fidelity and progresses. For more information.com/integrators . SOP verification Operator training First oil OTS provider activity Months from first oil 30 29 28 26 23 21 17 16 14 REMOVE WASTE HEAT WHILE KEEPING CONTAMINANTS OUT 8 7 6 0 food AT FO proc R essin g GRE norenproducts. ce ensure third-party vendors release proprietary software. This data is used to set safety interlock speed of response requirements. 4x | Stainless Steel | Washdown www. process and equipment data – preliminary Planning. visit: SOP’s may need to be written earlier to allow time for verification using the OTS. OTS contributors. Frequent changes and incremental manager and EPC and MAC coordinators are key positions that testing provides the opportunity for software errors to creep in.controleng. A rigorous Source: Control Engineering with information from Mustang Engineering management of change process must be in place. automation contractor (MAC) coordinator. How early the OTS can be delivered depends The client may need to exercise corporate agreements to on project specific realities and requirements. algoAuthor: Tom Shephard. process and equipment data – AFD Detailed engineering data for model update Engineering studies Model update PAS delivery PAS integration Integrated PAS and operating procedure checkout OTS design & integration completed OTS acceptance test Instructor training. 4. implement. directly impact project success. Sample organizational chart Client OTS project manager Feedback. but Dividing PAS acceptance tests into requires the right execution plan and multiple test periods to support staged software deliveries can aggressive plan execution by all parties. The client OTS project increase PAS scope and cost.322. thoughtfully distributed among quality plans. is a rithms or functional design information to the OTS provider. Mustang Engineering. Risks should be identified. PAS-integrated OTS is possible. approval. manBoth should be addressed in the MAC’s change management and aged and. FEED studies P&IDs. Response data from the OTS may prove to be more accurate than data derived through other means and should be explored.mustangeng.com/ccc 650. main automation contractor program manager and automation project manager. include review. COMPACT CABINET COOLER for sealed electrical enclosures Replaces air conditioning | Replaces compressed air | Easy installation | Energy efficient | NEMA 12. PMP.9500 12  •  DECEMBER 2009 CONTROL ENGINEERING SUPPLEMENT  •  www. act with the engineering procurement construcrequirements test.

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