Emerson Process Management - SESAM...
Transcript of Emerson Process Management - SESAM...
Emerson Process Emerson Process ManagementManagementMats Millnert, Emerson Process Management
IntroductionIntroductionIntroductionIntroduction
Mats Millnert, Account Manager for PSS in Denmark
Emerson Process Management
Emerson Process Management, Slide 2
AgendaAgendaAgendaAgenda� Introduction
� State of the Industry, challenges in todays projectEnvironment
� Different types of tools to facilitate the Engineering Process
– Industry drivers and customer benefits
– How these tools built technically and organisationally?
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– How these tools built technically and organisationally?
– How does Emerson apply these tools?
� Presentation of Emerson Process Management
� Roundup and Questions
State of the IndustryState of the IndustryState of the IndustryState of the Industry
Higher Demandson cost efficiency
Drive towardsEnterprise
standardisation Reduction of in-house engineering
Increased Globalisation
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engineering
TighterProject Schedules
Increased focusOn TCO
AgendaAgendaAgendaAgenda� Introduction
� State of the Industry, challenges in todays projectEnvironment
� Different types of tools to facilitate the Engineering Process
– Industry drivers and customer benefits
– How these tools built technically and organisationally?
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– How these tools built technically and organisationally?
– How does Emerson apply these tools?
� Presentation of Emerson Process Management
� Roundup and Questions
Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?
Technical Standards /Functional Libraries
Automated Configuration Tools
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Technical Processes
Manual Labor Tools
Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?
Technical Standards /Functional Libraries
Automated Configuration Tools
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Technical Processes
Manual Labor Tools
Technical Standards and Functional Technical Standards and Functional LibrariesLibrariesTechnical Standards and Functional Technical Standards and Functional LibrariesLibraries
� Industry Drivers:
� Increased focus on TCO
� Tight project deadlines
� Reduce project risk
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Technical Standards and Functional Technical Standards and Functional LibrariesLibrariesTechnical Standards and Functional Technical Standards and Functional LibrariesLibraries
What benefits are there to realise?
Project Benefits:
� More predictable outcome
� Faster project execution
TCO Benefits:
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TCO Benefits:
� Fully supported solution reducesownership costs
Emerson’s take on a standard LibraryEmerson’s take on a standard LibraryEmerson’s take on a standard LibraryEmerson’s take on a standard Library
� A configuration standard for use with our DCS DeltaV
– Named PCSD
� Started in 1997 (first DeltaV release)
� Used globally by Process Systems and Solutions Business Unit
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What’s in What’s in this this Configuration Configuration Standard?Standard?What’s in What’s in this this Configuration Configuration Standard?Standard?� Includes:
– Control Module templates
– Equipment Module and Batch Phase shells
– Graphic elements
– Ready made Design documents
– Test Specifications and Test Results documents
– Control Module templates for migrations from Provox
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for migrations from Provoxand RS3 systems
– Functional overview document
– Detailed overview presentation
What are the functional features of the What are the functional features of the Configuration Standard?Configuration Standard?What are the functional features of the What are the functional features of the Configuration Standard?Configuration Standard?
� Key Library features:
– Scalable control modules
• Allow for removal of certain elements within the Control Modules to reduce controller loading and memory usage
• Require no modifications to the graphic elements
– Guideline documents
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– Guideline documents
• Assist in design and configuration when using PCSD
– Controller loading calculator
• Determine loading based on types of control module templates
Application Building MethodologyApplication Building MethodologyApplication Building MethodologyApplication Building Methodology
PCSD
Module (Function) R201
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High Granularity
(Small)DeltaV
FunctionBlocks
(Large)PCSD Modules
(e.g., Control Modules,Equipment Modules)
Application(e.g., Fermentor,Boiler, Column)
Low Granularity
PCSD DevelopmentPCSD DevelopmentPCSD DevelopmentPCSD Development� PCSD is owned by the Project Management
Office (PMO)
– Global Organization, launched in August 2005
• Part of the Process Systems and Solutions division
• Global scope
• Developed and maintained by network of experienced Engineers
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Engineers
• Continuously updated with developments from ongoing projects which are using PCSD
Standard Library Standard Library DevelopmentDevelopmentStandard Library Standard Library DevelopmentDevelopment� PCSD Organization:
Director Country / Center
Director Country / Center
Director Country / Center
Projects / Engineering
Manager
Projects / Engineering
Manager
Projects / Engineering
Manager
PCSD Program Director
PCSD Program Technical Lead
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Manager Manager Manager
Technical LeaderTechnical LeaderTechnical Leader
Project Project ProjectProject Project ProjectProject Project
PCSD Champion PCSD Champion PCSD Champion
PCSD Development & Support Leader
PCSD Development & Support Team
PCSD SME Team
Standard Library Standard Library ReleasesReleasesStandard Library Standard Library ReleasesReleases� Major Releases
– synchronized with new DeltaV product release
– will typically include functional enhancements based on requests from project teams and customers
� Intermediate Releases
– address major functional enhancements or issues
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– address major functional enhancements or issues
• as determined by the PCSD Technical Steering Group
– typically not synchronized with DeltaV product releases
– full functional testing on the current DeltaV release
Standard Library Standard Library Technical SupportTechnical SupportStandard Library Standard Library Technical SupportTechnical Support� During Project Development:
– First line technical support
• primarily the responsibility of the Technical Leaders within each local Emerson operating entity
– Second line technical support
• responsibility of the PCSD Technical Steering Group
• provided via the internal Call Tracking System (CTS) - part of
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• provided via the internal Call Tracking System (CTS) - part of the Service Management System
• open access to the status of all calls provided via the PCSD web site to all internal PCSD users within Emerson
– Third line technical support
• PCSD development team
Standard Library Standard Library Technical SupportTechnical SupportStandard Library Standard Library Technical SupportTechnical Support� On-site Support:
– Possible to call directly to the Global Service Center(GSC) for any issues while at a customer site (including potential PCSD issues)
– If the issue is deemed to be related to PCSD, the PCSD development team will investigate and provide a resolution
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a resolution
Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?
Technical Standards /Functional Libraries
Automated Configuration Tools
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Technical Processes
Manual Labor Tools
Industry Industry driversdriversIndustry Industry driversdrivers
– Globalisation
• Increased competition
– Shorter time-to-market for our End-Usersproducts
• Tight project deadlines
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Customer benefits of using approved Customer benefits of using approved Technical Tools?Technical Tools?Customer benefits of using approved Customer benefits of using approved Technical Tools?Technical Tools?
� Defined customer interface methodology through the ‘Enter it Once’ philosophy
� Reduce variability in solution development
� Automatic and consistent document generation
� Leverage limited resources across more
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� Leverage limited resources across more projects
Emerson’s take on Automated Emerson’s take on Automated Configuration ToolsConfiguration ToolsEmerson’s take on Automated Emerson’s take on Automated Configuration ToolsConfiguration Tools� User Defined Bulk Import-Export functionality
– Excel or through ODBC interface to other databases
– Support creation of I/O, Batch formulas, Functionblocks, unit modules etc.
� Application Software Engineering Tool calledthe ASE tool.
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Process Database Management Concepts Process Database Management Concepts Process Database Management Concepts Process Database Management Concepts
V_12_50
C
BRev A
Rev 0
V_12_50
Customer dataImport / Export
Template format
C
BRev A
Rev 0
Map &
import
Original customer datamay not be in the format
provided by EMR(Data_requirement.xls)
ASE Tool DeltaV
module
parameter
parameter
parameter
parameter
parameter
parameter
parameter
parameter
parameter
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parameter
parameterDATABASE CREATION PROCESS
• Select / create module classes in DeltaV• Derive module templates• Define project specific parameter default values• Select / create related format file and export from
DeltaV to ASE• Instantiate and parameterize with customer data• Import back to DeltaV changed parameters
Project and/or Customer Default Data
PCSD Default Data
Module specific dataparameter
parameter
parameter
parameter
parameter
ASE ToolASE ToolASE ToolASE Tool
� The ASE tool along with user-defined DeltaV import/export facility is used to manage and speed up the configuration objects that are normally created in large quantities, like
– Conventional I/O cards and channels– Remote I/O cards and channels– Control modules – Landing Modules– Foundation Fieldbus devices– Profibus Devices
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– Profibus Devices– DeviceNet Devices– Interlocks/Permissives conditions– Variables / EQM Parameters– History Collection
The tool makes a number of checks on the input dataThe tool makes a number of checks on the input data
1. Check Controller: Checks if various DST’s of a module are assigned to a single controller.
2. Check Dupl Cards, Channels/FF Address: Checks uniqueness of Card tags, Channels
and FF addresses.
3. Check Duplicate DST: Checks if all DST tags are unique and also not same as module
names
4. Check Templates: Checks if referenced Fieldbus and Control Module templates are
declared
5. Check Tags: Checks that all tags are compliant with DeltaV naming convention.
6. Check Descriptors: Checks if the maximum length of the `description'-field in table
`DCS_Module_Tags' isn't violated.
7. Check Eng. Units:
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7. Check Eng. Units: Checks if engineering units in the `DCS_IO_Tags' table exist also in the
table `Proj_Eng_Units'.
8. Update Decimal Point: Fills in the decimal point data.
9. Check Duplicate IO_FUNC_CODE per module: Checks Uniqueness of
IO_FUNC_Code per module subtype.
10. Check Redundant Cards Addr: Checks that the slot address for redundant cards is an
odd number
11. Check Slot Addr: Checks that the card slot entry is between 1 and 64
Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?
Technical Standards /Functional Libraries
Automated Configuration Tools
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Technical Processes
Manual Labor Tools
The Industry DriversThe Industry DriversThe Industry DriversThe Industry Drivers
� Again, globalisation
� Increased demands on project consistency and quality
� Increased regulation
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quality /scope
The The Customer Customer BenefitsBenefitsThe The Customer Customer BenefitsBenefits
� Global Processes drives consistency and predictability
� Delivery on time on budget maintainshigh quality level
� Reduction of project risk
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� Reduction of project risk
quality /scope
Emerson’sEmerson’s taketake onon TechnicalTechnical processesprocessesEmerson’sEmerson’s taketake onon TechnicalTechnical processesprocesses
� For any company consistent project management processes is key to drive project results and customer loyalty
� Global Project Management Office (PMO) with dedicated executive leadership
� Scope
� Project Management Processes
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� Project Management Processes
� Examples and templates
� Certification Program
� Continuous improvement
Global Standard ProcessesGlobal Standard ProcessesGlobal Standard ProcessesGlobal Standard Processes
� The Project Management Office defines the global standard proceses and tools to be used by all disciplines on all projects
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Example Example –– Project ManagementProject Management
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Example Example –– Project ManagementProject ManagementExample Example –– Project ManagementProject Management
Activities and Deliverables
� Processes are built on standards, as :– PM PMI PMBOK
– SIS IEC 61511
– SP88
� Clicking on an active step will popup a detailed instruction with relevant templates attached
� Swimlane format defines who is responsible
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� Swimlane format defines who is responsible for the activity
� Links provided to key enterprise level tools for Estimating, Project management and Document Management
Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?Which types of engineering tools are there?
Technical Standards /Functional Libraries
Automated Configuration Tools
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Technical Processes
Manual Labor Tools
Industry Industry driversdriversIndustry Industry driversdrivers� Increased difficulty to find qualified automation
engineers
� Forecasting difficulties
� Once again, Globalisation
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Customer Benefits Customer Benefits Customer Benefits Customer Benefits � Access to a larger pool of qualified (specialised)
engineers
� Better cost
� Faster project execution
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Emerson‘sEmerson‘s OperationsOperations setupsetupEmerson‘sEmerson‘s OperationsOperations setupsetup
� Local Customer Project Centers
Focusing on customer facing activities
– FEED, Project Management, Lead Engineering & Consultancy
– Installation, Commissioning & Start Up
� Regional Support Hub
Project support center providing essential project activities
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Project support center providing essential project activities
– Procurement, Administration, Cost Control, Document Control
� Global Engineering Center
Major engineering services centre, organized to provide productivityand quality through dedicated industry, application and platform groups
Organizing for competitive value requires a clear strategy that continually improves productivity, whilst ensuring that customers
can access the key project resources necessary for success
Major Project CentersMajor Project CentersMajor Project CentersMajor Project Centers
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Global Engineering Center
Regional Support Hub
Customer Project Center
Customer project centers located in all key industrial areas throughout the world
Global Engineering CenterGlobal Engineering CenterGlobal Engineering CenterGlobal Engineering Center
Setup in Sept 1997
Serving 40 countries worldwide
More than 1200 Employees as on today
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Global Engineering Center ActivitiesGlobal Engineering Center ActivitiesGlobal Engineering Center ActivitiesGlobal Engineering Center Activities
DeltaV
DeltaV SIS
Migration
Transition
Site Startup
Sure Service / Tech Support
Standard Proposals
Strategic Proposals
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Transition
DeltaV Upgrade
Hardware
E&I
Strategic Proposals
C&I
Ovation SIS
AO Support
SBG SW Development & Support
AgendaAgendaAgendaAgenda� Introduction
� State of the Industry, challenges in todays projectEnvironment
� Different types of tools to facilitate the Engineering Process
– Industry drivers and customer benefits
– How these tools built technically and organisationally?
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– How these tools built technically and organisationally?
– How does Emerson apply these tools?
� Presentation of Emerson Process Management
� Roundup and Questions
Sales of $20.3bn (2010)
Emerson globallyEmerson globallyEmerson globallyEmerson globally
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NYSE: EMR Diversified global manufacturer
and technology provider
Approximately 110,000 employees worldwide
Headquarters in St. Louis, Mo.
Founded in 1890
200+ manufacturing sites, presence in 150+ countries
131 000 employees
On “2009 FORTUNE 100 list”
$685M investment in technology development
Emerson SalesEmerson SalesDiversified Businesses & Global Scope Diversified Businesses & Global Scope Emerson SalesEmerson SalesDiversified Businesses & Global Scope Diversified Businesses & Global Scope
2011 Sales by Segment
28%16%
8%Process
Management
Commercial & Residential Solutions
Climate Technologies
5%5%
United Statesand Canada
Latin America
2011 Sales by Geography
Middle East/Africa
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28%
27%
21%
16%
NetworkPower
Industrial Automation
45%
23%
22%
Asia
Europe
Emerson International SalesEmerson International SalesInternational Sales Have Exceeded 50% Since 2007International Sales Have Exceeded 50% Since 2007Emerson International SalesEmerson International SalesInternational Sales Have Exceeded 50% Since 2007International Sales Have Exceeded 50% Since 2007
75%
100%
United States Sales United States Sales %%
35%
65%
43
0%
25%
50%
1990 1993 1996 1999 2002 2005 2008 2011
All International Sales All International Sales %%
Emerging Markets Emerging Markets %%
35%
36%
59%
45%
2015T
�� 1000 1000 employeesemployees–– Of which Of which ~200 ~200 in R&Din R&D
�� $675M $675M revenuesrevenues
4 manufacturing sites4 manufacturing sites
Emerson Process Management Emerson Process Management in the Nordicsin the Nordics
Emerson Process Management Emerson Process Management in the Nordicsin the Nordics
�� 4 manufacturing sites4 manufacturing sites
Emerson Process Management offers all Emerson Process Management offers all four corner stones of Process Automationfour corner stones of Process AutomationEmerson Process Management offers all Emerson Process Management offers all four corner stones of Process Automationfour corner stones of Process Automation
Control Systems Valves & Regulators
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Measurement Instruments Asset Management
DeltaV ArchitectureDeltaV ArchitectureDeltaV ArchitectureDeltaV Architecture
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Roundup Roundup -- Questions?Questions?Roundup Roundup -- Questions?Questions?
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Novo Nordisk / Emerson Confidential, Slide 48