Session one:

What is the future of project

execution?

Dan Overly

Group VP, Product Management, Oil, Gas & Chemical

ABB

What is the future of project execution?

- Oil, gas and chemicals projects

have been engineered the same

way for decades.

- New approaches are required

and expected to drive significant

project and life cycle savings.

- 64% of projects today are facing

cost overruns*

- 73% are reporting schedule

delays*

64% 73%

*Source: 2014 EYGM Limited

Meet ABB Intelligent Projects

- ABB Intelligent Projects transforms the speed and

quality of project execution through single source

integration of power, automation and

telecommunication systems.

- Why did we develop this approach?

- To help customers:

- Create predictable costs and schedule

- Share risk

- Reduce complexity

- Increase efficiencies

- Enable safe operations

Our approach to agile project execution

ABB Intelligent Projects: Components for a world-

class execution model

Cut cost, schedule and risk

Decoupling tasks to solve project problems

– Dependencies drive a ‘serial’ approach

– Project information is supplied to automation supplier

– Hardware design is frozen, app programming begins

– Late changes create costly change orders

– Configuration and hardware builds start together

– Single channel Select I/O easily accommodates late cycle I/O additions, deletions and changes

– Activities performed in parallel to reduce project schedule

Traditional approach: dependency driven

New approach: technology enables decoupled, parallel tasks

Cloud engineering: emulation + virtualization + simulation

- Next wave: virtual control systems

Further reduction of server and controller hardware; less exposure to obsolescence issues

- Makes standard designs, methodologies and engineering workflows and support toolsaccessible to all of our project execution groups

- Facilitates distributed engineering, allowing ABB and EPC contractors to work from a single engineering database and set of common standardized designs

- Allows testing to be conducted off-site/after the staging area

- Paves the way for “virtual commissioning” using process models, which results in far less changes and modifications being required on-site during commissioning

Intelligent Projects: Component

Digital marshalling with flexible I/O solutions

Seamless control and I/O types Installation according to site needs

- Centralized Equipment Room

- Remote Equipment Rooms

- Remote I/O Cabinets

- Intelligent electrical and

process devices

- Zone 2, Zone 1

- Single Channel I/O

- Centralized I/O

- Serial Links

- Remote I/O

- Fieldbus

Many digital and hardwired I/O options available with ABB Ability System 800xA

Intelligent Projects: Component

Select I/O (new)

Traditional S800 I/O

New product launch

Digital marshalling delivered with xStream

EngineeringNew product launch

xStream Engineering overview Configure, Check, Connect: parallel project execution

• Definition:- Reduce project time by “de-coupling” automation tasks

from each other- Application programming performed in parallel with

hardware engineering using new “signals” concept

• xStream Engineering includes:- Engineering with “signals”- Ethernet I/O Wizard for:

- Reading the “as-built” configuration from the field- Configuring and checking the Select I/O in the field- Generating the I/O structures in Control Builder

- Digital marshalling of I/O to controllers- Support for late changes with late binding

Intelligent Projects: Component

- Standardization significantly drives down cost and reduces design schedule

- Standard designs for both application software and hardware

- Globally-accessible repository available to all project execution groups

- Seamlessly integrates with engineering support tools across all phases

- Examples include the development and use of:

- ABB TÜV-certified global Oil and Gas Reuse Library for application software

- Standard 800xA network topology and cabinet designs

- ABB TÜV-certified Functional Safety Management System template

Standardization

November 29,

Slide

Intelligent Projects: Component

Standardization enabled by Select I/O

Cabinet layout can always be the same

- Each channel can be configured as AI/AO/DI/DO

by inserting a specific module in the base

- I/O module types include safety SIL-certified

isolators, barriers and interfaces to higher

voltages

- Includes electronic current limitation and field

disconnect function

- Solution supports one common I/O cabinet

layout for all applications

- No external components are needed

Elimination of marshalling, auxiliary equipment and on-site cabinet testing reduces execution time and cost.

Easy to implement late-cycle I/O design changes.

Intelligent Projects: Component

Selecting signals by inserting specific I/O modules

Standardized remote cabinet with 90 single I/O channels

AI

AO

New product launch

Automated data management

Design applications: Commissioning I/O system:

- Hardware topology build-up (auto detection and

validate)

- Provides automatic I/O mapping and control

regardless of physical location – dissolving the barrier

between hardware and software systems

- Auto-HART device configuration, loop check and

documentation

- Converts data given to ABB in different formats from

a large number of sources into a common data format

for engineering purposes

- Auto-generates a large proportion of application

software and the associated hardware

documents

- Stores multiple revisions of the design data from

multiple data entry modules in the database

- Creates reports between versions

- Rolls back to any previous version

- Shortens time needed to transfer data, documents

and approvals

Intelligent Projects: Components

Main automation vendor for Sadara and partner from concept through long lifecycle

Sadara project execution– enabling world’s

largest petrochem complex built in one phaseCustomer situation:

- 26 manufacturing facilities

- Over 3 mn metric tons of capacity per year

ABB solution:

Providing digital infrastructure with

– 18 distributed control systems to each run more than 50 fully automated production lines

– 40 operator consoles work

– 260 work stations

– 450 servers

– 150,000 I/O devices

Improved efficiency, safety, lower cost and risk

Project Overview

Project value $20 bn

Manufacturing plants 26

Annual output 3 mn metric tons

Control systems 18

Operator consoles 64

Work stations 260

Redundant controllers 260

Servers 450

I/O devices 150,000

Summary : New technologies/new approaches

Physical

- 66% reduction in number of cabinets,

junction boxes, tray, etc.

- 70% reduction in number of wiring

terminations

- 40% reduction in-room footprint

- 30 to 40% reduction in automation hardware

costs

- Copper ‘home run’ field signal cables

replaced with fiber optic network cables

Taking automation off the critical path

What is the impact?

Engineering, construction, schedule reduction

- 30-40% reduction in IC&E engineering

- 20-30% reduction in construction

- 20-30% reduction in commissioning

- 25% compression of the automation schedule (start later when design is more mature)

- No hardware required FAT for standard equipment

- Fewer drawings to review/maintain