The M+W Group - Fhi · Uhde Voestalpine Our customers are globally active companies as well as...

M+W Process AutomationA Company of the M+W Group

Doc. Vers.: 14

The M+W Group

Our Industries

Energy & Environment Technologies

� Semiconductor� Flat Panel Display� Photovoltaics

� Pharma & Biotech� Food & Nutrition� Consumer Care

� Renewable Energy� Waste to Energy� Power Plants

� Science & Research� IT & Telecom� Space & Security

Advanced TechnologyFacilities

Life Science & Chemicals

High Tech Infrastructure

2 © M+W Process Automation – A Company of the M+W GroupTitel Doc.-Vers.: 1

Process Automation

Products & Services

� Photovoltaics� Battery Cells

� Consumer Care� Chemicals

� Power Plants� Oil & Gas

� Space & Security� General Industries

� Cleanroom Products� Air Handling Units� Contracting

� Controlled Environments� Technology Center� Operation & Maintenance

� Chemicals� Pharma & Biotech� Food & Nutrition

� Automotive� Semiconductor� Oil & Gas, Paper


Doc. Vers.: 14

Automation. Solutions. Competence.

May 2011

M+W Process Automationas a Total Automation Solution Supplier

� Our core business is to

deliver total automation

solutions via in-house

resources

� Independent

� Multi-discipline

� Focused on project

DCS- Development

- Manufacturing

Su

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ort

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Pro

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Ap

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DCSDelivery

DC

S M

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Total Solution Supplier

ConsultingDesign

SpecificationSupply Management

Validation

24/7 Service&

Hotline

Su

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Pro

ject

Ap

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on

(S

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ME

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Su

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lierStart-Up

Training Manufacturingand Business

Integration

SAPProduct


� Focused on project

and customer needs

Su

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ort

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Pro

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(S

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Pro

ject

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FS-PLC- Development

- Manufacturing

FS-PLCDelivery

Equipment-- Development

- Manufacturing

Equipment-Delivery

FS

-PL

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Man

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Basic

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Installation

Control Cabinet

Mounting

Hotline (So

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DevelopmentR

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ing

Satisfied Customers (excerpt)

Food andBeverage

Chemical Pharma/Biotech Automotive Other Industries

BASF

Bayer

Celanese

Clariant

Boehringer Ingelheim

Fresenius

Janssen Pharmaceutica

Audi

Daimler

Dürr

Eisenmann

Cargill

Kraft Foods

Südzucker

Uniferm

Exxon Mobil

K+S

Linde

Lurgi


Clariant

Evonik Industries

Henkel

LyondellBasell

Merck

Unilever

Wacker

Pharmaceutica

Novartis

Pfizer

Roche

Sanofi

Eisenmann

FFT EDAG

KUKA

Opel

Skoda

ThyssenKrupp Drauz Nothelfer

Volkswagen

Uniferm

Walter Rau

Lurgi

OMV

Sappi

Shell

Stora Enso

Uhde

Voestalpine

Our customers are globally active companies as well as medium-sized or small enterprises, whether in Germany, Europe or around the globe

Market experiences & trends – EPC market

� Brownfield vs. Greenfield projects

� Smaller size

� Higher complexity

� Design Responsibility is an issue

� One-shot for start-up only

� EPC Contractors

� Automation is no major issue (typical benchmark 10 to 15% of TIC)

� Decisions and push come from building & process engineers


� Decisions and push come from building & process engineers

� Are mostly missing Automation competences (little to no fixed staff for automation)

� Typically push responsibility towards suppliers for specialty instrumentation &

automation

� They do not execute automation projects, they manage them

� Take full responsibility but customer has limited (or no) influence on

� PCS platform (Vendor1, Vendor2, PLC, DCS, ...)

� Engineering environment (Intools, Eplan, ACAD, ...)

� Standards (electrical equipment, instrumentation, PCS libraries, ...)

Market experiences & trends – Automation

� DCS vendors want to act as a one-stop-shop (MAC/MAV/even EPC...)

� But who wants everything from 1 supplier? (DCS/ESD/MES/Instrum.)

� No real engineering capabilities in house

� Value engineering vs. low-cost solutions

� The lower prices go, the harder the claim strategy will show


� Focus is shifting from hardware selling to solution selling

Market experiences & trends – Customer side

� Current thread

� Retirement wave, loss of judgement competences

� Customer experiences/trends

� Move to EPC responsibilities, but under EPCM contracts

� Input on PCS architecture & automation standards (but failure to enforce in their

EPC contracts...)

� MAC/MAV concepts


� Reimbursable staff to maintain control (= no control on cost)

� EPC contracts for delegating risk & control of costs (= no control on design input)

� Customers stick to an Engineering contractor + DCS vendor for migration projects

� Project fast-tracking

� Requires optimal Interface & Change Management between the project disciplines

What are the alternatives ?

� Take automation out of the package of the EPC contractor, but

� More communication interfaces

� Shared risk between customer & automation partner

� Integrated multi-disciplinary project teams

� Proven concept within the M+W Group

Early project involvement from Automation in the project

Customer

EPC Autom.


� Early project involvement from Automation in the project

� Build up cross-discipline awareness

� Process Engineer should know design has impact on E,I,A

� Instrument Engineer should know about PCS architecture

� Automation engineer should be able to speak process language

� Project staff with both Design & Construction / Execution skills

� Team should focus on solutions, not on spending hours

Our approach

Process Engineer

Automation Engineer

• We have more than 25 years experience in executing DCS projects successfully

• We understand different ways of thinking and connect them optimally

• We satisfy our customers with our comprehensive approach


M+W ProcessAutomation

Engineer

ChemistryUser

Integrated Project Organisation

ProcurementEng Contr.

Project ControllingEng Contr.

SchedulingEng Contr.

Engineering Automation

PAArchitecture

Construction ManagementEng Contr.

Project LeadEng Contr.

QualificationEng Contr. /PA

Process-EngineeringEng Contr.


VT-UpstreamEng Contr.

VT-DownstreamEng Contr.

PCSPA

InstrumentationPA

Electric Engineering

PA

Package UnitsPA

DevicesEng Contr.

DesignEng Contr.

TGAEng Contr.

Eqt /Piping PlanningEng Contr.

ConstructionEng Contr.

HVACEng Contr.

VT-UtilitiesEng Contr.

Measurement and control technology management

PA

Project Organisation

� Engineering Contractor is main contractor with integrated Automation partner

� Regular meetings with customer according to meeting plan (specific day and time)

� Process

� Automation

� Regular internal project meetings with all parties involved

� Status information

� Sharing of information of all parties


� Coordination

� Project handbook with basic project definitions such as:

� Responsibilities, project org. chart customer and the Engineering Contractor

� Flow of information, e.g. project email addresses of the customer and the Engineering

Contractor

� Numbering systems

� Document templates in Word, Excel, meeting minutes

Planning process overview: Plant engineeringC

on

cep

t

A0Automation

Concept

A1URS PCS

A2Purchasing

PCS

G1Instrument list

( tag list )

G2Device-

specification

E1Consumer list

E2Specification

El. comp.

P1Specification

PU

P2Purchase PU

Q1Validation

master plan

Instrumentation

Ba

sic

Electrical PCS Package Units QualificationE+I installation

M1Erection / install.

Specification

De

tail

Q2SOPs


Co

mm

./O

Q

PCS

A3Functional

specification

A4Implementation

PCS

A5Erection-/

installation PCS

A6Commissioning

PCS

specification

G3Device-

purchasing

G4manufacturing

El. comp.

E3Purchase El. comp.

E4Manufacturing

El. comp.

P3Manufacturing

PU

P4Assembly PU

P5Commissioning

PU

Q3

Test

specifications IQ

Q4

Test

specifications OQ

Q5Execution IQ

Q6Execution OQ

Man

ufa

ctu

r./

Co

nstr

ucti

on

(IQ

)

Specification

M2Loops drawings

Hook ups

M3Purchase

Erection / install.

M4Erection /

installation

M5Commissioning

Support

De

tail

Execution Functional Specification (FS)

CreationPCD* and R+I

Activity PA

Release PCD* and R+I

Activity Eng. Contractor


Internal review FS

Review / release with customerFunctional Specifications

Creation FS

* PCD – Process control description

Execution Electric Engineering

Transfer in facility layout

Determine local install. place + qty., qty. MCC- and control cabinets

Activity PA

Creation consumer lists, tag list, facility layout , equipment

arrangement drawings

Activity Eng. Contractor


Transfer in facility layout

Determing cable trays (main and single)

Transfer in TFA Planning (MV/LV main distribution)

Determining power consumption per source,

(motors, control cabinets, RIO, SVI)

Transfer in TFA planning(Layout main cable tray)

Factors of Success

� We have a long and successful partnership with EPC’s in the field of planning of

various plants in the chemical, pharmaceutical and biotech industries

� 25 years experience in automation

� Over 600 engineers of which majority are long-time employees

� 450 of them are focused on automation


� Many projects jointly executed with EPC contractors

� Professional and effective teams with a minimum of interfaces

� Fast internal agreements, decisions are made efficiently and promptly

� Using web tools for internal data exchange

��one experienced team

Our view on the automation market

Easy Project Classification Complex

Low Risk High

Little Value Engineering High

Many Competitors Few

M+W GROUP


With functional responsibilitiesPeople leasing

Reimbursable servicesEngineering / Execution

of single projects

Engineering & Supply ofcomplete solutions in a

partnership


Doc.-Vers.: 1

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