Fig. High-Level OpreX Agile Project Execution Model
OpreX Agile Project Execution is the Yokogawa’s innovative method for delivering the process automation systems. The desired outcome of an OpreX based project is an on-time, non critical path delivery of the project allowing for flexibility in application software development, hardware delivery based construction schedules and late changes in the automation system.
OpreX processes enable application development and hardware manufacturing to be executed in parallel without interactions as shown in the above figure.
Executive Summary
Value Propositions
Yokogawa's OpreX Project Execution is an innovative approach utilizing standardized technology and flexible project execution processes to keep automation off the critical path during project execution. OpreX technology based projects result in:
- Lower cost of project execution
- Lower cost of installation
- A lower Total Cost of Ownership (TCO)
- Flexibility in project execution and delivery
- Lower project execution risks
Goals
The goals of OpreX Project Execution during the project lifecycle are:
- To increase the probability of the capital project success
- Keep Automation execution off the critical path of the capital project delivery
- To provide a high quality, integrated automation system based on the desired scope of supply
- For the integrated system to realize operational excellence
- To commit to customer satisfaction
Key drivers and Enablers for OpreX Project Execution
There are three key drivers for the OpreX delivery model: Virtualization, Modularization and Validation with the enablers as shown in the figure below.
Fig. Three key drivers and Enablers
Details
Virtualization
It consists of three solutions, Remote Delivery model, Cloud Based Engineering – yi-CLOUD, and Target System Virtualization.
Fig. Value drivers enabled by Virtulization
Remote Delivery (GDC)
Yokogawa’s global engineering resource centers (Global Delivery Centers) trained to implement OpreX, work on project engineering, perform third party system testing and testing of control and safety systems.
yi-CLOUD (CEE/CET)
Fig. Virtual Engineering & Test System in Cloud
No matter where the target system is being developed and no matter where the team members are located, Cloud Enabled Engineering and Testing provide stakeholders -Yokogawa’s front office and back-office operations, EPC(s) and end-users, the ability to implement and test the project application development.
Virtualization (Runtime)
Fig. Runtime Virtualization for Yokogawa ICSS Image zoom
It enables multiple virtual machines on a single physical server and the number of physical PCs and system cabinets can be reduced to help lower footprint, power & heat, cooling, and maintenance costs.
Modularization
It consists of N-IO based Standard Enclosure, Smart Junction Box (Smart JB) as hardware platform and Automation Design Suite (AD Suite) as software platform with Industry Libraries.
Fig. Value Drivers enabled by Modularization
Configurable I/O (N-IO with AD Suite)
N-IO with AD Suite enables application development and hardware manufacturing to occur in parallel without dependencies. N-IO supports multiple signal types on a per-channel basis and simplifies field device wiring, eliminates the need for marshalling systems and supports flexible binding. N-IO eliminates the need for specific wiring assignments and full utilization of all points in a module.
Fig. N-IO Universal I/O module
Standard Enclosure (with N-IO)
Fig. Standardized ICSS System Architecture
Standard enclosure enables standardization and ensures consistent design and quality. The use of N-IO eliminates cross-wiring and marshalling cabinet engineering. The I/O cabinet is fully standardized with software configurable I/O. Hardware engineering and the design approval processes are minimized with this standard enclosure approach. In this standards approach, enclosures can be ordered by datasheet without the repetitive recycling of drawing approvals. Everyone - Yokogawa, EPC and customer, benefits from reducing engineering man-hours in the design approval process
Smart JB (N-IO)
Fig. Filed Wiring Reduction by Smart JB
N-IO components are designed to be installed in the field. With Smart JB, field devices can be directly connected to the N-IO system. This Smart JB concept provides a significant benefit during construction. Thick and heavy-weight homerun cables are replaced by thin and light fiber optic cables and power cables. Total cable weight, cost, cable trays, related field engineering and documentation (e.g. loop diagrams) can be significantly reduced.
GES Industry Libraries (AD Suite)
Industry Library is one of the key components of Yokogawa’s Global Engineering Standard (GES) Toolkit as a foundation for the module-based engineering approach and it provides a pragmatic way for knowledge management in industrial automation and improves the application of best practices. The main objectives of the GES Toolkit are:
- To make use of proven implementations (learned from others)
- To enable consistent design & implementations
- To improve implementation efficiency
- To reduce known risks
Validation
It includes the various elements to fulfil requirements.
Smart DCS Engineering (Module Eng. with AD Suite)
Fig. Value Drivers enabled by Validation
Module-based engineering utilizing Yokogawa’s AD Suite is the unifying element in the OpreX Project Execution approach. AD Suite is the central engineering application and database for all aspects of an automation project. Yokogawa's engineering platform brings features that enable flexibility to project execution and Key features include:
- Bulk Engineering
- Modular application Engineering
- Automated Document Generation
- Late changes and Flexible Binding
- Re-use application assets (GES Industry Library, Customer standard application etc.)
- Change Management for traceability throughout the project lifecycle.
AD Suite retains the entire engineering history of the plant from design phase through commissioning and live operation, ensuring up-to-date plant knowledge with every expansion or hardware and software change throughout the system lifecycle.
Fig. Smart DCS Engineering
Smart SIS Engineering (Module Eng.)
Similar (almost identical) to the DCS application development, modularized application development is executed for Safety, ESD and F&G systems following the OpreX processes and workflows. This includes the use of Smart JB with Universal, Safety N-IO and configurable cabinets. Hardware follows the same application independent process as the DCS and can be shipped as needed for construction. Application development also follows the same modular development process and remote, continuous testing process previously described.
Functional Safety Management (FSM)
FSM is essential for the SIS project execution and it aims to reduce hazardous impact to human life, environment, and property to a socially acceptable risk level throughout a plant’s safety life-cycle. Yokogawa is applying FSM to the realization of Safety Solutions in accordance with the international standards IEC-61508 and IEC-61511. This is achieved by rigorous application of Yokogawa global procedures coupled with independent certification by the internationally respected TÜV Rheinland organization.
Fig. Yokogawa‘s FSM
Commissioning Support Package (F-CSP/PRM CSP)
Early devices and electronic check and site engagement are possible using Yokogawa’s N-IO and Filed – Commissioning Support Package (F-CSP). F-CSP performs N-IO node configuration and Input/Output validation and HART parameter download without the controller present. F-CSP validates the physical side of the field device and IO connection. PRM CSP Commissioning Support Tool can perform loop check automatically for HART devices through field control station. It is the tool supporting the works of connection, loop, range, engineering unit, signal conversion and interlock check for field digital field devices (HART and FOUNDATION Fieldbus H1) during commissioning phase and aims to achieve to:
- Reduce of commissioning time for field devices and its cost
- Improve the quality of commissioning of field devices
Flexible Binding (F-CSP with AD Suite)
Once the field information is validated by use of the Commissioning Support Package, it is reflected back into the system engineering database. The reflected database automatically binds into the application software. This is known as flexible binding which:
Fig.Late Binding vs Flexible Binding Image Zoom
- Allows for early shipping of Field Enclosures
- Facilitates early completion of field work without requiring the entire system to be ready at site.
- Enables flexible binding with DCS/SIS at any stage of SAT.
- Enables smoother commissioning and start-up.
- Accommodates late changes
The system has the full capability to accommodate any late modification and late change without compromising the overall project schedule.
Process Simulator (LCDS)
Dynamic Process Simulation has evolved over recent years. This has enabled simulation technology and a Life-Cycle Dynamic Simulator (LCDS) to be widely applied. The primary deliverables of LCDS throughout the project life-cycle are:
- Dynamic Process Simulation Model - Development of the process plant dynamic simulation model
- ICSS configurations & integration - Integration of the dynamic process model with an emulation of the automation system configuration
- ICSS Checkout - Testing with pre-defined operating scenarios (start-up, operations, abnormal conditions, alarm management)
- Operator Training – Testing of new ICSS platform, Standard Operating Procedure (SOP) validation and competency verification for initial and refresher training
LCDS deliverables can be progressively developed, used, re-used, and enhanced throughout the design & build and operation & maintenance phases of the project.
Foundation for Life-Cycle Management
Once the project has been turned over to the operations team, the OpreX methods provide the foundation for a sustainable plant all of the automation systems in the plant. A sustainable plant is Yokogawa‘s concept to maintain and improve the installed automation system providing a safe, secure, and robust installation at the lowest possible lifecycle cost. For more detail information, please check Sustainable Plant and Yokogawa System Upgrade Solution.
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