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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?



– 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


engineering

TighterProject Schedules

Increased focusOn TCO

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


Technical Processes

Manual Labor Tools





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


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:


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


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


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


– 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


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


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



Projects / Engineering

Manager


Manager


Manager

PCSD Program Director

PCSD Program Technical Lead


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


– 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


• 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


a resolution





Technical Processes

Manual Labor Tools

Industry Industry driversdriversIndustry Industry driversdrivers

– Globalisation

• Increased competition

– Shorter time-to-market for our End-Usersproducts

• Tight project deadlines


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


� 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.


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


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


– 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:


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





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


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


� 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


� 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


Example Example –– Project ManagementProject Management


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


� Swimlane format defines who is responsible for the activity

� Links provided to key enterprise level tools for Estimating, Project management and Document Management





Technical Processes

Manual Labor Tools

Industry Industry driversdriversIndustry Industry driversdrivers� Increased difficulty to find qualified automation

engineers

� Forecasting difficulties

� Once again, Globalisation


Customer Benefits Customer Benefits Customer Benefits Customer Benefits � Access to a larger pool of qualified (specialised)

engineers

� Better cost

� Faster project execution


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


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


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


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


Transition

DeltaV Upgrade

Hardware

E&I

Strategic Proposals

C&I

Ovation SIS

AO Support

SBG SW Development & Support

Sales of $20.3bn (2010)

Emerson globallyEmerson globallyEmerson globallyEmerson globally


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


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


Measurement Instruments Asset Management

DeltaV ArchitectureDeltaV ArchitectureDeltaV ArchitectureDeltaV Architecture


Roundup Roundup -- Questions?Questions?Roundup Roundup -- Questions?Questions?


Novo Nordisk / Emerson Confidential, Slide 48

emerson process management - sesam...

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