Fluor’s SmartPlant Instrumentation Implementation A Success Story

Name: John Dressel

Title: Principal Applications Specialist

Date: June 14, 2009

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Global SPI InitiativeConsiderations for establishing SmartPlant Instrumentation (SPI) as the Global Control Systems Reference System Software in all Fluor engineering centers around the world.

Number of offices and membersInconsistency between officesUnique Business Sectors Levels of local trainingTime differencesLegacy SystemsStandardizationDeliverables

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Global SPI InitiativeIn 1998 it was determined that Fluor needed a Control Systems automation tool that had the global capability of serving 20 Engineering Centers in 10 countries

The tool had to assure consistency between offices by using a data centric approach to engineeringThe tool needed to be flexible enough to meet the needs of several Fluor Business SectorsThe tool needed to be well documented and have tutorials and user training availableThe tool had to be web enabled and capable of round the clock operation across different Time zonesThe tool had to have at least an equivalent functionality of the Legacy Systems already in use in several Fluor officesThe tool had to assure standardization by having spec libraries, reference tables and default engineering data built inThe tool needed to create all the deliverables associated with the latest process control systems

The logical choice for Fluor’s Reference System at that time was INtools Later INtools was acquired by Intergraph and renamed SmartPlant Instrumentation

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Method for positioning SPI as the Fluor global reference system software for the Control Systems department

Organization Plan

Communication Plan

Implementation Plan

Training Plan +

Organization Plan

Communication Plan

Implementation Plan

Training Plan

Global Implementation=

Global SPI Initiative

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Control Systems Functional Leader

Leadership Team

Executive Sponsor

Global Automation Team

Global SPI Technical Specialists

Application Specialists TrainersAdministrators

User Base

Global SPI Initiative Manager

Leadership TeamsLeadership Teams

Intergraph Resources

Corporate

Global

Local

External

SPI Organization Plan

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Corporate OrganizationExecutive Sponsor – Highest ranking SPI administration team member – responsible for program funding and corporate standardizationControl Systems Functional Leader – Global discipline SPI coordinator – responsible for SPI budget dispersal and discipline standardization Global Automation Team – corporate engineering automation members – responsible for corporate wide reference system software distribution

Global SPI Implementation membersGlobal SPI Initiative Manager – Reports to the Functional Leader to develop and execute the SPI implementation plan Global SPI Technical Specialists – SPI Application specialist who develops SPI global work processes and training programs

External Support ServicesIntergraph – Software Licensor – Fluor established an extended agreement for access to Intergraph Sales Representative and Software Technical Support TeamAdditional Resources – Fluor maintains service and support contracts with Intergraph in several countries, Overload Services Inc. in the U.S. and CadView in Europe

SPI Organization Plan

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Local Leadership TeamsSPI Administrators – Each Fluor project is assigned one or more Administrators to setup the SPI database and maintain the implementation specification. The SPI administrator acts as the SPI lead on the project and is the primary SPI support source

SPI Application Specialists – Depending on the project scope, the local leadership team may require application specialists. These specialists or SPI Administrators are trained in the more obscure functions of SPI and often work multiple projects as needed

SPI Trainers – Local SPI trainers are available on the projects to assist users in developing their SPI skills. Trainers may be administrators, Specialists or Super Users with the ability to do One on One or Group training

SPI User Base – Every member of the Control Systems department assigned to projects are expected to use SPI to perform their specific project functions.

SPI Organization Plan

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Communication PlanDefine a clear objective of the SPI Communication PlanCreate and publish a Key Contacts and SPI Champions MatrixEstablish a SPI Knowledge Management System and Web PortalDevelop Knowledge Management SPI specific contentDefine Communication Methodologies▪ E-mail ▪ Summits▪ Telephone ▪ Net-Meetings▪ World Wide Web▪ Wide Area Network

SPI Communication Plan

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The objective of the SPI Communication PlanProvide each Fluor SPI user clear and concise information relating to the use of SPI and the most current support data available

The Global SPI Champions MatrixA list of SPI experts from all Fluor offices that are available to answer questions and offer user support on any project or in any Fluor office

The SPI Knowledge Management System (Knowledge Online)Fluor’s industry leading Knowledge Management System with Knowledge Packs and Forums devoted to SPI

The SPI Communication methodologies▪ E-mail – All champions email addresses are published to user base ▪ Summits – Global summits to train and align SPI champions from all offices▪ Telephone – All champions are available for telephone consultation ▪ Net Meetings – Periodic Net Meetings and workshops to discuss latest functions▪ World Wide Web – Create Websites to provide access to global user community ▪ Wide Area Network – Use of Knowledge Online as a resource for SPI documentation, user

guides and work practices

SPI Communication Plan

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Initial Implementation PlanEstablish SmartPlant Instrumentation as the official Global Reference system

Create internal support mechanism for Global, Local and Projects support

Determine level of support required and develop licensing agreements

Review existing global infrastructure to assure it meets the needs of SPI

Conduct office visits, summits, presentations and seminars to promote SPI

Develop SPI Operating Practice (Implementation Specification).

Create Standard Fluor Global Seed Files so projects initialize from a common basis with standard profiles and spec sheet libraries.

A BTO

SPI Implementation Plan - Then

THAT WAS THEN

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Current Implementation PlanRequire Global Reference system (SPI) to be used on all Fluor projects

Use the SPI Global Champions Matrix for Global, Local and Project support

Maintain corporate licensing agreements with Intergraph and support services

Do performance Validation and Verification of each new version of SPI

Conduct office visits, summits, presentations and seminars to support SPI

Require an SPI Implementation Specification on every project

Develop project seed from Implementation Specification or use client SPI seed

Fluor members actively participate in SPI user community activities

A BTO

SPI Implementation Plan - Now

THIS IS NOW

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SPI Training Plan – Key to SuccessGlobal SPI Training Plan

Establish permanent SPI Training Budget

Train the Trainers and use them to train the SPI users

Train the Trainers in all Intergraph SPI courses

Supplemental training from Oracle and other resources

Modify and develop SPI Tutorials to fit Fluor practices

Do SPI upgrade training after every major release

Local training plan to train all Control Systems SPI users

▪ Use Just-In-Time and On-The-Job training methods▪ Develop SPI Trainer in each engineering center▪ Use Fluor developed SPI Tutorials and Guides▪ When necessary use onsite training at the user location▪ Place training materials on KOL for self training

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FLUOR SPI Implementation specificationDefines SPI scope of work for all Fluor projects. Defines SPI configuration, support tables and deliverables

SPI Implementation Successes

Standardized SPI Global Work Processes

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FLUOR utilization of SPI Process ModuleProcess engineers load process data directly into SPIUse the SPI workflow to control process dataProcess engineers own the process dataSeamless process data flow to Instrument datasheets

SPI Implementation Successes

Cross Discipline Work Practices

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FLUOR Work Sharing Using SPIInter-discipline work sharing with SPI database.Use of high value work centers in Manila and New Delhi.Working in a global environment with Citrix.Shared SPI data with Clients and other Engineering companies

SPI Implementation Successes

Work Sharing using SPI Work Processes

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FLUOR SPI user training and developmentAll Control Systems members receive SPI training.Update training for technical support team members.Fluor developed SPI training presentations, manuals and guides.Knowledge Online and dedicated Knowledge Pack for SPI.

Build Large SPI User Base

SPI Implementation Successes

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SPI Implementation SuccessesFLUOR SPI Technical Support Team

SPI administrator on each project.Gets SPI support directly on the taskforce. Opens opportunity for One on One User training.SPI Global champions in every Fluor office

Communications – SPI Summits

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SPI Implementation SuccessesFLUOR realized savings using SPI

Time savings using “Out of the box SPI” and “Seed files”Cost savings when deliverables are electronic files Savings using data sharing capabilities of SPI Improved accuracy equates to reduced field costsEliminate cost of supporting and maintaining Legacy Systems

Global SPI Implementation = Savings

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SPI Implementation Successes2008 FLUOR SPI – INtools Global Resume

Used SPI or INtools over the last 11 years on 180 projects executed in 20 different Fluor offices generating almost 4000 segment diagrams and over 250,000 loop diagrams

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SPI Implementation Challenges Not every part of Fluor’s SPI Implementation Plan was a total success!

Fluor SPI Seed file concept was ineffective because no two projects were consistent enough to take advantage of it – The Fluor seed file was replaced with the Implementation SpecificationCreating deliverables over Citrix Server was unsuccessful because of generation speed over a remote connection and licensing issues – We now create all deliverables at the SPI database serverUsing “out of the box” spec library forms was costly because we were required to modify every spec to add P&ID numbers and ISO 9000 revision signature fields for almost every project – We now use overlaid title boxes and modified spec libraries.Using custom external reports failed because they weren’t transportable from version to version and some custom reports created with Access or Infomaker were declared intellectual property – Used SPI browser views as deliverable report forms Import of new tags into SPI had issues because users did not use the SPI Import Utility properly and took too many short cuts resulting in database corruption – Prohibited the use of the Import Utility for introducing new tags to the SPI Project databases

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Global SmartPlant Instrumentation Utilization

What’s Next ? – Fluor’s Next Generation Project Execution Solutions are enabled by a solid, data-centric foundation that enables multi-office and multi-party execution and rule based automation. At its core are the Intergraph SmartPlant® suite of tools, including SmartPlant Instrumentation and SmartPlant Foundation.