CHALLENGES IN ENGINEERING MANAGEMENT OF HIGH TECHNOLOGY SYSTEMS IN INDUSTRIAL PROJECTS - INDIAN PERSPECTIVE

A. Soni', Subir Ghosh'

'General Manager 'Dy. General Manager

Engineers India Limited 1, Bhikaiji Cama Place, New Delhi-110 066, India

-- Abstract- Challenges to manage the whole team work in industrial projects having engineering efforts of multidisciplinary team are enormous. Coupled with this the rapid innovation in every field of engineering and information technology systems have made great impact in technology and its management in such an environment. The cultural aspects of companies in particular and countries in general do add to the complexity in such management. The paper discusses these aspects taking examples of electrical, control and instrumentation disciplines where fast developments are going on in technology itself.

INTRODUCTION - - _ _ ~ - - Industrial Projects requiring a million engineering manhours for their implementation are not uncommon. Efficient deployment and dovetailing of multi-disciplinary skills has been a challenge for decades. The advent of Electronic Data Processing and enormous desk top computing capability was expected to bring in some relief. But even before we had got some hands-on experience, the expectations of the clients in terms of integrating the new innovations in the various fields of engineering in their new projects and reviewing various options of operations prior to implementation made the task even more complex. ' Further, for survival alone, the engineering companies need to operate globally. This requires knowledge of not only local rules, regulations and site specific parameters but an understanding of the culture of the country and the company. Thus contrary to all expectations of reductions of manhours input for implementation of large project because of the availability of high speed high quality implementation tools like computers, there has been perhaps a marginal increase because the new requirements have more than consumed the savings. It may perhaps suffice to take one example of innovations in technology in one area to demonstrate the impact. Keeping in view the field of interest of the audience, we selected to review the developments in the area of Electrical

Controls and Instrumentation.

Last three decades have seen a rapid change of technology in control and instrumentation discipline in terms of innovations, product development and applications for productivity improvement. The availability of inexpensive microprocessor chips (and hence single board computer and digital transmission technology) coupled with use of fibre optic media have entirely changed the scenario of supervision and control of industrial plants and the control panel part of electrical and instrumentation systems. With the introduction of new equipment and technology, advances in plant engineering activities, construction techniques and methodology have also taken place.

We have two classes of plants in real life:

a) A geographically bounded plant/ process (i.e. a petrochemical complex or a refinery).

b) A geographically distributed plant/process (i.e. a pipe line and power system)

Control and instrumentation system as applicable to above two classes of plants can be sub-divided into generic categories - Distributed controls and telesupservisory systems. For the pipeline and large power systems apart from telesupervisory system, an elaborate telecommunication system in also used.

The paper covers the various equipment in electrical, control and instrumentation system both for a plant within a geographic boundary and a plant which is geographically distributed, and the traditional. issues in engineering and construction management of these plants and how advanced methodologies have entered the scenario over the years. The planning and control of electrical, control and instrumentation jobs with modern technology e.g. computer aided management of man, material and quality assurance based on modern concepts of work

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break down structure is addressed. Their use in case of advanced level telecommunication and Telesupervisory system of a major pipeline project is discussed. We take this example as this represents large scale activities in the class of systems under our consideration and also represents the case of another cross country industry i.e. power system.

DESCRIPTION QE ELECTRICAL, CONTROL ANJ INSTRUMENTATION SYSTEM

Electrical, control and instrumentation system of a typical petrochemical or similar plants where activities are concentrated at one location and also for pipeline system where activities are distributed are outlined below:

-I Electrical _I---- ----- Plant --- and WgQment

Electrical plant in a facility has two subsystems i.e. generation system and distribution system. The electrical generation system has following equipent:

a!

b!

C)

d:

e!

f!

g :

h)

i)

Electrical generator-steam turbine, ?as turbine or diesel engine driven .First two are more popular).

Electrical switchgear - High, hqediur.1 and Low Voltage.

Transf ormers

Variable speed drives

Control panel {ConventionaliCRT based consoles!.

Cables - Power/Control/Communication.

Uninterrupted power supply system {Both A.C. and D.C.!

Lighting equipment.

Digital relays.

Apart from these, plant communication and fire alarm systems are required as part of overall safety system.

Electrical equipment in distribution plant are similar to above excepting the generating equipment at item a.

Amongst the new type of equipnent, switchgear with SF6 and vacuum as interrupting media, XLPE cables, Jelly filled cables, Nickel cadmiiln or alkaline batteries, cast resin transforlners, solid state variable speed drives have appeared in past two decades. Another important introduction has been the distributed microprocessor based remote supervision and control units with colour cathode ray tube, consoles, hard copy printers, and

colour copiers. These systems have replaced the conventional control panels (in some plants both are used together to facilitate operation in case of failure of microprocessor based system!. A data high way and sensor high way in some cases are run along the plant/units/substations for connecting various units. Last decade has seen introduction of a new element i.e. data high way and sensor high way of coaxial/fibre optic cable and their associated erection accessories e.g. a metallic duct for the cables in the plant equipment list.

In the communication sector, electronic PABX is becoming popular and due to very powerful evolving technology of digital communication, plant EPABX, communication system with paging facilities and fire alarin system are getting integrated into one sub-system.

Instrumentation gontrol System and - Equipment: Traditional instrumentation for a plantla pipeline include the following:

i: Pressure, flow, level and temperature measuring device and transmitters.

ii) Special measuring devices.

iii: Control valves and isolation valves.

ivb Analyser equipment.

v! Control panel.

vi) Flow computers.

The instrumentation/control sub-system has undergone tremendous change in the digital era with the introduction of distributed digital control system and

of electrical/digital signals . In this section hereinafter we will cover the case of pipeline with brief coverage on power system.

In case of a pipeline the system is identical for control of compressor/pump station to that for a typical petrochemical plant but different for a remote supervisory control for the entire piaeline. These class of systems are called telesupervisory systems having remote terminal units along the pipeline for data collection and command reception. The central station has computer, colour CRT, printer, co?ier and misic panel. The structure is similar in case of power system having control equiprnent in substation and for overall system.

Pipeline and power system operations are

transinission

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also aided by elaborate telecommunication facility for SCADA signals !Telemetry and Telecontrol signals) and voice signals (Local subscriber, Hot line telephones, Conference telephones, Mobile telephones, Facsimile signal and Teleprinter signals). To facilitate this 1 . 5 GHZ multichannel digital multiplex radio link, telephone exchange system, 150 MHZ mobile radio system, j satellite communication system, Auxiliary equipment (Facsimile, Teleprinter, Conference telephone etc.). Fibre optics or conventional cable media are also used. Telecommunication systems require certain cross country activities such as installation of towers, antenna, earth station and repeaters and laying of cables.

The telesupervisory and Telecommunication system and distributed computer control systems are different class of systems and are not extensions of traditional instrumentation activities. Specifically trained manpower having appropriate expertise is required to handle these. Only-plant interface items and cabling can be handled with conventional instrumentationfelectrjcal d i sci pl ine experience.

Software product/equipment

Over the years distributed digital control systems for both the electrical plant and process plant and Telesupervisory systems for pipelines and power system have grown in sophistication due to impact of fast growing field of software technology. A large part of engineering, installation, testing and commissioning is dependent on engineering and integration of softwares. Softwareffirmware for basic DIDC, SCADA and Telecom equipment (as applicable), advanced control and supervision system and the popular "application software system" for pipeline and power system project is providing greater challenges to project implementation, while creating a new work environment during the engineering phase, installation phase and commissioning phase and finally €or process operation and control for respective team. Successful system implementation calls for integrating the expertise drawn from vendor I s engineering, installation and commissioning personnel with the experience and knowledge of consultant's and owner's personnel.

TRADITIONAL ENGINEERING ANJ CONSTRUCTION ~CTIVITIES ELECTRICAL CONTROL AND

SYSTEM ADVANCES IN

In the sections below we discuss the basic engineering and construction activities in electrical control and instrumentation

' system and take note of changes/advances

that have taken place due to impact of new Technology and equipment. we will highlight the work connected with both engineering and construction by taking the case of construction activity first as this will reveal the aggregate work at site, which can be completed with greater accuracy if engineering work is done properly. Accordingly a close look at aggregate work at site and installation methodologies is necessary to assess total involvement in a project as well as to comprehend the engineering office's task. Further in our high technology systems as defined elsewhere we have been organising one team in a project or in a group of projects for engineering and specialised construction and commissioning activities for the requirement of specific specialisation. This has been the practice of some other companies as well. From this angle, a close look at aggregate work at site and installation methodologies is necessary to assess total involvement in a project .

Electrical construction activity is bas

i)

ii!

iii

For

cally centred around :

Equipment installation, testing and commissioning.

Cable laying, jointing and termination.

Control circuit checking and commissioning.

equipment erection. like generator, transformer, switchgear etc. technology has not changed much over .the years except that the following variant3 have some impact on erection:

i) Skid mounted equipment like generator e.g. gas turbine driven generator.

ii) Cast resin transformers with no requirement of handling oil as in traditional transformer.

iii) Introduction of SF6 switchgear !GIs) requiring additional precautions to prevent leakage.

In these areas advancement has taken place in the field of equipment handling and installation methodologies. New cable jointing procedures and cable ducting/trenching with new material have appeared.

Instruments installation activity is basically:

1 ) Field instrument, control valve installation.

2 ) Instrument cable laying, jointing and termination.

3 ) Instrument air line installation.

4 ) Field panel and marshalling rack installation.

5 ) Control panel installation.

In case of instrument installation the advancement has taken place mostly towards changing the instrumentation philosophy

distributed digital control system and their associated equipment. In case of field instruments continuous advancement is taking place i.e. from pneumatic to analog to digital transmissionlgeneration of signals. These have their own problemlmethodology mostly affecting the interface connection and commissioning. Mechanical installationlprocedure still remains the same.

altogether, i.e. introduction of

Engineerinq 4ctivities

Engineering activities connected with the above systems can be sub-divided into basic engineering and detailed engineering. During the conceptual design various system design options are evaluated and parameters having maximum impact on project implementation are finalised. These include design of the major systems/equipment, energy conservation measures , system optimisation, degree of plant automation, maintenance and flexibility needs, provision of future expansion etc.

Detailed engineering is the actual production phase of the engineering work. During this time, based on the system design finalised during the conceptual design stage/basic engineering stage, detailed design of the systems and facilities are developed, equipment specifications are completed and purchase orders for the equipment are released. Also, the construction drawings are prepared alongwith material take-off for procurement of the bulks.

Efficient management of resources during the engineering phase of the project plays a critical role in successful implementation of project within estimated costr anticipated schedule while maintaining overall quality which in the long run ensures the profitability of the organisation.

These class of systems are basically four:

i) Distributed digital control system.

ii)

iii)

iv)

Energy management system for utility system (e.g. Electrical Control System).

Supervisory control and data acquisition system.

Telecommunication system using microwave, satellite and fibre optic (or twisted pair.with loading coil and PCM cable) media.

These systems have appeared in large scale since early eighties. The engineering and installation methodology have come from EDP systems and traditional analog communication systems. Equipment with newer technology are being used for testing and commissioning of these systems. We can broadly classify activities for (i) to (iii) above as under:

a) Activities in central control station.

/ b) Activities at remote locations in

plant/sub-station.

In central control station following equipment are involved:

i)

ii)

iii)

iv)

V)

vi )

Computer

CRT based console.

printer and Copier

Magnetic media storage items.

Mimic panel.

Controller subsystem, Data acquisition subsystem, PLC panels and network interface panels.

Central control station equipment are normally installed on raised floor, in air conditioned environment and with EMI/RFI shielding. Manufactures are giving good guideline for floor preparation and grounding of equipment. Inter panel cabling is done below the floor.

These systems [item (i) & (ii)] also need data high way viz. coaxial/fibre optic cable and require a duct for their running in the complex. This duct is a new item which involves co-ordination work with cable trench, pipe rack and road crossing for cables in the complex. These need grounding also at intermediate locations.

In remote station we have remote data acquisition units (e.g. remote terminal units) and field multiplexer. These units are erected like any panel and have well defined guidelines for their erection and cable termination and grounding.

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These systems need good care for computer grounding and EMI/RFI shielding and air conditioning for system reliability.

ADVANCED TECHNIQUES 90% ENGINEERING AND CONSTRUCTION MANAGEMENT

Engineering management sf technology - - systems

We will cover in our discussion a DCS systems, a DCS based energy management system, a SCADA system and telecommunication system. In some cases these equipment are ordered on vendors as part of turnkey supply of a large system e.g. a power plant or a pipeline. The turnkey contractor engages specialist vendors for engineering and supply of equipment and in many cases the installation, testing and commissioning is also included in the contract. At engineering stage, the management of engineering is controlled by an Indian consulting company and essentially the various aspects of engineering design are broken down into several distinct activities and the contractor is encouraged to submit documents covering the aspects of each stage of design and engineering.

Major documents are:

Functional design specification and basic design document.

Equipment selection basis and material requisition.

Input/output list, data base document and man machine interface document.

Equipment layout, ergonomics study and control room layout.

Detailed engineering documents.

Factory acceptance test document.

Site acceptance test document.

Test run document.

These activities are new elements in our engineering office work and was absent a decade back.

Indian engineeqng companies have also to gear up in termg of speed at which these documents are to be disposed of and they are to match with the very high speed of first world suppliers in submitting these documents. These challenges are usually being met by engineers of developing countries like ours only by dedication to work. The engineering office environment needs to be more computer based enabling individual engineers using computers for

producing 110 list data base documents, interconnection drawings and graphics for onward transmission to vendors. These demands will increase further with more sophisticated systems appearing in market due to ever increasing innovation in digital systems. The communication system in engineering offices with engineer controlled fax machines, telephones with STD/ISD facilities and E-mail facilities and copying machines and secretarial assistance with computerised typing are all necessary to meet the challenge.

Apart from increased infrastructural and secretarial requirements, it is necessary to organise a team of trained professionals for these works and to continue updating the knowledge base of the team by imparting appropriate training. Engineering companies should also install a compuper based simulation platform to check effectiveness of various control and on line simula'fion and optimisation algorithms for laying down appropriate specification and assessing possible benefits of implementation of such systems. This would enable them to serve their client interests better. This computing environment could be interfaced to the CAD and other computing environment normally available in engineering offices and this would enable them to share data base resources over a network.

Computerised management techniques -- construction

K.T. Oakley Ltd (consulting engineers in U.K.) have developed and used a method for computerised management techniques. This system v~as made operatiopal in 1978 with much benefit in engineering and construcfion management of a project. This is reported here as an example case and similar arrangement can be chosen for large projects.

- Cmomuterised Management of Contractgi The tasks for cabling and erection work can be classified as:

i)

ii)

iii)

iv)

V)

Issuing work to contractor

Planning the work

Co-ordinating the work with that of other contractors.

Organising resources.

Control of the work, progress monitoring, valuation and cost control.

By 3 suitable computer network having computer at corporate office and site offices on the net work, it may be

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possible to have appropriate control of constpuction job. This has been done for CEGB project where erectable items were 15000 for power plant, 20000 for control and instrumentation and 30000 for lighting, small power heating and ventilation. Computer and terminal configuration for the same is shown in Annexure 1 (Computer and Terminal Configuration).

The data flow architecture for the same is shown in Annexure 2 (Data flow architecture).

Eo Breakdown Structure (WBS) For definite control of engineering and construction effort, use is made of the work breakdown structure concept. It is intended to accomplish the following ob j ec t ives . 1 . Correlate tasks, schedules, manhours,

performance and technical interfaces.

2. Relate plans directly to objectives

We briefly mention this technique by citing an example of construction progress measuring of a large pipeline project in India.

Different WBS was established for the fiJe different types of divisions in the system.

- Earth station

- Radio Relay System

- Master Station

- VHF Mobile

- Telecom system

The work categories were split in seven categories:

i) Civil work

ii) Repeater station

iii) Master station equipment

iv) Earth station equipment

v) Electrical work in Master station

vi) Air conditioning in Master station

vii) Completian of integration/ commissioning.

Weighted value of each division in a work category was established and weighted value of each work category in a division was also established.

Work category and work item list of two representative work e.g. equipment installation and electrical work in Master Station is given below for better clarity of the concept.

Equipment installation

Work category WBS Work item

Installation WB1 Hardware X WB2 Scada Y

software WB3 Application Z

software WB4 Pre- W

commissioning

WB5 others K

Weighted Value

(X + Y + Z + W + K) = 100

Electrical work

W* Category

WByB Work Weighted Value Item

WB1 Main X

WB2 Distribution, Y equipment

lighting, plugs, telephone

WB3 Commissioning Z WB4 Others W

( X + Y + z + W) = 100

The progress percentage for each work category is calculated by summing up the weighted value of each work item in the work category.

Pp = Sum (Pi x wi)

Pp = Progress of work category

Pi = Progress of work items

Wi = Weighted value of the work item in the work category.

coNcLus1oN

The paper is concerned with bringing out the salient features of the work connected with engineering and construction management for high technology systems in an industrial project. The work connected with two distinct disciplines e:g. electrical, control and instrumentation has been considered as- example cases. These works impose a great challenge for engineering and construction management due to increasing innovation in technology in various fields. Use of computer aided engineering and computer aided monitoring and work break down structure have been discussed in effective management of these activities.

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