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Project design

Flawless project
execution
ABB is the main automation and electrical contractor
for large industrial projects worldwide
Mike Connolly, Josh Caglar

As the pace of technology develop-


ment increases and the demand for
increased plant efficiency and im-
proved power consumption drives the
design of industrial facilities, manu-
facturers and plant operators are
turning to automation and electrical
product developers like ABB to pro-
vide industrial solutions that meet the
technical and execution requirements
of these complex facilities.

66 Process Automation Services & Capabilities


ABB Review
Flawless project execution

Project design

T his approach moves the product


developers from their traditional
role of vendor/equipment supplier –
1. The scope of supply involves ser-
vices and products, with the em-
phasis on the ability to provide the
solution and not the products that
make up the solution.

providing equipment to a customer- services element 2 . The scope of Second, it requires participation in the
developed specification – to that of an work requires participation of the FEED phase where the MAC/MEC
independent contractor performing MAC/MEC throughout the full proj- works closely with the customer and
the role of an engineering, procure- ect lifecycle, from front-end engi- overall plant designers to develop the
ment and construction (EPC) contrac- neering and design (FEED) to com- system concept and basic operational
tor and provider of engineered solu- pletions and startup. specifications.
tions 1 . ABB defines this role as that 2. The work requires significant coor-
of a main automation contractor dination and information exchange Third, once the project moves into the
(MAC) or main electrical contractor between multiple project partici- full execution phase, the MAC/MEC
(MEC). In making the transition from pants. has the responsibility, in addition
vendor to contractor, the MAC/MEC is 3. The MAC/MEC is responsible for to providing the product solution,
required to adopt a more proactive coordination of the overall systems to provide coordination and inter-
approach during the execution of the and manages the interfaces to facil- faces between the major EPC contrac-
work. This requires close cooperation itate integration. tors. This ensures that the concepts
with the client organization and other and requirements developed during
contractors and suppliers to develop There are also significant differences the FEED phase are implemented
best-in-class solutions, as well as to from a project execution perspective effectively and that design standard-
implement those solutions across the where these types of projects involve ization is achieved across the facili-
facilities and manage the interfaces multiple participants including process ties.
with other participants to ensure ef- designers, construction contractors,
fective integration of all components utility providers, regulatory authorities Fourth, the MAC/MEC provides the
and systems. and government agencies. product solution utilizing its own
products in combination with third-
This EPC approach is distinguished First, the scope of work is broader party products, integrates these with
from the traditional vendor/supplier than a conventional vendor/supplier the process and utility equipment pro-
role in three significant ways: scope and is focused on the overall vided by the EPC contractors, and as-

1 ABB’s comprehensive product and systems offering in power and automation technologies covers the entire spectrum of an
integrated scope of supply

Con-
HV & MV LV IndustrialIT Smart sulting /
Safety
Power Power MCC's Drives Motors Automation Telecoms field Analyzers HAZOP
systems
Dist. Dist. Solutions instr. / SIP /
HSE

Main electrical contractor Main automation contractor


(MEC) (MAC)

Flawless project execution


Risk management Greater operability
Lower project-cycle costs Lower training costs
Integrated technology Ease of life-cycle maintenance

Process Automation Services & Capabilities 67


ABB Review
Flawless project execution

Project design

sists with the installation of the com- Project execution between the MAC/MEC and the EPC
pleted systems under the direction of ABB’s execution methodology is contractors during each major project
the EPC contractors. based on modern project management phase. The map depicts the four main
techniques supported by well-trained project phases:
Finally, the MAC/MEC has responsibil- and qualified professional resources FEED
ity to work under the direction of the and proven systems and tools. The Detailed design, engineering and
EPC contractors at the construction focus of the approach is ensuring that manufacture
sites to achieve final commissioning the project scope is well defined at Construction/installation
and startup of the facilities. the outset, that the work is planned Completions and closeout
well in advance of execution activi-
ties, that execution responsibilities are FEED participation
ABB has developed identified and agreed upon between Early involvement in the development
a robust project execu- all participants, and that detailed proj- stage of a project has a tremendous
tion methodology that ect-specific plans covering all aspects impact on the overall effectiveness of
of the work are established, imple- the final solutions selected. The long-
provides customers mented and followed. term benefits achieved by “getting it
with a level of service right” early in the project yield results
To support the project management in total cost of ownership savings.
not available from the process, ABB has developed the MAC/
traditional EPC contrac- MEC Project Execution Map. The map The MAC/MEC participation in the
tors. outlines the structure and scope of a FEED phase of the project lays the
typical automation or electrification foundation for the development of a
project from the FEED phase through best-in-class solution for the project.
As a global leader in the design and to completions and acceptance. The The FEED phase has two basic ele-
supply of process automation and map provides information on the pri- ments: a technical aspect and a work
power systems for a broad range of mary execution processes and the var- process aspect. Working in coopera-
industries, ABB has easily made this ious project plans needed to support tion with the plant owner and process
transition from main product vendor flawless execution during the various designers, ABB utilizes its unique
to overall solutions provider. Leverag- project phases. The map portrays the combination of technical expertise
ing its expertise around the globe, relationships between the internal and detailed product knowledge to
ABB has developed the “Book of execution processes of the customer, provide the technical concept defini-
MAC/MEC,” a robust project execution MAC/MEC and the EPC contractors, tion, project standards, common func-
methodology that, combined with ex- and how these processes interact and tional design criteria and generic
tensive product and industry knowl- integrate in order to achieve a com- equipment specifications. The FEED
edge, provides customers with a level mon approach for project execution. phase is also the period when the
of service not available from the tradi- The map also indicates the high-level management systems and specific
tional EPC contractors. technical interface points that exist project plans to be employed during

2 A MAC/MEC approach provides value to the owner/operator in all phases of a project Factbox ABB MAC/MEC projects

MAC/MEC scope ABB has implemented numerous projects


Services
Project management as the main electrical and automation con-
Engineering design tractor on behalf of many of the world’s
Procurement Execution leading hydrocarbon companies in onshore
Configuration / Integration capability and offshore locations all over the world.
Startup Applications include gas distribution pipe-
Commissioning
lines, gas processing plants, offshore oil
Training
and gas platforms, onshore oil production
After market services MAC/MEC
facilities, and oil refineries.
value

Products ABB is a leading supplier of power and au-


Process control system tomation products, systems and solutions
Instrumentation and analytics to the oil and gas industry, with a complete
Fire and gas systems Technical
and integrated scope of supply capability
Power products capability
that ranges from plant electrification to
Electrification systems
control, optimization and safety systems,
Networking
Telecommunications smart field instrumentation, analyzers and
telecommunications systems.

68 Process Automation Services & Capabilities


ABB Review
Flawless project execution

Project design

project execution are defined and de-


veloped. Each organization (owner,
designers and ABB) has its own inter-
nal standards and requirements for
executing its work. These internal
processes reflect the basic tenets of
the respective organizations and are
the foundation for how each of them
approaches the various execution
phases. A balance between the proj-
ect-specific requirements and the
basic work processes of each of the
participants must be achieved. Basic
integration of the respective work
processes is necessary to make the
transfer of critical engineering data
and documentation possible. This
integration of work processes and
establishing a common approach to
execution are key elements in achiev- tabase. The status of all agreements is globally. The model structure is very
ing flawless execution. To facilitate monitored and reports produced on a flexible, allowing its elements to be
this, ABB utilizes the Interface man- regular basis indicating the overall tailored to reflect local practices, local
agement1) process. status. Constant monitoring highlights regulations and regional variations in
areas of criticality that can be quickly approach while maintaining a com-
Interface management addressed and brought under control. mon execution framework. This pro-
Interface management is one of the vides ABB with the ability to execute
most critical processes in achieving on a truly global basis making full use
flawless project execution. It involves The long-term benefits of its regional centers of excellence,
identifying and controlling the flow of achieved by “getting it high value engineering centers and
critical information between major global execution centers. It also pro-
project participants. For complex in- right” early in the project vides a common execution language,
dustrial projects there are multiple yield results in total cost allowing ABB to make full use of its
project participants, each of whom global resource pool to match the “on
will require data (technical, schedules,
of ownership savings. demand” resource requirements of
etc.) from other participants in order complex projects.
to perform their work. The timely Interface management is just one of a
identification, development and ex- complete suite of processes employed The ABB execution capability, cou-
change of this data are crucial to proj- by ABB in the overall execution mod- pled with ABB’s broad products port-
ect success. The interface manage- el. The processes have been devel- folio, technical expertise and global
ment process facilitates this through oped as a result of participation in manufacturing facilities, offers custom-
early identification of the data re- major projects around the globe cov- ers a range of project services that
quired and by establishing formal ering a wide variety of customers and provide predictable and consistent
agreements between the supplier and industrial sectors. These processes are results and help customers deliver
receiver on the required data and the foundation of flawless execution. their business objectives.
when it is to be delivered. They are based on the premise that
the work to be performed is fully de-
The process utilizes formal, docu- fined and responsibilities for execu-
mented interface agreements created tion are agreed and allocated. Goals
between ABB and the other project and objectives for success are estab-
participants. Agreements are also cre- lished and strategies developed to
ated internally within the various units achieve success. The strategies form
of the ABB organization to provide the guidelines for action planning. Mike Connolly
visibility of critical data and informa- Creation of the detailed plans, imple- Josh Caglar
tion. Each interface agreement has an mentation of the plans and constant ABB Process Automation
information owner (the sender) and monitoring of actual performance to- Houston, TX, USA
an information recipient (the receiv- wards achieving the defined objectives michael.connolly@us.abb.com
er), and lists the specific information are the keys to successful execution. josh.c.caglar@us.abb.com
required and the delivery require-
ments for it. Each interface agreement The ABB execution model has been Footnote
is given a unique identification num- developed using project management 1)
See “Information exchange” on page 70 of this
ber and is logged in the interface da- best practices and is implemented issue of ABB Review Special Report.

Process Automation Services & Capabilities 69


ABB Review