Fluor’s SmartPlant Instrumentation Implementation

A Success Story

Name: John Dressel

Title: Principal Applications Specialist
Date: June 14, 2009
Global SPI Initiative
ƒ Considerations for establishing SmartPlant Instrumentation (SPI) as the
Global Control Systems Reference System Software in all Fluor engineering
centers around the world.
ƒ Number of offices and members
ƒ Inconsistency between offices
ƒ Unique Business Sectors
ƒ Levels of local training
ƒ Time differences
ƒ Legacy Systems
ƒ Standardization
ƒ Deliverables

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 Global SPI Initiative
ƒ In 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
ƒ The tool had to assure consistency between offices by using a data centric approach to
engineering
ƒ The tool needed to be flexible enough to meet the needs of several Fluor Business Sectors
ƒ The tool needed to be well documented and have tutorials and user training available
ƒ The tool had to be web enabled and capable of round the clock operation across different Time
zones
ƒ The tool had to have at least an equivalent functionality of the Legacy Systems already in use in
several Fluor offices
ƒ The tool had to assure standardization by having spec libraries, reference tables and default
engineering data built in
ƒ The tool needed to create all the deliverables associated with the latest process control systems
ƒ The logical choice for Fluor’s Reference System at that time was INtools
ƒ Later INtools was acquired by Intergraph and renamed SmartPlant Instrumentation

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

ƒ Organization Plan Organization

Plan

ƒ Communication Plan Communication

Plan

ƒ Implementation Plan Implementation

Plan

+
Training
ƒ Training Plan Plan

= Global
Implementation

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SPI Organization Plan

Corporate Executive Control Systems Global

Sponsor Functional Leader Automation Team

Global Global SPI Initiative Manager Global SPI Technical Specialists

External Intergraph Resources

Leadership Teams Leadership Teams

Leadership Team

Local Administrators Application Specialists Trainers

User Base

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SPI Organization Plan
ƒ Corporate Organization
ƒ Executive Sponsor – Highest ranking SPI administration team member – responsible
for program funding and corporate standardization
ƒ Control Systems Functional Leader – Global discipline SPI coordinator – responsible for
SPI budget dispersal and discipline standardization
ƒ Global Automation Team – corporate engineering automation members – responsible
for corporate wide reference system software distribution
ƒ Global SPI Implementation members
ƒ Global SPI Initiative Manager – Reports to the Functional Leader to develop and
execute the SPI implementation plan
ƒ Global SPI Technical Specialists – SPI Application specialist who develops SPI global
work processes and training programs
ƒ External Support Services
ƒ Intergraph – Software Licensor – Fluor established an extended agreement for access
to Intergraph Sales Representative and Software Technical Support Team
ƒ Additional Resources – Fluor maintains service and support contracts with Intergraph in
several countries, Overload Services Inc. in the U.S. and CadView in Europe

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SPI Organization Plan
ƒ Local Leadership Teams
ƒ SPI 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

ƒ 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

ƒ 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

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

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SPI Communication Plan
ƒ Communication Plan
ƒ Define a clear objective of the SPI Communication Plan
ƒ Create and publish a Key Contacts and SPI Champions Matrix
ƒ Establish a SPI Knowledge Management System and Web Portal
ƒ Develop Knowledge Management SPI specific content
ƒ Define Communication Methodologies
▪ E-mail
▪ Summits
▪ Telephone
▪ Net-Meetings
▪ World Wide Web
▪ Wide Area Network

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SPI Communication Plan
ƒ The objective of the SPI Communication Plan
ƒ Provide each Fluor SPI user clear and concise information relating to the use of SPI and the
most current support data available
ƒ The Global SPI Champions Matrix
ƒ A 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
ƒ The SPI Knowledge Management System (Knowledge Online)
ƒ Fluor’s industry leading Knowledge Management System with Knowledge Packs and Forums
devoted to SPI
ƒ 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

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SPI Implementation Plan - Then
ƒ Initial Implementation Plan
ƒ Establish SmartPlant Instrumentation as the official Global Reference system

ƒ Create internal support mechanism for Global, Local and Projects support

ƒ Determine level of support required and develop licensing agreements

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

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

ƒ Develop SPI Operating Practice (Implementation Specification).

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

THAT WAS THEN

A TO
B
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SPI Implementation Plan - Now
ƒ Current Implementation Plan
ƒ Require Global Reference system (SPI) to be used on all Fluor projects

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

ƒ Maintain corporate licensing agreements with Intergraph and support services

ƒ Do performance Validation and Verification of each new version of SPI

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

ƒ Require an SPI Implementation Specification on every project

ƒ Develop project seed from Implementation Specification or use client SPI seed

ƒ Fluor members actively participate in SPI user community activities

THIS IS NOW

A TO
B
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 SPI Training Plan – Key to Success
ƒ Global SPI Training Plan
ƒ Establish permanent SPI Training Budget

ƒ Train the Trainers and use them to train the SPI users

ƒ Train the Trainers in all Intergraph SPI courses

ƒ Supplemental training from Oracle and other resources

ƒ Modify and develop SPI Tutorials to fit Fluor practices

ƒ Do SPI upgrade training after every major release

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

Standardized SPI Global Work Processes

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 SPI Implementation Successes
ƒ FLUOR utilization of SPI Process Module
ƒ Process engineers load process data directly into SPI
ƒ Use the SPI workflow to control process data
ƒ Process engineers own the process data
ƒ Seamless process data flow to Instrument datasheets

Cross Discipline Work Practices

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

Work Sharing using SPI Work Processes

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

Build Large SPI User Base

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 SPI Implementation Successes
ƒ FLUOR SPI Technical Support Team
ƒ SPI administrator on each project.
ƒ Gets SPI support directly on the taskforce.
ƒ Opens opportunity for One on One User training.
ƒ SPI Global champions in every Fluor office

Communications – SPI Summits

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

Global SPI Implementation = Savings

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SPI Implementation Successes
ƒ 2008 FLUOR SPI – INtools Global Resume
ƒ 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
ƒ Not every part of Fluor’s SPI Implementation Plan was a total success!
ƒ 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 Specification
ƒ Creating 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 server
ƒ Using “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.
ƒ 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
ƒ 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.

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