eBook

Agile Project Execution

The future of Industrial Process Automation projects

Yokogawa Electric Corpora1on. 2015

v1.4

EMK(VDS)-TR-EB-01 APEX eBook

Table of Contents
Intro

Agile Project Execution

Page 2.

Chapter 1

Conventional Project Execution

Page 4.

Chapter 2

Agile Project Execution as a Solution

Page 10.

Chapter 3

How can we do things better?

Page 21.

Yokogawa Electric Corpora1on. 2015

Evolving Automation Technology & Changing Project Execution

Process automation is undergoing major changes,
driven by customers desire for technological advances
from the main automation system integrators in the
industry. Representatives from different industries are
driving vendors like Yokogawa to re-evaluate how
large-scale automation projects are implemented.
The customer message is clear: projects take too long;
they are too engineering-intensive; and the automation
systems frequently become the critical path in the final
stages, often causing the project to fall behind
schedule.

Individually and collectively, they are applying their

knowledge of best practices and lessons learned to
answer the question, How can we do things better?
As a result, Yokogawa is being guided by the industries
it serves to develop and improve solutions that provide
the reliability, operability and safety expected from
control system platforms. Yokogawa is also being
asked to improve methodologies for assembling,
executing and deploying a complex process solution
with improved efficiency, lower installation cost and
greater adherence to schedule.

With several hundred major automation projects

executed globally each year, the industry system
integrators can draw on several decades of
experience working in various industries and with a
range of technologies.

Yokogawa Electric Corpora1on. 2015

Agile Project Execution

Most innovations tend to advance two main
categories: 1) project management and 2) technical
improvements. These two categories are deeply
intertwined on multiple levels and, as such, can work
together to improve projects.
This eBook will address Yokogawas vision on Project
Execution. We know that the challenge for automation
providers is, to develop technologies combined with
project execution processes designed to create the
greatest possible value.
The key to achieve this is, is to reduce or remove the
dependency of application engineering on the
hardware implementation, eliminate the constraints of
marshalling and termination, and allow system
independent commissioning of IO loops (no DCS
database required). The software side of automation
can be engineered and tested in a similar modular
fashion, independent of the actual target hardware
which can be assigned flexibly at any stage in the
project. Yokogawa calls this:

This approach to automation utilizes key Yokogawa

technologies to achieve smart, decoupled software
and hardware engineering, using a modular design
approach with flexible project implementation.
In order to better understand the evolving automation
landscape and the way automation projects are being
executed is changing, we will define what we call the
conventional project execution methodology in
chapter 1. We will also address the main challenges that
arise with this conventional approach.
In chapter 2 we dive deeper into the technical aspects
of these challenges and we will describe how
Yokogawa deals with them according to our Agile
Project Execution vision for automation projects.
In chapter 3 we will answer the main question: how can
we do things better?
For now, we hope that you will enjoy reading this eBook.

Agile Project Execution (APEX).

Yokogawa Electric Corpora1on. 2015

3.

CHAPTER

Yokogawa Electric Corpora1on. 2015

4.

From Serial to Parallel

For the last few decades, most projects have followed the same basic path. Each phase of this conventional
path takes place in a serial fashion and builds on the previous effort, shown in figure 1:

Conven@onal Project Execu@on

Fig. 1 -

Project Delivery
+ Start Up

Project Start
Deni1ons,
Standards, Detailed
Func1onal
Specica1ons

Control Logic,
Graphics, Alarms,
Procedures

SoQware to
Hardware Binding

Design
Applica1on
Hardware
Field Installa1on
Loop Check
Hardware, Cabinets
Marshalling, Ship to
Site

Hardware Installa1on,
Wiring, Device Congura1on,
Signal Termina1on

High
Applica1on
Dependency on
Hardware and
Field Wiring

Project Risk
Mi1ga1on
Yokogawa Electric Corpora1on. 2015

5.

5 Basic Project Phases

For the past few decades, most projects have followed
the same basic path shown in figure 1. Each phase
takes place in a serial fashion, as each builds on the
previous efforts:

Control logic, graphics, alarm configuration, tuning

parameters and so forth can be applicationengineered in this 2nd phase by a software team in a
single or in multiple locations.

1. The design phase typically includes development of

the functional, detailed specifications, and agreement
on project engineering standards, schema and,
sometimes, resources.

At the same time, controllers, I/O cabinets,

marshalling boxes and enclosures can be
manufactured, wired and tested by another
specialized team.

Deni1ons, Standards,
Detailed Func1onal
Specica1ons
Design

Control Logic, Graphics,

Alarms, Procedures
Applica1on
Hardware

2. This leads to the 2nd phase, the main engineering

work, which can be grouped into hardware-related and
software-related activities. During this phase it is
desirable to have as much parallel engineering as
possible with these activities, and the conventional
model achieves this up to a certain point.

Hardware, Cabinets
Marshalling, Ship to Site
Yokogawa Electric Corpora1on. 2015

6.

3. The significant dependence of application

engineering on the design hardware is a challenge. An
automation application must be configured to fit the
very specific controller, I/O module, marshalling,
termination and wiring plan for which it is designed.
4. Upon site delivery, the application piece is bound to
the hardware loop by loop. The conventional model
refers to this as binding. Late binding allows enough
time in the schedule for project design changes to be
implemented in both hardware and software before
final binding. Flexible binding, as we will show later on
in this eBook, allows for these changes, as well as
reconfiguration, at any point in the project.

5. Either after or during loop commissioning, the owner

signs off on the automation project, and the plant
starts up. Depending on the business environment,
schedule flexibility in start-up may be acceptable, but
late is never desired.

SoQware to Hardware
Binding

Field Installa1on

Hardware Installa1on, Wiring,

Device Congura1on, Signal
Termina1on

Loop Check

Yokogawa Electric Corpora1on. 2015

7.

Impact of Design Changes

If events unfold as planned, the
project can stay on schedule,
although the schedule might be
longer than the company considers
desirable. However, most projects
do not run exactly as planned
because process engineers may
realize a vessel is not in an ideal
location, the distillation tower is not
large enough, or another pump
needs to be added at some point
to maintain sufficient flow. Any of
these process equipment changes
will create process automation
system changes by moving or
adding hardware and related
instrumentation.

As figure 2 shows, such changes can extend the time necessary for
one or more project phases due to re-work, ultimately stretching out
the schedule and eventually pushing the project past the start-up
deadline. The automation system now becomes the critical path
item holding up the schedule.
Fig. 2 - Conven@onal Project Execu@on: impact of design changes
Project
Delivery +
Start Up

Project Start

Design
Applica1on

High Applica1on
Dependency on
Hardware and
Field Wiring

Hardware
Field Installa1on
Loop Check
Changes
Re-work

Late data changes can impact all

project pieces and require
engineering re-work

Project
Risk
Mi1ga1on
Yokogawa Electric Corpora1on. 2015

8.

Summary

As we have seen, any of the process equipment

changes will create process automation system
changes as well by moving or adding hardware and
related instrumentation.
The impact of such changes becomes all the greater
as the project moves farther along. Once it has
moved into the loop commissioning phase, late
arriving changes are expensive.

The conventional project model therefore, with its

high interdependency of the hardware and
software, cannot not respond well to late-arriving
changes. In the next chapter we will show how
Yokogawas Agile Project Execution approach
offers a solution to this challenge.

Such changes can extend the time necessary for one

or more project phases, ultimately stretching out the
schedule and eventually pushing the project past the
start-up deadline.
The automation system often becomes the critical
path item, delaying start-up and the realization of
revenue from the new installation.

Yokogawa Electric Corpora1on. 2015

9.

CHAPTER

Yokogawa Electric Corpora1on. 2015

10.

The Agile Approach

As described earlier, the challenge for many automation
providers is to develop and implement new technologies
combined with project execution processes designed to
create the greatest possible value.
In order to achieve this, the key is to reduce or remove
the dependency of application engineering on the
hardware implementation. Yokogawa calls this Agile
Project Execution (APEX).
This approach to automation utilizes key Yokogawa
technologies to achieve smart, decoupled software and
hardware engineering, using a modular design
approach with flexible project implementation.
By effectively separating the project into hardwareindependent and system-independent layers, it is
possible to advance the hardware project further
toward completion, with less consideration of the
application project status.

Utilizing System-Independent Loop Commissioning,

project activities normally requiring a completed
system, such as I/O-to-device loop commissioning,
may be accomplished with a mobile device before
the main controller is operating.
With the Agile Project Execution, application and
hardware can be equalized at any time, and final
binding can occur at any flexible time in the
schedule to ensure an airtight schedule as the
project advances toward final delivery.
In this chapter we will first outline the technical
aspects of the problem and then dive deeper into
our solution called Agile Project Execution.

Yokogawa Electric Corpora1on. 2015

11.

Technical Aspects of the Problem

and Solution

Compressing a project schedule by including more

parallel, instead of serial, activities depends on the
ability to decouple many elements of the process
and mechanical design from the automation system
details. To be effective, this requires a method of
maintaining overall project management and
information for automation software and hardware
layers, equalizing engineering documentation, and
facilitating final binding.
One reason why traditional automation projects
make such decoupling difficult is the highly
customized nature of the hardware, particularly I/O
and field wiring. These designs cannot be finalized
and built until the process and mechanical portions
of the plant are completed.

A typical example is as follows: A vessel in the

process needs a level sensor to ensure that the
amount of liquid is beyond a given point. For the
sake of simplicity and economy, a level switch is
specified with a digital on/off output and an
appropriate I/O channel created in the control
system to receive the signal. However, the process
designer later decides that it is critical to know the
actual level, and requests a modification.
A level transmitter must now be deployed in place
of a level switch alone, so it is necessary to change
from a digital signal to a 4-20 mA (HART) signal. Such
a change might not seems substantial, but in the
real world it can involve a whole series of steps, from
hardware implementation to documentation
updates. Multiply this process by a few (or even
dozens of) such changes, and construction begins
to fall behind schedule.
Fortunately, there is a solution to this problem, and it
lies with more flexible I/O systems.

Yokogawa Electric Corpora1on. 2015

12.

N-IO: Smart, Configurable

N-IO (Network I/O) is a key technology for Agile
Project Execution. It simplifies the whole process of
wiring field devices and supports flexible binding.

So when changes comes late in the project, such as

the shift from a point level sensor to a level transmitter,
as mentioned previously, it is a simple matter to
reconfigure the connection point in the cabinet.

Several industrial automaton vendors have

developed smart, configurable I/O technology
capable of supporting multiple signal types on a perchannel basis, and this development is arguably the
most critical for the parallel execution of process/
mechanical and automation system design.
It can support multiple signal types on a per-channel
basis, and this development is arguably the most
critical for parallel execution of process/mechanical
and automation system design (Fig. 3).
Increase in I/O count over the project duration can
be accommodated with a standard cabinet
mounted with N-IO, which can then be assigned
after termination earlier or later in the project.

Fig. 3. Congurable N-IO cabinets are a key element of new

project management techniques.
Yokogawa Electric Corpora1on. 2015

13.

N-IO: Smart, Configurable

The capability for changing configurations, as
described on the previous page, along with the
flexible binding of the automation hardware layer to
the software layer, support a seamless transition to
the final phase of project completion, without gaps
in the schedule. This is because much of the
hardware loop validation is accomplished during
system-independent loop commissioning. When the
I/O cabinet is in place and the field devices are
installed, the performance of the field device and its
interaction with the relevant final control element
can usually be verified, even before the control
system is installed.
When changes come late in the project, such as
with the point level sensor to a level transmitter
example, it is a simple matter to reconfigure the
connection point in the cabinet. This capability for
changing configurations, and flexible binding of the
automation hardware layer to the software layer,
supports a seamless transition to the final phases of
project completion without gaps in the schedule.

This is because much of the hardware loop validation is

accomplished during system-independent loop
commissioning using a Field Asset Validation and
Diagnostics tool, as we will show later on.
N-IO increases the independence of the automation
system from the process/mechanical design since it
supports system-independent loop commissioning.
Utilizing N-IO as part of Agile Project Execution can result
in very significant reduction in complexity, hardware and
total installation cost for the engineering firm, or end
users.

The new CENTUM VP DCS

Yokogawa Electric Corpora1on. 2015

14.

1)
2)

3)
4)

5)

6)

7)

It supports multiple signal types on a per-channel basis

Once a transmitter is replaced and all hardware tasks are
finished, the necessary application change can be done
centrally. All data and documents are consistent at any
time.
Spare hardware channels are 100% available at any time
without delay or physical adjustment
Application functions can be assigned to any available
hardware channel at any time during flexible binding,
enabling more independence in application engineering
and reducing project risk. No rewiring or exchange of signals
is required.
I/O cabinets can be ordered, shipped and wired as a
standard item, since they require no project specific
engineering (except size and layout), marshalling cabinets or
field terminations.
Changes in any section (Hardware, Software) do not affect
the other due to Flexible binding. Flexible binding of the
hardware layer to the software layer is achieved to
seamlessly transition to project completion without gaps in
the schedule, as much of the hardware loop validation is
accomplished during System-Independent Loop
Commissioning.
Marshalling cabinets are eliminated along with most
termination points. The number of wiring terminations from
each device to the control system is reduced from 20 or
even more, to perhaps 5.
Yokogawa Electric Corpora1on. 2015

15.

Field Asset Validation and Diagnostics

Another common element of the configurable
N-IO system is their ability to use latest digital
communication protocols for communication
with smart field devices, typically instruments and
analyzers. With natively supported
communication in place, the diagnostic
information form these smart field devices can
be gathered and used in a sophisticated assetmanagement program.
When the I/O cabinet is in place and the field
devices are installed, a field asset validation and
diagnostics tool can be used to verify
performance of the field device and its
interaction with the relevant final control
element, even before the control system is
installed.
System-Independent Loop Commissioning
The field asset validation and diagnostics tool
takes advantage of PCs and the software
configurability of N-IO to allow not just the
activation and configuration of the I/O modules,
but also the device-to-field loop check and
validation. This can happen if the devices are
available in the field, or as part of modular skid
building.

A screenshot of Yokogawas field asset validation and

diagnostics tool FieldMateTM Validator

Yokogawa Electric Corpora1on. 2015

16.

The Workflow for System-Independent Loop Commissioning & Flexible Binding

The workflow for system-independent loop

commissioning & flexible binding is very
simple:
1. While the application development work
is being done, I/O tags and information
can be exported and imported into the
field asset validation and diagnostics tool.
2. With that information, I/O tags can be
assigned to the real physical I/O, allowing
field loop check and validation much
earlier than conventionally possible.
3. With the field site instruments connected
to the I/O, accuracy and function checks
can also be carried out.
4. Reports can be generated after all the
fieldwork is completed.
5. Updated I/O information can be
transferred to the master database for
central application access.

Export &
Import
informa1on
transferred
to the
master
database

Generate
reports

Assign I/O
tags

Accuracy
and
func1on
checks

Yokogawa Electric Corpora1on. 2015

17.

Late Binding vs Flexible Binding

Flexible Binding:

Convenience to Avoid Rework

One of the most important parts of systemindependent loop commissioning is flexible

binding. The concept is simple, but results in huge
improvements.
Flexible binding allows assigning or re-assigning
any field I/O item to application control functions
at any convenient phase in the project.
Traditional conventional models make this
practical only during final site delivery of the
complete system, and then as costly rework.

Late binding is useful, allowing the hardware and software

pieces of a project to be developed in parallel and then
brought together, validated and tested late in a project;
however if there is any re-work beyond this phase, the cost is
high. Additionally, it means loop testing must wait until final
binding.
Flexible binding using a field asset validation and diagnostics
tool supports an even higher degree of separation, allowing
field loop checking to be carried out even earlier.
Yokogawa Electric Corpora1on. 2015

18.

The Software Story: Modular Control Engineering Software

Class based modular control engineering with
modular control engineering software is the
unifying element in the agile project execution
approach. Modular control engineering software
is, or should be, the central engineering
application and database for all aspects of an
automation project, making it a major element of
the larger Agile Project Execution program.
Modular control engineering software condenses
operating and procedural information into class
modules able containing:

Standardized engineering graphics

Control logic
Process-related intellectual property
Alarms
Loop tuning tools and parameters
Configurations for single pieces of equipment

These design patterns can be accessed from a

central repository managed by end users,
integrators and engineering firms.

The design patterns can utilize global and industry-based

class module libraries available for project engineering to
greatly reduce overall engineering effort for unique
applications by using defined project rules.
Modular control engineering software functions handle bulk
engineering, change management and auto
documentationreducing overall application engineering
time while adhering closely to company or project
standards.
Class modules provide a very useful way to capture and
institutionalize industry automation knowledge and best
practices, which is a critical activity as a wave of
experienced people move into retirement in the automation
field.
Most process automation vendors also maintain an extensive
library of class modules for various industry applications.
End users, integrators, engineering firms and technology
licensors can also maintain their intellectual property in local
class module repositories, taking advantage of modular
control engineering software and bulk engineering to
deploy standardized, tested applications.
Yokogawa Electric Corpora1on. 2015

19.

Modular Control Engineering Software

Automation Design Suite: Yokogawas smart engineering environment

The Automation Design Suite, Yokogawa's new engineering environment, retains the entire engineering history of your
plant from design phase, through commissioning and live operation; which ensures up-to-date plant knowledge with
every expansion, or hardware and software change throughout your lifecycle.
Yokogawa Electric Corpora1on. 2015

20.

CHAPTER

Yokogawa Electric Corpora1on. 2015

21.

Putting Technical Advances to Work

When N-IO, system-independent loop checking with a field asset validation and diagnostics tool
and flexible binding are used together with modular control engineering software, different functions can now
overlap to shorten project execution time and reduce required engineering resources.
With this project methodology,
there is significant risk reduction
as a result of parallel
engineering, reduced
automation hardware-tosoftware dependence, flexible
binding, and reusing
engineering modules and best
practices.
There is also additional
reduction in total project
installed cost due to much less
wiring, marshalling and field
terminations.
Additionally, project software
changes are accommodated
independent of field hardware
installation.

Automation
System
Changes
Yokogawa Electric Corpora1on. 2015

22.

Reducing Project Execution Time

Using these products and techniques, it is possible to envision
both parts of the automation effort, hardware and software,
as independent pieces assembled from reusable modules. This
allows each to follow its own schedule in parallel rather than in
serial, greatly reducing project execution time. More
equipment is purchased off-the-shelf, already engineered and
tested to relevant standards, then shipped and assembled in
modular fashion, with flexible binding applied at the
appropriate time.
This approach allows design changes and problems related to
late data to be contained within a particular execution piece,
reducing overall project impact. In fact, it becomes possible to
construct an entire process unit or skid, offsite, with its
associated devices, wiring, piping, equipment and so forth,
and mount N-IO cabinets as part of completed unit.

Yokogawa Electric Corpora1on. 2015

23.

A Flexible Approach

Process skid and unit device and I/O loops can be

checked and commissioned offsite, independent of
the plants automation system design specifics. The
construction and hardware piece can be factory
accepted, and then the entire unit can be shipped to
site for assembly and connection with the rest of the
plant, or adjacent units, all independent of the actual
application engineering or system platform at the site.
Process control system OEMs and user companies are
increasingly using engineering resources scattered
around the world. These resources can work with
growing class module libraries to avoid the need for
writing code from scratch specifically for a single
project.

Customers, integrators and suppliers alike are looking

for ways to use intellectual property repeatedly,
reducing time and costand class modules address
these needs.
New technologies from Yokogawa are making these
engineering approaches possible and more
practical.
They provide a great benefit to EPCs and technology
licensors, who can now protect their own technology
as well as execute projects utilizing these
methodologies to provide greater value.

Yokogawa Electric Corpora1on. 2015

24.

Thanks for reading this eBook!

For more detailed information about
Yokogawa & Agile Project Execution
Yokogawa offers a Free Consultation

Agile Project Execution

The future of automation projects

Author:

Eugene Spiropoulos
Business Consultant for
ProcessManagement&

Manufacturing Solutions

CLICK HERE
For a Free Consultation

About Yokogawa
Yokogawa's global network of 88 companies spans 56
countries. Founded in 1915, the US$3,5 billion conducts
cutting-edge research and innovation. Yokogawa is
engaged in the industrial automation and control (IA), test
and measurement, other business segments.
The IA segment plays a vital role in a wide range of
industries including oil, chemicals, natural gas, power, iron
and steel, pulp and paper, pharmaceuticals, and food.
More information: www.yokogawa.com

Yokogawa Electric Corpora1on. 2015

EMK(VDS)-TR-EB-01 APEX eBook