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The CEN ORCHID Roadmap
Standardising Information in the
Plant Engineering Supply Chain
                  Implementation Guide
Contents

Overview                                                                              Page 1



Key Implementation Steps for Information Standardisation                              Page 2



STEP 1:                                                                               Page 2
Understand key standardisation principles and the information standards relevant to
the business

STEP 2:
Assess the company’s position on the CEN ORCHID Roadmap                               Page 5

STEP 3:
Establish realistic targets for where the company wants to be on the CEN              Page 7
ORCHID Roadmap

STEP 4:
Plan and implement improvement measures                                               Page 8



Quick Wins                                                                            Page 8



ORCHID Contacts                                                                       Page 9
The CEN ORCHID Roadmap | Implementation Guide




Overview
The ORCHID (Orchestration of Industrial Data) Group is a            • More reliable plants
network of European companies and consortia dedicated to            • Improved safety and environmental performance
standardising information across the process industry engineering
                                                                    • Faster time to market
supply chain to build competitive advantage.
                                                                    • Lower costs
This document is a simple guide for companies on how to
                                                                    • Greater flexibility
standardise and exchange plant engineering information.
It aims to help companies achieve the following benefits of         The overall goal is to progress the industry toward the
standardisation:                                                    following vision of “interoperability”:



  “Companies in process industries shall be able to share and/or exchange
 electronically the information needed to design, build, operate and maintain
    process and power plants using internationally accepted standards.”

The key implementation steps are:


    STEP 1
    Understand key standardisation principles and the information standards
    relevant to the business


    STEP 2
    Assess the company’s position on the CEN ORCHID Roadmap



    STEP 3
    Establish realistic targets for where the company wants to be on the CEN
    ORCHID Roadmap


    STEP 4
    Plan and implement improvement measures


The practical steps outlined in this document are based directly on the CEN ORCHID Roadmap, which is described
in detail on the CEN website.




                                                                                                                              1
Step 1 Understand Key Standardisation
    Principles and Information Standards
    Relevant to your Business
    Key Principle 1: Agree and Document Core Internal                                                                          that are usually exchanged at each stage of activity across
    Business Activities and Processes                                                                                          the plant lifecycle.
    Companies need to codify and standardise internal business
                                                                                                                               Once this is done, companies can consult the CEN ORCHID
    activities and processes as the first step towards standardising
                                                                                                                               Landscape of Information Standards to identify the relevant,
    information for exchange internally and externally. This step alone
                                                                                                                               internationally accepted standards to use at each stage of the
    drives significant cost reduction and efficiency improvements
                                                                                                                               PISTEP Activity Model. Companies, application developers,
    before any information standardisation activity is undertaken.
                                                                                                                               service developers and standards development groups, are
    The CEN ORCHID Group recommends the PISTEP Activity                                                                        encouraged to use existing standards to prevent proliferation
    Model in Figure 1 below to help identify the information types                                                             of standards and reduce complexity (see Key Principle 2).




      Process Plant Engineering Activity Model
                                                                                                                                                                            Safety & Environment Case

        MANAGEMENT ACTIVITIES
                                                                                                                                                                                                                            REGULATORY
            SET ENGINEERING                         PRODUCE & MAINTAIN                CONTROL OPERATIONS                        OBTAIN
                POLICY &                               FEASIBILITY &                     & ENGINEERING                      AGREEMENT WITH                                                                                    BODIES
              STANDARDS                               FINANCIAL CASE                       ACTIVITIES                      REGULATORY BODIES
                                                                                                                                                                      Regulatory Requirements Authorizations



        Process Definition                                                          Performance Requirements                         As Built Drawings                                Plant Status
        Control Philosophy                                                          Operating Procedures                             Operating Procedures                             Ground Drains Status
        Costs, Benefits & Timings
                                                                                    Operating Conditions                             Acceptance Test results                          Safety Case
        Safety / Regulatory Requirements
                                                                                    Alarm / Trip Settings                            Handover Certificate                             As Built & As Modified Drawings
                                                                                    Safety and Environment Case



             PRODUCE
                                                                 PRODUCE DETAILED                                 COMMISSION PROCESS                                     OPERATE                                            DECOMMISSION
           CONCEPTUAL
                                                                  PROCESS DESIGN                                   & HANDOVER PLANT                                       PLANT                                                PLANT
          PROCESS DESIGN


            Process Stream Data               Detailed Process Design                                                         Engineering Work Requests
                                                                                 As Built Drawings                                                                                                      Plant Status
            Process Flow Diagrams             Availability Requirements                                                       Working Conditions Requirements
                                                                                 Equipment Commissioning Procedures                                                                                     Plant Records
            Costs, Benefits & Timings
                                              Safety Systems Specifications      Equipment Operating Procedures               Engineering Work Permits                                                  Inspection Requirements
                                              Operating Procedures               Inspection & Testing Records                 Acceptance of Engineering Work                                            Regulatory Approvals
                                              Codes & Standards                  Handover Certification

                                                                                                                              As Built Drawings
                                                                                                                                                                            Inspection Requirements
                                                                                                                              As Built Equipment Specifications                                              State of Equipment
               Preliminary Engineering Design                                                                                                                               Work Permit Requests
                                                                                           Detailed Engineering Design        Spares Lists                                                                   Value of Equipment
               Engineering Philosophies                                                                                                                                     Notification of Work
                                                                                           Equipment Procedures               Installation Procedures                                                        Equipment Records
               Availability Requirements                                                                                                                                    Completion
                                                                                           Vendor Drawings                    Maintenance Procedures
               Cost & Time Estimates
                                                                                           Spares Lists                       Inspection Results
               Safety / Regulatory Requirements
                                                                                                                              Unfinished Work Details
               Codes & Standards


                                                                                                                     CONSTRUCT &
                                                                 PRODUCE DETAILED                                                                                        MAINTAIN                                         DEMOLISH PLANT &
       PRODUCE CONCEPTUAL                                                                                           PRE-COMMISSION
                                                                ENGINEERING DESIGN                                                                                      EQUIPMENT                                           RESTORE SITE
           ENGINEERING                                                                                                   PLANT
             DESIGN

                                                Materials & Equipment                                                                                                                   Materials & Equipment
                                                Requirements & Specifications            Delivery Dates                                                                                 Requirements & Specifications
                                                                                                                                   Delivery Dates
        Materials & Equipment                   Required on Site Dates                   Vendor Drawings                                                                                Required on Site Dates
                                                                                                                                   Vendor Drawings
        Requirements &                                                                   Certification
                                                                                                                                   Certification
        Specifications                                                                   Equipment Procedures
                                                                                                                                   Equipment Procedures
        Required on Site Dates          Equipment Procedures                             Equipment & Materials                                                                                                           Disposal Records
                                                                                                                                   Equipment & Materials Catalogues
        Inspection Results              Delivery Dates                                   Catalogues                                                                                                                      Restoration Records
                                                                                                                                   Inspection Results
        Shipping Details                Vendor Drawings                                                                                                                                                                  Handover Records
                                                                                                                                   Shipping Details
        Payment Details                 Certification                                                                                                                                                                    Final Regulatory Approvals
                                        Equipment & Materials Catalogues
                                        Invoices


                 SUPPLIERS
                     &                                                     PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES ENGINEERING DESIGN
                FABRICATORS




    Figure 1: PISTEP Plant Engineering Activity Model.




2
The CEN ORCHID Roadmap | Implementation Guide




The CEN ORCHID Landscape of Information Standards also provides a framework of categories for the different types of standard
required (see Figure 2). The concept standards deal primarily with basic modelling of data as well as services and interfaces
for data handling. The content standards allow users to identify, classify, model and exchange information about objects and
products in the plant life cycle. All these standards produce their own terminology. It is important that all of this terminology
that is used within a company or within an industry community is based on a common dictionary to ensure interoperability.




    A: Management Activity Standards e.g. System Engineering, Quality, Configuration


      B: Concept Terminology                                         C: Content Terminology

                                                                         F: Transactions/Process
                                         E: Basic
                                        Modelling
                                                                         G1: Product                G2: Product
                                       Standards                         Definition                 Specification
                D:                    e.g. ISO, IES,                     Models                     Models
          Infrastructure                   W3C.
            Standards                    Includes
                                        Exchange
                                                                         H: Classification
                                         Formats
                                        e.g. XML

                                                                         I: Identification




Figure 2: The CEN ORCHID Landscape of Information Standards Framework.



Key Principle 2 - Always Use Internationally Accepted             Key Principle 3 - Agree on a Standardised Dictionary
Standards Where They Exist                                        of Classes

It is critical that, wherever possible, companies must use        Companies must agree a standardised dictionary of classes
internationally accepted standards. There are more than 50        to ensure that specification and definitions used in internal and
standards in use in the process and power industries and          external data exchanges are completely unambiguous. This is
many more proprietary and company standards. It is therefore      particularly important because:
prudent for companies to adopt common standards in use
                                                                  • Terminologies and definitions vary widely both within
rather than apply their own.
                                                                     companies and externally

To identify the right standard, companies are encouraged to       • Rigorous precision is needed to ensure the integrity and
consult the CEN ORCHID Landscape of Information Standards.           efficiency of assets
                                                                  • Most exchanges today are digital, which means that data
In cases where no standards exist, companies should first            can only be shared accurately if class definitions are identical
define the principles they will apply to augment standards to
                                                                  • Mapping tables are often ineffective as one-to-one relationships
bridge the gap to an existing standard. Subsequently, these
                                                                     are often impossible.
additions should be passed on to standards organisations to
                                                                  This rationale also applies to Key Principles 4, 5, and 6 on the
help the industry progress towards common definitions.
                                                                  content of information to be exchanged.




                                                                                                                                        3
Key Principle 4 - Agree Standardised                                  to agree the collection of attributes for the class to be used
    Attribute Definitions                                                 during the exchange of information. This is important because it
                                                                          narrows the potential universe of attributes that can be applied
    Once the dictionary of classes is agreed, the definitions of
                                                                          to an equipment class, based on the way that a stakeholder
    “attributes” linked to those classes must also be agreed. This
                                                                          will use equipment.
    means having common definitions for the dimensions and
    properties of equipment. For example, this will include definitions   Key Principle 7 - Agree on Additional Attributes for Use
    for the capacity, throughput or maximum operating temperature         by Stakeholders Across the Supply Chain
    of a pump. The level of granularity for these attributes will vary    Once small groupings of attributes are agreed (see Key Principle
    depending on the ultimate purpose of the information being            6 above), it is also important for all other stakeholders to agree
    exchanged, to ensure that technical and business needs are met.       on the additional attributes they may require for their specific
    Companies need to agree the appropriate level of granularity          activities. In the pump example, when owner operators define
    for attributes to ensure that the information exchanged is clear      their needs for electrical drives, then electrical manufacturer
    and meets needs, without being unnecessarily detailed.                stakeholders need to agree their incremental attribute
                                                                          requirements. Quite separately, steam turbine manufacturers
    Key Principle 5 - Agree on Units of Measure                           will need to agree their incremental attributes. These sub-sets
    There are great variations within companies and between               of attributes can be integrated as required, rather than creating
    companies, sectors, and even geographies in the way that units        an unnecessarily large number of attributes from the outset.
    of measure are used (mass, length and time). This results in
                                                                          Key Principle 8 - Agree on a Standardised Delivery
    unnecessary complexity and errors in information being shared.
                                                                          Envelope for Exchanging Information
    For example, capacity for a small pump may be measured in
    litres/minute, whereas a large capacity pump is measured in           After information content elements have been agreed, the
    metres3 per hour. In many cases, units of measure appear almost       information delivery envelope (also known as the “mechanism
    identical, but are actually quite different. For example, in the      for exchange”, or “hand-shake”) must be agreed. For example,
    measurement of pressure, the use of absolute versus gauge             companies or departments exchanging information need to
    can easily be misinterpreted. It is therefore vital that units of     decide whether they will both use XML for the exchange.
    measure are standardised and agreed internally and externally.
                                                                          It is important to note that complex IT systems are not
    The key to preventing misunderstanding is to provide clarity          essential for effective information exchange. Most IT systems
    on what is requested/communicated, and to use common                  in use today have adequate functionality to accommodate
    definitions/units of measure in the information exchange process.     information exchange.

                                                                          In summary, companies will need to move from a multiplicity of
    Key Principle 6 - Agree on the Collection of Attributes
                                                                          naming conventions and formats for information to common and
    for the Class to be Used For Any Given Activity
                                                                          integrated classifications for information, based on internationally
    Once the attribute definitions are agreed, companies also need        accepted standards.




4
The CEN ORCHID Roadmap | Implementation Guide




Step 2 Assess the Company’s Position
on the CEN ORCHID Roadmap
The ORCHID Roadmap Information Maturity Model in Figure 3 below helps companies identify stages of progression
on information standardisation internally or externally.




               X-1. ONE TO ONE EXCHANGE OF INFORMATION
               The exchange of information with external stakeholders
               is structured on a case-by-case (one-to-one) basis.



                                       X-2. CLOSED COMMUNITIES
                                       A small group of organizations agree on a common,
                                       but limited set of generic definitions, and exchange
                                       information according to these rules.


                                                         X-3. OPEN COMMUNITIES
                                                         A high level of integration and standardisation of the
                                                         exchange of information is reached with
              External                                   participating stakeholders.
              Information
              Maturity                                                   X-4. MATURING SUPPLY CHAIN EXCHANGE
              Levels
                                                                         Many-to-many integration and a high degree
                                                                         of collaboration is implemented, based on
                                                                         internationally agreed standards.



                                                                                                                      Time
                                                        I-4. EXTERNAL PROCESS INTEGRATION
                                                        Focus on information sharing with external
                                                        stakeholders, and alignment of that information with
              Internal                                  internal processes.
              Information
              Maturity
                                       I-3. INTERNAL PROCESS INTEGRATION
              Levels
                                       Integrates isolated work processes, reducing
                                       information overlap, and thereby achieving the next
                                       level of efficiency.


                           I-2. SUB PROCESS OPTIMISATION
                           Still focused on relatively isolated work processes,
                           but attempts to achieve efficiency by removing and
                           automating steps.


               I-1. WORK PROCESS STANDARDISATION
               Single repetitive processes within a certain group or
               discipline are standardised.



                   Internal Company Standards                          International Standards




Figure 3: The ORCHID Roadmap Information Maturity Model.


                                                                                                                             5
There are two aspects to assessing a company’s position.                Companies should note that phases can and very often do
    Firstly, identification of the one or more phases where the             overlap in time. Some activities associated with a certain phase
    company is operating on the Roadmap (see Figure 3). Secondly,           are also prerequisites to the following phase. The maturity level
    assessing the company’s progress or “maturity” within each              associated with a phase is the subset of requirements of this
    of the above phases. This is done by evaluating the company             phase, which in turn needs to be fulfilled before the next phase
    on the following five business dimensions as they apply to              can reasonably be started.
    management of information:
                                                                            Please note: assessment of a company’s level on the Roadmap
    • Business Processes                                                    and maturity within that level are qualitative and subjective
    • Stretegic Alignment                                                   assessments, based on the knowledge of those involved. The
                                                                            CEN ORCHID Roadmap phases and the maturity dimensions
    • People and Organisation
                                                                            are in fact part of a continuum. They are guideposts to support
    • Plant Lifecycle Information                                           progress, and should not be treated as having absolute
                                                                            boundaries.
    • ICT Technology & Infrastructure

    See the tables on pages 6 and 7 for actions to drive improvements
    in these areas within each phase.




    Actions to Drive Information Maturity Improvements within Each Internal Phase
    . INTERNAL              Work Process                                                                           External Process
                                                         Sub Process                  Internal Process
                            Standardisation              Optimisation                 Integration                  Integration


     BUSINESS               Standardise processes        Standardise company-          Adopt a holistic approach   Agree and align the
     PROCESSES              across a department.         wide on best practice         on company-wide             information to be
                                                         business processes.           best practice business      exchanged, and the
                                                                                       process standardisation.    process for exchanging it.
                                                                                       Optimise each process
                                                                                       and interrelationships.


     STRATEGIC              Agree and align the          Complete standardisation     Complete cross company       Align classifications
     ALIGNMENT              information to be            and classification           standardisation and          across the external
                            exchanged, and the           activities for the domain.   classification activities.   interface and agree how
                            process for exchanging it.                                                             to deal with exceptions.


     PEOPLE &               Develop staff skills and     Build capabilities for       Ensure overall process       Clearly define roles
     ORGANISATION           competencies required to     process ownership and        ownership, and               and responsibilities for
                            implement processes.         change management            implement cross process      internal and external
                                                         within the subprocess.       governance processes.        information management.


     PLANT LIFECYCLE        Define standards for one     Adopt international           Implement company-          Publish internal
     INFORMATION            or more departments for      and internal standards        wide information            rules for classifying
                            information, document        at business unit              quality management          information. Classify
                            management.                  level, including some         systems, and adoption of    information according to
                                                         classification norms.         classification systems.     internationally accepted
                                                         Agree formats for some                                    standards.
                                                         interdepartmental
                                                         information exchange.



     ICT TECHNOLOGY &       Provide a secure personal    Develop IT application        Establish a governing       Provide secure
     INFRASTRUCTURE         computing infrastructure.    governance structure          body for IT applications.   connections to external
                            Manage some work with        per domain. Rationalise       Integrate IT applications   parties. Adopt application
                            IT systems securely.         and standardise IT            between domains.            connectors to external
                                                         applications supporting                                   exchange standards.
                                                         standard business
                                                         processes.




6
The CEN ORCHID Roadmap | Implementation Guide




Actions to Drive Information Maturity Improvements Within Each External Phase

 EXTERNAL               One to One Exchange           Closed                           Open                          Maturing Supply Chain
                        of Information                Communities                      Communities                   Exchange


 BUSINESS               Accommodate/                  Agree a common process           Agree a common process        Implement assurance
 PROCESSES              adjust processes and          model for participating          model and standard            model for consistency of
                        operations for identified     companies. Connect this          contracts for participating   processes used across
                        interoperability barriers     common structure to the          companies. Connect            the supply chain.Ensure
                        on a case by case basis.      entity specific process          this common structure         automated processes are
                                                      structure.                       to the entity specific        in place for exchanging
                                                                                       process structure for all     information according to
                                                                                       exchanges.                    international (or de-facto)
                                                                                                                     standards.

 STRATEGIC              Adopt policy and              Agree a shared vision            Agree a shared vision         Agree a shared strategic
 ALIGNMENT              procedures to agree           and policies between             between participating         vision across the supply
                        case by case information      participating companies          companies to manage           chain on the use of
                        exchange.                     to manage information            information exchange at       internationally agreed
                                                      exchange at a project            a company level. Ensure       information standards.
                                                      level. Make incentive            standard contracts are        Ensure that work
                                                      based information                in place.                     methods, procedures
                                                      exchange contracts.                                            and contracts follow
                                                                                                                     international standards.
  PEOPLE &              Ensure skills are available   Ensure relevant skills are       Ensure relevant skills are    Develop relevant
  ORGANISATION          to identify, define and       available and mobilised          available and mobilised       knowledge and skills on
                        exchange information as       to:                              to:                           internationally agreed
                        agreed contractually.                                                                        information management
                                                      - Connect common                 - Connect common
                                                                                                                     standards, data quality
                                                      process models to                process models to
                                                                                                                     and exchange processes.
                                                      internal processes.              internal processes.
                                                      - Exchange information in        - Exchange information in
                                                      closed communities.              open communities.

  PLANT LIFECYCLE       Agree definition of           Agree information                Use agreed lifecycle data     Use available
  INFORMATION           handover points case by       standards to be used,            standards to specify          internationally agreed
                        case.                         and common, explicit             standardised handover         life cycle information
                                                      definitions of handover          points and standardised       standards to define and
                                                      points, and content for          content across open           dynamically exchange
                                                      each exchange.                   communities.                  all content. Ensure that
                                                                                                                     explicit status information
                                                                                                                     and provenance is
                                                                                                                     available for all content.

 ICT TECHNOLOGY &       Establish interoperability    Use secure IT systems            Use secure IT systems         Use secure IT systems for
 INFRASTRUCTURE         by mapping                    to automate mapping              to automate mapping           automated exchange and/
                        corresponding input           between input and output         between input and output      or mapping between input
                        and output files              files using a meta-level         files using a meta-level      and output files using:
                        manually. Develop             structure. Inconsistencies       structure. Inconsistencies    - A standardised meta-level
                        policy and infrastructure     resolved by manual               resolved by manual            structure
                        to automate future            interventions.                   interventions.                - Internationally agreed
                        exchanges.                                                                                   standards
                                                                                                                     Inconsistencies resolved
                                                                                                                     automatically by validation
                                                                                                                     mechanism.




Step 3 Establish Realistic Targets for
Where the Company Wants To Be
Experience has shown that progression in a phase is a significant           • The internal and external Roadmap levels they could
challenge because the information being exchanged is used in                    progress to
so many different processes in a company. To reach agreement,               • The maturity which could be achieved within each level
and change well established practices could take significant                Key considerations for setting targets are:
time and effort – both internally and between parties.                      • New regulatory requirements
                                                                            • Planned investment and expansion
Once companies have completed their evaluation, they can                    • Competitor positioning
set targets for where they would like to be in the future for:              • New customer demands




                                                                                                                                                   7
Step 4 Based on the Targets, Plan and
    Implement Improvement Measures
    Once targets have been set, companies can plan and implement improvements. This can be achieved by:

    a. Adopting one or more of the eight Key Information Standardisation Principles in this document. Please note, it is the rigour
       and extent of application of these Principles, which improves maturity and therefore moves a company across a phase and
       up phases on the ORCHID Roadmap.
    b. Consulting the CEN ORCHID Landscape of Information Standards, which provides a detailed framework for the types of
       standards a company may require (see Figures 1 and 2).
    c. Learning from information standardisation work completed by other companies. Examples of successful implementation
       from the following organisations and sectors are available from the CEN web-site:



        Shell                                             Zeiss Optical Instruments                          VdZ
        DSM                                               AT&S                                               Renault
        Siemens                                           Toshiba                                            Statoil
        BASF                                              ABB and Alstom
        Endress & Hauser                                  Croon




    Quick Wins
    The most important action for all companies involved in              •	 Use common definitions and terminology for all
    the process and power industries to achieve information                 classes, attributes, units and measures
    standardisation is to adopt a common dictionary of classes and       •	 Conform to internationally accepted information
    their definitions. This would support the creation of any number        standards – use the CEN ORCHID Landscape of
    of product model dictionaries. This collective standardisation          Information Standards to identify the standards
    action would remove the biggest barrier to interoperability             relevant for each project
    internally and between parties. This goal is being pursued by
                                                                         •	 Work with a common envelope/mechanism for
    the CEN ORCHID Group and would be a major step forward to
                                                                            exchange
    drive integration of information and ultimately competitiveness
    of these industries.                                                 These simple, practical measures will significantly help companies
                                                                         across the supply chain reduce costs, and improve the safety,
    The quickest wins for individual companies seeking to standardise
                                                                         reliability, speed and flexibility of their operations.
    their lifecycle information are to adopt the following summarised
    version of the Key Standardisation Principles for all internal and
    external exchanges of information:




8
The CEN ORCHID Roadmap | Implementation Guide




ORCHID Contacts

1. Review the full suite of CEN ORCHID Materials
www.cen.eu/cen/Sectors/Sectors/ISSS/Workshops/Pages/workshopORCHID.aspx




2. Contact the offices of the European groups involved in the CEN ORCHID Project


    Industry groups                   Country of residence                 Website

    USPI-NL                           The Netherlands                      www.uspi.nl
    PROLIST INT                       Germany                              www.prolist.org
    eCl@ss                            Germany                              www.eclass.de
    VdZ                               Germany                              www.vdz.de
    ICAAMC                            UK                                   www.icaamc.org
    POSCCaesar                        Norway                               www.posccaesar.com
    THTH                              Finland                              www.ththry.org
    PIDX                              UK                                   www.pidx.org
    ETIM                              The Netherlands                      www.etim-international.com
    2BA                               The Netherlands                      www.2BA.nl




                       For further information on the ORCHID Group, contact Mr. Paul van Exel - Stichting USPI-NL
                       Tel : +31334657679, stichting@uspi.nl

                       The ORCHID Group would like to thank the following organisations that have contributed
                       to the development of the Roadmap: Shell Projects & Technology, Bayer Technology
                       Services, BASF, Siemens, Fluor, LyondellBasell, Croon TBI Techniek, Endress+Hauser, Rösberg
                       Engineering, Pepperl & Fuchs, DAMO Tec, Aalto University, Cure Maintenance Consultants,
                       Paradine, AVEVA, Intergraph, Improvia, PLM Consultancy, VTT Technical Research Centre,
                       TACOS, Idoro, Fachhochschule Vorarlberg, WS Cataloguing Solutions, University of Hagen/
                       Semaino, Red-Bag, Pragmeta Knowledge Clout, BGS Systemplanung, Aachen – University of
                       Applied Sciences.




                                                                                                                     9
The work was supported by the European Commission, Directorate Enterprise
          and Industry and the European Free Trade Association.

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OrchiD Standards Guide

  • 1. The CEN ORCHID Roadmap Standardising Information in the Plant Engineering Supply Chain Implementation Guide
  • 2. Contents Overview Page 1 Key Implementation Steps for Information Standardisation Page 2 STEP 1: Page 2 Understand key standardisation principles and the information standards relevant to the business STEP 2: Assess the company’s position on the CEN ORCHID Roadmap Page 5 STEP 3: Establish realistic targets for where the company wants to be on the CEN Page 7 ORCHID Roadmap STEP 4: Plan and implement improvement measures Page 8 Quick Wins Page 8 ORCHID Contacts Page 9
  • 3. The CEN ORCHID Roadmap | Implementation Guide Overview The ORCHID (Orchestration of Industrial Data) Group is a • More reliable plants network of European companies and consortia dedicated to • Improved safety and environmental performance standardising information across the process industry engineering • Faster time to market supply chain to build competitive advantage. • Lower costs This document is a simple guide for companies on how to • Greater flexibility standardise and exchange plant engineering information. It aims to help companies achieve the following benefits of The overall goal is to progress the industry toward the standardisation: following vision of “interoperability”: “Companies in process industries shall be able to share and/or exchange electronically the information needed to design, build, operate and maintain process and power plants using internationally accepted standards.” The key implementation steps are: STEP 1 Understand key standardisation principles and the information standards relevant to the business STEP 2 Assess the company’s position on the CEN ORCHID Roadmap STEP 3 Establish realistic targets for where the company wants to be on the CEN ORCHID Roadmap STEP 4 Plan and implement improvement measures The practical steps outlined in this document are based directly on the CEN ORCHID Roadmap, which is described in detail on the CEN website. 1
  • 4. Step 1 Understand Key Standardisation Principles and Information Standards Relevant to your Business Key Principle 1: Agree and Document Core Internal that are usually exchanged at each stage of activity across Business Activities and Processes the plant lifecycle. Companies need to codify and standardise internal business Once this is done, companies can consult the CEN ORCHID activities and processes as the first step towards standardising Landscape of Information Standards to identify the relevant, information for exchange internally and externally. This step alone internationally accepted standards to use at each stage of the drives significant cost reduction and efficiency improvements PISTEP Activity Model. Companies, application developers, before any information standardisation activity is undertaken. service developers and standards development groups, are The CEN ORCHID Group recommends the PISTEP Activity encouraged to use existing standards to prevent proliferation Model in Figure 1 below to help identify the information types of standards and reduce complexity (see Key Principle 2). Process Plant Engineering Activity Model Safety & Environment Case MANAGEMENT ACTIVITIES REGULATORY SET ENGINEERING PRODUCE & MAINTAIN CONTROL OPERATIONS OBTAIN POLICY & FEASIBILITY & & ENGINEERING AGREEMENT WITH BODIES STANDARDS FINANCIAL CASE ACTIVITIES REGULATORY BODIES Regulatory Requirements Authorizations Process Definition Performance Requirements As Built Drawings Plant Status Control Philosophy Operating Procedures Operating Procedures Ground Drains Status Costs, Benefits & Timings Operating Conditions Acceptance Test results Safety Case Safety / Regulatory Requirements Alarm / Trip Settings Handover Certificate As Built & As Modified Drawings Safety and Environment Case PRODUCE PRODUCE DETAILED COMMISSION PROCESS OPERATE DECOMMISSION CONCEPTUAL PROCESS DESIGN & HANDOVER PLANT PLANT PLANT PROCESS DESIGN Process Stream Data Detailed Process Design Engineering Work Requests As Built Drawings Plant Status Process Flow Diagrams Availability Requirements Working Conditions Requirements Equipment Commissioning Procedures Plant Records Costs, Benefits & Timings Safety Systems Specifications Equipment Operating Procedures Engineering Work Permits Inspection Requirements Operating Procedures Inspection & Testing Records Acceptance of Engineering Work Regulatory Approvals Codes & Standards Handover Certification As Built Drawings Inspection Requirements As Built Equipment Specifications State of Equipment Preliminary Engineering Design Work Permit Requests Detailed Engineering Design Spares Lists Value of Equipment Engineering Philosophies Notification of Work Equipment Procedures Installation Procedures Equipment Records Availability Requirements Completion Vendor Drawings Maintenance Procedures Cost & Time Estimates Spares Lists Inspection Results Safety / Regulatory Requirements Unfinished Work Details Codes & Standards CONSTRUCT & PRODUCE DETAILED MAINTAIN DEMOLISH PLANT & PRODUCE CONCEPTUAL PRE-COMMISSION ENGINEERING DESIGN EQUIPMENT RESTORE SITE ENGINEERING PLANT DESIGN Materials & Equipment Materials & Equipment Requirements & Specifications Delivery Dates Requirements & Specifications Delivery Dates Materials & Equipment Required on Site Dates Vendor Drawings Required on Site Dates Vendor Drawings Requirements & Certification Certification Specifications Equipment Procedures Equipment Procedures Required on Site Dates Equipment Procedures Equipment & Materials Disposal Records Equipment & Materials Catalogues Inspection Results Delivery Dates Catalogues Restoration Records Inspection Results Shipping Details Vendor Drawings Handover Records Shipping Details Payment Details Certification Final Regulatory Approvals Equipment & Materials Catalogues Invoices SUPPLIERS & PROCURE & CONTROL EQUIPMENT, MATERIALS & SERVICES ENGINEERING DESIGN FABRICATORS Figure 1: PISTEP Plant Engineering Activity Model. 2
  • 5. The CEN ORCHID Roadmap | Implementation Guide The CEN ORCHID Landscape of Information Standards also provides a framework of categories for the different types of standard required (see Figure 2). The concept standards deal primarily with basic modelling of data as well as services and interfaces for data handling. The content standards allow users to identify, classify, model and exchange information about objects and products in the plant life cycle. All these standards produce their own terminology. It is important that all of this terminology that is used within a company or within an industry community is based on a common dictionary to ensure interoperability. A: Management Activity Standards e.g. System Engineering, Quality, Configuration B: Concept Terminology C: Content Terminology F: Transactions/Process E: Basic Modelling G1: Product G2: Product Standards Definition Specification D: e.g. ISO, IES, Models Models Infrastructure W3C. Standards Includes Exchange H: Classification Formats e.g. XML I: Identification Figure 2: The CEN ORCHID Landscape of Information Standards Framework. Key Principle 2 - Always Use Internationally Accepted Key Principle 3 - Agree on a Standardised Dictionary Standards Where They Exist of Classes It is critical that, wherever possible, companies must use Companies must agree a standardised dictionary of classes internationally accepted standards. There are more than 50 to ensure that specification and definitions used in internal and standards in use in the process and power industries and external data exchanges are completely unambiguous. This is many more proprietary and company standards. It is therefore particularly important because: prudent for companies to adopt common standards in use • Terminologies and definitions vary widely both within rather than apply their own. companies and externally To identify the right standard, companies are encouraged to • Rigorous precision is needed to ensure the integrity and consult the CEN ORCHID Landscape of Information Standards. efficiency of assets • Most exchanges today are digital, which means that data In cases where no standards exist, companies should first can only be shared accurately if class definitions are identical define the principles they will apply to augment standards to • Mapping tables are often ineffective as one-to-one relationships bridge the gap to an existing standard. Subsequently, these are often impossible. additions should be passed on to standards organisations to This rationale also applies to Key Principles 4, 5, and 6 on the help the industry progress towards common definitions. content of information to be exchanged. 3
  • 6. Key Principle 4 - Agree Standardised to agree the collection of attributes for the class to be used Attribute Definitions during the exchange of information. This is important because it narrows the potential universe of attributes that can be applied Once the dictionary of classes is agreed, the definitions of to an equipment class, based on the way that a stakeholder “attributes” linked to those classes must also be agreed. This will use equipment. means having common definitions for the dimensions and properties of equipment. For example, this will include definitions Key Principle 7 - Agree on Additional Attributes for Use for the capacity, throughput or maximum operating temperature by Stakeholders Across the Supply Chain of a pump. The level of granularity for these attributes will vary Once small groupings of attributes are agreed (see Key Principle depending on the ultimate purpose of the information being 6 above), it is also important for all other stakeholders to agree exchanged, to ensure that technical and business needs are met. on the additional attributes they may require for their specific Companies need to agree the appropriate level of granularity activities. In the pump example, when owner operators define for attributes to ensure that the information exchanged is clear their needs for electrical drives, then electrical manufacturer and meets needs, without being unnecessarily detailed. stakeholders need to agree their incremental attribute requirements. Quite separately, steam turbine manufacturers Key Principle 5 - Agree on Units of Measure will need to agree their incremental attributes. These sub-sets There are great variations within companies and between of attributes can be integrated as required, rather than creating companies, sectors, and even geographies in the way that units an unnecessarily large number of attributes from the outset. of measure are used (mass, length and time). This results in Key Principle 8 - Agree on a Standardised Delivery unnecessary complexity and errors in information being shared. Envelope for Exchanging Information For example, capacity for a small pump may be measured in litres/minute, whereas a large capacity pump is measured in After information content elements have been agreed, the metres3 per hour. In many cases, units of measure appear almost information delivery envelope (also known as the “mechanism identical, but are actually quite different. For example, in the for exchange”, or “hand-shake”) must be agreed. For example, measurement of pressure, the use of absolute versus gauge companies or departments exchanging information need to can easily be misinterpreted. It is therefore vital that units of decide whether they will both use XML for the exchange. measure are standardised and agreed internally and externally. It is important to note that complex IT systems are not The key to preventing misunderstanding is to provide clarity essential for effective information exchange. Most IT systems on what is requested/communicated, and to use common in use today have adequate functionality to accommodate definitions/units of measure in the information exchange process. information exchange. In summary, companies will need to move from a multiplicity of Key Principle 6 - Agree on the Collection of Attributes naming conventions and formats for information to common and for the Class to be Used For Any Given Activity integrated classifications for information, based on internationally Once the attribute definitions are agreed, companies also need accepted standards. 4
  • 7. The CEN ORCHID Roadmap | Implementation Guide Step 2 Assess the Company’s Position on the CEN ORCHID Roadmap The ORCHID Roadmap Information Maturity Model in Figure 3 below helps companies identify stages of progression on information standardisation internally or externally. X-1. ONE TO ONE EXCHANGE OF INFORMATION The exchange of information with external stakeholders is structured on a case-by-case (one-to-one) basis. X-2. CLOSED COMMUNITIES A small group of organizations agree on a common, but limited set of generic definitions, and exchange information according to these rules. X-3. OPEN COMMUNITIES A high level of integration and standardisation of the exchange of information is reached with External participating stakeholders. Information Maturity X-4. MATURING SUPPLY CHAIN EXCHANGE Levels Many-to-many integration and a high degree of collaboration is implemented, based on internationally agreed standards. Time I-4. EXTERNAL PROCESS INTEGRATION Focus on information sharing with external stakeholders, and alignment of that information with Internal internal processes. Information Maturity I-3. INTERNAL PROCESS INTEGRATION Levels Integrates isolated work processes, reducing information overlap, and thereby achieving the next level of efficiency. I-2. SUB PROCESS OPTIMISATION Still focused on relatively isolated work processes, but attempts to achieve efficiency by removing and automating steps. I-1. WORK PROCESS STANDARDISATION Single repetitive processes within a certain group or discipline are standardised. Internal Company Standards International Standards Figure 3: The ORCHID Roadmap Information Maturity Model. 5
  • 8. There are two aspects to assessing a company’s position. Companies should note that phases can and very often do Firstly, identification of the one or more phases where the overlap in time. Some activities associated with a certain phase company is operating on the Roadmap (see Figure 3). Secondly, are also prerequisites to the following phase. The maturity level assessing the company’s progress or “maturity” within each associated with a phase is the subset of requirements of this of the above phases. This is done by evaluating the company phase, which in turn needs to be fulfilled before the next phase on the following five business dimensions as they apply to can reasonably be started. management of information: Please note: assessment of a company’s level on the Roadmap • Business Processes and maturity within that level are qualitative and subjective • Stretegic Alignment assessments, based on the knowledge of those involved. The CEN ORCHID Roadmap phases and the maturity dimensions • People and Organisation are in fact part of a continuum. They are guideposts to support • Plant Lifecycle Information progress, and should not be treated as having absolute boundaries. • ICT Technology & Infrastructure See the tables on pages 6 and 7 for actions to drive improvements in these areas within each phase. Actions to Drive Information Maturity Improvements within Each Internal Phase . INTERNAL Work Process External Process Sub Process Internal Process Standardisation Optimisation Integration Integration BUSINESS Standardise processes Standardise company- Adopt a holistic approach Agree and align the PROCESSES across a department. wide on best practice on company-wide information to be business processes. best practice business exchanged, and the process standardisation. process for exchanging it. Optimise each process and interrelationships. STRATEGIC Agree and align the Complete standardisation Complete cross company Align classifications ALIGNMENT information to be and classification standardisation and across the external exchanged, and the activities for the domain. classification activities. interface and agree how process for exchanging it. to deal with exceptions. PEOPLE & Develop staff skills and Build capabilities for Ensure overall process Clearly define roles ORGANISATION competencies required to process ownership and ownership, and and responsibilities for implement processes. change management implement cross process internal and external within the subprocess. governance processes. information management. PLANT LIFECYCLE Define standards for one Adopt international Implement company- Publish internal INFORMATION or more departments for and internal standards wide information rules for classifying information, document at business unit quality management information. Classify management. level, including some systems, and adoption of information according to classification norms. classification systems. internationally accepted Agree formats for some standards. interdepartmental information exchange. ICT TECHNOLOGY & Provide a secure personal Develop IT application Establish a governing Provide secure INFRASTRUCTURE computing infrastructure. governance structure body for IT applications. connections to external Manage some work with per domain. Rationalise Integrate IT applications parties. Adopt application IT systems securely. and standardise IT between domains. connectors to external applications supporting exchange standards. standard business processes. 6
  • 9. The CEN ORCHID Roadmap | Implementation Guide Actions to Drive Information Maturity Improvements Within Each External Phase EXTERNAL One to One Exchange Closed Open Maturing Supply Chain of Information Communities Communities Exchange BUSINESS Accommodate/ Agree a common process Agree a common process Implement assurance PROCESSES adjust processes and model for participating model and standard model for consistency of operations for identified companies. Connect this contracts for participating processes used across interoperability barriers common structure to the companies. Connect the supply chain.Ensure on a case by case basis. entity specific process this common structure automated processes are structure. to the entity specific in place for exchanging process structure for all information according to exchanges. international (or de-facto) standards. STRATEGIC Adopt policy and Agree a shared vision Agree a shared vision Agree a shared strategic ALIGNMENT procedures to agree and policies between between participating vision across the supply case by case information participating companies companies to manage chain on the use of exchange. to manage information information exchange at internationally agreed exchange at a project a company level. Ensure information standards. level. Make incentive standard contracts are Ensure that work based information in place. methods, procedures exchange contracts. and contracts follow international standards. PEOPLE & Ensure skills are available Ensure relevant skills are Ensure relevant skills are Develop relevant ORGANISATION to identify, define and available and mobilised available and mobilised knowledge and skills on exchange information as to: to: internationally agreed agreed contractually. information management - Connect common - Connect common standards, data quality process models to process models to and exchange processes. internal processes. internal processes. - Exchange information in - Exchange information in closed communities. open communities. PLANT LIFECYCLE Agree definition of Agree information Use agreed lifecycle data Use available INFORMATION handover points case by standards to be used, standards to specify internationally agreed case. and common, explicit standardised handover life cycle information definitions of handover points and standardised standards to define and points, and content for content across open dynamically exchange each exchange. communities. all content. Ensure that explicit status information and provenance is available for all content. ICT TECHNOLOGY & Establish interoperability Use secure IT systems Use secure IT systems Use secure IT systems for INFRASTRUCTURE by mapping to automate mapping to automate mapping automated exchange and/ corresponding input between input and output between input and output or mapping between input and output files files using a meta-level files using a meta-level and output files using: manually. Develop structure. Inconsistencies structure. Inconsistencies - A standardised meta-level policy and infrastructure resolved by manual resolved by manual structure to automate future interventions. interventions. - Internationally agreed exchanges. standards Inconsistencies resolved automatically by validation mechanism. Step 3 Establish Realistic Targets for Where the Company Wants To Be Experience has shown that progression in a phase is a significant • The internal and external Roadmap levels they could challenge because the information being exchanged is used in progress to so many different processes in a company. To reach agreement, • The maturity which could be achieved within each level and change well established practices could take significant Key considerations for setting targets are: time and effort – both internally and between parties. • New regulatory requirements • Planned investment and expansion Once companies have completed their evaluation, they can • Competitor positioning set targets for where they would like to be in the future for: • New customer demands 7
  • 10. Step 4 Based on the Targets, Plan and Implement Improvement Measures Once targets have been set, companies can plan and implement improvements. This can be achieved by: a. Adopting one or more of the eight Key Information Standardisation Principles in this document. Please note, it is the rigour and extent of application of these Principles, which improves maturity and therefore moves a company across a phase and up phases on the ORCHID Roadmap. b. Consulting the CEN ORCHID Landscape of Information Standards, which provides a detailed framework for the types of standards a company may require (see Figures 1 and 2). c. Learning from information standardisation work completed by other companies. Examples of successful implementation from the following organisations and sectors are available from the CEN web-site: Shell Zeiss Optical Instruments VdZ DSM AT&S Renault Siemens Toshiba Statoil BASF ABB and Alstom Endress & Hauser Croon Quick Wins The most important action for all companies involved in • Use common definitions and terminology for all the process and power industries to achieve information classes, attributes, units and measures standardisation is to adopt a common dictionary of classes and • Conform to internationally accepted information their definitions. This would support the creation of any number standards – use the CEN ORCHID Landscape of of product model dictionaries. This collective standardisation Information Standards to identify the standards action would remove the biggest barrier to interoperability relevant for each project internally and between parties. This goal is being pursued by • Work with a common envelope/mechanism for the CEN ORCHID Group and would be a major step forward to exchange drive integration of information and ultimately competitiveness of these industries. These simple, practical measures will significantly help companies across the supply chain reduce costs, and improve the safety, The quickest wins for individual companies seeking to standardise reliability, speed and flexibility of their operations. their lifecycle information are to adopt the following summarised version of the Key Standardisation Principles for all internal and external exchanges of information: 8
  • 11. The CEN ORCHID Roadmap | Implementation Guide ORCHID Contacts 1. Review the full suite of CEN ORCHID Materials www.cen.eu/cen/Sectors/Sectors/ISSS/Workshops/Pages/workshopORCHID.aspx 2. Contact the offices of the European groups involved in the CEN ORCHID Project Industry groups Country of residence Website USPI-NL The Netherlands www.uspi.nl PROLIST INT Germany www.prolist.org eCl@ss Germany www.eclass.de VdZ Germany www.vdz.de ICAAMC UK www.icaamc.org POSCCaesar Norway www.posccaesar.com THTH Finland www.ththry.org PIDX UK www.pidx.org ETIM The Netherlands www.etim-international.com 2BA The Netherlands www.2BA.nl For further information on the ORCHID Group, contact Mr. Paul van Exel - Stichting USPI-NL Tel : +31334657679, stichting@uspi.nl The ORCHID Group would like to thank the following organisations that have contributed to the development of the Roadmap: Shell Projects & Technology, Bayer Technology Services, BASF, Siemens, Fluor, LyondellBasell, Croon TBI Techniek, Endress+Hauser, Rösberg Engineering, Pepperl & Fuchs, DAMO Tec, Aalto University, Cure Maintenance Consultants, Paradine, AVEVA, Intergraph, Improvia, PLM Consultancy, VTT Technical Research Centre, TACOS, Idoro, Fachhochschule Vorarlberg, WS Cataloguing Solutions, University of Hagen/ Semaino, Red-Bag, Pragmeta Knowledge Clout, BGS Systemplanung, Aachen – University of Applied Sciences. 9
  • 12. The work was supported by the European Commission, Directorate Enterprise and Industry and the European Free Trade Association.