Category: Digital Twin

PLM tales from a true megaproject ch. 5 - Spatial Integration

9/20/2019

Image courtesy of ESS Spatial Integration Team

In the past chapters I’ve talked an awful lot about structured data and information structures, and yes, in my view this is very important as it is the very essence to obtain effective Plant Lifecycle Management, however in this chapter let’s take breather from the data structures and have a look at how ESS manages the aspect of space management (which is also a structure….. Of course I almost hear you say, but it looks a lot shinier, and by the way, yes it is connected to the tag structure (FBS) and the other information structures).

At ESS there is a team headed by Fabien Rey, responsible for Spatial Integration which includes an all discipline 3D master-model called the EPL (ESS Plant Layout) of the entire facility.

So, what is this Spatial Integration?

It is defined as configuration management of the space available. This means that everything that is designed and that will go into the facility and will occupy space, must have received an initial space claim which is then refined throughout the engineering process. This is true for all disciplines from conventional building, machine systems, product engineering, plant & process to electrical.

Image courtesy of ESS Spatial Integration Team

When examining the EPL from afar, it looks pretty much like what you would expect from any architectural model, but when focusing on the machine aspects in the facility it gets more interesting, however as ESS is a huge facility, so, still not much detail

Image courtesy of ESS Spatial Integration Team

Let’s zoom in on the tiny little area at the bottom right corner, which is where the proton beam starts its journey towards the target to create spallation of neutrons.

Image courtesy of ESS Spatial Integration Team

Here we get a taste for the enormous level of detail we are talking about.
The person to the right is to get a feel for the scale. This picture only shows the first few meters of the 650-meter-long accelerator.
The image is from the Virtual Reality room at ESS. The VR room is used for several different purposes, but among them, multi-discipline reviews for everything from design to installation and commissioning activities.

Let's look the other way

Image courtesy of ESS Spatial Integration Team

The next picture is taken, not from the VR room, but still the same EPL.
This time from a different software with a slightly different purpose. What is unique in my experience is that it is the same model, under configuration control, loaded into different environments for different purposes.

Image courtesy of Piero Valente, Group Leader Plant & Process at European Spallation Source ERIC

So how does ESS control all of this from a process point of view?

If you look at the picture below, you’ll see the actual engineering process (high level) together with the evolution of a space claim and refinement of design space, or rather the space allocation.

Image courtesy of ESS Spatial Integration

BUT WAIT!

Why does the process continue from as-designed into as-built and as-scanned??

Well, I never said that the EPL was purely design space configuration management. ESS has taken it a huge step forward to also incorporate, not only as built models, but rather As-Scanned models as well, which means there is a huge infrastructure in place to secure detailed 3D scans that can be imported into the EPL and put as an “overlay” to the design model like in the picture of the models below.

Image courtesy of ESS Spatial Integration Team

In such a model, inaccuracies between design model and actually installed becomes painfully apparent. I choose this image because I wanted to commend the extreme accuracy of this piping section, however there are numerous examples where errors have been caught which would have posed problems for other installation disciplines afterwards. Early correction of such mistakes is vital to avoid cascading effects for installation, and therefore scans are performed regularly and compared with the design model.

Below you can see an example of an As-Scanned Colored 3D Point Cloud only…. Remember the pipe from the previous picture….

Image courtesy of ESS Spatial Integration Team

As we have now visually seen design requirements compared to actually installed, from a spatial integration perspective, I will show the same for tag requirements and installed physical assets in the next chapter. I know I promised this in the last chapter, but I could not resist showing it from a spatial integration perspective first.

It is my hope that this article can serve as inspiration for other companies as well as software vendors. I also want to express my gratitude to the European Spallation Source and to Peter Rådahl, Head of Engineering and Integration department in particular for allowing me to share this with you.

Bjorn Fidjeland

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PLM tales from a true megaproject Ch. 4

6/20/2019

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Image courtesy of European Spallation Source ERIC

In chapter four we will enter familiar and traditional PLM territory as we will take a closer look at product designs and EBOM’s (Engineering Bill Of Materials). European Spallation Source face the complexities of pure Engineer To Order (ETO) which means that they will only manufacture one of the designed products in the facility, as well as product designs that will be manufactured in series.
It is important to note that some of the products going into the facility was not even invented at the time the decision was made to build the European Spallation Source.

If you would like to read the previous chapters first before we take a deeper dive, you can find them here:
PLM tales from a true megaproject Ch. 1
PLM tales from a true megaproject Ch. 2 – Functional Breakdown Structure
PLM tales from a true megaproject Ch. 3 – Location Breakdown Structure

If you’d like to familiarize yourself more with the concepts of the different structures, please visit:
Plant Information Management - Information Structures

Figure 1.

As the management of product designs and their data is the home turf of any PLM system (Product Lifecycle Management), this area of the plant PLM platform has been left as much out of the box as possible, but I’ll go through some examples all the same.
The EBOM consists of Parts ordered in a hierarchical structure usually largely defined by mechanical product engineering and their design model. The structure is in itself multidiscipline, meaning that it contains mechanical parts, electrical parts and sometimes parts representing other things like drops of glue, software etc.
Based on an EBOM, one or many products can be manufactured. In other words, it is generic in nature.

Figure 2. Image courtesy of European Spallation Source ERIC

The image above is from the plant PLM system and shows a simple EBOM which we can see is released. So what does released mean? Well It means that it is ready seen from the product engineering aspect. Such a released product design can be selected to fulfill one or many functional locations (tags) in the overall facility, as we discussed in chapter 1.
A part is specified by a specification, so it has specifying documentation connected in the form of a 3D model, a drawing or a document

Figure 3. Image courtesy of European Spallation Source ERIC

In our example in figure 3 there is a 3D model associated, which is specifying the mechanical aspects of the part (note: I have masked owner and released date).
In order to release a part and ultimately an EBOM consisting of parts, a few PLM principles must be observed. Specifying information must always be released prior to the release of the part. So bottom up.
The same is true for the EBOM. Child parts must be released before the parent part can be released. (this is the opposite of the release of the functional structure, but we’ll discuss that in a later chapter)

To govern the release process, a Change Order is used (in PLM also referred to as ECO or Engineering Change Order). In many serial manufacturing companies, it is common to have a process prior to deciding if a change should be implemented. This is because they want to make very sure that they understand all possible impacts a design change might have before they manufacture millions of their products based on the new design.
Such a process, in PLM often referred to as ECR or Engineering Change Request, is omitted at ESS, however the same analysis is performed early on in the change order process.
The release process is one of the areas where ESS have deviated from the out of the box solution in order to streamline as much as possible for their needs.
Let’s have a look at the process with another example.

Figure 4. Image courtesy of European Spallation Source ERIC

Figure 4 shows an EBOM structure used for training at ESS (It is not an ESS design, but merely an example I’ve created in their plant PLM system). Please observe that the EBOM of this plug valve contains a few parts, is three levels deep and is currently in a lifecycle state called In Work (there are more lifecycle states than showed in the images of this article). All Parts and specifications have individual lifecycle states.

Figure 5. Image courtesy of European Spallation Source ERIC

The image above is seen from the Change Order governing the move of both parts and specifications through their lifecycle states. We can see at the top left of the image that the CO (Change Order) is in “In Work” state. I’ve chosen to let one CO be responsible for the release of the full EBOM and all associated specifications, but I could have split the responsibility across multiple CO’s if I’d wanted to.
In figure 5 we can also see that all parts and their specifications are in state Approved. This means that the responsible engineering discipline feels that they are ready and have done their part of the work

Figure 6. Image courtesy of European Spallation Source ERIC

The last stretch of the release process is to move all the parts and their specifications from the Approved state to the Released state.
A workflow with electronic signatures is responsible for doing this. The workflow above states that Bjorn Fidjeland… (Yes, me) is responsible for reviewing the entire EBOM and all specifications. In a real live process, the members of a CDR (Critical Design Review) are listed as reviewers, and one or more final approvers assumes responsibility for the release. At ESS the CDR is a multi-discipline review with both internal and external stakeholders.
Normally it is not allowed to have the same person as both reviewer and approver, but since I’ve got admin rights to this environment, and did not want to show the names of ESS reviewers and approvers, the example is as it is.

When the last person in the workflow sequence has approved, all specifications and parts governed by the Change Order are automatically promoted from Approved state to Released state, and the Change Order itself is marked complete. The system itself takes care of the bottom up release rules of the EBOM.

Figure 7. Image courtesy of European Spallation Source ERIC

Figure 7 shows the fully released EBOM, including all specifications governed by this one Change Order.

The next chapter will be about how ESS manages information about their physical assets, how physically installed assets are linked to the facility’s tag requirements in the Functional Breakdown Structure, where they are located in the Location Breakdown Structure and from what product design they originate from.

It is my hope that this article can serve as inspiration for other companies as well as software vendors.
I also want to express my gratitude to the European Spallation Source and to Peter Rådahl, Head of Engineering and Integration department in particular for allowing me to share this with you.

Bjorn Fidjeland

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PLM tales from a true megaproject Ch. 3

5/23/2019

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Image courtesy of European Spallation Source ERIC

In this chapter we are going to take a look at how the location breakdown structure is implemented at the European Spallation Source.
The location structure is a decomposition of physical locations of areas into buildings, levels, rooms, cells and sub-cells. The Location Breakdown Structure contains a consolidated view of all data from a physical location perspective.

This chapter is built up much the same way as the previous one about the functional breakdown structure, due to their similar look and feel, even though they describe different aspects of the facility.

If you would like to read previous chapters first before we take a deeper dive, you can find it here:
PLM tales from a true megaproject Ch. 1
PLM tales from a true megaproject Ch. 2 – Functional Breakdown Structure
If you’d like to familiarize yourself more with the concepts of the different structures, please visit:
Plant Information Management - Information Structures

Figure 1.

When examining the location breakdown structure, you’ll notice that is looks like it also has a form of tag.
This is entirely correct, the standard used at ESS, EN/ISO 81346, was among other things selected for its ability to name multiple aspects, where the functional aspect is indicated with a equal sign, and the location aspect is indicated with a plus sign.

Figure 2. Image courtesy of European Spallation Source ERIC

The image above is from the plant PLM system and shows a small part of the location breakdown structure at ESS.
Let’s go through what we see in the image, and use the TS2 Area (Test Stand 2) row 15 – +ESS.G02.100.1001.102 as an example.

Figure 3. Image courtesy of European Spallation Source ERIC

The first column shows the location name of the individual location object.
The second column with the little green icon gives you the option to zoom in on the location if further details are needed, for instance attribute values of the location such as owner of the location, status, specifications, reference documents, history etc.

The third column shows a paperclip if there are specifying documentation associated with the location. In figure 4 we can see that the Tunnel has 308 documents associated whereas 271 of them are considered specifying documentation to the location and 7 are requirement specifications (the green check mark means that it has the lifecycle state released). We can also see that 37 documents are regarded as reference documents. This means that they are describing the location, but are not regarded as specifying to the location.

Figure 4. Image courtesy of European Spallation Source ERIC

The Tag column shows the full location tag , and the description column indicates a description of the location.
The type column indicates the type of area. At ESS this can be area, building, level (where 100 is floor level), room, cell and sub cells.
The FBS (Functional Breakdown Structure) column in figure 3 allows you to see at what functional locations, so Tags, the physical location actually contains. The functional locations are displayed in the split view as shown in figure 5.

Figure 5. Image courtesy of European Spallation Source ERIC

We can clearly see that the TS2 Area currently contains 258 functional tags (master tags), and all information regarding each functional tag is directly available in this view.

The IS column in figure 3 refers to the actually installed assets in the plant that is used to implement the functional object requirements that are located in the physical location of TS2 Area (an asset is a physical thing that typically has a serial number). See figure 6.

Figure 6. Image courtesy of European Spallation Source ERIC

The released part column in figure 3 gives an overview of what released product designs (Engineering Bill Of Materials) or standard parts that can fulfill the functional object requirements physically located in the TS2 Area (there might be several options prior to procurement, however the installed asset will only have an association to one part as it was manufactured based on that particular product design).

The last column in figure 3, called Change Order displays a link to the Change Order responsible for releasing the physical location together with all specifying documentation.

So, from one view in the plant PLM system, the European Spallation Source is able to access all related data to all physical locations in their location breakdown structure from engineering and design through installation, commissioning, operations, maintenance and ultimately decommissioning.

The next chapter will be about how ESS manages product design (Engineering Bill Of Materials), both from an Engineer To Order perspective and a serial manufacturing perspective.

It is my hope that this article can serve as inspiration for other companies as well as software vendors. I also want to express my gratitude to the European Spallation Source and to Peter Rådahl, Head of Engineering and Integration department in particular for allowing me to share this with you.

Bjorn Fidjeland

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PLM tales from a true megaproject Ch. 2

4/12/2019

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Image courtesy of Fabien Rey, Group Leader Machine Engineering Service Group at European Spallation Source ERIC

In this chapter we are going to take a look at how the functional breakdown structure is implemented at the European Spallation Source. The functional structure is a functional decomposition of systems and subsystems all the way down to individual functions, or as ESS calls them, components. The Functional Breakdown Structure contains a consolidated view of data from all plant engineering disciplines including electrical, plant & process and mechanical.
If you would like to read chapter one first before we take a deeper dive, you can find it here:
PLM tales from a true megaproject Ch. 1

If you’d like to familiarize yourself more with the concepts of the different structures, please visit:
Plant Information Management - Information Structures and
Plant Engineering meets Product Engineering in capital projects

Figure 1.

The first thing you’ll notice is the tagging. It was decided to use the standard EN/ISO 81346 as a common master tag at the European Spallation Source. The equal sign means that it is the functional aspect, however anybody familiar with the standard will notice something a bit odd. The first 2 levels are not quite according to standard. It was decided that the first level was to be ESS, and the second levels ACC (Accelerator), TS (Target Station), NSS (Neutron Scattering Systems) and INFR (Infrastructure). Anything below the first and second level is according to the guidelines of the standard.

Figure 2. Image courtesy of European Spallation Source ERIC

The image above is from the plant PLM system and shows the functional breakdown structure of the Test Stand 2 piping system as an example. At the time of writing, the functional breakdown structure contains about 50.000 tags, but is expected to grow to well over 1 million tags.
Let’s go through what we see in the image, and use the first row – W02 (the Test Stand 2 piping system) as an example in the beginning.

Figure 3. Image courtesy of European Spallation Source ERIC

The first column shows the tag name of the individual functional object (W02). The second column with the little green icon gives you the option to zoom in on the object if further details are needed, for instance all the attribute values of the object coming from object type or class (European Spallation Source uses ISO 15926-4 as a basis for their master reference data).
The third column shows a paperclip if there are specifying documentation associated with the tag. In figure 4 we can see that the Test Stand 2 piping system has one released P&ID (the green check mark means that it has the lifecycle state released), and that there are 15 other reference documents associated.

Figure 4. Image courtesy of European Spallation Source ERIC

The Tag column shows the full functional master tag, and the description column indicates a description of the functional object.
The classification column shows what kind of functional object it is. This refers to the master reference data class that is used to describe the properties or attributes this specific tag has got. In order to explain better we need to take a step back.

I mentioned that the European Spallation Source opted to use ISO 15926-4 as a basis for their master reference data. This means that there is a vast library of classes that defines what attributes, let’s say a Temperature Sensor should have, and also what letter codes (defined based on EN 81346) it should have. So, when a functional object is first created, it only has basic attributes that are shared across all functional objects, however when the system is told that it is a Temperature Sensor, it gets all the attributes defined for the class Temperature Sensor in addition to it’s tag which is computed by the parent object’s tag, the letter code and the number of other Temperature Sensors at this level in the functional breakdown structure plus one.

Figure 5. Image courtesy of European Spallation Source ERIC

The image above shows some of the attributes for the selected Temperature Sensor tag, but without operational data.

The LBS (Location Breakdown Structure) column in figure 3 allows you to see at what physical location the functional object is located.
If the functional object is a pipe or cable that spans multiple locations, then several physical locations are displayed in the split view as shown in figure 6.

Figure 6. Image courtesy of European Spallation Source ERIC

The IS column in figure 3 refers to the actually installed asset in the plant that implements the functional object requirements (physical item with serial number). See figure 7.

Figure 7. Image courtesy of European Spallation Source ERIC

The released part column in figure 2 gives an overview of what released product designs (Engineering Bill Of Materials) or standard parts that can fulfill the functional object requirements (there might be several options prior to procurement, however the installed asset will only have an association to one part as it was manufactured based on that particular product design).

So from one view in the plant PLM system, the European Spallation Source is able to access all related data to all functional objects in their functional breakdown structure from design and engineering through installation, commissioning, operations, maintenance and ultimately decommissioning.
The next chapter will be about the Location Breakdown Structure.

It is my hope that this article can serve as inspiration for other companies as well as software vendors. I also want to express my gratitude to the European Spallation Source and to Peter Rådahl, Head of Engineering and Integration department in particular for allowing me to share this with you.

Bjorn Fidjeland

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PLM tales from a true mega-project Ch. 1

3/27/2019

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Image courtesy of European Spallation Source ERIC

I’ve been asked on several occasions if I can share some more details from any of the projects I’ve been involved with. Especially the ones addressing plant lifecycle management and the use of structured data.
Naturally, most commercial companies who face fierce competition every day are reluctant to do so, as it is deemed highly important for their competitiveness. Or as one client put it “This is truly our backbone, while our master-data is our lifeblood”

However, there is one very special company I’ve been fortunate to be involved with for several years now who has agreed to share some of their details.
It is the European Spallation Source ERIC or ESS for short. An organization tasked with executing a true mega-project, to design, build and operate the world’s brightest neutron source for scientific use.

So what is the European Spallation Source?
In short it is a 750 meters long and 250 meters wide facility that houses a huge linear proton accelerator or LINAC. The accelerator is responsible for accelerating protons produced by an Ion Source up to 96% of the speed of light. The protons are then collided into the target which is a 2.6 m-diameter stainless steel disk containing bricks of a neutron-rich heavy metal called Tungsten. This is where Spallation occurs, where neutrons are flung out from the target wheel. These neutrons are the main product of the European Spallation Source, and they are guided through neutron guides to the instruments that allow researchers to do their research. It is anticipated that 22 instruments will be installed in total.
For more information, check out europeanspallationsource.se

Image courtesy of Fabien Rey, Group Leader Machine Engineering Service Group at European Spallation Source ERIC

What kind of research will be conducted?
Some examples are: chemistry of materials, magnetic & electronic phenomena, life science & soft condensed matter, engineering materials, geosciences, archeology & heritage conservation, fast neutron applications and particle physics

Well, back to the real question at hand. What have they done with respect to plant lifecycle management and technical information management?
If you want to freshen up on my views with respect to needed information structures, you may do so here:
Plant Information Management - Information Structures
Archive of articles

What ESS has put in place is truly remarkable. By extending a Product Lifecycle Management (PLM) system to also manage:

Functional Breakdown Structure (Tags)
Location Breakdown Structure (Physical Locations)
Engineering Bill of Material (EBOM for product designs, traditionally the home turf of a PLM system)
Management of all installed assets or physically installed items (the front end for asset management and warehouse management is an Enterprise Asset Management system, whereas assets installed in the facility are also created and consolidated in the PLM system together with relationships to their corresponding Tag, Location, Part and their common reference data class with attributes)

Reference data: A class library of common reference data used across Functional Breakdown Structure, Engineering Bill of Material and Assets. Each class has attributes defined deemed important to ESS.

In addition to the actual data structures, each object in any structure is governed by revision control and change management, not only of the objects themselves but also their associated specifications in the form of 3D design models, drawings, certificates and reports etc.

Why has the European Spallation Source done this when they are only building one such facility?
The main reason is to support the European Spallation Source evolution from project to a sustainable facility enabling world-leading science for ≥40 years, and to establish the foundation needed for future cost-efficient operation and maintenance.

A second reason is the fact that the facility in some areas is producing radiation in the form of radioactivity. This means that parts of the facility fall under the regulatory requirements of the Swedish Radiation Safety Authority which in turn means rigorous control of all technical information as well as configuration management of such information.

In the coming articles I will address each information structure, as well as the topics of digital twin, master reference data, change management and revision control with live examples from the European Spallation Source.

In this regard I would like to offer a special thanks to Peter Rådahl, Head of Engineering and Integration department at the European Spallation Source whom I’ve had the privilege to serve as an advisor for several years now. Peter Raadahl had a clear vision from the start on how to best serve the European Spallation Source with respect to managing technical information, formed a strategy for how to get there and stuck to the strategy through many an obstacle.

Bjorn Fidjeland

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PLM tales from a true megaproject ch. 5 - Spatial Integration

PLM tales from a true megaproject Ch. 4

PLM tales from a true megaproject Ch. 3

PLM tales from a true megaproject Ch. 2

PLM tales from a true mega-project Ch. 1

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