In the past, the EPC project requirements exclusively referred to the hardwired ones, focusing on operating principles, design, and materials. It is not acceptable anymore. Today, they should be merged with the softwired ones, bringing intelligence and efficiency growth to the plant operation planned to last 20 – 30 years.
The softwired requirements are no different from those for a cellular phone or EV. They should outline how information is to be stored and processed (for instance, to compile an operational report). The former task requires a Common Data Environment (CDE) introduced in the ISO 19650 standard series, while the latter involves a set of applications that may ultimately transform the plant from "locally driven" to "remotely driven" and ultimately to "self-driving".
CDE
CDE is common as it encompasses all three domains of the project-plant lifecycle - design, construction, operation and maintenance. CDE stores data included in the project handover scope from P&IDs and 3D models to inspections and tests, and the SCADA programs. CDE is not intended for operational data storage.
CDE should offer quick online search, retrieval, and logical navigation of information, as well as a gateway to external applications that retrieve data. (Logical navigation follows the physical links between different pieces of equipment. This requirement effectively blocks usage of outdated file directories.)
Obviously, the engineering company shall build CDE for its own needs before initiating any project. What the client will get is a "read-only" permission for shareable information.
The core principles of the CDE implementation by crenger.com are described in "10 Axioms of Business Digitization" and "Information Modeling".
CDE secures the next step – maintenance-related data processing using plug-in services having a "read-write" permission. The top-priority ones are non-negotiable; they are described below.
AI Data Factory Service
AI Data Factory Service App (DFS) stores operational data in the cloud (separately from CDE) and provides means for its retrieval by consulting companies engaged in AI-powered data analytics.
For sending data to the cloud, It is advisable to select between REST+JSON or MQTT protocols. The latter is ideal for resource-constrained devices and low-bandwidth networks, making it widely used for efficient data transmission from sensors and edge devices to gateways and cloud platforms.
The principles of the DFS implementation by crenger.com are described in "Selecting AI Strategy".
Warranty Service
Warranty Service App (WSA) handles warranty-related interactions between OEM, the EPC contractor, and the plant operator. The WSA functionality is described here.
WMA requests CDE provide unrestricted access of any mentioned party to the operational data on the warranted product – maintenance activities and the time series of parameters covered by the performance warranty (if included in the product extended warranty).
Inventory Service
Inventory Service App (ISA) manages spare parts and items stocks – local and centralized, serving a network of plants. ISA implements standard algorithms for Reorder Point, Economic Order Quantity, and Safety Stock Calculations. ISA is a main source of the reliability data – MTBF and MTTR - critical for both the plant operator and designer.
Maintenance Service
Maintenance Service App (MSA) handles scheduling and execution of maintenance tasks included in warranty agreements and refurbishments. The MSA main points are discussed in "Scheduled Maintenance Automation".
Next, MSA shall include reverse osmosis membrane management (ROMM). It handles three basic tasks - monitoring the membrane state, selecting its cleaning program, and managing the membrane elements' reshuffling inside the pressure vessel. The ROMM content is outlined in "Requirements for Reverse Osmosis Membranes Management Framework".
The final group of the MSA tasks is related to operational safety and continuity – planned inspections of equipment under pressure and emergency systems, valve exercises, instrument calibration, permit renewals, and others.
Financial Service
Financial Service App (FSA) manages financial and scheduling aspects of all the above-mentioned services and the purchasing agreements on spare parts and consumables transferred to the client during the plant handover. FSA is expected to be pre-loaded with price information on any equipment piece under maintenance, and a list of preferred vendors and service providers.
Training Service
Training Service App (TSA) guarantees the continuity of the plant's trouble-free operation after the main contractor’s operators leave the field. It is critical as the complexity of desalination plants is on the rise, and the plant operator experience is not entirely shareable.
The service shall manage the operator’s e-certification on normal, abnormal, and batch operations of the plant systems, equipment maintenance procedures, troubleshooting, etc. Reference implementation of TSA for the plant designers may be tested here.
For desalination megaplants with a life expectancy of over 20 years, all the above-mentioned services are non-negotiable.