Technology Overview & New Innovations. Ignace Verhamme, Rudi Bott Customer Marketing Honeywell Process Solutions

Transcription

1 Technology Overview & New Innovations Ignace Verhamme, Rudi Bott Customer Marketing Honeywell Process Solutions

2 Transforming the Way We Implement, Operate, and Maintain

3 Agenda Transformation in Operation Transformation in Execution Experion for Oil & Gas Cyber Security Experion R431 Infrastructure (Coffee Break) Safety Manager Continuous Evolution The Smart Field

4 Operations Transformation Last Generation Panel Controls Supervisory Computers Enabling Broader Operator Scope While Improving Safety and Reliability

5 Operator Environment Today Operator Responsibility Continues to Grow 15-Yr.-Old Displays Alarms & Limits Written Procedures CCTV More Complex Than Ever

6 Operations Transformation New Generation Supervisory Computers Experion Orion Console Released Eliminate Complexity, Better Operational Performance, Fewer Consoles

7 Experion Orion Console & HMI Transformation Similar in Magnitude to Moving from Panel to Supervisory Computer New Context Based Visualization Integrated Alarm & Limit Management Integrated Procedures More Situational Awareness, Faster Response, Operate Closer to Limits

8 Fundamentals: ASM Model The ASM Model of Human Supervisory Control Reflexive Behavior Path External Inputs from Process (Signals, Instructions, Environment) Orienting (1) Sensing, Perception and/or Discrimination Evaluating (2) Analysis, Interpretation and/or (3) Projection Situation Awareness (1-3) Acting Physical and/or Verbal Response Outputs to Process (SP, OP%, Manual Adjustments) Internal Feedback Assessing External Feedback Adaptation of Supervisory Control Activity models of Jens Rasmussen and David Woods.

9 Scenario #1: Flawless Unit Startups Have you experienced issues with unit startup?...30% of all reports had procedural operations as one of the causes. A Study of Effective Procedural Practices in Refining and Chemical Operations, Peter T. Bullemer, John R. Hajdukiewicz, Proceedings of the Human Factors and Ergonomics Society s 48th Annual Meeting, New Orleans, LA. September 20-24, 2004 Using Automation, New Visualization & Collaboration

10 Scenario #2: Flawless Operations Last Generation Contextual Information, Orient & Guide Run Process Closer to Limits for Longer Period of Time

11 Data in Context = Information Which is more effective for determining detail? Tray Tray Tray Tray Tray Tray Tray Tray 58 Tray 49 Tray 40 Tray 31 Tray 22 Tray 13 Tray 4 10:00 10:30 11:00 11:30 12:00 OR

12 Let The Machine Do The Work Old type Controller Normal Abnormal Uses SP versus PV 50 A 50 % 50 A 70 % New type Controller Uses Deviation >10% A A Timer make a note! 0

13 Let The Machine Do The Work 50 A 52 % 50 A 43 % 50 A 50 % 50 A 49 % 50 A 53 % 50 A 50 % 50 A 65 % 50 A 54 % 50 A 48 % 50 A 50 % 50 A 51 % 50 A 54 % 50 A 44 % 50 A 32 % 50 A 46 % 50 A 48 % 50 A 50 % 50 A 70 % 50 A 56 % 50 A 49 % And now with a other controller shape

14 Let The Machine Do The Work A A A A A A A A A A A A A A A A A A A A

15 Pan and Zoom Displays Thumbnail with viewport & active alarms Pan & zoom using natural interaction techniques Thumbnail popup HyperZoom Efficient Navigation of Large Displays

16 Scenario #3: Reducing Abnormal Situations Quickly Determine Root Cause of Alarms Provide Guidance to Recover Better Visualization & Integrated Alarm Management

17 Orion Console Base Unit Two Position Base Unit Three Position Base Unit

18 Operator Touch Panel Orchestration Zone Control Zone Display Zone Navigation Zone Alarm Zone

19 Auxiliary Equipment Unit Center Curved no Turret End Right no Turret Center Straight Single Turret Double Turret

20 Collaboration Station Location Pane

21 Collaboration Station Implementation Collaboration Station - Up to 4 per eserver Experion eserver in DMZ - Connect to up to 60 Experion Servers Distributed System Architecture

22 Transforming Project Execution

23 Industry-Wide Capital Project Challenges Gap Between Project Length and Cost Cost ($) Plan Actual 70% of projects overrun Of 47 mega-projects analyzed by PwC, the average cost overrun was 88% 1 Time (months) 1. Correcting the Course of Capital Projects, Oct 2013, PricewaterhouseCoopers LLP Transforming the Project Execution Model is More Important Than Ever

24 What Causes Capital Project Overruns? Increase in Size and Complexity More Remote Locations Design Errors = Scope Growth & Late Changes Lack of Skilled Labor Complexity Requires Increased Collaboration Between End User, EPC, Automation Supplier

25 What If? Schedule Change Orders Freeze Dates Skills Deliver 2-3 months earlier 80% reduction time Months of additional flexibility Bring work to engineer reduce travel by 70% What If You Could Eliminate a Significant Amount of Work and Take Automation Off the Critical Path of Your Capital Project?

26 Lean Execution of Automation Projects Universal IO Lean Execution of Automation Projects LEAP Cloud Engineering Virtualization Transformational New Project Execution Model

27 LEAP Enabling Technology Universal IO Universal IO Cloud Engineering Virtualization

28 Universal IO Universal Safety IO Universal Process IO Universal Channel Technology Only Honeywell Offers True Universal Process and Safety IO

29 What is True Universal IO? Traditional Cabinets Wait for final definition of instruments and then build custom cabinets Universal Cabinets Standard cabinet that can adapt to late wiring changes Eliminate Complexity and Build Standard Cabinets Sooner Based on IO Count, Not Mix

30 Universal Cabinets Making Projects Simpler Traditional Cabinets Single Model Number for Fully Populated Standard Cabinet

31 Simplifying IO Order, Build and Configure Traditional Universal Type Count Type Count 1. Analog In 1, Analog Out 1, Digital In 1, Digital Out 1,200 Total 5,000 # of IO Modules with 20% Spares 273 Example project with 5000 IO Universal 5,000 # of Universal Cabinets 7 Standard Work Dramatically Simplifying Order Process, Supply Chain, Project Execution and Lifecycle Support

32 Traditional Instrumentation and IO Wiring Significant Cost in Equipment, Labor, Documentation and Checkout DI DI AI AI DO DO AO AO DI DI AI AI DO DO AO AO DI DI AI AI DO DO AO AO Junction box Junction box Multi Core Cables Marshalling Cabinet System Integration Cables

33 Universal IO in the Field Fewer Wires, Fewer Engineering Hours, Less Space = Greater Savings Junction box Junction box Marshalling Cabinet DI AI DO AO DI AI DO AO DI AI DO AO DI AI DO AO DI AI DO AO Multi Core Cables Controllers System Integration Cables

34 Universal Remote Modular Cabinet Fiber Optic Media Convertors Fiber Optic Termination Universal I/O Modules Universal Isolators by P&F Redundant Power Supply Field Power and Terminations

35 The Universal Isolator Introducing the Universal Isolator Compliments Universal Channel Technology Works for both process and safety IO Universal Isolator with Adaptive Signal Technology Capable to have 24VDC AI, AO, DI and DO connected IO Universal Isolator Cabinets 16 Isolator with 16 pair prefabricated cable 32 Isolator with two 16 prefabricated system cables. 64 Isolator with four 16 pair prefabricated cable Environmental Specifications -40C to +70C, same as Universal IO Marine and HazLoc, same as Universal IO Not a Honeywell product (P&F) Other suppliers will offer similar solutions

36 LEAP Enabling Technology Universal IO Virtualization Cloud Engineering Virtualization

37 Virtualization Before 2 Experion Servers Sim FDM Alm Mgmt 18 Operator Stations ACE Domain Control Experion Virtualization 5 Engineering Stations 80%+ Reduction in Maintenance, Space, Energy Use and Better Security

38 Blade Server Each blade is a server Experion Virtualization Blade Experion Virtualization Additional 80% reduction Released High Reliability, Simpler, Modular and Pre-Configured

39 LEAP Enabling Technology Universal IO Cloud Engineering Cloud Engineering Virtualization

40 Cloud Engineering Traditional Cloud Engineering People and equipment staged early in project in a single location Project staged in data center & people distributed Apply the Best Resources Wherever They are in the World

41 LEAP Enabling Technology Late Binding Lean Execution of Automation Projects LEAP Enhanced Design Cloud Engineering Universal IO Flexible Hardware Procurement Virtualization Improved Agility and Flexibility

42 Traditional Project Workflow Application Application Physical Some Generic Controls and Display Templates Develop Control Strategies, Displays Upgrade PCs Physical Physical FAT Instrument Freeze IO Cabinets, Servers, PCs Development System

43 Traditional Project Workflow Transformed Application Application Physical Some Generic Controls and Display Templates Can start engineering sooner & without travel Develop Control Strategies, Displays Can work without having physical equipment Don t need system upgrade Upgrade PCs Physical Physical FAT No development system Development System Instrument Freeze IO Cabinets, Servers, PCs Freeze not needed Big bang testing eliminated

44 Lean Execution of Automation Projects (LEAP) Application Honeywell Data Center EPC Honeywell Customer Physical Direct to Site! Minimal Checkout Servers Standard Cabinets Work in Parallel, Eliminate FAT and Ship to Site Earlier

45 Labor FTEs LEAP Project Curve LEAP Traditional approach is often back end-loaded Traditional 5 0 Months Reduce Schedule with Lower Risk

46 Experion Orion for Oil and Gas

47 Experion SCADA Released Project Efficiency Wellhead Templates, Autogenerated Displays Operations Efficiency Pan & Zoom Applications Linepack, Flow Calcs, Compressor Modeling, Leak Detection Experion Orion R2 Enhanced SCADA

48 Experion Orion R2 Efficiency for Common Assets Traditional Points 1000 s New Equipment Template Replicated Standard Work Algorithms Displays Trends 100 s 100 s 10 s Task Filters Reduce 1000 s of Custom Actions with Equipment Templates

49 Autogenerated Displays Equipment Template Intuitive & Packed with Context Eliminate Substantial Amount of Work Associated with Custom Graphics

50 Pan and Zoom Displays Thumbnail with viewport & active alarms Pan & zoom using natural interaction techniques Thumbnail popup HyperZoom Efficient Navigation of Large Displays

51 RTU2020 Ultra Low Power HART Enabled Released DNP & Modbus -40C to 75C; Zone 2 IEC Languages Flow Calculations RTU for Wellhead or Pipeline Applications

52 CYBER SECURITY Security = Safety

53 Protecting Open Systems Released Upgrade Your Windows XP Systems to Experion R400+ Whitelisting Secure Services Secure Products and Secure Processes; Secure Services

54 Experion Secure Communications Fault-tolerant Ethernet Released Experion Station C300 Experion Server C300 Protection Against: Man in the Middle Attack Unauthorized Nodes on Network Tampering with Communications Encrypted and Authenticated Communications Between Experion PCs and C300 Controllers

55

56 Cyber Security Lab & Dashboard Proactive Cyber Security Intelligence

57 Experion PKS R431 Infrastructure 63 Document control number Honeywell Proprietary

58 Flex Server Introduction Alternative configuration for small clusters with Experion and/or SCADA controllers Ideal for: - Smaller Experion PKS servers - Remote Experion PKS servers - Skids integrated with Experion PKS systems - Default solution for most smaller systems, unless specified otherwise Windows 2007 Experion Flex Server Cluster Up to 3 ES-C Windows 2008 R2 Experion Server Cluster Up to 5 DSA connections - Up to 10 C300 - Up to 5050 process points

59 Flex Server deployment example DSA connectivity Each Flex Cluster has: 2 x Server/Station dual or single screen Max 10 Experion controllers DSA Functionality with central control room cluster Central Control Room Standard Cluster Distributed System Architecture Gathering Station Flex Server Cluster Pumping Station A Flex Server Cluster Pumping Station B Flex Server Cluster Terminal Flex Server Cluster

60 Experion PKS R431 Integration 66 Document control number Honeywell Proprietary

61 IEC Data Flow Redundant Experion Control Server DSA HMI Redundant Experion IEC61850 Client Server C300-50ms FTE Network 850M NTP Time Master MMS & RCB Alarms, Events, Supervisory Control, and HMI IED Tools FW IEC61850 Network I/O I/O MMS IED IED IED IED

62 Profibus Topology Future FDM Redundant Experion Control Server HMI DP network Time-Synchronization, DPV1 alarms & diagnostics PGM C300 1.PGM can scan and cache the following HART data: Tag, ID, message, descriptor, range Device & Dynamic variables, Standard and Device-specific diagnostics HART data is available for control and indication. 2.Users can read and write selected DPV1 data resident in DP slaves. STAHL Turck EXCOM Other Third party comp. HART Devices CEAG Siemens PROC Siemens PROV Simatic S7 400 PLC HART Devices Danfoss VLT2800 Drive ABB ACS 800 Drive

63 FMC 722 Control Integration Diagnostic Data Experion Server Quick Builder / OPC integrator FMC Server Experion Server CDA ACE-2 ACE-1 CDA OPC DA CDA Non process data Tofino Firewall Tofino Firewall C300 C300 FMC722 over TCP FMC TPU Topsides C300 C300 FMC722 over TCP FMC TPU Process data Process data R410 SEM 001 SEM nnn Subsea R431 SEM 001 SEM nnn Subsea

64 FDM R450 FDM R450 Compatible with Experion R431 Also works with R430, and R410 Target for R400 at a future time DE Protocol Support Support DE Protocol devices on TPS networks PVST Planner (HART) Major customer cost mitigation for compliance and safety Automatically schedule and run PVST tests Start with support for most popular devices Designed so others can be added release independent

65 Continuous Evolution New Field Instrumentation Safety, Reliability, Efficiency Solutions

66 The Evolution Continues: EHPM Fault-tolerant Ethernet 2012 Experion Station TPS Experion Station TPS EHPM C300 LCN HM ENIM Preservation of displays and controls: US graphics work as-is AM controls work as-is HPM controls and IO work as-is HPM Evolves to Modern Ethernet Network Eliminating UCN

67 Unifying Multiple Generations of Control Fault-tolerant Ethernet Released Experion Station TPS Experion Station TPS EHPM C300 LCN HM ENIM Safety Manager EHPM, C300, and Safety Manager Peer-to-Peer Control

68 Shift LCN Communication to FTE Fault-tolerant Ethernet Released Experion History 2015 Displays Experion Station TPS EHPM C300 LCN ENIM Eliminate LCN Bottlenecks

69 TDC Merges into Experion Fault-tolerant Ethernet Vision Experion Station EHPM C300 Safety Manager LCN Components Gradually Melt into Experion

70 Experion PKS R431 Continuous Evolution TDC / TPS and the ETN 80 Document control number Honeywell Proprietary

71 TPS Virtualisation

72 Virtual Environment Virtual machine on a server that connects to the K4LCN-ETNI processor boards through the FTE. Thin clients are used to provide user interaction with virtual machines.

73 Honeywell Delivers the Lowest Lifecycle Costs Year 0 Year 20 Year years of life avoids costly rip and replace HPM, LCN Current 2025 Stepwise Migrations That Protect Investments in Control, Graphics & Wiring

74 Honeywell Delivers the Lowest Lifecycle Costs Year 0 Year 20 Year years of life avoids costly rip and replace EHPM 2035! Upgrade to EST Upgrade to EHPM/SM Lifecycle Contract Ten Additional Years of Life with Upgrade to EST, EHPM/SM and Lifecycle Contract

75 Experion PKS R431 Continuous Evolution UHIO 85 Document control number Honeywell Proprietary

76 Hiway Evolution Fault-tolerant Ethernet Experion Station TPS AM HG LCN Hiway Boxes 40 Year Anniversary!

77 Universal IO Hiway Fault-tolerant Ethernet Released Experion Station TPS Mount in Hiway Cabinets C300 LCN Preserve Hiway Wiring AM HG Integrated HART Universal IO Hiway Simple Zero-Footprint Basic and Extended Controller Cutover to Experion Orion

78 Hiway Migration Fault-tolerant Ethernet Experion Station TPS LCN Full Integration Between TDC3000 and Experion Orion C300 AM HG Decommission HG? Universal IO Hiway Migrate Graphics to Experion Station, Migrate AM Controls to C300

79 Experion PKS R431 Continuous Evolution EHB 89 Document control number Honeywell Proprietary

80 Experion Hiway Bridge Offline Released Fault-tolerant Ethernet Phase 2: 2015 Online Experion Station TPS C300 AM EHB LCN Hiway Gateway Becomes Hiway Bridge to C300 Universal IO Hiway Migrate Hiway But Preserve TPS US Graphics and AM Controls Simple

81 What s Your Roadmap? Year 0 Year 20 Year years of life avoids costly rip and replace Define multi-year automation plan Justify upgrades with operational benefits Creating New Benefits and Evolving Equipment At Your Pace

82 Assurance 360 Services Program Proactive Managed Services model Maintains system to assure highest levels of reliability Assured results with established baseline and defined metrics Managed Services to Ensure Excellent Operational Condition

84 SmartLine A Platform for a New Generation of Smart Transmitters Simplifying Installation, Operation and Maintenance

85 SmartLine Pressure/Temperature/Level Now Introducing SmartLine Temperature! Released Featuring the Same Benefits as SmartLine Pressure: Leading Performance Smart Connection Suite Lowest Total Cost of Ownership State-of-the-Art Dual Chamber Temperature Transmitter

86

88