Integrated Automation Assessments (IAA) Identify Opportunities to Improve Efficiency, Reliability and Safety

Transcription

1 Integrated Automation Assessments (IAA) Identify Opportunities to Improve Efficiency, Reliability and Safety

2 Know Where You Stand Assess your control system Assess your control performance

3 Assessing Your Control System Executive Summary LCN Network Health System Performance Baseline for Company ABC Network Health Caution Healthy Poor Security Security Patches Antivirus Signatures Performance Baseline Performance Track Conditions Configuration Check Against Best Practices Lifecycle Status & Path Forward Supportability Status Risk to Plant Operations Cost to Maintain & Support Technology Refresh Comprehensive System Health Assessment With Recommendations

4 Covering Control System Aspects Experion System CONFIGURATION Assessment FTE Netw ork Configuration Experion Controller Configuration Experion Client Server Configuration HMI Display Configuration Back Up and Recovery Configuration SECURITY Assessment Security Configuration Anti-Virus Status Microsoft Security Updates Installed Softw are Analyzed by Global TAC Analyzed by Global TAC TPS Integration CONFIGURATION Assessment Experion System PERFORMANCE Assessment PC Performance Server Communications Performance Sw itch Performance Controller Performance Reviewed by Certified Engineers Experion / TPS Integration Configuration TPS System PERFORMANCE Assessment Overall LCN Loading Overall UCN Loading LCN Node Statistics UCN Node Statistics Nodes Exceeding Recommended Guidelines Node Type Specific Reports Reviewed by Certified Engineers

5 Lifecycle Status & Path Forward Detailed Migration, Upgrades Options & Recommendations TECHNOLOGY REFRESH OPTION: The GUS stations are under Windows XP, which is after April 8, 2014, discontinued from Microsoft. This means that while the operating system may continue to operate beyond the end of life date, Microsoft will not release new security updates, security hot fixes, provide technical phone support, or online technical content updates. Without this support, the XP operating system could become increasingly vulnerable to cyber security threats. Honeywell recommendation is to upgrade GUS to ES-Ts Obsolescence Chart - Technology Refresh Option is also recommended to upgrade APMs to EHPMs BENEFITS: The ES-Ts will run on R410 and R430 under Windows 7 Operating System with full support from Microsoft and Honeywell and will add the Experion console station functionality to the Native Window functionality. This new Experion functionality can be implemented on process, on a self paced schedule. - EHPM migration will retain all IP as well as using existing PM I/O in its CPU Racks Detailed Assessment of the Supportability Status for Each Module & Controller IB Life Cycle Management traffic light 2 D at e run: 0 5/ 0 2 / Account Name Site Name Master Asset SID Last Audit Date AM AM-R (EAMR) AMC AMX APM APM-R APP CUSTOMER01 16/10/ Customer Madrid CUSTOMER08 16/10/ Grand Total Account Name Site Name Master Asset SID Last Audit Date HG HLPIU HMON HPM HPM-R LEPIU LLPIU CUSTOMER01 16/10/ Customer Madrid CUSTOMER08 16/10/ Grand Total

6 Assess Your Control Performance Control Performance Poor performing loop prioritization Energy efficiency assessment in Fired Heaters Units Alarm Performance Alarm chatter identification

7 LOOPS REPORT Assessing Control Performance Tagname DCSUnit ProcArea Description LoopType Performance Criticality CritAreaOpportunity ValveStictionProbability OscillationPeriod CPI COV CHFC_007 CH ENERGIA CONTROL H2 CARGA flow R-1 poor m 50s CHFC_008 CH ENERGIA CONTROL H2 LECHOS flow R-1 poor m 8s CHFC_014 CH ENERGIA LLCN A TANQUE flow poor m 25s CHLC_002 CH ENERGIA NIV BOTELL CARG level HN-V-1 acceptable N/A 200m 6s CHLC_024 CH ENERGIA CONTROL NIVEL level HN-V6 fair N/A 502m 18s CHLC_034 CH ENERGIA NIVEL ESTABILZADORA level HNV8acceptable N/A 983m 33s CHLC_037 CH ENERGIA DEPOSIT CONDENSADO level HNV10 fair N/A 500m 0s CHTC_005 CH ENERGIA CTROL TEMP ENTRADA temperature SHU fair N/A 999m 60s CHTC_044 CH ENERGIA TEMP A SALIDA temperature DE HNE8 fair N/A 1000m 0s CHTC_049 CH ENERGIA ENTRADA A REACTOR temperature HNR2 fair N/A 999m 60s CHTC_083 CH ENERGIA ENTRADA REACT temperature SHDS HNR3fair N/A 1000m 0s CHFC006A CH ENERGIA CTROL CARGA flow HC AL REACTOinactive none 1 none 1 3m 20s N/A 0 CHFC035A CH ENERGIA SALIDA ENFRIADOR flow HNE15B inactive none 1 none 1 none N/A 0 CHFC040A CH ENERGIA NAFTA INERTE flow HNV11 HNV1 inactive none 1 none 1 none N/A 0 CHFC_001 CH ENERGIA HCN DE FCC - CARGA flow HDT inactive none 1 none 1 33m 20s N/A 0 CHFC_002 CH ENERGIA LCN DE FCC - CARGA flow V-1 inactive none 1 none 1 0m 32s N/A 0 CHFC_004 CH ENERGIA MINIMO FLUJO flow HN-P-1A/B saturated none 1 none 1 none N/A 0.68 CHFC_006 CH ENERGIA CONTROL CARGA flowr-1 fair none 1 none 14 3m 47s CHFC_013 CH ENERGIA REFLUJO A SPLITTER flow V-2 inactive none 1 none 9 0m 18s N/A 0.51 CHFC_015 CH ENERGIA MINIMO FLUJO flow HN-P-4A/B acceptable none 1 none 7 1m 34s CHFC_016 CH ENERGIA COND. MEDIA flow CALENT E-8 acceptable none 1 none 1 5m 39s CHFC_018 CH ENERGIA CARGA A R-2 LECHO flow N? 1 excellent none 1 none 1 0m 31s CHFC_019 CH ENERGIA CARGA A R-2 BY-PASS flow E-9 excellent none 1 none 1 0m 6s Detailed Status Of All The Loops With Each Unit, With Direct Identification Of Oscillation Interactions And Sticky Valves

8 Alarm Performance EEMUA Benchmark Rank Shown Several Alarm Activity Benchmarks Displayed

9 IAA Process Get Site Data Non-invasive collectors gather a comprehensive data sample for diagnostics. Checklists employed for additional data collection Data Security Data is encrypted and bundled then sent to Honeywell expert team for analysis and report generation SME Inputs Report is generated to summarize performance and highlight issues Engagement The report is presented in a consultative face-to-face environment with customer 3 days at site 8 days at back office

10 Deliverables Standard Enhanced 1. Control System Update & Performance Audits X X - FTE Network Installation and Configuration x x - Security Updates and Antivirus Verification x x - Operating System Performance x x - EPKS Client Server Configuration x x - Verification of Graphics Performance x x - Back Up and Recovery Assessment x x 2. Technology Integration X X - TPS Audit x x - System Performance Baseline x x 3. Lifecycle Optima Evolution Path X X - Update on the Status of the Installed Base x x 4. Process Control Performance Audit X 5. Alarm Benchmark X "Standard" IAA Pricing: EPKS TPS Price Per System: Customers with existing SPB options in contracts: "Enhanced" IAA Pricing: EPKS TPS Price Per System: Customers with existing SPB options in contracts: Optional: Integrated Automation Assessment - IAA

11 Performance Proactive Maintenance Model CORRECTIVE TIME BASED PERFORMANCE-BASED BEST PRACTICES Reactive Time based Audits Best Practices - MTTR Driven Linked to immediate qualified labor response maintenance Hot Fix Updates Test Protocols On condition monitoring Performance Indicators Lifecycle Management Performance Continued Improvement Availability of Spares P1 & p2 24/7 Availability AV updates Loop Diagnosis Valve Diagnostics

12 Recommending the Right Solutions IAA LSS Solution Sustained Benefits Best Practices Set Up & Configuration System Performance Supportability Process Control Alarm Benchmark Proactive Maintenance K&E and LSS Services SESP & Tech Refresh CPM and Tuning Services Alarm Management FSC/SM K&E and Services Optimum Reliability Best Performance Lowest Cost to Own Best Efficiency Operational Safety Safety in Control KPIs Management: Reliability Improvement Efficiency Increase Lifecycle Cost Reduction Safety Typical Benefits: 50% Failure Rate Reduction 2% Efficiency 5% of Installed Base Cost 0.1% Production Systematic Measureable And Continuous Improvement Of Customer Kpis

13 Thank You