experion pks orion - transforming the way we implement, operate

Transforming the Way We Implement, Operate, and Maintain

CONTROL ROOM OF THE FUTURE

Experion Orion Console

More Efficient Operations

Orion Console

Experion R430

More Situational Awareness

Reduced Operator Fatigue

Increased Operator Mobility

Traditional Operator Environment

“Fatigue causes cognitive fixation and impaired

judgment and could lead operators to fixate on one operational parameter”1

1) Cheryl MacKenzie, US Chemical Safety Board Investigation Report No. 2005-04-I-TX, March 2007

Lack of Mobility, Poor Operator Workspace, and Inefficient Graphics Contribute to Operator Fatigue

Operator Fatigue Challenge

Orion Console

Dramatically Improving Operator Experience

Upgrading Operators to Orion Class Experion R430

More Screen Real Estate

Alarm Lighting

Ergonomic Design

Pan & Zoom

Tabbed Display

Advanced Visualization Elements

Advanced Display Technology

Build Better Graphics with Better Situational Awareness

Experion R430

Unchain Operators from Console

Console Operator Mobility

Mobile Station

Large Screen Interaction

Experion R430

Better Collaboration Solves Problems Faster in the Control Room

Experion Collaboration Station Released!

Collaboration Interactive Touch

Shift Handovers, Situation Assessment

Engage Remote Experts

Traditional

Orion console, mobile and collaboration stations enable efficiency

High or Low Speed

Remote Operations – the New Operations Model

WAN

Centralize Operations and Expertise

Universal IO

Universal Safety

IO

Universal Process

IO Universal Channel

Technology

Only Honeywell Offers True Universal Process and Safety IO

Eliminate Complexity and Build Standard Cabinets Sooner Based on IO Count, Not Mix

What is True Universal IO?

Universal Cabinets

Universal IO

Standard cabinet that can adapt to late wiring changes

Cabinet 1 Cabinet 2

Cabinet 3 Cabinet 4

Traditional Cabinets

AO

Cabinet 1 Cabinet 2

Cabinet 3 Cabinet 4

AI DI DO

Wait for final definition of instruments

and then build custom

cabinets

Universal Cabinets Making Projects Simpler

Traditional Cabinets

AO

Cabinet 1 Cabinet 2

Cabinet 3 Cabinet 4

AI DI DO

Single Model Number for Fully Populated Standard Cabinet

Universal NEW

Traditional

Simplifying IO Order, Build and Configure

Example project with

5000 IO Type Count

1. Analog In 1,500

2. Analog Out 1,000

3. Digital In 1,300

4. Digital Out 1,200

Total 5,000

# of IO Modules with 20% Spares 273

Standard Work Dramatically Simplifying Order Process, Supply Chain, Project Execution and Lifecycle Support

Universal

Type Count

Universal 5,000

# of Universal Cabinets 7

Traditional Instrumentation and IO Wiring

Significant Cost in Equipment, Labor, Documentation and Checkout Junction box

DI AI

DO AO

DI AI

DO AO

DI AI

DO AO

Junction box

Multi Core Cables

Marshalling Cabinet

System Integration Cables

Junction box

DI AI

DO AO

DI AI

DO AO

DI AI

DO AO

Junction box

Multi Core Cables

Marshalling Cabinet

System Integration Cables

Universal IO in the Field

Controllers DI AI DO AO

DI AI DO AO

Fewer Wires, Fewer Engineering Hours, Less Space = Greater Savings

Virtualization

Before

2 Experion Servers

18 Operator Stations

5 Engineering Stations

Sim FDM Alm Mgm

t

ACE Domain Control

30-node System

2 Experion Servers

18 Operator Stations

5 Engineering Stations

Sim FDM Alm Mgm

t

ACE Domain Control

Virtualization

Before

Experion Virtualization

80%+ Reduction in Maintenance, Space, Energy Use and Better Security

Each blade is a server

Experion Virtualization – Blade

Additional

80% reduction

Blade Server

High Reliability, Simpler, Modular, and Pre-Configured

Released

Experion Virtualization

Instrument Freeze

FAT

Application

Some Generic Controls and

Display Templates

Traditional Project Workflow

Physical

Upgrade PCs

Physical

IO Cabinets, Servers, PCs

Application

Develop Control Strategies, Displays

Physical

Development System

Instrument Freeze

FAT

Application

Some Generic Controls and

Display Templates

Physical

Upgrade PCs

Physical

IO Cabinets, Servers, PCs

Application

Develop Control Strategies, Displays

Physical

Development System

Can work without having physical

equipment Don’t need

system upgrade

Can start engineering

sooner & without travel

Big bang testing eliminated

Freeze Not Needed

No Development System

Instrument Freeze

Traditional Project Workflow Transformed

Work in Parallel, Eliminate FAT and Ship to Site Earlier

Experion Orion Project Workflow

Minimal Checkout Eliminates big bang testing with virtual FAT

Application EPC

Honeywell

Honeywell Data

Center

Customer

Direct to Site! Physical

Standard Cabinets Servers

Traditional approach is often back end-loaded

Experion Orion Project Curve (Universal + Virtual)

Months 0

5

10

15

20

25

30

Traditional

Orion Labo

r FTE

s

Reduce Schedule with Lower Risk

Security = Safety

CYBER SECURITY

DCS and Safety – Cyber-certified

Experion C300 Safety Manager

Do You Trust a System That Isn’t ISA Secure?

Secure Services & Dashboard

Whitelisting

Protecting Open Systems

Secure Products and Secure Processes; Secure Services

Securing your critical infrastructure

is an evolving process with four distinct phases.

Released

Encrypted and Authenticated Communications Between Experion PCs and C300 Controllers

Experion Secure Communications

Fault-tolerant Ethernet

C300

C300 Experion Server

Experion Station

Experion R430

Protection Against:

Man in the Middle Attack

Unauthorized Nodes on Network

Tampering with Communications

Orion-Enabled Solution

Wellhead Templates, Autogenerated Displays

Linepack, Flow Calcs, Compressor Modeling,

Leak Detection

Project Efficiency Operations Efficiency

Pan & Zoom

Applications

Experion SCADA Experion R430

Enhanced Experion SCADA

RTU Development

Low Power, Flexible Communications

HART Enabled

DNP & Modbus

-40C to 75C; Zone 2

IEC61131-3 Languages

Flow Calculations

Coming Soon

RTU for Wellhead or Pipeline Applications

Safety, Reliability, Efficiency Solutions

New Field Instrumentation Continuous

Evolution

Stepwise Migrations That Protect Investments in Control, Graphics, Wiring

40+ years of life – avoids costly rip

and replace

Year 20 Year 40+ Year 0

Honeywell Delivers the Lowest Lifecycle Costs

HPM, LCN Current – 2025

A Walk Through Time 1990s

Revolutionary Technology…Delivered in an Evolutionary Way

US and GUS

TDC/TPS

HPM NIM

LCN

HM

Experion Station TPS

HPM NIM

LCN

HM

Experion Station TPS Introduction

IP protection: US, GUS, and Experion HMI

all in one


2004

New Operational Benefits with Modern Human Interface and Alarming

Experion Station TPS and New C300

C300 and Series C

2007

Unified Human Interface for TDC/TPS and Experion


HPM NIM

LCN

HM


The Evolution Continues: EHPM

EHPM

Released!

HPM Evolves to Modern Ethernet Network – Eliminating UCN


ENIM

LCN

HM


Preservation of displays

and controls:

• US graphics – work as-is • AM controls – work as-is • HPM controls and IO – work as-is

C300

Safety Manager

Unifying Multiple Generations of Control Experion R430

EHPM, C300, and Safety Manager Peer-to-Peer Control



ENIM

LCN

HM

EHPM C300

Safety Manager

EHPM C300

TPS Merges into Experion

LCN Components Gradually Melt into Experion

Vision


Experion Station

EHPM

Ten Additional Years of Life with Upgrade to EST, EHPM/SM and Lifecycle Contract


and replace


Honeywell Delivering Longest Lifecycle

EHPM 2035! • Upgrade to EST • Upgrade to EHPM/SM • Lifecycle Contract

Hiway Evolution

Hiway Boxes

46 Years of Life in 2020 – Exciting New Migration Capabilities



HG

LCN

AM

Simple Zero Footprint Basic and Extended Controller Cutover to Experion Orion

Universal IO – Hiway

Universal IO –

Hiway

Experion R430


HG

LCN

AM

Mount in Hiway Cabinets

Preserve Hiway Wiring

Integrated HART

C300


Hiway Migration

Migrate Graphics to Experion Station, Migrate AM Controls to C300

Universal IO –

Hiway


LCN

C300

Decommission HG?

Full Integration Between TDC3000 and Experion Orion


HG AM

Experion Hiway Bridge

Migrate Hiway But Preserve TPS US Graphics and AM Controls – Simple

Universal IO –

Hiway


EHB

LCN

AM

C300 Hiway Gateway Becomes Hiway Bridge to C300

Phase 2: 2015 – Online Phase 1: Experion R430 – Offline


Creating New Benefits and Evolving Equipment – At Your Pace

Define multi-year automation plan Justify upgrades with operational benefits Flexible finance approaches

What’s Your Roadmap?


and replace


Assurance 360 Service Program

Proactive Support Model

Maintain and Manage all Aspects of your Automation Systems

Defined Metrics and Assured Results

Focus on Your Process and Not Your System



Evolution

Where to Focus?

Many Root Cause Similarities With Safety Incidents

ad been inadequate for dealing with a l and sustained plant

42% of process incidents are

linked to improper operation or action

42% People

22% Process

Source: ASM Consortium

36% Equipment

Training and Practice are Fundamental to Top Performance in Any Industry

Learn from others’ mistakes

Train on best practices

Prepare for upcoming operations

UniSim – Improve Operator Competency

Reproduce the performance of your best operator...

…every day, every shift

Components of Effective Simulator-based Training (SBT)

Operator Competency

Model

Learning Objectives

Performance Metrics

Training Excercises

Performance Feedback

Operators Were Overwhelmed by Alarm Floods

Alarms are Frequently Cited

too many alarms and they prioritised.

utes before the explosion the d to recognise, acknowledge arms.

b. Manage instrumentation and alarms in a manner that ensures that they are sufficient and functional for all anticipated potential conditions and that there are no start-ups without tested and documented functioning of these systems.

Enforce & Change Management

Manage Alarms Throughout the Lifecycle

Systematic Approach to Improve Alarm Management

Alarm Management

Rationalize & Document

Benchmark

Average alarms per day

Average standing alarms

Peak alarms per 10 minutes

Average alarms per 10-minute interval

Distribution % (low/med/high)

144

9

10

1

80/15/5

EEMUA Alarm Guidelines

Average standing alarms

Do You See More Than 9 Standing Alarms on Your Consoles?

Compliance With Alarm Guidelines New

Alarm Dashboard

Monitor Your KPIs

Benchmarking indicates 70% of reliability issues are operations related1

1. Birchfield, G (2000) Solomon Associates, Plant Reliability – A New Approach to Understanding Plant Reliability

Plants with Best Process Control Have Fewer Slowdowns and Shutdowns

Eliminate Process Variability

Correlation Between Uptime and APC Implemented2

95%

65% 55%

15%

Uptime

2. Birchfield, G., Solomon Associates – “Olefin Plant Reliability”

Analyze constraints and operate within them

Reduces operator manipulation by 80%

Profit Suite

Profit Suite Making it Simple

Profit Suite Delivers Benefits Faster and Stays Online Longer

Traditional

Gets Turned Off

Modeling is an art

Requires steady state

Profit Suite

Easy to Setup & Maintain

Modeling is a process

Dynamic optimization

Increase Process Performance

Linear Control

Non-linear Control

Sustain

Collaborative Remote Services Programs

Control Performance

Improving Your Plant Control

Identify & Fix Control Performance Issues

Control Performance

Monitor

Manage Instruments, Valves, and Complex Equipment

Analyze Act Portal for Managing Your Instruments, Valves, and Equipment

Asset Manager Condition-based monitoring

Compressor, pump, heat exchanger models

Asset Performance & Health

Field Device Manager HART, Fieldbus, Profibus

DTM support for popular valve applications

Instruments & Valves

PHD Enterprise Historian

Experion Integration

New System Management

New Enterprise Event Journal

Uniformance – Collecting Data and Events

Millions of Tags, Decades of Data, Thousands of Users

New Integrated Analysis Tools Correlate Trend Data with Events

Collaborate Act Anticipate

Intuition Executive Visualization & Collaboration

Making Data More Transparent and Decisions More Clear

Unlocking the Value of Your Data

Alarm Management Only

Intuition Operations Monitoring

Alarms define safe operating window

Monitoring defines profitable operating window

Released

Run Your Process in the Most Profitable Zone

Alarm Management and Intuition Operations

Monitoring

Tighter operational constraints

Intuition KPI Dashboard

Anticipate

Proactively Monitor Process Performance and Equipment Metrics

Electrical Production

Value

93.5 Limit: 100

Cost Per Unit Production (Net Margin)

Value

178.9 Limit: 250 !

Electrical Production

Value

98.6 Limit: 96

Cost Per Unit Production (Net Margin)

Value

52.5 Limit: 30

Released



Evolution

SmartLine

Our SmartLine Transmitter Just Got Smarter

Leading Performance

Smart Connection Suite

Lowest Total Cost of Ownership

Setting a New Standard

Released!

Leading Performance

Stab

ility

– S

hift

Ove

r Tim

e

Time – Years

Traditional options – unstable and random accuracy

0 10

Improved Accuracy Stability = Spend Less Time Calibrating

Our SmartLine Transmitter Just Got Smarter

How does it deliver the best value?

Released!

Lowest Total Cost of Ownership

Modular Transmitter

SmartLine Stock parts

Repair / upgrade in field

Upgrade or Replace Components in Field; Stock Only What You Need

Traditional Stock full device

Repair in shop, upgrade?

Ultimate Flexibility, Faster Maintenance and Lower Inventory Costs

Advanced Display

Graphic Display Lets You See Your Process the Way You Want

Traditional Limited information

SmartLine Graphic and intuitive –

full information

Unique Polarity Insensitivity

Either Connection will OPERATE Correctly

+ – Field Wiring

+ – +

– + Field Wiring

+ – +

or

Save Time on Start-ups and Avoid Maintenance Errors; Only Supplier to Support This for HART

Automatically Corrects Polarity

Our SmartLine Transmitter Just Got Smarter Released!

Smart Connection Suite How does it deliver the best value?

Ensures the Right Device, Right Action and Right Mode for Safe Maintenance

SmartLine Confidence

Transmitter Messaging & Maintenance Mode

Traditional Is it safe?

Send a Message to the Display Indicating Device is Available for Maintenance

Transmitters just got smarter – SmartLine.

High Accuracy Gas Custody Transfer

Gas Ultrasonic Flow Meters

Global certifications

120 and 200 kHz

High pressure 1500 psi

Gas metering software

January 2014

Fusion 4 Multistream Additive Controller

Most Intuitive Field Controller on the Market

Up to 12 additive injectors

Simple wiring and configuration

Tight control avoids quality giveaway

Integrated audit trail

NEW



Evolution

experion pks orion - transforming the way we implement, operate

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