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2013 Honeywell Us ers Group As ia Pacific Sympos ium
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Universal Process I/O Greg Belcher
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Transformed by a single device with multiple functions
What Changed in the Real World?
Purpose-Built Gadgets
Multiple Devices, Single Function Universal Device
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Why Not Extend to Industrial World?
Multiple IO, Single Function Universal IO
Transformed by a single device with multiple functions
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What makes it UNIVERSAL?
UNIVERSAL Channel Technology Made it Possible
Environmentally Hardened
Analog Input
Analog Output
Digital Output
Digital Input
Universal IO – Experion’s Multi-Tool
• 32 Universal Channels
• Each channel SOFT configurable as DI, DO, AI & AO • HART 7 Compatible
• Full Redundancy
• Extended Temp. Range (-40 to +70 Deg C)
• Local & Remote capability
• Cabinet Mounted & DIN RAIL
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Universal Channel Technology (UCT) • New concept introduced with Experion Orion (June 2012)
• Completely liberates safety and process I/O, as well as the control cabinets from channel type dependency through Universal I/O module.
• Flexible marshalling – Reduce or eliminate marshalling
• Universal cabinets – Allow cabinets to be standardised
– Any field signal can be connected to any I/O channel
– Drastically reduce engineering cost and schedule
UCT Used in UIO &RUSIO
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What makes it Different?
Just Configure to be the Type Needed
Change hardware & software
AI
AI
AI
AI AI
AI
AI AI
AO AO
AO
AO AO
AO
AO AO
DI
DI DI
DI DI
DI
DI DI
DO
DO DO
DO
DO DO DO
DO
32 Non Redundant Modules
1 Redundant Module
The Honeywell
Way
The Other Way
Creating Unique Differentiation – IO on Unconditional Demand
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What makes it Beneficial?
• SOFT configuration – IO on demand without extra hardware
• Simpler engineering
– make changes late in design
• True redundancy
– maintains single channel integrity
• Remote / Harsh environment mounting
– Reduces cables & marshalling cabinets
– Reduces HVAC needs
Simplicity, Flexibility, & Reliability
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Standard Cabinet Design
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
Build Standard Cabinets Sooner Based on IO Count, Not Mix
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Universal Traditional
Less I/O Modules
Universal Reduces IO Modules by 30%
Example project with 5000 IO
Type Count
1. Analog In 1500
2. Analog Out 1000
3. Digital In 1300
4. Digital Out 1200
Total 5000
# IO Modules 240
Type Count
Universal 5000
# IO Modules 157
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Safety Manager
System Integration Cables
DI AI DO AO
DI AI DO AO
DI AI DO AO
Junction box
Multi Core
Cables
Marshalling Cabinet
Safety Manager
What if we eliminate marshalling?
DI AI DO AO
DI AI DO AO
UIO Field Mounted
Control System
DI AI DO AO
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Traditional
Type Need Count
Analog In 10 16
Analog Out
4 16
Digital In 8 32
Digital Out
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Total 28 96 # IO Modules 4
Remote I/O Savings - Small, Distributed IO
Universal IO Reduces 4 Modules to 1 – Save Space, Maintenance, Cost
Small IO counts can waste many
channels
Universal
Type Count
Universal 32
# IO Modules 1
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1. Oil & Gas onshore & offshore platforms
2. LNG Carriers & FPSOs
3. Skid Mounted Equipment
4. Remote Instrument Enclosures
5. Remote Area Applications
6. Distributed I/O architectures
7. Expansions / Add-on projects
8. Revamp & Modernization projects
9. Ultra fast track projects
10. Mix n Match in standard projects
And Many More….
Who will Benefit?
Benefits are Universal
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What makes it VALUABLE? • Universal Cabinet
– Packaged Solution for Faster Project Execution
• Easily Adapts to Changes – mitigates delays due to late design inputs / changes at
any stage in project
• Reduced Hardware – Eliminate marshalling with direct landing from field – Reduce/Simplify marshalling with no cross-wiring – Remote IO eliminates multi-core cables
• Reduce Infrastructure Costs – Saves precious control room space
• Fewer spares – One UIO module vs. Four Standard Modules
Productivity, Dependability & Sustainability
Reduce cost up to
33%
Reduce Space up to 28%
Reduce schedule up
to 25%
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UIO Roadmap
• Universal Process IO Module Available – Now
• UIO DIN RAIL Availability – H2-2013
• DO Fan-Out & Pulse Input Availability – H2-2013
• 4 Wire AI & SOE Availability – H2-2014
• Universal Cabinets Available – Now
• Remote Modular Cabinet Available - Now
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The Changing Face of Projects
• Iterative Approach to Engineering Design – Drives changes into system requirements
• Compressed schedules – Drive later design inputs
• Process modularization – Drives earlier hardware delivery
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Project Workflow Transformation
• Separation of physical and functional – Parallel execution of hardware and software design
• Breaking down task dependencies – Removing hardware design dependence from functional
configuration
• Simplifying designs with multi-functional hardware – Applying multi-function hardware to simplify designs
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Project Workflow Transformation
• Typical control system project flow • Task are executed in fixed sequence to meet install
dates • Outputs from one task are required for following task
Define Design Manuf Config Test Install
1 year 2 years Start
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Project Workflow Transformation
• When changes appear in definition after Design or Manufacture has begun this initiates a subsequent modification package or ‘modpack’
The later the change the greater the rework
Define Design Manuf Config Test Install
1 year 2 years Start
Change Design Manuf Modpack #1
Change Design Manuf Config Modpack #2
Change Design Manuf Config Modpack #3 Test
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Separation of physical and functional
• Separating physical and functional allows for task independence
Leveraging technology to revolutionise project delivery
Define Design Manuf Config Test Install
1 year 2 years Start
= Hard end-start task linkage
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Separation of physical and functional
• Separating physical and functional allows for task independence
• The schedule can now be compressed
Leveraging technology to revolutionise project delivery
1 year 2 years Start
Define Design Manuf Install Config Test Physical
Functional
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Separation of physical and functional
• Design start can be pushed back to allow for the field definition to mature
Leveraging technology to revolutionise project delivery
Config Test
Install Define Design Manuf Physical
Functional
1 year 2 years Start
Later design freeze allows for more mature data inputs and fewer changes
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Separation of physical and functional
• Design start can be pushed back to allow fro the field definition to mature
• Or the Install date can come forward to support earlier delivery required by modular construction
Define Design Manuf Install Physical
Config Test Functional
1 year 2 years Start
Standard designs for earlier manufacture and installation
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Separation of physical and functional
• Or benefits can be taken at both ends of the schedule
Config Test Functional
1 year 2 years Start
Define Design Manuf Install Physical
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Late Data Binding
• Configuration tasks can be executed earlier, prior to design completion
• The functional and physical designs are then bound together at the completion of both workflows
Leveraging technology to revolutionise project delivery
Define Design Manuf Install Physical
Config Test Functional
Late Binding
Separating physical and functional allows for task
independence
1 year 2 years Start
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Define Design Physical
Applying Universal Cabinets
• Applying standard universal cabinets eliminates the dependency on custom designs
Manuf Install Standard Designs
1 year 2 years Start
Late Binding Config Test
Functional
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Applying Universal Cabinets
• Allowing the factory manufacture task to be bought forward in the schedule
Leveraging technology to revolutionise project delivery
Define Design Physical
Manuf Install Standard Designs
1 year 2 years Start
Late Binding Config Test
Functional
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Applying Universal Cabinets
• Or the Design activities can be pushed back to allow for better definition to reduce design changes
Define Design Physical
1 year 2 years Start
Late Binding Config Test
Functional
Manuf Install Standard Designs
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Applying Universal Cabinets
• The Definition stage can then be extended to accommodate more mature design inputs
Late Binding Config Test
Functional
Manuf Install Standard Designs
Define Design Physical
1 year 2 years Start
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Applying Universal Cabinets
• 25% Earlier in I/O cabinet on site dates
Define Design Physical
1 year 2 years Start
Late Binding Config Test
Functional
25% Earlier
Manuf Install Standard Designs
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Applying Universal Cabinets
• 25% Earlier in I/O cabinet on site dates
• 25% Later design inputs and freeze dates
Late Binding Config Test
Functional
25% Earlier
25 % Later
Manuf Install Standard Designs
Define Design Physical
1 year 2 years Start
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Project Workflow Transformation
• Traditional Work Process
Adding Flexibility to Reduce Project Risk
Define Design
Manuf
Config Test
Install
Late Binding
Longer define phase allows for more mature data inputs and fewer
changes
Standard designs for earlier manufacture and installation
Separating physical and functional allows for task
independence
Later design inputs and freeze dates
Earlier install on modules
Define Design Manuf Config Test Install
1 year 2 years Start
• ‘Optimised’ Parallel Work Processes
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Questions
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Thank You
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Summary
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Ease of Design, Implementation & Change management
Fewer Components, Redundant Design & Extended Temp. range
Sustainability Reliability Flexibility
Fewer Spares, Easy Maintenance
Sustain-Ability thru Universal-Ability
Offshore Platform
Remote Location
Skid Equip
LNG Carrier
Legacy Migration
Onshore Facility
Analog Input
Digital Input
Analog Output
Digital Output
HART Input
HART Output
FPSO Revamp
RIE Add-ons
Fast Track
Regular Projects
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What Problem does it solve?
• Lower Cost/Reduce Risk/Improve Schedule - Take advantage of standard design marshalling cabinets
• Reduced custom engineering and documentation • Faster delivery time • Flexibility of design needed due to lack of available information
• Reduce Risk– Greatly improve Project Execution Efficiencies • Supply Chain Efficiencies • Implementation of the wiring and documentation minimised
• Improve Schedule - Take advantage of flexibility of UIO to accommodate fast track project schedule
• System may be tested and shipped prior to completion of field designs • Termination details may not be known until construction • Adapt quickly to late project I/O changes
Reduce Cost / Risk / Schedule
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What Problem does it solve? • Lower Cost - Eliminate / reduce marshalling cabinet
requirements in Remote I/O locations • Direct termination onto Universal IO IOTA
• Lower Cost - Less Universal I/O modules required vs. Standard Lower Cost - Reduce total number of installed spare
required on project • Flexibility to move signals around locations without large penalties • Flexibility to provide fewer spares based on anticipated lifecycle
needs
Benefits are Universal
Reduce Cost / Risk / Schedule
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Skid Mounted Equipment Rooms
• Customer Problem • Space Constraint • Short time to integrate, test & commission • non-environmentally controlled
• Honeywell Solution • UIO’s for AI, AO, DI & DO’s • Rail Mounted design in modular cabinet
• Customer Benefits • Reduced system footprint by 30% • UIO in RAIL mount version provides most
modular design • No need of marshalling • No cross wiring needed • Ease of commissioning • Ease of Maintenance
Compact design, Quick install