Satnam Bhogal and
Joe Bastone
27 Oct 2016
LEAP FOR EPCS
1
Agenda
•
•
•
•
•
EPC Challenges
Traditional Project Workflow
LEAP
Automated Device Commissioning
The Evolution of LEAP
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2
EPC Challenges
What’s Changed?
• Projects are larger / more complex / more expensive
• No single EPC to take full ownership
• No single owner to take full ownership
• Scarcity of skill resources
What does this mean?
• Work is done by multiple EPCs in multiple offices
• Work is done under multiple owner guidelines
• Some deliverables are impacted more severely
DATA
will be late!
COST
will be an issue!
PROCESSES
will change!
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Automation Projects on Critical Path
3
Traditional Project Workflow
Start
Finish
FUNCTIONAL
PHYSICAL
Define
Design
Manuf
Config
Test
Install
Cable
Designs
Marshalling
Design
Hardware
Definition
IO
Assignment
I/O Counts,
Locations
Instrument
Index
System
Configuration
System
FAT
Control
Configuration
Alarm Studies,
Set Points
Alarm
Configuration
P&IDs,
Narratives
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Configuration
FAT
HMI
Configuration
Site
Commission
4
Modular Construction
• Schedule optimized approach drives faster startup
- Modular construction increases complexity
 Geographically dispersed
 Cabinets required earlier
- Individual modules integrate late in project
 Critical path
 Third party integration is challenging
 Capturing documentation critical at end of project
Traditional Project
30
Labor FTEs
25
20
15
10
5
$ + Risk
0
Months
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Keep Automation Project off Critical Path
5
LEAP Philosophy
• Based on Lean Execution Principles – Elimination of Waste
- Repetitive Tasks
 Entering the same data over and over again
- Rework
 Editing the same data over and over again
- Redundant Tasks
 Validation the same data over and over again
• Application of LEAP Principles in Product Development
- Product Design to Adapt to Change
 Standardize Hardware – Software Customization
 Common Platform with Software “Personalities”
- Expand the range of Integration, standardization and simplification
 Edge Control Integration
 Universal Connected Assets
 Cloud Based Execution
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It is not Effective to Efficiently do what is not Required!
6
LEAP Enabling Technologies
Integrated solutions
increase value
of individual benefits!
Universal IO
Keep Automation off of the critical path!
Eliminate activities that generate rework!
Be virtually free from hardware dependencies
Cloud
Engineering
Virtualization
Reduce travel costs by 50%
Gain 25% flexibility in your schedule
Reduce your MAC capital by 30%
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LEAP for Automation Projects
7
LEAP
Start
PHYSICAL
Define
Design
FUNCTIONAL
Manuf
Config
Test
Off the
Critical
Path
Finish
Install
Late
Binding
• Cloud Engineering enabled by Controller and IO Simulators in Virtual Machines
- Project team can be dispersed globally
- Configuration Acceptance Test can be done in the cloud
- Order production hardware late in project, eliminate hardware refresh
• Universal Channel Technology removes marshalling requirement
- Standard Cabinets, with Hazardous Location / Marine Certifications, from the factory
- Hardware becomes standard, customization is through software
- Automated Device Commissioning simplifies and documents late changes
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Late Binding is LEAP Enabler
8
Universal Remote Modular Cabinet
• Traditional Marshalling
- 15+ Terminations
- Complex marshalling  Complex documentation
- Difficult troubleshooting
• Universal Channel Technology
- Soft configurable for IO type
- Remove marshalling  Simplified documentation
- You can’t make a mistake!
Field IO
Universal
Junction
Standard
Box
Cabinet
LER or RIE
Marshalling
Cabinet
Junction
box
Controller
and
Controller
IOCabinet
Cabinet
Multi
Core
Cables
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30% Capitial Savings
Automated Device Commissioning
SPI Intools
FT_304
SMV3000
AI
…
FV_233
DVC6200
AO
…
PT_101
ST800
AI
…
TT_103
STT250
AI
…
…
…
…
…
I/O List
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Control Builder
Automated Device Commissioning
AI (PT_101)
PID
AO (FV_233)
Device Assignment
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FIC_133
Device Association
Automated Device Commissioning
Rework
FIC_133
PT_101
Yes
FV_233
…
…
Issues
Found?
Testing in Cloud
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
No
Ready for
Site
Automated Device Commissioning
PT_101
UIO_2-151
FV_233
Start ADC
Process
CAB_151
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Automated Device Commissioning
• Automatic Detection and Interrogation of Devices
Device
IO Module
Ch #
Device
IO Module
Ch #
FT_304
SIMIOM
N/A
FT_304
UIO-2
3
FV_233
UIO-2
4
FV_233
UIO-2
7
PT_101
UIO-2
5
PT_101
UIO-2
8
TT_103
SIMIOM
N/A
TT_103
UIO-2
12
…
…
…
…
…
…
IO Assignment
Updated
As Found in Cabinet
As Built in Cloud
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Automatically Update Assignments
14
Automated Device Commissioning
• Device Configuration
PT_101
Device
LRV
URV
…
FT_304
0
500
…
FV_233
-5
105
…
PT_101
0
1000
…
TT_103
-40
300
…
…
…
…
…
FV_233
As Built in Cloud
Device Configuration
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Eliminate Multiple Configuration Steps
15
Automated Device Commissioning
• Testing Infrastructure
PT_101
• Supports Automated Testing and Assisted Testing
• Supports all devices
• Results are kept in report in Experion
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Centralized Device Test Reports
16
Automated Device Commissioning
• Document Device Configuration
UIO2_151
PT_101
Information
Value
Controller
C300_147
Cabinet
CAB_151
IO Module
UIO2_151
Channel
6
Drawing
013-499123
CM
FIC_233
C300_147
CAB_151
PT_101
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Full Device Documentation in Experion
17
Automated Device Commissioning Summary
•
•
•
•
•
•
•
•
Initial Device Configuration in Cloud
Functional Testing in Cloud
Devices Installed in Field, Connected to IO Modules
Start ADC for each Cabinet
Automatically Detect and Interrogate Devices
Configure Devices
Test Devices
Document Device Location
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Joe Bastone
October 2016
THE EVOLUTION OF LEAP
Enabling Technologies
19
Industrial Cyber Evolution - IIoT
Operate
Field
Devices
Plant
Data
Maintain
Equipment
Optimize
Experion PKS
Honeywell Process Solutions
Honeywell solutions deliver deeper Integration
with Process Licensors, Critical vendors,
providing secure access to data, embedding
domain knowledge into new technology
platforms and driving excellence in project
execution, plant optimization, operations &
maintenance
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Industrial Internet of Things
A network of networks that uses the internet to
connect people, processes and assets enabling a
new way to optimize business results. It
leverages smart connected assets, enterprise
integrated automation, secured cloud-based data,
and advanced analytics.
20
Transformative Equation
HPS + LEAP + IIoT = Transformation
HPS Philosophy
of deep
integration and
Continuous
Evolution
LEAP Principles
of LEAN
Execution,
Simplification and
risk mitigation
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
IIoT Cloud Based
Execution, Edge
Device Integration
and Smart
Connected Assets.
Experion
PKS
Evolution
21
Evolution of LEAP Enabling Technologies
Universal IO
Cloud
Engineering
Virtualization
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Cloud Enabled
Execution
Edge Device
Integration
Universal
Connected
Assets
22
Evolution of LEAP Enabling Technologies
Build – Run – Optimize
Virtualization & Hardware Independence
Cloud Engineering with Smart Test in the VEP
Automated Documentation & MOC
Cyber Security Solutions with Risk Manager
Cloud Enabled
Execution
Edge Device
Integration
Universal
Connected
Assets
Simplify Integration
for Edge Control
Right Integration for
Right Application
ControlEdge PLC
EPKS as ECMS
rd
3 Party Skid Integration
Experion Profit Controller
Automated Device Commissioning
Ethernet Interface Module ( IEC 61850, EIP)
Universal Channel Technology for (DCS, Safety & PLC)
Universal Wireless IO (ISA100 & WirelessHART)
Universal Remote Modular Cabinets (DCS, Safety, F&G)
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23
Applied LEAP Enabling Technologies
Execute Faster
Run Better
Cloud
Enabled
Execution
Cloud
Enabled
Execution
Edge Device
Integration
Edge Device
Integration
Universal
Connected
Assets
Project Execution
•
•
•
•
•
•
•
Accelerate Optimization
Cloud Engineering with VEP
Next Generation Virtualization
Physical & Functional Separation
Virtual CAT / No-FAT
UIO for DCS, Safety & PLC
Auto Device Commissioning
Auto Document and MOC
Cloud
Enabled
Execution
Universal
Connected
Assets
Edge Device
Integration
Run / Maintain
•
•
•
•
•
•
•
Experion Orion Console
Experion Profit Controller
IIoT – SME access
Cyber Security Solutions
Win10 Extended Lifecycle
A360 & Experion Updates
Auto Document and MOC
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Universal
Connected
Assets
Optimize
•
•
•
•
•
•
•
Cyber Security Services
Advanced Control & Optimization
Advanced Alarm Management
Proactive Asset Management
Real-time Analytics
Optimized OPM Migrations
Experion Profit Controller
The Evolution Continues
24
Simulation &
Competency
Solutions
Experion Server
Optimization
& Advanced
Control
Data
Analytics &
Collaboration
Cyber
Security &
Risk Manager
Supply Chain
& Production
Management
Alarms &
Operations
Management
PHD Server
Experion SCADA
Experion Historian
Experion Station
Experion eServer
Premium
Virtualization
Solutions
Fault
Tolerant
Virtual
Machines
UOP / SME
Managed
Access
Experion Orion
Console
Universal Safety IO
Universal Process IO
ControlEdge PLC
Honeywell
SmartLine
OneWireless
Universal Systems
Series C Control
Experion Profit Controller
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RTU2020
Emergency Shutdown
Fire and GAS
Honeywell
Analytics
Experion PKS is IIoT Ready