2012 Honeywell Users Group EMEA. Sustain.Ability. Andy Coward, Honeywell Integrated Automation Assessments

Transcription

1 2012 Honeywell Users Group EMEA Sustain.Ability. Andy Coward, Honeywell Integrated Automation Assessments

2 Agenda Automation Systems ` and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

3 Vision for Performance Services To deliver audits that enable customers to determine value from the SESP contracts and to identify the potential business value that can be delivered / retained through system improvements Enable the audit to be performed easily and quickly by FSE/FSL teams and to grow a team who can both clearly demonstrate the business value to the customer organisation and then deliver the value add items identified To develop technology that adds value to both the customer and Honeywell, which drives the wider business improvement Create an audit process that can scale and grow in scope with team experience and increasing value to the customer

4 Others Words Yokogawa One of the most fundamental and often overlooked factors for maximizing revenue is the reliability and maintainability of an automation system. Maximizing system availability is a key prerequisite for plant uptime. ABB Maintenance and field services reduce costly downtime and maximize the performance of your process control system. Six Sigma Continuous efforts to achieve stable and predictable process results are of vital importance to business success

5 Electrical Equipment Failure Mean Time Between Failure: Explanation & Standards, White Paper 78, Wendy Torell and Victor Avelar Where are you on this curve?

6 Agenda Automation Systems and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

7 Honeywell Technology Changes World s first smart transmitter: Smartline Patented 4-20mA signal transmission World s most advanced integrated operator solution: World s first Operations Management Pro automation vendor to incorporate 2004 ASM research 1999 World s first TUV SIL3 (61508) Safety System World s first distributed control system: TDC World s most popular DCS I/O released: PM I/O 1998 World s first hybrid control system: PlantScape 2002 World s first Process Knowledge System: Experion PKS 2006 World s most innovative platform technology: Experion R Honeywell Proprietary 7

8 Automation Lifecycle Change Process Development Test Release Operate Retire Honeywell Proprietary

9 Why are Assessments Needed? Knowledge of system performance is key Hardware release against support status Open system hardware status & performance Control system software performance Integration LCN UCN Protection of the software & hardware (virus, cyber) Backup & restore functionality System performance in relation to the process (loops, alarm) Once knowledge is gained, improvements can be planned

10 Understand the Issues Assess your control system functionality Assess your control system performance Understand the risks and exposure Understand the missed opportunity

11 If You Don t Know, You Can t Take Action! Clear elucidation of architecture and support status Identification of exposure to obsolescence Engagement for migration and enhancement opportunities 24,14% Obsolescence Chart 10,34% 65,52% Quantity Contract Support Current Support Extended Support IB Life Cycle Management Traffic Light 2 Date run: 05/02/2010 Account Master Last Name Site Name Asset SID Audit Date AM AM-R (EAMR) AMC AMX APM APM-R APP Company Site 16/10/ /10/ Grand Total HG HLPIU HMON HPM HPM-R LEPIU LLPIU Company Site 16/10/ /10/ Grand 2012 Total

12 Assessing Your Control System Security Security Patches Antivirus Signatures Performance Baseline Performance Track Conditions Configuration Check to Best Practices Schematic loading etc. Lifecycle status & path forward Unsupported products Risk to plant operations Cost to maintain & support Technology refresh

13 Assess Your Control Performance Loop Attainment First Quartile Second Quartile Third Quartile Fourth Quartile Control Performance Poor performing loop prioritization Identification of control loop issues Resolution plan generation Alarm Performance Alarm initiation rates Identification of worst actors Comparison to legislative requirements Layout of resolution plan

14 Agenda Automation Systems and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

15 What is an IAA? IAA is a consultative led approach to proactively identifying issues with the system obsolescence, system operation, system performance and system ergonomics It is both consultative and diagnostic in form Questions to identify softer process issues Non-invasive collectors to gather and collate data driven diagnostics Report is generated to highlight issues, both good and bad Consultatively fed back to create support and budget release Simple aim: To find and help to fix issues across the systems we have installed

16 Why is this Different to Other Audits? Integrated Automation Assessments are multi-faceted, covering: The state of support of the installed hardware The performance of the open system hardware The performance of the system operating software The status of cyber protection against best performance The performance of the alarm system against best practice The performance of the control loops against theoretical best performance The performance of activities such as Backup & Restore All of this information is provided in a consultative document, highlighting areas of exposure and opportunity, unlike other technical audits

17 Agenda Automation Systems and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

18 How is the Audit Performed? Data is collected non-invasively Collection performed by local Service team Collected from files on the system, or data collected over time Data is then transferred to Honeywell data server System performance metrics and benchmarking handled System architecture compared to current support recommendations Report is then presented back to site Hard copy of detailed report Presentation and discussion over findings

19 Data Collectors Existing collectors are used on the system Installed and preconfigured in most cases Some installation needed on some sites Evolution path to automated data collection TPC & Experion systems Collectors run behind the scenes Collect system information and diagnostics Only loop performance collection requires configuration Encrypted files are downloaded onto removable media

20 Data Files Once collected, data files are uploaded to a Honeywell server Secure, protected environment Anonymised data used Honeywell domain engines are used for processing Files are processed and collated into report Analysis of issues, performance Analysis of hardware against support status Feedback from audit questions Report then reviewed for content, issues and quality Feedback presentation then developed

21 Agenda Automation Systems and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

22 Deliverables Report covering multiple aspects Heat map to focus attention High level overview of key issues Focus on soft aspects as well as deterministic metrics Detailed sections on; System Performance Baseline TAC Audits PC Audits Cyber security audits Control & Alarm performance Benchmarks

23 Agenda Automation Systems and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

24 Performance Progressing Towards a Proactive Maintenance Model Based on Performance Corrective Time Based Centered on Performance Best Practices Reactive, MTTR driven Linked to immediate qualified labor response Availability of spares P1 & P2 24/7 availability Time based maintenance Hot fix updates Test protocols AV updates Audits On condition monitoring Performance indicators Loop diagnostics Valve diagnostics Benchmarking Lifecycle management Performance continual improvement

25 Closing the Loop for Continuous Improvement Integrated Automation Assessment LSS Solution Sustained Benefits System Performance Technology Integration Life Cycle Process Control Alarm Benchmark SESP & LSS Services K&E & LSS Services Continuous Evolution Pr. CPM & Perf. Services Alarm Management Optimum Reliability High Performance Lowest Cost to Own Best Efficiency Operational Safety Standardized Automation Audit Safety Controller Typical Yearly Savings: FSC/SM K&E and Serv. Reliability improvement: % production +1x FTE cost Efficiency increase: - 2 % fuel efficiency Lifecycle cost reduction: - 5% of installed base cost Safety: - 0.1% production Safety in Control Systematic Measureable and Continuous Improvement of Customer KPIs

26 Tracking Your Improvement Certify Your System to Industry Best Practices Creating the tools that allow our customers to better understand their automation assets to support its continuous improvement Verifying the evolution of your system integrity Keeping the Best System Performance Optimize the efficiency of your process control

27 Improving Your Results Get the right knowledge and tools to the right people to enable them to improve their effectiveness and make the right process, and... execute that process with results!

28 Starting the process Talk to your Account Manager Details of the Experion clusters Details of the LCN s to be covered Timing and detail levels required Price based on Scope L1 or L2 Audits Existing SESP contracts

29 Agenda Automation Systems and Performance Why are assessments necessary? What is an Integrated Automation Assessment? What does an IAA entail? What does an IAA look like? What would I use the IAA for? Questions

30 Questions

31 Sustain.Ability Honeywell Users Group EMEA