LEAP FOR BROWNFIELD Optimizing Control System Migrations

Transcription

1 Connected Industrial LEAP FOR BROWNFIELD Optimizing Control System Migrations White Paper

2 Table of Contents Ageing disgracefully: Challenges from legacy systems... 3 The problem with project execution processes... 4 Backend Loading: Rising risks and costs... 5 Three key technologies... 5 Brownfield project transformation... 6 All the benefits... 7 A smooth transition for any system... 8 In it for the long haul: Assurance services... 8 Take the LEAP today PAGE 2 -

3 Ageing disgracefully: Challenges from legacy systems As control and automation systems age, the costs of operation begin to outweigh the costs of replacement. Declining reliability erodes efficiency, and the risk of unplanned downtime or even safety and environmental incidents grow. Maintenance costs are exacerbated by the trouble sourcing spares or even scarce system-specific expertise. Technology that has outlasted its effective life also constrains rather than empowers the business. Obsolescent control systems can hamper the ability of plants to expand or alter the process, and limit Counting the costs of legacy systems Production losses Costly spares Process inefficiency Regulatory penalties Constrained capacity Lost opportunities Babies and Bathwater Despite the problems outdated systems bring, moves to a modern control platform present their own challenges. The dangers and weaknesses that upgrading addresses can also undermine a smooth migration. Concerns over potential disruption or downtime, the uncertainty of rapidly changing markets, and limited domain knowledge must all be addressed. Finally, businesses need, or in some cases want to choose, to retain their legacy data and application IP to ensure continued operations, enable a smooth transition, minimize training or safeguard previous investments. - PAGE 3 -

4 The problem with project execution processes Traditional project execution strategies add to the difficulties. A rigid approach to project engineering sees the project progress from abstract idea to validated engineering designs. Each successive step is dependent on completion of the last. After the scope and design, equipment is bought and then configured, tested and, finally, installed. It looks like a simple, linear progression from project definition to installation; in practice every step is fraught with repetition, reworks and redundancy. Backend Loading: Rising risks and costs A rigid project execution process is poorly adapted to cater for inevitable revisions and changes to the design at later stages of the project. These push up costs and put schedules at risk. Because the process is linear, a delay in any stage will delay all those that follow. Risks and costs in a traditional project are therefore pushed to the later stages, resulting in cost overruns, missed schedules, and unexpected disruption to operations. - PAGE 4 -

5 Finding a better way: Introducing LEAP Honeywell s Lean automation projects methodology, LEAP addresses the shortcomings of traditional approaches. Reducing waste from redundant tasks and rework, LEAP takes lean execution further, eliminating traditional dependencies that dictate a sequential workflow. It dramatically improves the project schedule, keeping automation systems off the critical path. Taking the LEAP Keep automation off the critical path Eliminate activities that generate rework Free projects from hardware dependencies Gain 25% flexibility in your schedule Reduce travel costs by 50% Three key technologies The LEAP methodology in part relies on separating the physical and functional design, with its parallel workflows and use of standardized designs. Moreover, it includes a set of solutions that makes for a flexible deployment strategy with an emphasis on squeezing as much value out of the project and the subsequent operations. LEAP is built on the following technological pillars: Universal and Connected Assets with its Universal Channel Technology capability, covers both Process and Safety controller I/O and integral to ControlEdge TM PLC and ControlEdge RTU in providing much greater levels of integration. The Ethernet Interface Module (EIM) addresses the need to integrate to other subsystem such as ECMS motor devices or other third party PLC s that exists on an Ethernet IP network. Edge Device Integration includes functionality for Automated Device Commissioning where HART field devices are detected and interrogated in allowing I/O channels to be automatically configured with associated loop check documentation readily available. This reduces commissioning from hours to minutes. Honeywell SmartLine transmitters has the added benefit of being configured in the cloud and delivered with configuration parameters preinstalled. Cloud Enabled Execution serves as a virtual environment in which to develop configuration and test the system without physical hardware, With Honeywell Trace, clear linkage is provided between the initial project development, and functionality that allows for managing and documenting future changes made to the system. - PAGE 5 -

6 Brownfield project transformation Leveraging the LEAP methodology, these technologies offer substantial benefits for Brownfield projects. They possibly outweigh the gains in terms of speed, efficiency and cost control demonstrated at Greenfield sites. This is because of the additional complexity in the early stages of Brownfield projects: the need to capture and retain application data and graphics as well as existing cable schedules, marshalling details and so on (below). LEAP can simplify and accelerate the process, removing complexity and waste. From this: To this: - PAGE 6 -

7 The process still begins with a site survey, with audits, assessments and backups of all databases. However, for the physical assets, we now simply need to know the number of cabinets and total I/O count. With Universal I/O the type is irrelevant. Virtualization and the Cloud, meanwhile, introduce much greater flexibility to the schedule. The control configuration application development can begin much earlier in the process, and continue progressively and iteratively during the course of the project. The FAT of the configuration, too, no longer has to wait until the end when hardware is in place. And automated device commissioning, automatically catalogues field devices and makes necessary adjustments to the application for faster completion. With engineering in the Cloud, the various teams involved can work collaboratively on the project, wherever they re based. All the benefits LEAP for Brownfield delivers a leaner project execution, reducing costs and risks, minimizing equipment, and boosting productivity: Replacing PLC control panels in the field to eliminate black-boxes Removing the cost of custom designs Eliminating wiring errors Removing marshalling cabinets Achieving a smaller system footprint in LER Eliminating travel to staging locations Cutting maintenance for subsequent upgrades Reducing work through automatic documentation The result is simpler, cheaper, more effective project execution, with a 30% increase in project efficiency and less hardware for a more powerful, reliable system. Controlling the risks Every Brownfield LEAP project starts with a system audit to fully understand the legacy system functionality and evaluate the risks and opportunities. A site report includes a high-level overview of key issues; a focus on functional plant areas; a focus on soft aspects; and key metrics to determine success. Detailed sections cover all major areas: General plant details Central and local control room details Network topology Software applications Existing L3/L4 applications. A smooth transition for any system Honeywell s tools significantly accelerate the migration of the existing system to minimize disruption and risk when transferring from an older Honeywell or third party system. Control Match enables legacy databases to be quickly transferred into Experion s graphical interface with fast selection and parsing; identifying loops and Experion templates; generating the control and IOM modules; generating the I/O assignment; and bulk building CM, IOM and I/O assignment. The tool can quickly migrates a wide range of Honeywell TDC 2000 family Hiway Boxes and TDC 3000 UCN Nodes, as well as many third party systems from major manufacturers: - PAGE 7 -

8 Bailey (ABB) Provox (Emerson) Foxboro (Invensys) RS3 (Emerson) MOD300 (ABB) Teleperm (Siemens) Moore APACS (Siemens) Centum (Yokogawa) Toshiba Yamatake Graphics Match migrates custom graphic files to avoid human error in project engineering and reduce project execution time. US/GUS/PlantScape, Foxboro, ABB Bailey, Provox, and Yamatake graphics files are all supported, with support for Siemens Teleperm and Yokogawa systems in development. Retain your wiring to simplify migration We ll minimize costs by minimizing changes to the I/O infrastructure. Wire adapter kits help retain existing wiring to connect to Experion. This eliminates the need to disconnect and remove old terminations, install new I/O, and rewire to the Experion system. Instead, intermediate panels connecting to our series C I/O can cut wiring time by 75%. Automated Hot Cutover Innovative technology that can be applied to all plant facilities that has requirements for hot cutovers or where there is limited downtime available. It has the advantage that all fieldwork involving bypass valves, signal regeneration and manual valve control is avoided, leading to a cutover that is completed in far less time with less risk in providing a better solution. This works for migrations of older Honeywell Hiway or TDC 3000 to Experion as well migration from third party systems In it for the long haul: Assurance services Honeywell s Assurance 360 services ensure migration benefits are realized and retained over the long term through multi-year cooperative service arrangements. Helping maintain, support and optimize the performance of the new Honeywell control systems, A360 services help minimize the cost of ownership and provide cost certainty for your new system and future upgrades. Supporting, maintaining, upgrading and optimizing our portfolio of services guarantee you the tools you need to meet expected service levels: Software upgrades GTAC support Hardware refresh Parts holding Parts replacement Preferred access to technical support Preventive maintenance Cyber security Control tuning Alarm rationalization System performance monitoring Assessments Change management Off-line testing, training Change management Performance monitoring and remote connectivity Proactive service management Upgrade and new installation project interface Contract performance metrics Reporting - PAGE 8 -

9 Take the LEAP today With LEAP for Brownfield Honeywell is changing the way projects are delivered: Letting you address the challenges associated with obsolescence, LEAP delivers a lower risk, less disruptive migration that will optimize your operations, minimize overall expenses and maximize benefits from the control system upgrade. LEAN principles, phased migrations and ongoing system support ensure reliability and uptime to give you certainty for the future. To find out more about LEAP for Brownfield, contact your Honeywell representative or visit For More Information Learn more about how Honeywell s LEAP for Brownfield can improve your control system migration, visit honeywellprocess.com or contact your Honeywell Account Manager. Honeywell Process Solutions 1250 West Sam Houston Parkway South Houston, TX Honeywell House, Skimped Hill Lane Bracknell, Berkshire, England RG12 1EB UK Building #1, 555 Huanke Road, Zhangjiang Hi- Tech Industrial Park, Pudong New Area, Shanghai WP ENG September Honeywell International Inc. - PAGE 9 -