Vimal Kapur President, Honeywell Process Solutions
Welcome 1,000+ Attendees 409 Customers 207 Channel Partners 27 th 15 Media Outlets
Agenda Challenges IIoT Solutions Conclusions
Industries are challenged to do more with less CAPEX 2015 EMEA CAPEX ($B) Power O&G Batch MMM Water Ref Chem P2 Total $ 583B Source: IHS Oct 2015 Estimates Nominal CapEx $164 $159 $102 $70 $36 $20 $19 $13 CAGR 2010 14 CAGR 2014 15 2% -10% 5% -20% 2% -7% -1% -9% 6% -7% 4% -23% 3% -11% -1% -8% Four main drivers hindering CapEx outlook in EMEA: Sustained lower oil prices Weaker demand due to a Chinaled global economic slowdown Currency depreciation Geopolitical and security risks
as well as do more with less OPEX 11.0% Change in OPEX Spending vs Prior Year 16.7% -2.9% -0.3% -1.4% 2009 2010 2011 2012 2013 2014 2015-20.9% -20.1% Source: IHS Oct 2015 Estimates Bounced Back Just After Recession; Very Tight Spending Since Then with Further Declines in 2015
Industries facing skills attrition as experienced employees retire Years of Experience in the Industry Younger Workforce % workforce with less than 4 years in the Industry Aging Workforce % workforce with more than 20 years in the Industry X 2.1 times in 4 years 42% 29% Almost halved in 4 years 20% 16% 2010 2014 2010 2014 Source: Hays Oil & Gas Global Salary Guide 2015 Industries Must Ensure Thorough Knowledge Transfer Among Shifting Workforce Demographics
Accelerated change increasing pace of Obsolescence of legacy assets Time interval between two technological releases Data Hi-way TDC3000 Experion R100 R200 R300 R400 R431.1 IIoT Drivers of accelerated change Shift from Hardware to Software Faster turnaround of software releases with higher functionality Implications for customers Rate of change is increasing dramatically Managing obsolescence is becoming increasingly challenging 1975 1985 2003 2006 2010 2015
Increasing Threat of Cyber Attacks Millions of Detected Attacks Across All Industries 48% 42.8 48% increase in overall number of detected attacks 22.7 24.9 28.9 Power & Utility companies reported a 6-fold increase in number of detected threats from the year before 9.4 3.4 2009 2010 2011 2012 2013 2014 Source: PWC The Global State of Information Security Survey 2015
Safety Remains the Highest Priority but is Plateauing Total Recordable Injury Rate per One Million Hours Worked in the European Oil & Gas Industry Injury rate continues to drop, however 0 3.9 3.5 3.1 2.8 2.6 2.6 2.6 is the goal 2008 2009 2010 2011 2012 2013 2014 Source: International Association of Oil & Gas Producers, June 2015
In summary as operators you are asked to: 1 2 3 4 CapEx & OpEx Skills Safety & Security Technology Do more with less Manage the skills gap & ensure knowledge transfer Operate safely and securely Leverage existing & new technology to stay relevant & competitive
Agenda Challenges IIoT Solutions Conclusions
Deploying IIoT in Process Industry The questions we ve heard from our customers on IIoT: 1 2 3 4 How can IIoT solve my challenges How can IIoT benefit my legacy assets What are the skills required and how to train my team What should be my IIoT roadmap????
IIoT opportunities are not possible without Connectivity & Visibility to Industrial Data v Field Devices Plant Data Operate Maintain v Equipment DCS Optimize The Industrial Internet of Things is 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
HON iiot thought leadership in action: ASM case example Data Gathering 20+ years experience in the process industry and gathering data Predictive Analytics HON Safety Analysts / Data Scientists Developed proprietary Pattern Recognition algorithms Leading to an IIoT intelligent offering suite Alarm management Early event detection Events monitoring Simulation training User friendly graphics Reduction in overall and nuisance alarms by up to 80% 40%+ improvement in time to solve problem Faster recovery from abnormal situations Challenge Solved Safety
OPC UA is the universal standard that allows connectivity & visibility to industrial data Benefits Native security Multi-platform implementation Scalability from embedded smart sensors to mainframes Easy engineering Connectivity with context (value & timestamp) OPC UA is one of the most important modern standards for industrial facilities and many further scenarios in an intelligent and connected world. OPC UA is considered a central building block on the way towards Industry 4.0. It is the first unified, worldwide recognized industrial protocol for a secure smart factory. Holger Junker, Federal Office for Information Security, (BSI), Head of Division
We are also increasing training flexibility thanks to the Cloud Honeywell-maintained Training System Virtual OTS in the Cloud Hosted by Honeywell Accessed over a private secure network Very small footprint at customer site Honeywell Support & Engineering groups have instant access Subscription pricing model Challenge Solved Skills
We leverage connectivity and collaboration to resolve real time alerts Alerts that interest you Multiple data sources can send alerts Subscribe to the ones you want Unsubscribe I just got a Pulse Timely delivery with appropriate content Related info pre-packaged Faster decision making and awareness Create your own alerting criteria Act on alerts Comment, forward, take ownership Share input from personnel not at location Browse Historians Browse tags Graph tag data Challenge Solved Technology
What benefits will it bring to the industry Production Efficiency Reliability Enterprise Optimization Maximize production throughput and reduce OpEx Enable the plant to run at peak performance with no incidents or shutdowns in a sustained and prolonged manner Optimize the end to end profitability of when, where and what to produce Proven impact $5-15M per site per year Proven impact $7-20M per year Achieve $3-5M per site per year
Agenda Challenges IIoT Solutions Conclusions
Using modular and standardized designs, we reduce CapEx costs and construction lead times Modular Gas Plants Factory Built not site built Better quality standardize, pre-test Improved Change Management Automation off critical path Support one week faster startup +$30M 30% lower installed ICSS cost Integrated Security Fire and Gas Detectors Fiber optic cables are run directly from remote cabinets to the controller cabinet without intermediate marshalling saves time and cost & site work Process Skid Module is pre-wired with remote universal IO standard cabinet (URMC) in factory then shipped to site no site eng Preconfigured displays, alarms and procedures enables rapid time to first production and full capacity (Modular Control Room) Factory-built plant with: Standard cabinets Remote UIO Modular control room Standard instrumentation Integrated Safety & Security Up to 6 months reduction of construction lead time 30% construction cost reduction (~$50M) Standard Instrumentation Automatic device commissioning for HART devices Prefabricated Modular Control Room with Reduced footprint CapEx Challenge Solved
Equipment Templates for UOP Licensed Processes LNG Pre-treatment Complex Oleflex Complex Aromatics Complex 2Q 2015 4Q 2015 1H 2016 UOPR Gas Plant Naphtha Complex (incl. Modular) Provides schematic representation of equipment References to master tags UOP PIC system interfaces Embedded procedures OpEx Challenge Solved
Process Solution Suites for UOP Orion Operator Workspace for UOP Unit Advantage of Experion Solution Suite UOP knowledge and experience captured into preengineered solution suite for Experion Reduce Start-up and Operations Risk and DCS schedule by as much as 40% Solution Suites consists of: Operational Knowledge Control Knowledge Safety Knowledge Alarm Knowledge Experion pre-integration for UOP critical control system packages OpEx Challenge Solved
Comprehensive & Integrated Process Safety Management Detect Prevent Protect Perimeter Monitoring Access Control & Monitoring Operator Training Emergency Shut Down Gas Detection Alarm Management Asset Management Worker Safety Challenge Solved Safety
Providing innovative solutions to continuously assess cyber risks in real time Developed specifically for industrial environments Actionable intelligence with advice and decision support Intuitive interface with at-a-glance visibility and understanding with clear KPIs and drill down detail Immediate information for ongoing situational awareness Game-changing, platform delivering real time monitoring and management of cyber security risks Proactively identifies cyber vulnerabilities and threats and quantifies and prioritizes risks Challenge Solved Security
Leveraging technology to stay relevant & competitive by migrating old systems Impact of Obsolescence Why choose HPS OR 21st Century technology to reduce risk, improve operability and efficiency Product no longer available on the market and has limited serviceability remaining Can disrupt plant operations and impact: - Safety - Reliability - Capacity - Efficiency Lean Execution of Migrations Proven project execution Capability Maintain, Support and Optimize Challenge Solved Technology
Proactively reducing breakdowns and sustaining plant performance Predict equipment failure Define maintenance program and shutdown (when, how long and how many staff required) Optimize spare part and inventory Proven impact $7-20Mn per site per year OpEx Challenge Solved
Maintaining our leadership in Pulp & Paper through innovation Experion MX Fibre Optic Sensors ZipLine Optimize quality & productivity of paper machines & coaters Unique sensor technology to monitor quality parameters on the machine Revolutionary Wireless Measurement device for Continuous Web Applications Unique Solutions to Increase Paper Mill Productivity & Improve Asset Performance OpEx Challenge Solved
Differentiation Getting more value from a complete portfolio of field devices and modular systems Field Instrumentation Tank Gauging Gas Instrumentation Modular Systems Pressure Temperature Level Smart Multi-Variable (2016) Analytical (Future) Enraf SmartRadar Enraf Servo Level Gauge Tank Temperature Measurement Comprehensive Gas Pressure Regulating Metering Products & Solutions Comprehensive portfolio of Modular systems consisting of Experion LX, HC900, MasterLogic, RTU2020 Reduce Start-Up Time up to 50% on loop check Up to 60% reduction in configuration & set-up Accurate Tank Gauging Inventory management Tank Terminal operations Easy to order, easy to install easy to maintain Reduce billing discrepancy Proven and Reliable, easy to use Lowest Total Cost of Ownership Challenge Solved Technology
In summary, Everything We do is focused on helping you to 1 2 3 4 CapEx & OpEx Skills Safety & Security Technology Do more with less Manage the skills gap & ensure knowledge transfer Operate safely and securely Leverage existing & new technology to stay relevant & competitive HPS Offering summary Cloud Engineering Experion Solution Suites for UOP UniSim Assurance 360 Intuition Executive Integrated Process Safety Manager Cyber Security ASM OPC UA Pulse SmartLine
Agenda Challenges IIoT Solutions Conclusions
Our objective is to put you, the customer, at the center of everything we do On-time proposals Presales Expected quality Time to bill Access to information Invoice accuracy Cash 1 Order On-time product delivery Product quality Technical support Support 6 5 Customer Touch Points 4 2 3 Project engineering Order acceptance and confirmation Timeliness of communication Product quality Expected delivery time Expected lead time Delivery On-track with schedule Critical path avoidance Re-work
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My Priorities Continue to innovate to address your biggest concerns Do more with less Manage the skills gap and ensure knowledge transfer Operate safely, securely and in compliance Leverage existing and new technology to stay relevant and competitive Continue to invest in technology differentiation and leading edge automation solutions Build and strengthen our HPS culture to put customer experience at the heart of everything we do