Integrated Automation Assessments (IAA) Identify Opportunities to Improve Efficiency, Reliability and Safety
Know Where You Stand • Assess your control system • Assess your control performance
Assessing Your Control System • Security – Security Patches – Antivirus Signatures System Performance Baseline for Company ABC • Performance Executive Summary – Baseline Performance Network Health LCN Network Health – Track Conditions • Configuration Caution – Check Against Best Practices Healthy • Lifecycle Status & Path Forward Poor – Supportability Status – Risk to Plant Operations – Cost to Maintain & Support – Technology Refresh Comprehensive System Health Assessment With Recommendations
Covering Control System Aspects Experion System CONFIGURATION Assessment SECURITY Assessment | FTE Netw ork Configuration | Security Configuration | Experion Controller Configuration | Anti-Virus Status | Experion Client Server Configuration | Microsoft Security Updates | HMI Display Configuration | Installed Softw are | Back Up and Recovery Configuration Analyzed by Global TAC Analyzed by Global TAC TPS Integration CONFIGURATION Assessment | Experion System PERFORMANCE Assessment Experion / TPS Integration Configuration | TPS System PERFORMANCE Assessment PC Performance | | Server Communications Performance Overall LCN Loading | | Overall UCN Loading Sw itch Performance | LCN Node Statistics | Controller Performance | UCN Node Statistics | Nodes Exceeding Recommended Guidelines | Node Type Specific Reports Reviewed by Certified Engineers Reviewed by Certified Engineers
Lifecycle Status & Path Forward Obsolescence Chart Detailed Migration, Upgrades Options & Recommendations TECHNOLOGY REFRESH OPTION: The GUS stations are under Windows XP , which is after April 8, 2014, discontinued from Microsoft. This means that while the operating system may continue to operate beyond the end of life date, Microsoft will not release new security updates, security hot fixes, provide technical phone support, or online technical content updates. Without this support, the XP operating system could become increasingly vulnerable to cyber security threats. Honeywell recommendation is to upgrade GUS to ES-Ts - Technology Refresh Option is also recommended to upgrade APMs to EHPMs BENEFITS: The ES-Ts will run on R410 and R430 under Windows 7 Operating System with full support from Microsoft and Honeywell and will add the Experion console station functionality to the Native Window functionality. This new Experion functionality can be implemented on process, on a self paced schedule. - EHPM migration will retain all IP as well as using existing PM I/O in its CPU Racks Detailed Assessment of the Supportability Status for Each Module & Controller IB Life Cycle Management traffic light 2 Dat e run: 0 5/ 0 2 / 2 0 10 Account Name Site Name Master Asset SID Last Audit Date AM AM-R (EAMR) AMC AMX APM APM-R APP CUSTOMER01 16/10/2009 2 0 0 0 0 1 4 Customer Madrid CUSTOMER08 16/10/2009 0 0 0 0 0 0 2 Grand Total 2 0 0 0 0 1 6 Account Name Site Name Master Asset SID Last Audit Date HG HLPIU HMON HPM HPM-R LEPIU LLPIU CUSTOMER01 16/10/2009 6 0 4 0 19 5 0 Customer Madrid CUSTOMER08 16/10/2009 5 4 3 0 11 2 0 Grand Total 11 4 7 0 30 7 0
Assess Your Control Performance • Control Performance – Poor performing loop prioritization – Energy efficiency assessment in Fired Heaters Units • Alarm Performance – Alarm chatter identification
Assessing Control Performance Tagname DCSUnit ProcArea Description LoopType Performance Critica CritAreaOppor ValveSti OscillationPer CPI COV CH ENERGIA CONTROL� H2� CA flow poor 3 4 40 56 1m� 50s 0.45 4.28 CHFC_007 CHFC_008 CH ENERGIA CONTROL� H2� LE flow poor 3 4 40 34 0m� 8s 0.23 24.83 CH ENERGIA LLCN� A� TANQUE flow poor 3 4 40 1 0m� 25s 0.48 0.47 CHFC_014 CH ENERGIA NIV� BOTELL� CAR level acceptable 3 4 8 N/A 200m� 6s 0.03 10.61 CHLC_002 LOOPS REPORT CHLC_024 CH ENERGIA CONTROL� NIVEL level fair 3 4 32 N/A 502m� 18s 0.04 7.57 CH ENERGIA NIVEL� ESTABILZ level acceptable 3 4 8 N/A 983m� 33s 0.27 11.21 CHLC_034 CH ENERGIA DEPOSIT� CONDE level fair 3 4 32 N/A 500m� 0s 0.09 4.58 CHLC_037 CH ENERGIA CTROL� TEMP� EN temperature fair 3 4 32 N/A 999m� 60s 0.3 38.31 CHTC_005 CHTC_044 CH ENERGIA TEMP� A� SALIDA temperature fair 3 4 32 N/A 1000m� 0s 0.01 11.66 CH ENERGIA ENTRADA� A� REA temperature fair 3 4 32 N/A 999m� 60s 0.02 22.15 CHTC_049 CH ENERGIA ENTRADA� REAC temperature fair 3 4 32 N/A 1000m� 0s 0.12 19.37 CHTC_083 CHFC006A CH ENERGIA CTROL� CARGA� flow H inactive none 1 none 1 3m� 20s N/A 0 CH ENERGIA SALIDA� ENFRIAD flow inactive none 1 none 1 none N/A 0 CHFC035A CH ENERGIA NAFTA� INERTE� flow H inactive none 1 none 1 none N/A 0 CHFC040A CH ENERGIA HCN� DE� FCC� -� C flow inactive none 1 none 1 33m� 20s N/A 0 CHFC_001 CHFC_002 CH ENERGIA LCN� DE� FCC� -� CA flow inactive none 1 none 1 0m� 32s N/A 0 CH ENERGIA MINIMO� FLUJO flow saturated none 1 none 1 none N/A 0.68 CHFC_004 CH ENERGIA CONTROL� CARG flow fair none 1 none 14 3m� 47s 0.44 0.55 CHFC_006 CHFC_013 CH ENERGIA REFLUJO� A� SPLI flow inactive none 1 none 9 0m� 18s N/A 0.51 CH ENERGIA MINIMO� FLUJO flow acceptable none 1 none 7 1m� 34s 0.27 0.45 CHFC_015 CH ENERGIA COND.� MEDIA� flow C acceptable none 1 none 1 5m� 39s 0.77 0.56 CHFC_016 CH ENERGIA CARGA� A� R-2� LE flow excellent none 1 none 1 0m� 31s 0.61 0.36 CHFC_018 CHFC_019 CH ENERGIA CARGA� A� R-2� BY flow excellent none 1 none 1 0m� 6s 0.63 0.42 Detailed Status Of All The Loops With Each Unit, With Direct Identification Of Oscillation Interactions And Sticky Valves
Alarm Performance • EEMUA Benchmark Rank Shown • Several Alarm Activity Benchmarks Displayed
IAA Process Non-invasive collectors gather a comprehensive data sample for Get Site Data diagnostics. Checklists employed for additional data collection Data is encrypted and bundled then sent to Honeywell expert Data Security team for analysis and report generation Report is generated to summarize performance and highlight SME Inputs issues The report is presented in a consultative face-to-face environment Engagement with customer 8 days at back office 3 days at site
Deliverables Integrated Automation Assessment - IAA Standard Enhanced 1. Control System Update & Performance Audits X X - FTE Network Installation and Configuration x x - Security Updates and Antivirus Verification x x - Operating System Performance x x - EPKS Client Server Configuration x x - Verification of Graphics Performance x x - Back Up and Recovery Assessment x x 2. Technology Integration X X - TPS Audit x x - System Performance Baseline x x 3. Lifecycle Optima Evolution Path X X - Update on the Status of the Installed Base x x 4. Process Control Performance Audit X 5. Alarm Benchmark X "Standard" IAA Pricing: EPKS TPS Price Per System: Customers with existing SPB options in contracts: "Enhanced" IAA Pricing: EPKS TPS Price Per System: Customers with existing SPB options in contracts: Optional:
Proactive Maintenance Model Performance BEST PRACTICES CORRECTIVE TIME BASED PERFORMANCE-BASED • Best Practices • Reactive • • Audits Time based maintenance • Lifecycle Management • - MTTR Driven On condition monitoring • Hot Fix Updates • Performance Continued • Linked to immediate • qualified labor Improvement Performance • Test Protocols response Indicators • AV updates • Availability of Spares • Loop Diagnosis P1 & p2 • Valve Diagnostics • 24/7 Availability
Recommending the Right Solutions IAA LSS Solution Sustained Benefits • Best Practices Set • Proactive • Optimum Reliability Up & Configuration Maintenance • Best Performance • System • K&E and LSS • Lowest Cost to Own • Best Efficiency Performance Services • Supportability • SESP & Tech • Operational Safety • Process Control Refresh • Safety in Control • Alarm Benchmark • CPM and Tuning Services • Alarm Management • FSC/SM K&E and Services KPIs Management: Typical Benefits: • Reliability Improvement • 50% Failure Rate Reduction • Efficiency Increase • 2% Efficiency • Lifecycle Cost Reduction • 5% of Installed Base Cost • Safety • 0.1% Production Systematic Measureable And Continuous Improvement Of Customer Kpis
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