Integrated Automation Assessments (IAA) Identify Opportunities to - - PowerPoint PPT Presentation

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

• Performance

– Baseline Performance – Track Conditions

• Configuration

– Check Against Best Practices

• Lifecycle Status & Path Forward

– Supportability Status – Risk to Plant Operations – Cost to Maintain & Support – Technology Refresh

Comprehensive System Health Assessment With Recommendations

Executive Summary LCN Network Health

Network Health

Healthy Caution Poor System Performance Baseline for Company ABC

Covering Control System Aspects

Experion System CONFIGURATION Assessment

PC Performance

|

Server Communications Performance

|

Sw itch Performance

|

Controller Performance

|

Experion System PERFORMANCE Assessment Reviewed by Certified Engineers Analyzed by Global TAC

FTE Netw ork Configuration

|

Experion Controller Configuration

|

Experion Client Server Configuration

|

HMI Display Configuration

|

Back Up and Recovery Configuration

|

Overall LCN Loading

|

Overall UCN Loading

|

LCN Node Statistics

|

UCN Node Statistics

|

Nodes Exceeding Recommended Guidelines

|

Node Type Specific Reports

|

TPS Integration CONFIGURATION Assessment TPS System PERFORMANCE Assessment

Experion / TPS Integration Configuration

|

Security Configuration

|

Anti-Virus Status

|

Microsoft Security Updates

|

Installed Softw are

| SECURITY Assessment

Reviewed by Certified Engineers

Analyzed by Global TAC

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 1 4 CUSTOMER08 16/10/2009 2 2 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 4 19 5 CUSTOMER08 16/10/2009 5 4 3 11 2 11 4 7 30 7 Grand Total

IB Life Cycle Management traffic light 2

Dat e run: 0 5/ 0 2 / 2 0 10

Customer Madrid Grand Total Customer Madrid

Obsolescence Chart Detailed Assessment of the Supportability Status for Each Module & Controller 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,

• n a self paced schedule.
• EHPM migration will retain all IP as well as using existing PM I/O in its CPU Racks

Lifecycle Status & Path Forward

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 CHFC_007

CH ENERGIA CONTROL H2 CA flow poor 3 4 40 56 1m 50s 0.45 4.28

CHFC_008

CH ENERGIA CONTROL H2 LE flow poor 3 4 40 34 0m 8s 0.23 24.83

CHFC_014

CH ENERGIA LLCN A TANQUE flow poor 3 4 40 1 0m 25s 0.48 0.47

CHLC_002

CH ENERGIA NIV BOTELL CAR level acceptable 3 4 8 N/A 200m 6s 0.03 10.61

CHLC_024

CH ENERGIA CONTROL NIVEL level fair 3 4 32 N/A 502m 18s 0.04 7.57

CHLC_034

CH ENERGIA NIVEL ESTABILZ level acceptable 3 4 8 N/A 983m 33s 0.27 11.21

CHLC_037

CH ENERGIA DEPOSIT CONDE level fair 3 4 32 N/A 500m 0s 0.09 4.58

CHTC_005

CH ENERGIA CTROL TEMP EN temperature fair 3 4 32 N/A 999m 60s 0.3 38.31

CHTC_044

CH ENERGIA TEMP A SALIDA temperature fair 3 4 32 N/A 1000m 0s 0.01 11.66

CHTC_049

CH ENERGIA ENTRADA A REA temperature fair 3 4 32 N/A 999m 60s 0.02 22.15

CHTC_083

CH ENERGIA ENTRADA REAC temperature fair 3 4 32 N/A 1000m 0s 0.12 19.37

CHFC006A

CH ENERGIA CTROL CARGA H flow inactive none 1 none 1 3m 20s N/A

CHFC035A

CH ENERGIA SALIDA ENFRIAD flow inactive none 1 none 1 none N/A

CHFC040A

CH ENERGIA NAFTA INERTE H flow inactive none 1 none 1 none N/A

CHFC_001

CH ENERGIA HCN DE FCC

• C

flow inactive none 1 none 1 33m 20s N/A

CHFC_002

CH ENERGIA LCN DE FCC

• CA

flow inactive none 1 none 1 0m 32s N/A

CHFC_004

CH ENERGIA MINIMO FLUJO flow saturated none 1 none 1 none N/A 0.68

CHFC_006

CH ENERGIA CONTROL CARG flow fair none 1 none 14 3m 47s 0.44 0.55

CHFC_013

CH ENERGIA REFLUJO A SPLI flow inactive none 1 none 9 0m 18s N/A 0.51

CHFC_015

CH ENERGIA MINIMO FLUJO flow acceptable none 1 none 7 1m 34s 0.27 0.45

CHFC_016

CH ENERGIA COND. MEDIA C flow acceptable none 1 none 1 5m 39s 0.77 0.56

CHFC_018

CH ENERGIA CARGA A R-2 LE flow excellent none 1 none 1 0m 31s 0.61 0.36

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

LOOPS REPORT

Alarm Performance

• EEMUA Benchmark Rank Shown
• Several Alarm Activity Benchmarks Displayed

IAA Process

Non-invasive collectors gather a comprehensive data sample for

• diagnostics. Checklists employed for additional data collection

Data is encrypted and bundled then sent to Honeywell expert team for analysis and report generation Report is generated to summarize performance and highlight issues The report is presented in a consultative face-to-face environment with customer

Get Site Data

Data Security SME Inputs Engagement

3 days at site 8 days at back office

Deliverables

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:

Integrated Automation Assessment - IAA

• Reactive
• MTTR Driven
• Linked to immediate

qualified labor response

• Availability of Spares

P1 & p2

• 24/7 Availability
• Best Practices
• Lifecycle Management
• Performance Continued

Improvement

• Time based

maintenance

• Hot Fix Updates
• Test Protocols
• AV updates
• Audits
• On condition

monitoring

• Performance

Indicators

• Loop Diagnosis
• Valve Diagnostics

CORRECTIVE

Performance

BEST PRACTICES

PERFORMANCE-BASED

TIME BASED

Proactive Maintenance Model

Recommending the Right Solutions

Systematic Measureable And Continuous Improvement Of Customer Kpis

IAA LSS Solution Sustained Benefits

• Best Practices Set

Up & Configuration

• System

Performance

• Supportability
• Process Control
• Alarm Benchmark
• Proactive

Maintenance

• K&E and LSS

Services

• SESP & Tech

Refresh

• CPM and Tuning

Services

• Alarm Management
• FSC/SM K&E and

Services

• Optimum Reliability
• Best Performance
• Lowest Cost to Own
• Best Efficiency
• Operational Safety
• Safety in Control

KPIs Management:

• Reliability Improvement
• Efficiency Increase
• Lifecycle Cost Reduction
• Safety

Typical Benefits:

• 50% Failure Rate Reduction
• 2% Efficiency
• 5% of Installed Base Cost
• 0.1% Production

Thank You