integrated automation assessment (iaa) - honeywell process · pdf fileiaa process non-invasive...
TRANSCRIPT
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 0 0 0 0 1 4
CUSTOMER08 16/10/2009 0 0 0 0 0 0 2
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
CUSTOMER08 16/10/2009 5 4 3 0 11 2 0
11 4 7 0 30 7 0Grand Total
IB Life Cycle Management traffic light 2D at 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,
on 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 CriticalityCritAreaOpportunityValveStictionProbabilityOscillationPeriodCPI COV
CHFC_007 CH ENERGIA CONTROLH2CARGAR-1flow poor 3 4 40 56 1m50s 0.45 4.28
CHFC_008 CH ENERGIA CONTROLH2LECHOSR-1flow poor 3 4 40 34 0m8s 0.23 24.83
CHFC_014 CH ENERGIA LLCNATANQUEflow poor 3 4 40 1 0m25s 0.48 0.47
CHLC_002 CH ENERGIA NIVBOTELLCARGHN-V-1level acceptable 3 4 8 N/A 200m6s 0.03 10.61
CHLC_024 CH ENERGIA CONTROLNIVELHN-V6level fair 3 4 32 N/A 502m18s 0.04 7.57
CHLC_034 CH ENERGIA NIVELESTABILZADORAHNV8level acceptable 3 4 8 N/A 983m33s 0.27 11.21
CHLC_037 CH ENERGIA DEPOSITCONDENSADOHNV10level fair 3 4 32 N/A 500m0s 0.09 4.58
CHTC_005 CH ENERGIA CTROLTEMPENTRADASHUtemperature fair 3 4 32 N/A 999m60s 0.3 38.31
CHTC_044 CH ENERGIA TEMPASALIDADEHNE8temperature fair 3 4 32 N/A 1000m0s 0.01 11.66
CHTC_049 CH ENERGIA ENTRADAAREACTORHNR2temperature fair 3 4 32 N/A 999m60s 0.02 22.15
CHTC_083 CH ENERGIA ENTRADAREACTSHDSHNR3temperature fair 3 4 32 N/A 1000m0s 0.12 19.37
CHFC006A CH ENERGIA CTROLCARGAHCALREACTOflow inactive none 1 none 1 3m20s N/A 0
CHFC035A CH ENERGIA SALIDAENFRIADORHNE15Bflow inactive none 1 none 1 none N/A 0
CHFC040A CH ENERGIA NAFTAINERTEHNV11HNV1flow inactive none 1 none 1 none N/A 0
CHFC_001 CH ENERGIA HCNDEFCC-CARGAHDTflow inactive none 1 none 1 33m20s N/A 0
CHFC_002 CH ENERGIA LCNDEFCC-CARGAV-1flow inactive none 1 none 1 0m32s N/A 0
CHFC_004 CH ENERGIA MINIMOFLUJOHN-P-1A/Bflow saturated none 1 none 1 none N/A 0.68
CHFC_006 CH ENERGIA CONTROLCARGAR-1flow fair none 1 none 14 3m47s 0.44 0.55
CHFC_013 CH ENERGIA REFLUJOASPLITTERV-2flow inactive none 1 none 9 0m18s N/A 0.51
CHFC_015 CH ENERGIA MINIMOFLUJOHN-P-4A/Bflow acceptable none 1 none 7 1m34s 0.27 0.45
CHFC_016 CH ENERGIA COND.MEDIACALENTE-8flow acceptable none 1 none 1 5m39s 0.77 0.56
CHFC_018 CH ENERGIA CARGAAR-2LECHON?1flow excellent none 1 none 1 0m31s 0.61 0.36
CHFC_019 CH ENERGIA CARGAAR-2BY-PASSE-9flow excellent none 1 none 1 0m6s 0.63 0.42
Detailed Status Of All The Loops With Each Unit, With Direct Identification Of
Oscillation Interactions And Sticky Valves
LO
OP
S R
EP
OR
T
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
Perf
orm
ance
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