2012 Honeywell Users Group Americas. 2012 Honeywell Users Group Americas 1 Management of Change...
Transcript of 2012 Honeywell Users Group Americas. 2012 Honeywell Users Group Americas 1 Management of Change...
Sustain.Ability.
2012 Honeywell Users Group Americas
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Management of Change
Cindy Bloodgood, Sr. Strategic Marketing Manager
James Cage, Americas Principle Sales Consultant
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Industry Challenges for Managing Automation Assets
• Multiple automation systems & vendors – DCS – APC – SIS – PLC – Historians
• Best in breed preferences
• Aging workforce/Turnover
• Legacy system migrations
• Expansion Projects
• Management of change
Environmental
Growth Aging Workforce
Reliability & Safety
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Challenges in Managing Automation Assets
• Increasing Integration and Interoperability
• Inadequate Documentation
• Loss of Knowledge and Critical Skills
• Poor Configuration Integrity
• Lack of Adequate Change Tracking
• Managing Spare Capacity
Failing to manage these challenges exposes
the company to unnecessary risks.
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Risks and Vulnerabilities
• Degraded safety and environmental compliance
• Reduced production and profitability
• Damaged plant equipment
• Tarnished good neighbor reputation
• Impaired ability to restart after a disaster
A plant’s License to Operate is dependent
upon effectively managing its automation
assets.
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Levels of Automation*
SAP, Oracle & IBM
APC & Optimization, Historians, PID Tuning &
Alarm Management
DCS, SIS, PLC, SCADA & Industrial Wireless
Control Valves, Meters, Sensors, Analyzers &
CCTV
Production Planning, Operations Management, Yield Accounting & Reliability
Solutions
*Developed at Purdue University School of Electrical and Computer Engineering
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What Are Automation Assets?
• Automation Assets include – Electronic and computer HW &
SW
– Operating systems
– Software applications
– Engineering configuration
• Function of Automation Assets
– Gather filed process measurements
– Provide control and optimization
– Provide operator interface
– Archive process data
– Provide safety interlock
– Provide reports and more
Field Instruments Sensors/Transmitters
Control Valves
Analyzers
Control Systems Basic Regulatory Control
Safety Instrumented Systems
Programmable Logic Controllers
Advanced Applications Advanced Process Control
Optimization
Historians
Production Management Production Planning
Operations Management
Yield Accounting
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Characteristics of Automation Assets
• Complex maze of information
– Field signal travels through multiple levels
– Complex interrelationships & dependencies
• Heterogeneous technologies
– Manufacturers prefer “best in breed”
– No single supplier dominates all levels
• Continuous improvement & change
– Control strategies, reporting, more
– Continuous change is a norm
• Limited documentation available
– Limited auto-documentation per system
– No inter-system documentation
• No inter-system genealogy map Field Instruments Emerson, Yokogawa
Invensys
Honeywell
Control Systems ABB, Emerson
Honeywell, Invensys
Siemens, Yokogawa
Advanced Applications AspenTech, PAS
Honeywell, Invensys
OSISoft
Production Management SAP
Oracle
People Soft
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• Physical Assets
• Compressors, Valves, Transmitters, etc
-Can easily be classified and managed
-A pump is a pump, and a compressor is a
compressor - you cannot change the
function of the device. The physical
attributes define the function.
• Many applications exist to manage these
assets
Automation Assets (Physical vs. Soft)
• Configuration Assets
• Control Strategies, Programs, Graphics, Databases, etc. - Knowledge is transformed into computer programs - Continuously changing - Lifeline of the plant
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Physical Assets Vs. Automation Assets
Ph
ysi
cal
Ass
ets
Asset
Availability
Co
nd
itio
n
Mo
nit
orin
g
Pre
dic
tin
g
Ma
inte
na
nce
Sch
ed
uli
ng
Tra
ck
ing
Ch
an
ge
His
tory
Wo
rk
Ord
er
Init
iati
on
Change
Management
Uti
liza
tion
Au
dit
ing
&
Rep
orti
ng
Ass
et
Mo
deli
ng
Asset
Tracking
Meridium (Meridium)
DOC4000 (Honeywell)
Maximo (IBM)
Solution for
Best Practices
Enterprise Asset Management (SAP)
Proprietary and Confidential
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What’s in an Automation Asset?
Automation Systems Configuration
• Process chemistry (formulae)
• Control strategies
• Batch / Automated procedures
• Safe operating limits
• Alarm limits
• Safety instrumented systems
• Production history
• Environmental performance
• PHA recommendations
• Throughput and economic controls
• Intellectual property
Field Instruments • Sensors/Transmitters • Control Valves • Analyzers
Control Systems • Basic Regulatory Control • Safety Instrumented Systems • Programmable Logic Controllers
Advanced Applications • Advanced Process Control • Optimization • Historians
Production Management • Production Planning • Operations Management • Yield Accounting
Operations & Maintenance Knowledge is Protected
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The Automation & Configuration Maze
CL Apps
Standard
Graphics
GUS
Graphics
TDC3000
Sub
Pictures
Button
Configs
Controllers
Logic Blocks Indicators
Discrete
TAGS
Alarms Others
MV
CV
I/O
MVC
MV
CV
I/O
MVC
MV
CV
I/O
MVC
CL Apps
Standard
Graphics
Graphics
Sub
Pictures
Button
Configs
Controllers
Logic Blocks Indicators
Discrete
TAGS
Alarms Others
PLC Instrument Shutdown
CL Apps
Standard
Graphics
Graphics
Experion
Sub
Pictures
Button
Configs
Controllers
Logic Blocks Indicators
Discrete
TAGS
Alarms Others
PLC Instrument Shutdown PLC Instrument Shutdown
MV
CV
I/O
MVC
MV
CV
I/O
MVC
Tags
Applications
I/O
Historian
Calculations
History
Graphics
Emerson Delta V
Automation Asset Best Practices Simplifies this!
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Strategic Valuation of Automation Assets
• Significant engineering investment
– Initial engineering & configuration
– Ongoing improvement & reengineering
– ARC estimates 4.5 X investment in HW
• Trade secrets and intellectual property assets
– APC & Optimization, Recipes, Reports
– Competitive differentiation
– Significant economic loss if compromised
• Business continuation platform
– The “heartbeat” of the plant/mill
– Without automation assets manufacturing stops
The value of automation systems some times
may be equal to the value of plant production
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What is Automation Asset Management?
• Industry Best Practices for Automation Asset management – Update inventory of automation assets – Documentation and Visualization – Internal and external referencing – Integrity analysis – Change tracking – Up to date genealogy mapping – Spare capacity knowledge management – Knowledge retention – Security & risk management – Data mining and inventory and asset replacement
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Traditional Automation Systems Configuration Management
• Technology limitations
– Documentation often obsolete
– Limited self-documentation
– Signal genealogy non-existent
• Work process deficits
– Segregated responsibilities
– Limited coordination among groups
– Absence of collaboration platform
• Human factor
– Knowledge resides with SME’s
– Engineers don’t enjoy documentation
– People eventually leave
• Turnover , Layoffs, etc…..
• Aging workforce
Traditional Approaches Fail Due to the Human Factor
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Benefits of Automation Asset Management
• Reduced life cycle cost – Higher Plant Availability – Increased Personnel Productivity – Improved Utilization of Available Capacity
• Improved Safety Performance – Accurate and Available Documentation – Work Process – Asset Model Information
• Improved Return on Asset Performance – Asset Visualization – Continuous Improvement – Risk Management – Disaster Recovery
• Support For Regulatory Compliance – OSHA 1910.119 Process Safety Management – 21 CFR Part 11 Electronic Records & Signatures – Cyber Security for automation assets
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DOC4000 - Solving Industry Management Challenges
• Productivity Enhancement – Engineering and Maintenance – Property, tag research time reduced
– Faster troubleshooting
• Aging Workforce/Turnover – Knowledge transfer mechanism
• Complexity of Assets
– Signal genealogy maps
• Management of Change – All config. changes documented
• Plant Availability – Incident prevention
• Safety – PHA process enhancement
• Catastrophic Incident Recovery – Baseline to rebuild
• Migration and Expansion Projects – Legacy system snapshot – Spares reservation
Automation System Asset
Management
Improve Your Bottom Line
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Best Practice Solution Should Provide
• Accurate, Self-Updating System of Documentation
• Increased System Integrity • Config. defect tracker
• Improved Maintenance Planning • Manage spare capacity
• Maintain Regulatory Compliance • Management of change
• Project cost savings • Migrations
DOC4000 Improves the Bottom Line
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What Should a Best Practice Solution Do?
• Document
• Tracks changes
• Exposes interdependencies
• Identifies configuration errors
Field Instruments • Sensors • Control Valves • Analyzers
Control Systems • DCS & Basic Regulatory Control • Safety Instrumented Systems • Programmable Logic Controllers
Advanced Applications • Advanced Process Control • Optimization • Historians
Production Management • Production Planning • Operations Management • Yield Accounting
• Transmitters • Switches • Wiring
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DOC4000 Will
• Increase productivity in order to move faster and make important
decision accurately.
• Decrease project documentation cost with faster and better
documented for projects and day-to-day activities.
• Assist to comply with governmental regulations such as OSHA
1910.119 for change management of control system configuration
removing the risk of fines from the government
• Reduce the risk of unplanned shutdowns or unit upsets by
identifying what will be effected when something is taken offline
allowing operation to know the true impact
• Decrease unit startups and trouble shooting time by proactively
interrogating the system for configuration defects and identifying
probable causes
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A Real World Example
A major North American petrochemical facility extended the periods between turnarounds, which forced them to perform online interlock testing
1. The procedure called for bypassing an SIS output and ramping the transmitter value to test the interlock
2. As expected, the interlock in the SIS tripped, but did not trip the shutdown valve
3. Due to inadequate documentation, the testers were unaware of a configured link to operator start-up assistance logic in DCS
4. The DCS logic sensed the interlock trip, placed all controllers in manual, and set all valve outputs to the fail-safe position (shutdown)
• Consequences
• Loss of production estimated at $150,000
• Regulatory fines from the environmental excursion estimated at $25,000
This incident could have easily been
prevented!
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How Could This Have Been Prevented?
Timely access to relevant information
directly impacts quality.
For The Instrument Tech For The Operator
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DOC4000 Could have Prevented It
Access to all Relevant Information at the desktop should be
accessible from the desktop (L4)
•Logic Diagrams •SIS Tag Configuration
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Access to all relevant information at the desktop
Query Capability
DOC4000 Could have Prevented It
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Tag Configuration & References
Access to all relevant information at the desktop
DOC4000 Could have Prevented It
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DOC4000™ Software
DOC4000 Is Modular
• DOC4000 Essentials
• DOC4000 Advanced Elements
• DOC4000 Asset Models
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DOC4000 Essentials
• Foundation (base software) – A universal framework for aggregating and
contextualizing data
– Captures and archives explicit knowledge from plant information sources
– Maps the genealogy of dataflow
– Provides search and advanced query functions
– Compiles and generates reports
• Asset Hierarchy (tree structure to navigate) – Organizes data from automation assets into tree
structures (S95 Plant Hierarchy)
– Enables drill down discovery
• Reference Explorer (internal and external references) • Provides data views, filters, and cross-references for the entire automation system. • Displays connectivity among objects from the same and/or different systems. • Hyperlinks are provided for all connections to a selected object.
• Mapping (references are visualized) • Graphical visualization of automation configuration, providing detailed control strategy and logic drawings. • Drawings are exportable to Microsoft Visio.
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DOC4000 Essentials • Smart Link
• Searches selected text in Microsoft Office documents for occurrences within DOC4000
• Links that text to associated objects within the DOC4000 database
• Email Explorer • Allows users to tag (designate) emails for use within DOC4000
• Aggregates and contextualizes tagged emails
• Searches and shares tagged emails in context
• Defect Finder • Performs defect checks across single or multiple automation subsystems and applications automatically find
configuration defects
• Change Tracker • Change Tracker displays the complete history of configuration changes including:
• Addition of Objects and Properties (for example, tags and their associated parameters)
• Deletion of Objects and Properties
• Modification of Properties
• Results are displayed per asset over a configurable time period. Time period options include:
• By Specific Import
• Rolling Range (e.g. last 7 days)
• Between Specific Dates
• DOC4000 Spares Capacity • Identifies available hardware spare capacity
• Enables reserving of spares for projects use
• System capacity can be searched by system-specific criteria and allocated to projects.
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DOC4000 Advanced Elements
• DOC4000 Loop Sheets – Provides an integrated field and control strategy loop drawing
– Identifies discrepancies between instrumentation and control system
databases
– Requires the Intergraph SmartPlant® Instrumentation asset model
• DOC4000 Backup and Disaster Recovery – Central backup and recovery for all automation systems
– Identifies health of backup databases
– Provides step-by-step recovery procedure per system
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DOC4000 Loop Sheets
• DOC4000 automatically detects and maps every configured connection among and within automation systems
• When combined with Intergraph’s SmartPlant Instrumentation, DOC4000:
• Provides automatically generated loop sheets • From the sensor to every configured use of the measurement
• DOC4000 provides “where used” references for all parameters
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DOC4000 Disaster Recovery
Provides a structured mechanism to collect and archive
current configuration files that make up the plants
controls systems and facilitate restoration and restart in
the event of a data disaster
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Disaster Recovery
Archive Collection • DOC4000 automatically collects configuration data from all connected
systems and archives it
Recovery Procedure • Document system recovery process in DOC4000 • Associate the collected files with the equipment they support • Configuration of Contact information for recovery assistance
Health Monitor • Continually monitors the condition of the archive
Restore
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DOC4000 Asset Models
• Plug-ins that facilitate capture and
aggregation of genome data
• Translate data from disparate
systems into a common format for the
DOC4000 database
• Provide specific user interfaces for
different automation systems
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Sampling of Available Asset Models
• ABB Process Portal B • AimStar Historian • Allen-Bradley ControlLogix • Allen-Bradley PLC2 • Allen-Bradley PLC3 • Allen-Bradley PLC-5 • Allen-Bradley SLC150 • Allen-Bradley SLC500 • AspenTech DMCPlus • AspenTech InfoPlus • AspenTech IP21 • AspenTech IQ • AspenTech VSCalc • Bentley Rebis • Emerson AMS • Emerson DeltaV • Emerson Ovation
• Emerson RS3 • GE Fanuc 90 • Honeywell EPKS • Honeywell FSC • Honeywell Logic Manager • Honeywell PHD • Honeywell RMPCT • Honeywell Safety Manager • Honeywell TPS • Intergraph SmartPlant
Instrumentation • Invensys Foxboro I/A Series • Invensys Infusion • Matrikon ProcessNet • Metso Max DNA • Modicon ProWORX+ • OSISoft PI/Process Book
• PC and Network • Siemens S7-400 • Triconex MSW • Triconex TS1131 • Yamatake APS • Yamatake DEO • Yokogawa Centum CS • Yokogawa Centum CS3000 • Wonderware InTouch
Sustain.Ability.
2012 Honeywell Users Group Americas
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Managing the Underlying
Automation Infrastructure
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Recon Asset Model
Monitors computers and networks, including their:
– Hardware
– Operating system information
– Files Systems
– Installed Software
– Networking Devices
– Peripheral Devices
– Domains
– Groups and Users
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DOC4000 Recon
• Monitors and reports vital
information and vulnerabilities
• Helps the automation organization
to better manage their system
infrastructure
• Allows IT to securely
monitor different aspects
of the control systems
• As an Advanced
Element, it is web-based
and accessible from
virtually anywhere
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DOC4000 Recon and COE Compliance
• DOC4000 Recon manages
multiple COEs simultaneously
• It interrogates systems for COE
compliance and reports on
discrepancies from the spec
• It maintains individual change
histories for each server, workstation, and desktop
• In addition to COE compliance, DOC4000 Recon reports other
key information including: – Serial numbers
– Correct operation of active directories
– Compliance to available drive capacity guidelines
– Disabled and stale user accounts
– Application and operating system services status, start mode, and state
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Licensing and Vendor Compliance
• Licenses – Sometimes distributed using the honor system
– Can be difficult to track
– IT is responsible for licensing enforcement enterprise wide, but they
have limited visibility into the automation networks
• Automation systems warranties – Some software installations and updates can inadvertently void the
manufacturer’s warranty
• DOC4000 Recon helps: – Track the number of licenses
– Optimally distribute licenses
– Verify software and components are
vendor compliant
– Simplify audits
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Contact Information
Lauhael Godinho Honeywell Channel Manager – The Americas
direct: (281) 204 1315
cell: (281) 253 7907
email: [email protected]
James Cage Lead Americas Consultant for DOC4000 Suite of Solutions
Phone: 770-689-0125
Email: [email protected]
Cindy Bloodgood Sr. Strategic Marketing Manager
Phone: 480-236-4006
Email: [email protected]
Brian Murphy Manager – Global Channels
mobile: +1.832.646.1899
email: [email protected]
DOC4000 Trained Consultants:
Reggie Barnett
Kevin Boatright
Ken Carfagno
Benoit Comtois
Humberto Defferrari
Lonnie Faucheux
Eric Hinh
Ole Kristensen
Jack Lobingier
Gijs-Jan, Peek
Jaime Salome
Stuart Sanderson
Jerry Schuryk
Sivakumar Sundararajan
Steve Zarichniak