Assuring Long-term Benefits from your Advanced Applications
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Transcript of Assuring Long-term Benefits from your Advanced Applications
2015 Honeywell Users Group
Europe, Middle East and Africa
Assuring Long-term Benefits from your Advanced Applications
Daren Lewis, Honeywell
2 © 2015 Honeywell International All Rights Reserved
• Advanced Solutions continue to be the largest
provider of Advanced Applications for the Process
Industry and established a wealth of experience
supporting these applications through the following
main service offerings:
‒ Benefits Guardianship Program (BGP) – entry level software
maintenance and support program designed to provide technical
assistance and free software updates
‒ BGP Plus – addition of scheduled engineering services designed
to maintain performance and extend the life of the applications
‒ BGP Performa – addition of proactive sustainment program via
secure remote service centers designed to maximize uptime and
performance at all times
Background
New
BGP Performa aligned with Assurance 360 Performa
3 © 2015 Honeywell International All Rights Reserved
The Sustainability Problem
Reduce Total Cost of Ownership
Knowledge
Management
Optimize or Sustain
Performance
Benefits from Advanced
Applications can quickly
decline without proper
maintenance effort
•Health monitoring
•Latest functionality
•Technology Refresh
•Address changes to people,
processes, plant, equipment
and operating conditions
Failure to address
support early will greatly
reduce long-term
benefits
•Dealing with scarce
resources
•Leverage Technology
•Consistent Asset Mgmt
strategies
•Avoid obsolescence
Skilled support resources are
difficult to find, train and
retain
•Awareness / training
•End user handover and acceptance
•Knowledge transfer & retention
•Consistency for multi-site installations
4 © 2015 Honeywell International All Rights Reserved
Typical Customer Benefits
Sustaining These Benefit Levels is the Real Challenge!
0
1
2
3
4
5
6
7
Operator Training & Simulation, Asset
Management
Production Management
Advanced Planning & Scheduling
Blending & Movement
Management
Operations Management
Advanced Process Control &
Optimization
An
nu
al B
en
efit
s: $
Mill
ion
s
2.0
1.5
1.0
0.5 Typ
ical
pay
bac
k p
eri
od
s (y
ear
s)
Typical Benefits Range from $10M - $50M Per Year Per Site (Actual Benefits Depend on Industry & Plant Scale)
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20
40
60
80
100
120
0 6 12 18 24
Be
nef
its
(as
% o
f o
rigi
nal
)
Time (months)
No Maintenance
Basic Maintenance
Reactive Maintenance
Proactive Maintenance
Opportunity Assessment
Understanding the High Cost of Neglect
“…applications can quickly degrade to yield nominal benefits of <25% if they are not properly
monitored and maintained from point of installation” Customer, Honeywell Users Group Forum
• Good initial benefits
from Advanced
Applications
• Potential for rapid
degradation of benefits
without proper
monitoring and
maintenance
Position after circa 12 months
No Maintenance 50% loss
Basic Maintenance 20% loss
Reactive maintenance 10% loss
Proactive Maintenance 5% loss
Opportunity Assessment +5% gain
Related to sample data: Results will depend on
many factors, so indicative only.
6 © 2015 Honeywell International All Rights Reserved
BGP Optima
BGP Performa
BGPPlus
BGP
“On demand” services to provide technical
resources for non-periodic activities
Benefits Guardianship Tiered Services
Clear and Simple portfolio
In simple terms:
BGP Performa is a collaborative service
whereby Honeywell commits to jointly maintain
agreed plant / unit performance targets, with
regular progress reviews.
Honeywell will provide remote monitoring
and alerting to issues likely to impact on
Performance targets, with the recommended
(and prioritized) actions that the customer
should undertake.
Honeywell will work with the customer to
ensure their in-house resources are suitably
skilled to undertake the actions and tasks.
7 © 2015 Honeywell International All Rights Reserved
Sweating
Assets for longer
• How to see when our Advanced Applications are performing?
• How to increase uptime of our Advanced Applications?
Skilled Resources
• How to best deploy our limited in-house resources?
• How to ensure our in-house skills remain competent?
Operational Effectiveness
• How can we focus more on our core competencies?
• How to sustain increased benefits through proactive Performance management?
Cost of Ownership
• How to get faster incident responses and resolutions?
• How can we better manage change and technology upgrades?
Meeting needs with BGP Performa
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Monitoring of System and Application health
provides a solid foundation to allow primary
focus on meeting Performance objectives
Foundations to deliver BGP Performa
To ensure the system is capable of running
the Advanced Application with no
impediments
To ensure the Application is working
correctly and is capable of delivering its
performance objectives
To ensure the Application is performing as
designed and continues to deliver
sustained benefits
BGP Performa: for business critical applications such as Advanced Process Control (APC), Process History & Analytics (PHD), OptiVision, Blending & Movements Automation (BMA), etc.
9 © 2015 Honeywell International All Rights Reserved
BGP Performa: Key responsibilities
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The balanced scorecard
shows the top-level metrics
and targets that have been
agreed and adopted by the
BGP Performa teams.
Where possible, it also
shows the estimated $ value
that has been delivered
The KPI’s give confidence
that the system is robust
and performing more
effectively than ever before.
The scorecard is reviewed monthly and reflects the overall status and
trends of the collaborative program between Honeywell and the
customer.
Regular review of performance
11 © 2015 Honeywell International All Rights Reserved
Typical examples of
indicators and hierarchy
Low disk
space
System
Read time
System
Write time
Disk queue
length
Disk
Cache
Processor
load
Processor
interrupts
Processor
queue
length
Virtual
memory
Available
memory
Page files
Free page
tables
Page/ non
page bytes
Page per
second
Input bytes
/ second
Output
queue
length
Disk CPU Memory Network Disk Network CPU Memory
Quickly identify
trends and
thresholds Server
A
Server
B
Server
C
Monitoring System Health metrics
12 © 2015 Honeywell International All Rights Reserved
Typical examples of
indicators and hierarchy
OPC fail time /
frequency
TPN load read /
write
TPN interface
queue
TPN HCI client
connection
EPKS HCI client
connection
EPKS load read /
write
Controller
handle
count
Scheduling
overlaps
Disk
space
Handle
count
PHD handle
count
RDI handle
count
API handle
count
UDB handle
count
Security handle
count
PHD start
handle
RAPI handle
count
RDI state
Interface
state
Point age
Point
confidence
Ping time
Lost
connectio
n
Con store
failed
User count
Process
leaks
RDI
status
Server
status RDI Status Server StatusProcess Leaks
Application
health
Comms URT
platform Comms URT Platform App Health
Monitoring Application Health metrics
13 © 2015 Honeywell International All Rights Reserved
Performance monitoring with BGP Performa
• Increased efficiency and output across multiple plant & assets
• Control costs
• Make resourcing and management decisions
• Efficiently meet production plans
• Reduce unplanned downtime
• Identify bad actors
• Better deploy in-house resources
• Measure performance of Systems against key metrics and thresholds
• Proactive alerts
• Prioritized action list for intervention and improvement
Performance monitoring caters to needs of different stakeholders
Different Stakeholders
14 © 2015 Honeywell International All Rights Reserved
Plant
Crude Unit
CDU
APC Attainment
Usefulness
CV
Violation of hard limits
MV
Clamping
DATA
Reliability Acceptance Value Criticality
Objective Functionality
Inferential Attainment
Uptime
Historical trend
STAB SPLT
FCCU
MFRR DEBUT
Performance Monitoring: APC
•Performance KPI’s mapped into an aggregated Hierarchy across Enterprise
•Easy to see interactions and drilldown for better understanding of events
•“Icons” can reflect real data ( status, trends, thresholds and deviations)
15 © 2015 Honeywell International All Rights Reserved
Plant
Crude Unit
CDU
APC Attainment
Usefulness
CV
Violation of hard limits
MV
Clamping
DATA
Reliability Acceptance Value Criticality
Objective Functionality
Inferential Attainment
Uptime
Historical trend
STAB SPLT
FCCU
MFRR DEBUT
Performance Monitoring: APC
Example Commentary: “Overall performance is healthy but there are early
indications of performance drift in CDU Diesel and an ongoing instrumentation
issue with the Naphtha Splitter”
Example Recommendations (Prioritized To Do List)
1. Investigate increase in MV clamping on the FCCU debutanizer controller
63DEBUT.
2. Investigate loss of performance in CDU Diesel 95% inferential.
3. Recommend retuning furnace outlet temperature controller 51TIC002.
16 © 2015 Honeywell International All Rights Reserved
Plant
Crude Unit
CDU
APC Attainment
Usefulness
CV
Violation of hard limits
MV
Clamping
DATA
Reliability Acceptance Value Criticality
Objective Functionality
Inferential Attainment
Uptime
Historical trend
STAB SPLT
FCCU
MFRR DEBUT
Performance Monitoring: APC
17 © 2015 Honeywell International All Rights Reserved
Plant
Crude Unit
CDU
APC Attainment
Usefulness
CV
Violation of hard limits
MV
Clamping
DATA
Reliability Acceptance Value Criticality
Objective Functionality
Inferential Attainment
Uptime
Historical trend
STAB SPLT
FCCU
MFRR DEBUT
Performance Monitoring: APC
18 © 2015 Honeywell International All Rights Reserved
Performance Monitoring: APC
Plant
Crude Unit
CDU
APC Attainment
Usefulness
CV
Violation of hard limits
MV
Clamping
DATA
Reliability Acceptance Value Criticality
Objective Functionality
Inferential Attainment
Uptime
Historical trend
STAB SPLT
FCCU
MFRR DEBUT
19 © 2015 Honeywell International All Rights Reserved
Performance Monitoring: APC
Plant
Crude Unit
CDU
APC Attainment
Usefulness
CV
Violation of hard limits
MV
Clamping
DATA
Reliability Acceptance Value Criticality
Objective Functionality
Inferential Attainment
Uptime
Historical trend
STAB SPLT
FCCU
MFRR DEBUT
Including
Traditional
Profit Expert
Reports
20 © 2015 Honeywell International All Rights Reserved
DEDICATED PERFORMA SERVICE LEAD
OVERSIGHT OF KPIs AND OUTCOMES
LONG-TERM GUARDIANSHIP
LEVERAGE OF HONEYWELL’s EXPERTISE
ALERTING AND TRENDING
REMOTE PERFORMANCE MONITORING
SUSTAINED $ BENEFITS
BGP Performa on 1 slide
D
O
L
L
A
R
S
21 © 2015 Honeywell International All Rights Reserved
BGP Performa helps reduce the Total Cost of Ownership
• Honeywell provides faster incident response and resolutions
• Proactive service reduces number of incidents and increases uptime
• Effective planning and management of change and technology upgrades
• Cyber Security protection for remote connectivity
• Most effective deployment of in-house resources
BGP Performa helps to improve Operational Effectiveness
• Allows customers to focus on their core competency and Honeywell to take
responsibility for overall Performance of Advanced Applications.
• Honeywell guides the customer on most appropriate actions and priorities
• Honeywell helps to improve in-house skills and capabilities
Executive Summary
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www.honeywellprocess.com
Questions
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EMEA
Daren Lewis: Global Services Director
Matt Townley: Regional Service Leader (ENA)
Jayant Diwan: Regional Service Leader (ME)
Gerhard Kotze: Regional Business Leader (SSA)
Who to contact (in EMEA)
24 © 2015 Honeywell International All Rights Reserved