Getting the Most out of Your Brownfield Projects

LEAP for Brownfield

GETTING THE MOST OUT OF YOUR BROWNFIELD PROJECTSatnam Bhogal

20th June 2016

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.

Agenda

• Challenges of Legacy System

• LEAP Transition

• Continuous Innovation

• LEAP Methodology - Brownfield

• Applying LEAN Principles

• Tools Overview

• Lifecycle Services

• Summary


Challenges of Legacy System

2

• Pending threat of outage/incident

• Costly to maintain with lack of spare

parts availability

• Demands of IT in providing economic

advantage cannot be met

• Difficulties in harnessing new business

opportunity with current limitations of

system

• Response to rapid shifts in customer

demands undermined by inflexibility

• Insufficient visuality in preventing

abnormal situations and equipment

breakdown from developing

• Unable to expand cost-effectively to

meet capacity requirements


Transition

Cloud

Engineering

A360

Methodology Tools

Virtualization

Universal

IO

How do we do this?

3

LegacyHow much longer?

FutureproofWhat do we want to achieve?

+

LEAP

Continuous Innovation

LEAP Transition


Transition Process

4

Methodology

A360/Life CycleManagement

SYSTEMATICWORKFLOW

CONTINUOUS INNOVATION

ASSESSMENT/IMPACT

FUNCTIONALConversion

Tools

$


Marshalling Design

HMI Configuration

Alarm Configuration

System FAT

LateBinding

Hardware Definition

IO Mapping

Control Configuration

Site

Commission

Configuration FAT

System

Configuration

Methodology

Legacy Data

Audit

Checklists

System Backup

Inventory Tool

Domain Knowledge

Fro

nt

En

d E

ng

ine

eri

ng

Des

ign

Control Match

Graphics Match

Control Narratives

& P&IDs

Alarm Studies

Set Points


Repetitive Tasks Rework Redundant Tasks

Lean Execution Eliminates Waste

Non-value Add Processes are Considered “Waste”

Entering the same data

over and over again

Editing the same data

over and over again

Validating the same data

over and over again

If “Time is Money”, Then “Wasting Time is Wasting Money?”

6


Graphics Match is used for migrating custom graphic files from the

following systems.

- US/GUS/PlantScape

- Foxboro

- ABB Bailey

- Provox-Emerson

- Siemens Teleperm (In development for current projects)

- Yokogawa (In development for current projects)

- Yamatake

Graphic Migration - Graphic Match tool

Experion HMIWeb


Graphic Migration - Graphic Match tool

Migrate Graphics

using tool


Controller DB Migration – Control Match tool

Honeywell TDC System includes

- TDC 2000 family Hiway Boxes Basic Controller (CB)

Extended Controller (EC)

Multi Function Controller (MC)

Advanced Multi Function Controller (AMC)

HLPIU, LLPIU, LEPIU (High/Low Level, Low Energy Process Interface Units)

- TDC 3000 family UCN Nodes Process Manager (PM)

Advanced Process Manager (APM)

High Performance Process Manager (HPM)

Application Module (AM)

Legacy Competitor System includes- Bailey

- Provox

- Foxboro

- RS3 (Emerson)

- ABB MOD300

- Siemens Teleperm

- Yokogawa (In development for current projects)

- Toshiba

- Yamatake


Controller DB Migration – Control Match tool

Control Match tool helps to retain the Customer IP

Migrate DB using

tool


Retain Wiring Investment and Simplify Migration

Rewiring Tasks -for 16 point I/O card

Disconnect of old terminations

Removal of old terminations

Install new Series C I/O

Rewire from new terminal blocks to Experion

Documentation

Using Wiring Kits –16 point I/O card

Install intermediate panels and New Series C I/O

Connect cables

Documentation

Save about 75% of time when using wiring kit

If labor is $100 per hour, $800 saved per 16

channel card!

PROVOX Series 10, Series 20

Bailey Infi90, NET90

GSE Quantum

Yokogawa

All Others


AI MIGRATION CABLE

DI MIGRATION CABLES

DO MIGRATION CABLES

AO MIGRATION CABLE

Foxboro Honeywell

AI

AO

DO

DI

Analog

Input TU

Analog

Output TU

Digital Input(24, 120, 240)

Digital Output(24 VDC, relay)

Digital Input (24, 120, 240)

Digital Output(24 VDC , relay)

TCA to Series C Migration Hardware

Preserve the

wiring


What We DeliverFaster Response &

Resolution

Incident Reduction

Cyber Security

Optimize the

Process

Change

Management

Contract Performance

Lifecycle Services – Assurance 360

• Software upgrades

• GTAC support

• Hardware refresh

• Parts holding

• Parts replacement

• Preferred access to technical support

• Preventive maintenance

• Cyber security

• Control tuning

• Alarm rationalization

• System performance monitoring

• Assessments

• Change management

• Off-line testing, training

• Assurance that your Automation

System won’t let you down

With Assurance 360 we

deliver more than service,

we deliver results!


Summary

• Early migration of Control Configuration to establish as-is basis and reduce post FAT re-work

• UCT enables a phased Migration

• Guaranteed outcome (and support)

• No risk of obsolescence

• No customer left behind

• Established tools for ageing/obsolete system that provides assure of execution capability

21st Century Technology

• Universal Channel Technology

• Virtualization

• VEP

+

Assurance 360

• Guaranteed availability

• Continuous evolution

Proven Project Execution

Capability

• GPM

• Experience in migrating

competitive systems

• Tools for audits and migrations

+


More Continuous Innovation!• Come see us in the Knowledge Center

• Sign up for Live Demo Sessions - Knowledge Center Spotlight Area – Limited Seating and Prizes

- Migrate from Coax based LCN to Experion LCN

Tuesday June 21 @ 5:30pm

- Migrate from HPM to EHPM On Process

Wednesday June 22 @ 5:30pm

• Technology Sessions and Round Tables

- Monday 10:15 am session

Getting the Most out of your Brownfield Projects

3rd Party Migration

- Tuesday 10:15am session

Prepare for 2025 start your Experion LCN Migration Plan Now

Control System Migration Planning: Are you prepared for the Perfect Storm

- Tuesday 1pm session

No CAPEX? No Problem

Multi-Year Incremental Migrations Experiences

- Wednesday 10:15 am session

How to Solve Your Biggest Business Challenges and Deliver the Outcome Your Management Expects

What is the Price/Value Relationship of Assurance 360

- Wednesday 1pm session

Retiring Knowledge? EHPM On Process Migration Made Easy

Service Advisory Council Explores the Benefits and Challenges of Upgrades and Migrations

• TPS to Experion Migration Training Thursday 1pm and Friday 8:30am


www.honeywell.com

Getting the Most out of Your Brownfield Projects

Technology

Transcript of Getting the Most out of Your Brownfield Projects