HONEYWELL FORGE FOR INDUSTRIAL · Achieving and Sustaining Peak Performance Sandeep Chandran...

Achieving and Sustaining Peak Performance

HONEYWELL FORGE FOR INDUSTRIALSandeep Chandran

June 2019

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.

OPERATOR CHALLENGES

Longer, harsher operatingcycles between turnarounds, at peakperformance

• Demanding products, and quality commitments

• Older equipment stretched to meet demand

• Increasing safety, environmental compliance and stewardship

• Global competitive marketplace

Differing outcomes acrossshifts, units, plants andenterprise

• Knowledge Retention & Adoption

• Loss of expertise due to graying workforce

• Disconnected Solutions

• Inconsistent User created insights

Lack of Integrated insightsacross the operatingspectrum

• Rapid identification of Root Causes

• Access to alerts and actionable recommendations

• Closed-loop workflows

• Enterprise analytics for meaningful insights

Increasing

Operational

Complexity

Changing

Workforce

Demographics

Data Integration

to Intelligence

Integration

Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.

PROCESS AUTOMATION INDUSTRY DIGITAL TRANSFORMATION

Digital Debt, Digital Dividend and Digital Penalty

ARE YOU READY for New Wave ?

20102000

• Industry adopted WINTEL

• Opened wider innovation opportunities

Va

lue

to

th

e C

us

tom

er

Innovations by Time Period

1975

DCS as Innovation

Industry 3.0

>2015

New Wave of Innovation

o Cloud

o IIoT

o Virtual Reality

o Machine Learning

o Digitization

Industry 4.0

The rate of change

ahead of us is steep

and accelerating


Technology is now enabling us to truly understand

the interdependencies of the complete ecosystem

of people, assets and process

Co

st

of

Wa

itin

g

Time

Digital transformation late-

adopter curve

Previous late-

adopter curve

LATE ADOPTION COSTS WILL BE 2–3X GREATER THAN BEFORE

3


HONEYWELL FORGE FOR INDUSTRIALENTERPRISE PERFORMANCE MANAGEMENT

Connected Plant Portal

Delivers actionable insights

for intelligent operations using real

time models, domain expertise and

visual analytics

• Role-based, comprehensive visual

analytics to optimize your process,

assets and people performance

• Identify process & asset equipment

issues and inter-relationships

• Actionable insights that improve ability

to collect, analyse and act on data -

highlights potential financial opportunity

• Deployment in a cloud environment

• Developed to meet industry’s highest

cyber security standards

Asset Alerts

OpportunitiesPerformance Metrics

Recommendations


BEFORE HONEYWELL FORGE FOR INDUSTRIAL

APC

Process engineer observes that APC

for the unit is not performing well

Trend analysis in Historian

Equipment analysis in

Reliability system (if exists)

Discuss with operations &

conduct other relevant

investigations

To further investigate, the engineer

conducts some of these actions

Manually assemble the insights, come up

with recommendations and action plan

Challenges:

1. Manual, time consuming and reactive

2. Difficult to uncover inter relationships

3. Determine actions

1 2 3

Analyze APC performance

OPPORTUNITY COST


AFTER HONEYWELL FORGE FOR INDUSTRIAL

Engineer accesses Honeywell Forge

✓ Digital Twins compares current process performance to optimal performance

✓ Analytics identifies areas where constraints prevent units from achieving optimal operations, providing recommended actions.

✓ Economic impact analysis is presented in dashboard to orient action plan to highest value issues

APC Digital Twin

Process Digital Twin

Asset Digital TwinRecommendations

Opportunities

Performance Metrics

1

https://www.youtube.com/watch?v=fop7w5SGfBs&feature=youtu.be


Consumer Grade User Apps

Intuitive apps that enable user

adoption

API as a Service

Partner/OEM enablement; Ease

of integration & Migration

Intelligent Model Framework

Runs 3rd Party and Honeywell

models

Connectivity

Real-time for critical, near real-

time connections, ease of install,

single sign-on. Designed to to

meet industry’s highest cyber

security standards

Value Delivered

APIs extend the solution to

3rd party applications

Honeywell domain with

machine learning models

drive actionable insights

Minimize IT need to manage

connections across assets

Protect current investments

with an extensible solution

ModulesHoneywell Forge for Industrial

Clo

ud

Ind

ustr

ials

&

Ed

ge

HOW IT WORKS


First Principle Process Models (Process Simulation...)

Commonly used for process evaluation

Comprehensive representation of process and asset design

Empirical Models (Advanced Process Control..)

Commonly used for control & optimization

Represents process and equipment constraints that are fine

tuned using cause and effect

Knowledge Based, Statistical Models (Asset Performance

Management..)

Commonly used for equipment health monitoring

Uses operational knowledge and historical statistics to identify

abnormal operating conditions

Designed to quickly identify the best

path to peak performance

Model Libraries

Visual Analytics

Integrating Analytics and Recommendation

from Underlying Modules

INTELLIGENT MODEL FRAMEWORK


Process Reliability AdvisorUse real-time operating data to detect and

diagnose issues to improve unit performance

Leverage Honeywell UOP’s comprehensive

experience to assess process constraints and

proactively mitigate operational issues

Process Optimization AdvisorGain expert operational recommendations to utilize assets and derive maximum profitability from the complex

Provide an optimal set of operating conditions, based on customer economics, for the unit to run at minimal cost and waste

Improve throughput, yield, process & catalyst reliability through early event detection

Improve plant performance & increase profitability by over

$0.30-0.50/bbl in Refining

$10-20/MT in Petrochemicals

Underlying Intelligence

PROCESS PERFORMANCE

Extensions to Partner Units


Monitor

Real time APC performance accessible

at any time

... Prioritize

Visualization of APC performance in order of

economic impact

! Diagnose

Correlate economic performance of APC

towards process operations issues

Resolve

Detailed analysis identifies process

bottlenecks

$700,000

$750,000

$800,000

$850,000

$900,000

0 10 20 30W…

Profit Performance Monitor Identify degradation of unit performance and provide expert guidance through actionable instructions to

maintain unit profit performance

Provide visibility into the economic consequences of plant process performance as cost of lost

opportunity

Ensure sustainable benefits over varying operating conditions, visualizing real time unit profitability

Identify process, advanced control issues contributing to lost performance

Sustain throughput & yield for longer periods of time

Identify 10 to 20% lost benefits/year per APC application

CONTROL PERFORMANCE


Data from controls &

edge devices1

SENSORS

CONTROL NETWORK

SECURED DATA

Asset digital twins & analytic models

2 3Metrics

Asset Alerts

Opportunities

Recommendations

4Asset Performance Management

• Predictive analytics deliver early insight to

impending issues

• Integrated process and asset data models

identify new levels of untapped

productivity

• Unified enterprise connectivity drives

common workflow across engineering,

maintenance, and operations

Cloud-based event/fault detection

Recurring annual savings of

$1M+ in small

$5-10M in larger deployments

ASSET PERFORMANCE


EMBEDDED ASSET TEMPLATES – DEPLOY

QUICKLY

12

The Honeywell Asset Performance Library

• Plug-n-play model creation

• Quickly create digital twins

• Models across asset and industry types

• Embedded expertiseCENTRIFUGAL PUMPS

HEAT EXCHANGERS

ELECTRIC MOTORS

VALVES

TURBO & RECIPROCATING

COMPRESSORS

FURNACES

GAS & STEAM TURBINES

FANS & BLOWERS

HAUL TRUCKS, EXCAVATORS,

SHOVELS

CRUSHERS, DRILLS, DOZERS

REACTOR COLUMNS

OXIDIZERS

ESP’s (ELECTRIC SUBMERSIBLE

PUMPS)

Refining & Petrochemicals

Oil & GasMining &

MetalsPower

Real-time Digital Twins

Head =3960*HP /

Flow

Performance CalculationsExchanger

Turbine

Compressor

Pump

Furnace

Asset

Library

Data Cleansing

Health Monitoring

Cloud Analytics

Sample equipment types available within the library (partial list)


Honeywell Forge for Inspection

Rounds

An end-to-end mobile solution for field

operations to manage daily operator rounds.

Standardized and automated processes,

connecting and orchestrating field operations

Works on any mobile device, or smart

wearable, – enabling maximization of existing

IT investments.

Safely and efficiently executing tasks and workflows

PEOPLE PERFORMANCE

Increase number

of closed-loop

workflows

Increase visibility

and transparency

Enhance process

and productivity

Reduce incidents

Reduce downtime

Reduce time spent

on root-cause

analysis

Reduce OPEX

Create operational

best practices, set standards


Combine digital twins of

process units & equipment

assets to generate insights

Augment intelligence from

underlying applications for

actionable insights

Shorten Ideation to Value

Delivery lifecycle

Increased profitability and

efficiency via integrated

and more accurate models

Visualizing analytical results

from multiple sources to

identify issues - leading to

action

Extensible and flexible platform

maximizing value generation

from a single interface

Integrating point solutions

to a single, common

persona-based solution

Deeper insights through

predictive analytics guidance

for faster decision making

HONEYWELL FORGE FOR INDUSTRIAL

Portable and extensible

platform to meet highest

cyber security standards

Identity Mgmt

API Gateway

Logging & Monitoring

App Hosting

Deployment

Platform Services/

Capabilities

Licensing

Access Mgmt


INTEGRATING DATA AND MODELS FOR AN ENTERPRISE VIEW

15

Make informed decisions by seeing the whole picture

Honeywell Forge for Industrial

Real-time data and visual intelligence to help

optimize production and increase profitability

Quickly spot opportunities, and provide

recommendations to improve processes,

equipment performance and automation.

Benchmark actual process and asset

performance against expected optimal

performance with digital twins

Quickly identify the best path to peak performance


HONEYWELL FORGE FOR INDUSTRIAL SESSIONS

• 11:30 AM – 12:15 PM Application of Process Reliability Advisor to Drive Operational ExcellenceKatherine Jones, Honeywell – MIRO Room

• 1:30 PM- 2:15 PMHoneywell Cloud Asset Performance Solution Helps Avoid Machinery Downtime within its PMT DivisionWilliam Olp, Honeywell PMT Orange – MIRO Room

• 2:30 PM – 3:15 PM Digitization of Operator Field Rounds at Reliance Pratik Naik, Reliance Industries Ltd – MIRO Room

• 3:45 PM – 4:30 PM Spotlight: Closing the Gap Between Planning & Control with Honeywell Profit Executive Perry Nord, Honeywell – Demo Center

• 4:45 PM – 5:30 PMHoneywell Forge for Inspection Rounds and other Technology EnablersSebastian Loeb and Veronica Turner – Honeywell – MIRO Room

THANK YOUwww.hwll.co/symphonite

HONEYWELL FORGE FOR INDUSTRIAL · Achieving and Sustaining Peak Performance Sandeep Chandran...

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