Sustain.Ability.

2012 Honeywell Users Group Americas

1

Management of Change

Cindy Bloodgood, Sr. Strategic Marketing Manager

James Cage, Americas Principle Sales Consultant

2

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

3

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.

4

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.

5

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

6

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

7

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

8

• 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

9

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

Page 9

10

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

11

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!

12

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

13

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

14

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

15

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

16

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

17

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

18

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

19

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

20

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!

21

How Could This Have Been Prevented?

Timely access to relevant information

directly impacts quality.

For The Instrument Tech For The Operator

22

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

23

Access to all relevant information at the desktop

Query Capability

DOC4000 Could have Prevented It

24

Tag Configuration & References

Access to all relevant information at the desktop

DOC4000 Could have Prevented It

25

DOC4000™ Software

DOC4000 Is Modular

• DOC4000 Essentials

• DOC4000 Advanced Elements

• DOC4000 Asset Models

26

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.

27

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.

28

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

29

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

30

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

31

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

32

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

33

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

34

Managing the Underlying

Automation Infrastructure

35

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

36

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

37

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

38

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

39

Contact Information

Lauhael Godinho Honeywell Channel Manager – The Americas

direct: (281) 204 1315

cell: (281) 253 7907

email: lgodinho@pas.com

James Cage Lead Americas Consultant for DOC4000 Suite of Solutions

Phone: 770-689-0125

Email: james.cage@honeywell.com

Cindy Bloodgood Sr. Strategic Marketing Manager

Phone: 480-236-4006

Email: cindy.bloodgood@honeywell.com

Brian Murphy Manager – Global Channels

mobile: +1.832.646.1899

email: bmurphy@pas.com

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