Honeywell Trace™
DOCUMENTATION & CHANGE
MANAGEMENT FOR YOUR PLANTFredrick Moore
Monday, June 19, 2017
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Overview: Honeywell Trace™
• Problem Statement
• Why Documentation for Your Plant?
• The Solution: Honeywell Trace
• Product Technology & Differentiators
• Trace Licensing & Architecture
• Q & A
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
Problem Statement
Plant shutdown & production losses due to:
01. Stale process control data
02. Non availability of engineering change history
03. System dependencies
The process control data flow is very complex. Engineer is unable to see the holistic view of all the systems.
??
?
01. CluelessThe process control data flow is too
complex to understand. Engineer is
unable to see the holistic view of all the
systems. Thousands of undocumented
changes has happened over the past
years, post commissioning.
A Day in a Plant Without Trace
04. What Went Wrong?Root Cause Analysis (RCA) is
conducted to understand what really
went wrong and why? It is understood
that the engineer had limited view of
node dependencies. Also he was using
a stale document.
02. Misinformed ChangeWithout access to change history or by
referring to a stale document the
instrument /node is serviced.
03. Disaster StrikesThe plant trips and there are excessive
flaring & dark smoke plumes released.
The plant has to be shutdown with
imminent loss to production / lives.
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
“I prefer all
the plant
resolutions to
be
automatically
updated in my
document.
Safety is my
top priority”
Jerry HatfieldMaintenance Engineer
46 yrs. old, Calgary.
“It is difficult
to track the
change
history,
rationale for
change,
people
responsible
for
approvals
Salah NawazService Engineer
43 yrs. old, Qatar.
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Honeywell Trace - Key Use Case (Downtime is $$$$$)
Productivity, Safety & Transparency
• To get production back online:
- Identify problem
- Get back into production in 30 minutes
- Avoid changes in the system while down
• All incidents accounted for:
- Avoid administrative RCFAs
- Asset and inventory management
- Fast track investigations
- Develop effective CA’s to be proactive
• Better operational effectiveness & reduce unplanned downtime costs
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Solution:
Honeywell Trace™
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Up to 80% reduction in manual documentation.
80%
3 times faster than the competition in data collection.
300X
~50% reduction in customer acceptance test time
50%
Honeywell Trace™ Trace is a system documentation and change management application for
process plants that enables enhanced analysis of engineering and control changes.
Comprehensive Tag Reference Search
CHALLENGEUnderstanding of Data Flows, Navigation of Connected Tags, &
Knowledge Share
SOLUTIONWildcard & Global Search Protocol w/ Document Attachment in
3 Viewing Options
Key Benefits:
• Three Viewing Options
- Connection Type
- Graphical
- Tabular
• Easily understand data
flows
• Print & download tags
and their properties
Wildcard search
Connection Type
Graphical View
Tabular View
Key Benefits:
• Better planning
• Better visibility at the
system component level
• Improve communication
by adding customized
notes on where system
anomalies occurred
Logical Views
CHALLENGECan’t See Plant’s Logical Hierarchy and Drill Down to Function
Block Level
SOLUTION Logical View Showing Changes & Anomalies
BLUE - CHANGES
RED – ANOMALIES
Key Benefits:
• No confusing menus and
interfaces filled with
cramped data
• Mapped window for
smoother navigation
• See by yellow / green
connection
Hardware & Network Views
CHALLENGEPerform Maintenance on Systems & Detect Changes Without
Using Spreadsheets
SOLUTIONVisually See Hardware/Network Relationships & Get Changes
Right the First Time
Smart Change Detection
CHALLENGETo See Changes We’re Most Interested In & Filter, Sort, &
Compare by Authorization
SOLUTIONDetects & Aggregates Every Granular Change — Providing
Simple Filter Options
Key Benefits:
• Suppress changes
• Quickly respond preventing
downtime
• Restrict unauthorized
changes
Key Benefits:
• Easily Highlight Changes
• Easy searching for
complex programing
• Reduction in manual
work
• Comparisons can be
done between any two
snapshots
File Comparison
CHALLENGE View Advanced Control Coding
SOLUTION Comparisons can be done between any two snapshots
Channel Spare Management
CHALLENGEReliable Technology for Channel Utilization Mgt. for Better
Project Efficiency
SOLUTION Ability to Assign Hardware to Ongoing System Configurations
Key Benefits:
• Reserve hardware
• Assign hardware and
leave comments
• View by project name
• Better forecasting and
planning of plant
resources
Parameter Query
CHALLENGE Search Across Assets & CMs Without Complex Coding
SOLUTIONSimple UI-based Query Creation for the Most Complex of
Queries
Key Benefits:
• No SQL Scripting
Knowledge Needed
• Easy searching for
complex data
descriptions
Experion Icons
Data Collection
CHALLENGE Takes Too Many Days to Capture Data and It Ties-Up My System
SOLUTION Typically Takes 3-4 Hours Per Snapshot
Key Benefits:
• No impact to system load
• System available during
data collection
• Reduces incident
escalations
• See changes by shift
Schedule data
collection
Collection Status
Snapshot
History
Key Benefits:
• No SQL Scripting
Knowledge Needed
• Easy reporting on
complex data
Performance Reporting
CHALLENGENo View Into the Degradation of System Performance When
Changes Occur
SOLUTIONGenerate System Performance Report On-demand From Trace
Server
• Performance
Reports
• System Device
Reports
• Change Reports
• Security Reports
Reduced Costs
Quality Operations
Performance
Metrics
Enhanced
Compliance
Healthy
Caution
Poor
Trace Workflow & Change Requests (Live Demo at Spotlight)
CHALLENGENeed a System to Trace & Track Change Request & Work Order
Procedures
SOLUTIONTrace Workflow where Users Can Evaluate, Approve, Test, and
Close Work Orders
Key Benefits:
• Checklists for each
process phase
• Work order status,
descriptions, and audit
logs
• Alternate workflows and
assign users / owners
EVALUATE
APPROVE
CLOSE
Intuitive Navigation
CHALLENGEKey Data was Hidden in Menu Tabs and Needed Better
Categorization
SOLUTION Designed to Follow Honeywell User Experience (HUE) Design
Key Benefits:
• Explore
• Manage
• Configure
• Developed to give a
better experience — user
friendly & intuitive
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Automated Data
Collection
Up to 200K Tags Hardware - Network view
Best in class data collection time for TPS
Zero Footprint web based clients
Adheres to all HPS security guidelines
Quick & Easy Deployment
10X Faster Enables users to schedule frequent
snapshots and identify
unauthorized changes and
engineering anomalies quickly.
Smart Impact Analysis
8 Patents FiledSmart Change Analyzer
Optimized snapshot storage to reduce
hardware resources
ISA standard representation of control logic
Integration with ERP
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Product Technology &
Differentiators
Functional Feature
• Network view (includes networking
equipment)
• Auto discovery of all the nodes
• Seamless navigation from one view to another
• Engineering Anomaly, customer engineering
anomaly
• System Health Reports
• ISA representation of control logics
• Smart Change Management
• Auto discovery of references between systems
Technology Features
• Zero Footprint client
• Automatic/Scheduled data collection
• Zero impact on source system during data
collection
• Store delta changes to reduce resource needs
• Plug-In architecture for easy addition of systems
in future
• User Interface design per HUE best practices
• Generic database to accommodate disparate
systems
• Security aspects of the solution from architecture
and development point of view.
Honeywell Trace Differentiators
Productivity, Safety & Transparency
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Trace Roadmap, Licensing, &
Architecture
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Customer Centric Product Development
OVOCs / VOCs
Insights & Pain points
Stakeholder Mapping
Installed Beta version
at select customer sites
for feedback
R110 ReleasedFinal Market release with
refined functionalities –
R120
First Beta Release
ControlledRelease
CommercialRelease
01 02 03 04
SELECT CUSTOMERS FOR DIRECT FEEDBACK
NOV 2015 AUG 2016 MARCH 2017
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
UNDERSTAND IDEATE & ITERATE VALIDATE LAUNCH
Customer Engagement
2014
R120 R121/
R130R140 R150
Experion DCS
TPN/TPS
Safety Manager
PHD
OSISoft PI
Experion SCADA
InTool/SPI
Triconex
FSC
TDC – HG nodes
ESVT
Matrikon OPC
AB CLX, PLC5
Bentley Nevada MMS
EHPM, ENIM –HW/NW View
Siemens S7
PMD
QCS
CPM
FDM
Profit Suite
Emerson Provox
Emerson RS3
Feature Set 1
Tag reference search
Logical view
Change Detection
Defect Management
Query and Report
Users and Groups
Licensing
Performance Reports
Spare Management
NW view
User Defined Defects
HW view
Workflow
Notifications
L4 client support
Switch configurations and anomalies
System Performance Reports
Feature Set 2
HW View-SM, FSC,
Triconex Updates
Workflow Ph2
Display (view only – HMI &
GUS)
Ladder Logic
Multiple-L3 support (1-X)
Disconnected mode
(import)
Feature Set 4
Enterprise Level Analysis ERP Integration
Risk Manager Integration
Dynamo Integration
Performance Analyzers Intg.
Data Analytics
Physical View
System User Manual Integration
2017 –
Q12017 –
Q3
2018 –
Q32019 –
Q1
Honeywell
Trace
™
Roadmaps are a statement of intent and subject to change.
COMMON
SYSTEM
PLATFORM
Product Roadmap
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
PROPOSED
Feature Set 3
Changes by Users
Trace as Service (VEP)
Phone/Mobile support
Inventory portal integration
Localization
Multi-Site support
Display changes (graphical
comparison – HMI & GUS)
PHD as a System
FDM
Matricon OPC
Modicon Quantum
Foxboro IA
IP21
Delta V
ControlEdge PLC
Trace Package Options
Track & Trace
5-25 Users Option
Includes:
Tag Reference Search, Network View, Logical View, Defect Management, Change Detection, Create & Run Query, Report Generation
Does not include: Support, Installation, Hardware & Training
Performance
5-25 Users Option
Bronze plus:
Performance Reports, Optional Annual IAA Report (additional), Channel Spare Management, Hardware View, Mobile w/ Pulse*
Does not include: Support, Installation, Hardware & Training
Workflow & Change Management
5-25 Users Option
Silver plus:
Change Management, Workflow, & L4 Access
Does not include: Support, Installation, Hardware & Training
BRONZE SILVER GOLD
WA
RR
AN
TY
• 1 Year Included • 2 Year Prepaid – 20%• 3 Year Prepaid – 18%
• 1 Year Included• 2 Year Prepaid – 18%• 3 Year Prepaid – 16%
• 1 Year Included • 2 Year Prepaid – 16%• 3 Year Prepaid – 15% W
AR
RA
NTY
WA
RR
AN
TY
Trace Architecture
L3
Trace
Node
Web Server
App Server
Data Server
Trigger
Data Collection
Data Share
Store Output Files
L2/L3
HTML Client
Client Access
L2
Agent Store & Execution
Systems for Data Collection
Trace Relay Trace Server
Fire
wa
ll
Fire
wa
ll
L4 Domain L3.5 Domain
(DMZ)L3 Domain
Full Application
Workflow
Database
Reports
L4 Clients
Data Collection
L3 Clients
L4 AD
L3 AD
Licensing Service
Replication traffic Outbound L3 to L3.5
DB Sync ServiceL3 Router
L4 Client Support – New Proposal for Honeywell Trace™
Application & Web Server
Workflow
Database
Licensing Service
Reports DB Sync Service
L3.5 AD
Browser thin client access viaHTTPS
L4 and L3.5 user authentication
Trust between L4 and L3.5 ADs
Browser thin client access viaHTTPS
L3 user authentication
L3.5 Clients
Browser thin client access viaHTTPS
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Trace Spotlight:
Tuesday: 11:15 - Change Management & Workflow
Wednesday: 10:15 – Change Management & Workflow
Visit HoneywellTrace.com for quick access to more information!