fredrick moore management for your plant · fredrick moore management for your plant monday, june...

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


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.

Why Documentation & Change Management?

??

?

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.


“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 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


Solution:

Honeywell Trace™


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


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


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


Trace Roadmap, Licensing, &

Architecture


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


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


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*


Workflow & Change Management

5-25 Users Option

Silver plus:

Change Management, Workflow, & L4 Access


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


L3 user authentication

L3.5 Clients



Trace Spotlight:

Tuesday: 11:15 - Change Management & Workflow

Wednesday: 10:15 – Change Management & Workflow

Visit HoneywellTrace.com for quick access to more information!

http://www.honeywelltrace.com/

Thank you! Honeywell Process Solutions. LSS.

•Need to Change a Control Strategy?

- Document current control strategy

- Plan changes (prepare MOC)

- Implement and Commission Changes

- Detect Changes and assign to MOC

- Document implemented changes

Typical work flow for Trace

32

Capture Strategy

Plan MOC ImplementDetect

ChangesDocument

fredrick moore management for your plant · fredrick moore management for your plant monday, june...

Documents