universal process i/o · pdf fileuniversal process i/o . greg belcher . 2 ... reduces hvac...

2013 Honeywell Us ers Group As ia Pacific Sympos ium

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Universal Process I/O Greg Belcher

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Transformed by a single device with multiple functions

What Changed in the Real World?

Purpose-Built Gadgets

Multiple Devices, Single Function Universal Device

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Why Not Extend to Industrial World?

Multiple IO, Single Function Universal IO

Transformed by a single device with multiple functions

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What makes it UNIVERSAL?

UNIVERSAL Channel Technology Made it Possible

Environmentally Hardened

Analog Input

Analog Output

Digital Output

Digital Input

Universal IO – Experion’s Multi-Tool

• 32 Universal Channels

• Each channel SOFT configurable as DI, DO, AI & AO • HART 7 Compatible

• Full Redundancy

• Extended Temp. Range (-40 to +70 Deg C)

• Local & Remote capability

• Cabinet Mounted & DIN RAIL

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Universal Channel Technology (UCT) • New concept introduced with Experion Orion (June 2012)

• Completely liberates safety and process I/O, as well as the control cabinets from channel type dependency through Universal I/O module.

• Flexible marshalling – Reduce or eliminate marshalling

• Universal cabinets – Allow cabinets to be standardised

– Any field signal can be connected to any I/O channel

– Drastically reduce engineering cost and schedule

UCT Used in UIO &RUSIO

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What makes it Different?

Just Configure to be the Type Needed

Change hardware & software

AI

AI

AI

AI AI

AI

AI AI

AO AO

AO

AO AO

AO

AO AO

DI

DI DI

DI DI

DI

DI DI

DO

DO DO

DO

DO DO DO

DO

32 Non Redundant Modules

1 Redundant Module

The Honeywell

Way

The Other Way

Creating Unique Differentiation – IO on Unconditional Demand

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What makes it Beneficial?

• SOFT configuration – IO on demand without extra hardware

• Simpler engineering

– make changes late in design

• True redundancy

– maintains single channel integrity

• Remote / Harsh environment mounting

– Reduces cables & marshalling cabinets

– Reduces HVAC needs

Simplicity, Flexibility, & Reliability

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Standard Cabinet Design

Universal Cabinets

Universal IO

Standard cabinet that can adapt to late wiring changes

Cabinet 1 Cabinet 2

Cabinet 3 Cabinet 4

Traditional Cabinets

AO

Cabinet 1 Cabinet 2

Cabinet 3 Cabinet 4

AI DI

DO

Wait for final definition of instruments

and then build custom

cabinets

Build Standard Cabinets Sooner Based on IO Count, Not Mix

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Universal Traditional

Less I/O Modules

Universal Reduces IO Modules by 30%

Example project with 5000 IO

Type Count

1. Analog In 1500

2. Analog Out 1000

3. Digital In 1300

4. Digital Out 1200

Total 5000

# IO Modules 240

Type Count

Universal 5000

# IO Modules 157

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Safety Manager

System Integration Cables

DI AI DO AO

DI AI DO AO

DI AI DO AO

Junction box

Multi Core

Cables

Marshalling Cabinet

Safety Manager

What if we eliminate marshalling?

DI AI DO AO

DI AI DO AO

UIO Field Mounted

Control System

DI AI DO AO

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Traditional

Type Need Count

Analog In 10 16

Analog Out

4 16

Digital In 8 32

Digital Out

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Total 28 96 # IO Modules 4

Remote I/O Savings - Small, Distributed IO

Universal IO Reduces 4 Modules to 1 – Save Space, Maintenance, Cost

Small IO counts can waste many

channels

Universal

Type Count

Universal 32

# IO Modules 1

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1. Oil & Gas onshore & offshore platforms

2. LNG Carriers & FPSOs

3. Skid Mounted Equipment

4. Remote Instrument Enclosures

5. Remote Area Applications

6. Distributed I/O architectures

7. Expansions / Add-on projects

8. Revamp & Modernization projects

9. Ultra fast track projects

10. Mix n Match in standard projects

And Many More….

Who will Benefit?

Benefits are Universal

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What makes it VALUABLE? • Universal Cabinet

– Packaged Solution for Faster Project Execution

• Easily Adapts to Changes – mitigates delays due to late design inputs / changes at

any stage in project

• Reduced Hardware – Eliminate marshalling with direct landing from field – Reduce/Simplify marshalling with no cross-wiring – Remote IO eliminates multi-core cables

• Reduce Infrastructure Costs – Saves precious control room space

• Fewer spares – One UIO module vs. Four Standard Modules

Productivity, Dependability & Sustainability

Reduce cost up to

33%

Reduce Space up to 28%

Reduce schedule up

to 25%

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UIO Roadmap

• Universal Process IO Module Available – Now

• UIO DIN RAIL Availability – H2-2013

• DO Fan-Out & Pulse Input Availability – H2-2013

• 4 Wire AI & SOE Availability – H2-2014

• Universal Cabinets Available – Now

• Remote Modular Cabinet Available - Now

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The Changing Face of Projects

• Iterative Approach to Engineering Design – Drives changes into system requirements

• Compressed schedules – Drive later design inputs

• Process modularization – Drives earlier hardware delivery

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Project Workflow Transformation

• Separation of physical and functional – Parallel execution of hardware and software design

• Breaking down task dependencies – Removing hardware design dependence from functional

configuration

• Simplifying designs with multi-functional hardware – Applying multi-function hardware to simplify designs

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• Typical control system project flow • Task are executed in fixed sequence to meet install

dates • Outputs from one task are required for following task

Define Design Manuf Config Test Install

1 year 2 years Start

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• When changes appear in definition after Design or Manufacture has begun this initiates a subsequent modification package or ‘modpack’

The later the change the greater the rework



Change Design Manuf Modpack #1

Change Design Manuf Config Modpack #2

Change Design Manuf Config Modpack #3 Test

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Separation of physical and functional

• Separating physical and functional allows for task independence

Leveraging technology to revolutionise project delivery



= Hard end-start task linkage

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• Separating physical and functional allows for task independence

• The schedule can now be compressed



Define Design Manuf Install Config Test Physical

Functional

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• Design start can be pushed back to allow for the field definition to mature


Config Test

Install Define Design Manuf Physical

Functional


Later design freeze allows for more mature data inputs and fewer changes

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• Design start can be pushed back to allow fro the field definition to mature

• Or the Install date can come forward to support earlier delivery required by modular construction

Define Design Manuf Install Physical

Config Test Functional


Standard designs for earlier manufacture and installation

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• Or benefits can be taken at both ends of the schedule




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Late Data Binding

• Configuration tasks can be executed earlier, prior to design completion

• The functional and physical designs are then bound together at the completion of both workflows




Late Binding

Separating physical and functional allows for task

independence


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Define Design Physical

Applying Universal Cabinets

• Applying standard universal cabinets eliminates the dependency on custom designs

Manuf Install Standard Designs


Late Binding Config Test

Functional

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• Allowing the factory manufacture task to be bought forward in the schedule






Functional

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• Or the Design activities can be pushed back to allow for better definition to reduce design changes




Functional


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• The Definition stage can then be extended to accommodate more mature design inputs


Functional




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• 25% Earlier in I/O cabinet on site dates




Functional

25% Earlier


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• 25% Earlier in I/O cabinet on site dates

• 25% Later design inputs and freeze dates


Functional

25% Earlier

25 % Later




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• Traditional Work Process

Adding Flexibility to Reduce Project Risk

Define Design

Manuf

Config Test

Install

Late Binding

Longer define phase allows for more mature data inputs and fewer

changes

Standard designs for earlier manufacture and installation

Separating physical and functional allows for task

independence

Later design inputs and freeze dates

Earlier install on modules



• ‘Optimised’ Parallel Work Processes

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Questions

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Thank You

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Summary

-

Ease of Design, Implementation & Change management

Fewer Components, Redundant Design & Extended Temp. range

Sustainability Reliability Flexibility

Fewer Spares, Easy Maintenance

Sustain-Ability thru Universal-Ability

Offshore Platform

Remote Location

Skid Equip

LNG Carrier

Legacy Migration

Onshore Facility

Analog Input

Digital Input

Analog Output

Digital Output

HART Input

HART Output

FPSO Revamp

RIE Add-ons

Fast Track

Regular Projects

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What Problem does it solve?

• Lower Cost/Reduce Risk/Improve Schedule - Take advantage of standard design marshalling cabinets

• Reduced custom engineering and documentation • Faster delivery time • Flexibility of design needed due to lack of available information

• Reduce Risk– Greatly improve Project Execution Efficiencies • Supply Chain Efficiencies • Implementation of the wiring and documentation minimised

• Improve Schedule - Take advantage of flexibility of UIO to accommodate fast track project schedule

• System may be tested and shipped prior to completion of field designs • Termination details may not be known until construction • Adapt quickly to late project I/O changes

Reduce Cost / Risk / Schedule

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What Problem does it solve? • Lower Cost - Eliminate / reduce marshalling cabinet

requirements in Remote I/O locations • Direct termination onto Universal IO IOTA

• Lower Cost - Less Universal I/O modules required vs. Standard Lower Cost - Reduce total number of installed spare

required on project • Flexibility to move signals around locations without large penalties • Flexibility to provide fewer spares based on anticipated lifecycle

needs

Benefits are Universal

Reduce Cost / Risk / Schedule

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Skid Mounted Equipment Rooms

• Customer Problem • Space Constraint • Short time to integrate, test & commission • non-environmentally controlled

• Honeywell Solution • UIO’s for AI, AO, DI & DO’s • Rail Mounted design in modular cabinet

• Customer Benefits • Reduced system footprint by 30% • UIO in RAIL mount version provides most

modular design • No need of marshalling • No cross wiring needed • Ease of commissioning • Ease of Maintenance

Compact design, Quick install

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