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Transforming the Way We Implement, Operate, and Maintain
CONTROL ROOM OF THE FUTURE
Experion Orion Console
More Efficient Operations
Orion Console
Experion R430
More Situational Awareness
Reduced Operator Fatigue
Increased Operator Mobility
Traditional Operator Environment
“Fatigue causes cognitive fixation and impaired
judgment and could lead operators to fixate on one operational parameter”1
1) Cheryl MacKenzie, US Chemical Safety Board Investigation Report No. 2005-04-I-TX, March 2007
Lack of Mobility, Poor Operator Workspace, and Inefficient Graphics Contribute to Operator Fatigue
Operator Fatigue Challenge
Orion Console
Dramatically Improving Operator Experience
Upgrading Operators to Orion Class Experion R430
More Screen Real Estate
Alarm Lighting
Ergonomic Design
Pan & Zoom
Tabbed Display
Advanced Visualization Elements
Advanced Display Technology
Build Better Graphics with Better Situational Awareness
Experion R430
Unchain Operators from Console
Console Operator Mobility
Mobile Station
Large Screen Interaction
Experion R430
Better Collaboration Solves Problems Faster in the Control Room
Experion Collaboration Station Released!
Collaboration Interactive Touch
Shift Handovers, Situation Assessment
Engage Remote Experts
Traditional
Orion console, mobile and collaboration stations enable efficiency
High or Low Speed
Remote Operations – the New Operations Model
WAN
Centralize Operations and Expertise
Universal IO
Universal Safety
IO
Universal Process
IO Universal Channel
Technology
Only Honeywell Offers True Universal Process and Safety IO
Eliminate Complexity and Build Standard Cabinets Sooner Based on IO Count, Not Mix
What is True Universal IO?
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
Universal Cabinets Making Projects Simpler
Traditional Cabinets
AO
Cabinet 1 Cabinet 2
Cabinet 3 Cabinet 4
AI DI DO
Single Model Number for Fully Populated Standard Cabinet
Universal NEW
Traditional
Simplifying IO Order, Build and Configure
Example project with
5000 IO Type Count
1. Analog In 1,500
2. Analog Out 1,000
3. Digital In 1,300
4. Digital Out 1,200
Total 5,000
# of IO Modules with 20% Spares 273
Standard Work Dramatically Simplifying Order Process, Supply Chain, Project Execution and Lifecycle Support
Universal
Type Count
Universal 5,000
# of Universal Cabinets 7
Traditional Instrumentation and IO Wiring
Significant Cost in Equipment, Labor, Documentation and Checkout Junction box
DI AI
DO AO
DI AI
DO AO
DI AI
DO AO
Junction box
Multi Core Cables
Marshalling Cabinet
System Integration Cables
Junction box
DI AI
DO AO
DI AI
DO AO
DI AI
DO AO
Junction box
Multi Core Cables
Marshalling Cabinet
System Integration Cables
Universal IO in the Field
Controllers DI AI DO AO
DI AI DO AO
Fewer Wires, Fewer Engineering Hours, Less Space = Greater Savings
Virtualization
Before
2 Experion Servers
18 Operator Stations
5 Engineering Stations
Sim FDM Alm Mgm
t
ACE Domain Control
30-node System
2 Experion Servers
18 Operator Stations
5 Engineering Stations
Sim FDM Alm Mgm
t
ACE Domain Control
Virtualization
Before
Experion Virtualization
80%+ Reduction in Maintenance, Space, Energy Use and Better Security
Each blade is a server
Experion Virtualization – Blade
Additional
80% reduction
Blade Server
High Reliability, Simpler, Modular, and Pre-Configured
Released
Experion Virtualization
Instrument Freeze
FAT
Application
Some Generic Controls and
Display Templates
Traditional Project Workflow
Physical
Upgrade PCs
Physical
IO Cabinets, Servers, PCs
Application
Develop Control Strategies, Displays
Physical
Development System
Instrument Freeze
FAT
Application
Some Generic Controls and
Display Templates
Physical
Upgrade PCs
Physical
IO Cabinets, Servers, PCs
Application
Develop Control Strategies, Displays
Physical
Development System
Can work without having physical
equipment Don’t need
system upgrade
Can start engineering
sooner & without travel
Big bang testing eliminated
Freeze Not Needed
No Development System
Instrument Freeze
Traditional Project Workflow Transformed
Work in Parallel, Eliminate FAT and Ship to Site Earlier
Experion Orion Project Workflow
Minimal Checkout Eliminates big bang testing with virtual FAT
Application EPC
Honeywell
Honeywell Data
Center
Customer
Direct to Site! Physical
Standard Cabinets Servers
Traditional approach is often back end-loaded
Experion Orion Project Curve (Universal + Virtual)
Months 0
5
10
15
20
25
30
Traditional
Orion Labo
r FTE
s
Reduce Schedule with Lower Risk
Security = Safety
CYBER SECURITY
DCS and Safety – Cyber-certified
Experion C300 Safety Manager
Do You Trust a System That Isn’t ISA Secure?
Secure Services & Dashboard
Whitelisting
Protecting Open Systems
Secure Products and Secure Processes; Secure Services
Securing your critical infrastructure
is an evolving process with four distinct phases.
Released
Encrypted and Authenticated Communications Between Experion PCs and C300 Controllers
Experion Secure Communications
Fault-tolerant Ethernet
C300
C300 Experion Server
Experion Station
Experion R430
Protection Against:
Man in the Middle Attack
Unauthorized Nodes on Network
Tampering with Communications
Orion-Enabled Solution
Wellhead Templates, Autogenerated Displays
Linepack, Flow Calcs, Compressor Modeling,
Leak Detection
Project Efficiency Operations Efficiency
Pan & Zoom
Applications
Experion SCADA Experion R430
Enhanced Experion SCADA
RTU Development
Low Power, Flexible Communications
HART Enabled
DNP & Modbus
-40C to 75C; Zone 2
IEC61131-3 Languages
Flow Calculations
Coming Soon
RTU for Wellhead or Pipeline Applications
Safety, Reliability, Efficiency Solutions
New Field Instrumentation Continuous
Evolution
Stepwise Migrations That Protect Investments in Control, Graphics, Wiring
40+ years of life – avoids costly rip
and replace
Year 20 Year 40+ Year 0
Honeywell Delivers the Lowest Lifecycle Costs
HPM, LCN Current – 2025
A Walk Through Time 1990s
Revolutionary Technology…Delivered in an Evolutionary Way
US and GUS
TDC/TPS
HPM NIM
LCN
HM
Experion Station TPS
HPM NIM
LCN
HM
Experion Station TPS Introduction
IP protection: US, GUS, and Experion HMI
all in one
Fault-tolerant Ethernet
2004
New Operational Benefits with Modern Human Interface and Alarming
Experion Station TPS and New C300
C300 and Series C
2007
Unified Human Interface for TDC/TPS and Experion
Experion Station TPS
HPM NIM
LCN
HM
Fault-tolerant Ethernet
The Evolution Continues: EHPM
EHPM
Released!
HPM Evolves to Modern Ethernet Network – Eliminating UCN
Experion Station TPS
ENIM
LCN
HM
Fault-tolerant Ethernet
Preservation of displays
and controls:
• US graphics – work as-is • AM controls – work as-is • HPM controls and IO – work as-is
C300
Safety Manager
Unifying Multiple Generations of Control Experion R430
EHPM, C300, and Safety Manager Peer-to-Peer Control
Fault-tolerant Ethernet
Experion Station TPS
ENIM
LCN
HM
EHPM C300
Safety Manager
EHPM C300
TPS Merges into Experion
LCN Components Gradually Melt into Experion
Vision
Fault-tolerant Ethernet
Experion Station
EHPM
Ten Additional Years of Life with Upgrade to EST, EHPM/SM and Lifecycle Contract
50+ years of life – avoids costly rip
and replace
Year 20 Year 50+ Year 0
Honeywell Delivering Longest Lifecycle
EHPM 2035! • Upgrade to EST • Upgrade to EHPM/SM • Lifecycle Contract
Hiway Evolution
Hiway Boxes
46 Years of Life in 2020 – Exciting New Migration Capabilities
Fault-tolerant Ethernet
Experion Station TPS
HG
LCN
AM
Simple Zero Footprint Basic and Extended Controller Cutover to Experion Orion
Universal IO – Hiway
Universal IO –
Hiway
Experion R430
Experion Station TPS
HG
LCN
AM
Mount in Hiway Cabinets
Preserve Hiway Wiring
Integrated HART
C300
Fault-tolerant Ethernet
Hiway Migration
Migrate Graphics to Experion Station, Migrate AM Controls to C300
Universal IO –
Hiway
Experion Station TPS
LCN
C300
Decommission HG?
Full Integration Between TDC3000 and Experion Orion
Fault-tolerant Ethernet
HG AM
Experion Hiway Bridge
Migrate Hiway But Preserve TPS US Graphics and AM Controls – Simple
Universal IO –
Hiway
Experion Station TPS
EHB
LCN
AM
C300 Hiway Gateway Becomes Hiway Bridge to C300
Phase 2: 2015 – Online Phase 1: Experion R430 – Offline
Fault-tolerant Ethernet
Creating New Benefits and Evolving Equipment – At Your Pace
Define multi-year automation plan Justify upgrades with operational benefits Flexible finance approaches
What’s Your Roadmap?
50+ years of life – avoids costly rip
and replace
Year 20 Year 50+ Year 0
Assurance 360 Service Program
Proactive Support Model
Maintain and Manage all Aspects of your Automation Systems
Defined Metrics and Assured Results
Focus on Your Process and Not Your System
Safety, Reliability, Efficiency Solutions
New Field Instrumentation Continuous
Evolution
Safety, Reliability, Efficiency Solutions
Safety, Reliability, Efficiency Solutions
Safety, Reliability, Efficiency Solutions
Where to Focus?
Many Root Cause Similarities With Safety Incidents
ad been inadequate for dealing with a l and sustained plant
42% of process incidents are
linked to improper operation or action
42% People
22% Process
Source: ASM Consortium
36% Equipment
Training and Practice are Fundamental to Top Performance in Any Industry
Learn from others’ mistakes
Train on best practices
Prepare for upcoming operations
UniSim – Improve Operator Competency
Reproduce the performance of your best operator...
…every day, every shift
Components of Effective Simulator-based Training (SBT)
Operator Competency
Model
Learning Objectives
Performance Metrics
Training Excercises
Performance Feedback
Operators Were Overwhelmed by Alarm Floods
Alarms are Frequently Cited
too many alarms and they prioritised.
utes before the explosion the d to recognise, acknowledge arms.
b. Manage instrumentation and alarms in a manner that ensures that they are sufficient and functional for all anticipated potential conditions and that there are no start-ups without tested and documented functioning of these systems.
Enforce & Change Management
Manage Alarms Throughout the Lifecycle
Systematic Approach to Improve Alarm Management
Alarm Management
Rationalize & Document
Benchmark
Average alarms per day
Average standing alarms
Peak alarms per 10 minutes
Average alarms per 10-minute interval
Distribution % (low/med/high)
144
9
10
1
80/15/5
EEMUA Alarm Guidelines
Average standing alarms
Do You See More Than 9 Standing Alarms on Your Consoles?
Compliance With Alarm Guidelines New
Alarm Dashboard
Monitor Your KPIs
Benchmarking indicates 70% of reliability issues are operations related1
1. Birchfield, G (2000) Solomon Associates, Plant Reliability – A New Approach to Understanding Plant Reliability
Plants with Best Process Control Have Fewer Slowdowns and Shutdowns
Eliminate Process Variability
Correlation Between Uptime and APC Implemented2
95%
65% 55%
15%
Uptime
2. Birchfield, G., Solomon Associates – “Olefin Plant Reliability”
Analyze constraints and operate within them
Reduces operator manipulation by 80%
Profit Suite
Profit Suite Making it Simple
Profit Suite Delivers Benefits Faster and Stays Online Longer
Traditional
Gets Turned Off
Modeling is an art
Requires steady state
Profit Suite
Easy to Setup & Maintain
Modeling is a process
Dynamic optimization
Increase Process Performance
Linear Control
Non-linear Control
Sustain
Collaborative Remote Services Programs
Control Performance
Improving Your Plant Control
Identify & Fix Control Performance Issues
Control Performance
Monitor
Manage Instruments, Valves, and Complex Equipment
Analyze Act Portal for Managing Your Instruments, Valves, and Equipment
Asset Manager Condition-based monitoring
Compressor, pump, heat exchanger models
Asset Performance & Health
Field Device Manager HART, Fieldbus, Profibus
DTM support for popular valve applications
Instruments & Valves
PHD Enterprise Historian
Experion Integration
New System Management
New Enterprise Event Journal
Uniformance – Collecting Data and Events
Millions of Tags, Decades of Data, Thousands of Users
New Integrated Analysis Tools Correlate Trend Data with Events
Collaborate Act Anticipate
Intuition Executive Visualization & Collaboration
Making Data More Transparent and Decisions More Clear
Unlocking the Value of Your Data
Alarm Management Only
Intuition Operations Monitoring
Alarms define safe operating window
Monitoring defines profitable operating window
Released
Run Your Process in the Most Profitable Zone
Alarm Management and Intuition Operations
Monitoring
Tighter operational constraints
Intuition KPI Dashboard
Anticipate
Proactively Monitor Process Performance and Equipment Metrics
Electrical Production
Value
93.5 Limit: 100
Cost Per Unit Production (Net Margin)
Value
178.9 Limit: 250 !
Electrical Production
Value
98.6 Limit: 96
Cost Per Unit Production (Net Margin)
Value
52.5 Limit: 30
Released
Safety, Reliability, Efficiency Solutions
New Field Instrumentation Continuous
Evolution
SmartLine
Our SmartLine Transmitter Just Got Smarter
Leading Performance
Smart Connection Suite
Lowest Total Cost of Ownership
Setting a New Standard
Released!
Leading Performance
Stab
ility
– S
hift
Ove
r Tim
e
Time – Years
Traditional options – unstable and random accuracy
0 10
Improved Accuracy Stability = Spend Less Time Calibrating
Our SmartLine Transmitter Just Got Smarter
How does it deliver the best value?
Released!
Lowest Total Cost of Ownership
Modular Transmitter
SmartLine Stock parts
Repair / upgrade in field
Upgrade or Replace Components in Field; Stock Only What You Need
Traditional Stock full device
Repair in shop, upgrade?
Ultimate Flexibility, Faster Maintenance and Lower Inventory Costs
Advanced Display
Graphic Display Lets You See Your Process the Way You Want
Traditional Limited information
SmartLine Graphic and intuitive –
full information
Unique Polarity Insensitivity
Either Connection will OPERATE Correctly
+ – Field Wiring
+ – +
– + Field Wiring
+ – +
or
Save Time on Start-ups and Avoid Maintenance Errors; Only Supplier to Support This for HART
Automatically Corrects Polarity
Our SmartLine Transmitter Just Got Smarter Released!
Smart Connection Suite How does it deliver the best value?
Ensures the Right Device, Right Action and Right Mode for Safe Maintenance
SmartLine Confidence
Transmitter Messaging & Maintenance Mode
Traditional Is it safe?
Send a Message to the Display Indicating Device is Available for Maintenance
Transmitters just got smarter – SmartLine.
High Accuracy Gas Custody Transfer
Gas Ultrasonic Flow Meters
Global certifications
120 and 200 kHz
High pressure 1500 psi
Gas metering software
January 2014
Fusion 4 Multistream Additive Controller
Most Intuitive Field Controller on the Market
Up to 12 additive injectors
Simple wiring and configuration
Tight control avoids quality giveaway
Integrated audit trail
NEW
Safety, Reliability, Efficiency Solutions
New Field Instrumentation Continuous
Evolution
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