25 years of Profit - honeywellprocess.com · $0.4-$0.5/BBL. DynAMo Dynamics (future) Work Flow Solutions ERP / SAP Planning/Scheduling. Asset Twins. Asset Performance. DynAMo. Connected

Americas HUG

25 YEARS OF PROFITJaideep Bhattacharya

11th June 2019

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.

Agenda

Where have we been?

• A look back at the past 25 years of Profit Suite Innovation

Where is Profit Suite Today?

• Honeywell’s solutions to modern APC problems and a look at where the Suite stands today

What is the Future of Profit Suite?

• The future of Profit Suite and its position within Honeywell Connected Plant


What was happening in 1994?

3

• Bill Clinton was President of the United States

• First episode of “Friends” debuted on NBC

• “The Lion King” and “Forrest Gump” were released in theaters

• This first PlayStation Console was released

• The Channel Tunnel connecting the United Kingdom to France was official opened

• The United States hosted the FIFA World Cup

• Nokia releases the Nokia 2110i cell phone

• Apple’s stock fluctuated between $1-$1.50 per share


What was happening at Honeywell?

1994: Honeywell purchased Profimatics, Inc. and formed Hi-Spec Solutions

• Honeywell RMPC algorithm was merged with the Profimatics PCT controller to create Honeywell’s RMPCT solution

• RMPCT is today known as Profit Controller and is the foundation of Honeywell’s Profit Suite

4

Profit Controller is integral to Honeywell’s layered approach to optimization

Profimatics Inc.


Profit Suite Versions Through the Years…….

PS R160

• On the fly model read,

• CV transformations,

• Profit Trender

PS R200

• Shadow pricing,

• Gain mapping for Profit Controller,

• Embedded history

PS R205.1

• Open Loop Stepper

• OPC 2.0 compliance

PS R220.1

• BLC Templates

PS R300

• URT Platform, PSOS

• CLID, Close loop stepper

• Control model separation

• MV prioritization,

• Tiered pricing

PS R320

• Stepper Improvements

• Integration with UPS

• Profit Controller Express

PSR400

• Virtualization Support

• Profit Controller NL

• PSOS web in L4

PS R410

• Profit AES

• History playback in PSOS

PS R411

• DMC Conversion tool

• Auto Documentation

PS R430

• PSES Stepper

• Benefit Study in PSES

• PSP in PSES

• AES in PSES

• Operator guidance in PSOS

PS 440

• UOP Oleflex and Hydroprocessing MV Transforms

• Profit Web Viewer

• Models from Historical Data

PS 441,442

• Proxy limits

• PWV enhancements

• Experion Profit Controller

- Profit Controller in CEE (C300/ACE)

- Part of ExperionR500, includes design and visualization

PS R500

• Profit Executive

• PWV enhancements

• Profit Performance Monitor

PS R501• Profit Executive :

Gain Mapping Functionality

• Level 4 Access for Profit Web Viewer

• PSES Enhancements


Profit Suite Evolution

~$4M+ Annual Profit Suite Technology Investment

Expertise distributed throughout the

organization: R&D, Projects, Services, and

Marketing

U.S. Patents Granted▪ 2012: RT-SQP via Hessian Matrix Update ▪ 2009: Equation Editor for ChE Eqns and Model Development▪ 2010: Framework for Closed-loop Model ID and Simulation▪ 2010: UI for switch between Linear and Nonlinear controller online▪ 2009: Real-Time Business Optimization▪ 2007: Operator Visualization▪ 2007: Model Quality Analysis▪ 2006: Nonlinear Control▪ 2006: Closed-Loop ID▪ 2005: OperTune▪ 2005: Profit Expert▪ 2005: Profit Stepper ▪ 2004: Profit Stepper▪ 2003: Profit Loop Assistant▪ 2002: Profit Loop▪ 2001: Profit PID▪ 2000: Profit Optimizer▪ 2000: Profit Optimizer▪ 1998: Profit Controller

▪ 2003: Profit Loop Assistant▪ 2002: Profit Loop▪ 2001: Profit PID▪ 2000: Profit Optimizer▪ 2000: Profit Optimizer▪ 1998: Profit Controller▪ 1996: Profit Controller▪ 1996: Profit Controller▪ 1996: Profit Controller▪ 1994: Profit Controller

R160 R200

R205

R300

R310

R320

R400

R410

R500

Design Implement Operate Maintain

R501

WHERE IS PROFIT SUITETODAY?

Footer, Honeywell Sans Bold 10pt 7


Where are we Today?

8

Profit Controller Profit Optimizer Profit Executive Profit Stepper TaiJi PIDControl

Performance Monitor

Profit Performance

Monitor

Profit Sensor Pro

Profit Suite

Spans from improving regulatory loop control to optimizing entire processes

Robust Suite of solutions that addresses all aspects of advanced process control (APC)


Overview of the Profit Portfolio

9

Three Ingredients of Success…

Profit Control Profit Optimization Profit Monitoring

Profit Controller• Linear Model Based Multivariable Control• Suitable for majority of Process Units

Profit Executive• Dynamic Plant-Wide optimization • Integrating Planning/scheduling model with Control model• Spans from Multi-Unit to Site-wide

Profit Performance Monitor • Economic lost opportunity monitoring

of current APC performance• Designed for Plant Operations• CLOUD Hosted

Profit Controller Express• Only SS GAINs, no dynamics• Suitable for simpler units• Quick install

Profit Optimizer + Profit Bridge Model• Dynamic Optimization• Coordinating Linear Multivariable Control (APCs), • Handles non-linearity through GAIN UPDATE• Spans from 1 unit to Multi-Unit

Cloud Control Performance Monitor • Condition-based monitoring & maintenance

of Instruments, Analyzers, PID, APC• KPIs & workflow for Control Engineers• CLOUD hosted

Profit Controller NL• Empirical Dynamic• Used for non-liners processes like polymers

Profit Optimizer• Dynamic Optimization• Coordinating Linear Multivariable Control (APCs)• Spans from 1 unit to Multi-Unit

Control Performance Monitor• Condition-based monitoring & maintenance

of Instruments, Analyzers, PID, APC• KPIs & workflow for Control Engineers• Installed On-premisesProfit Sensor Pro

• Soft Sensing • Statistical Modeling• Lab/Analyzer Management

Profit Stepper• Automated Testing and Identification


Honeywell’s Layered Approach to On-line Optimization

• Profit Controller forms the basis of Honeywell’s comprehensive, unified, and layered optimization solution

• Enables scalability and evolution of optimization technology applications

Local Optimization

Process Unit

Multi-Unit Optimization

Process

Unit 1

Process

Unit 2

Process

Unit 3


Process

Unit 1

Process

Unit 2

Process

Unit 3

Layer 1: Model Predictive Control and Single Unit OptimizationProfit Controller

Layer 2: Multi Unit Dynamic OptimizationProfit Optimizer

Layer 3: Plant Wide Dynamic OptimizationProfit Executive


Process

Unit 1

Process

Unit 2

Process

Unit 3

Plant-Wide Optimization

Layer 1

Layer 2

Layer 3


Small Scale vs. Large Scale Optimization

Single Unit Optimization

• Smaller scope of optimization (i.e. Single Unit)

• Traditional scope of most optimization applications

• May not achieve full optimization benefits if upstream unit optimization results in downstream constraint violations

• Typically smaller scope(10-20 independent variables, 50,000 equations)


• Larger scope of optimization, (i.e. Multi-Unit)

• current focus of optimization development

• Achieves greater optimization benefits because unit interactions considered, resulting in global optimum

• More difficult to solve because of larger scope (50-100 independent variables, 200,000+ equations)

Plant-Wide to Multi-SiteOptimization

• Largest scope of optimization

• Dynamically maximizes production across all assets

• Optimize production for future operating conditions by linking planning and scheduling to control

Flexible and scalable solution to fit optimization needs


Profit Controller

• What issues were we solving?

• Complex processes required a controller that could drive unit efficiency by:

▪ Maximizing production

▪ Minimizing energy consumption

▪ Eliminating controller noise

• Quick success

• Just six years later in 2000, Hi-Spec Solutions ranked #1 in APC and RTO*

• Profit Controller laid the groundwork for forming Honeywell’s unique layered approach to optimization

12




*ARC January 2000 Report - “Real-time Process Optimization and Training Worldwide Outlook


Profit Optimizer


• Optimization implementations with conflicting objectives often “fought” one another, leaving one unit to be optimized at the expense of another

• In 1996, Honeywell introduced a new solution using Distributed Quadratic Programming (DPQ) technology – now know as Profit Optimizer

• Redefined real time optimization (RTO) methodology by solving multi-unit and plant-wide optimization on a minute by minute basis

13

Multi-Unit/Global Coordination and Optimization





Profit Executive


• Planning and scheduling had no insight into real-time controller execution, leaving unrealized plant efficiency on the table.

• In 2018, Honeywell launched a solution for plant-wide dynamic optimization: Profit Executive

• Covers an even larger footprint by bridging the gap between planning and execution

• Controls product quality in real time, thereby reconciling the production plan within the context of the operating limits of each unit

14





Profit Executive – What is it?

15

• Real-time gate to gate optimization that goes beyond typical APC boundaries

• Encompasses Planning/scheduling models with APC/Optimization models

• Increases site-wide benefits by improving profit margin and increasing production

• Provides returns of over $1/BBL benefit without any change in process or equipment

• Advanced Process Control agnostic solution


Market-Leading Optimization Technology

Then (2000)

▪ 30+ Higher Level Optimization Applications

▪ 1000+ Multivariable Predictive Controller Applications

▪ 250+ Industrial Sites

▪ 150+ Customers Worldwide

Today (2019)

▪ 150+ Higher Level Optimization Applications

▪ 3500+ Multivariable Controller Applications

▪ 550+ Industrial Sites

▪ 300+ Customers Worldwide

Over $5 Billion in Delivered since 1994!


Profit Suit: Global Team of Experts

• Development/Product Management

• >30 developers world-wide

• Project Services

• >200 representatives globally

• Advanced Application Aftermarket and Support Services

• >60 dedicated Application Support personnel

Depth of education, experience and knowledge in technology and domain expertise spread across all functions

More than 3,500 years Domain Experience

"Local expertise, globally networked”

Worldwide Service and Support Capabilities

WHAT IS THE FUTURE OF PROFIT SUITE?

Footer, Honeywell Sans Bold 10pt 18


Where are we going? Honeywell FORGE

Connected Plant Portal

Next level intelligence for your

industrial enterprise

Role-based, comprehensive visualization

of all aspects of your connected plant

performance.

Process & asset equipment issues and

inter-relationships

Actionable recommendations that highlight

potential financial opportunity

Cloud Enabled & Cyber Secure

Asset Alerts

OpportunitiesPerformance Metrics

Recommendations

19

https://www.youtube.com/watch?v=fop7w5SGfBs&feature=youtu.be


APC Performance

20

Profit™ Performance Monitor

Cloud-based performance monitoring solution enables collaboration across operations, process engineering, APC teams and management to understand what is limiting APC from driving the unit to its best potential

Identify degradation of unit performance and provide expert guidance through actionable instructions to maintain unit profit performance

Provide visibility into the economic consequences of plant process performance as cost of lost opportunity

Ensure sustainable benefits over varying operating conditions, visualizing real time unit profitability.

Identify process, advanced control issues contributing to lost performance. Sustain

throughput & yield for longer periods of time

Identify 10 to 20% lost benefits/yearper APC application


Honeywell FORGE Industrial Solutions

21

Unit-wide Optimization Capacity

Quality $0.1-$0.3/BBL

Profit APC PBM OTSDynAMo

Monitor PIDs & Controllers (Control Performance Monitor)

Identify Lost Opportunities and Recommended Actions

(Profit Performance Monitor)

Maintain Unit Optimum

Right Quantity, Right Specification, Right Time (Profit Executive)

Move to Plant Optimum

Local Unit Optimization -

pushing unit against

constraints for optimal

performance

KPI’s on PID and APC Performance

Improved Uptime & Performance

Process Reliability Advisor

Process Twins

Process Optimization Advisor

Plant-wide Optimization across All Unit APCs

$0.75-$1.0/BBL

Rigorous Process Inputs

& Guidance

Performance Analysis

LP Vector Updates

$0.4-$0.5/BBL

DynAMo Dynamics

(future)

Work Flow Solutions ERP /

SAPPlanning/Scheduling

Asset Twins

Asset Performance

DynAMo

Connected Solutions

Gains

PBM Dynamics(future)

UniSim eLearn

PBM OTSAPC APC APC

CompetencyReliability

Right & Fast

Integrated Insights Solving New Problems

• Optimization with Operational Best Practices

• Equipment Reliability Monitoring

• Role-based Solutions

EfficiencyProductivity

https://www.youtube.com/watch?v=fop7w5SGfBs&feature=youtu.be


25 YEARS OF PROFIT

22

Documents

25 years of Profit - honeywellprocess.com · $0.4-$0.5/BBL. DynAMo Dynamics (future) Work Flow Solutions ERP / SAP Planning/Scheduling. Asset Twins. Asset Performance. DynAMo. Connected