Ali Raza, Honeywell Process Solutions · 2015 Japan Technology Summit Yokohama, September 9-10 Digital Transformation for Operations Excellence, Next Generation Advanced Solutions

2015 Japan Technology Summit

Yokohama, September 9-10

Digital Transformation for Operations Excellence, Next

Generation Advanced Solutions

Ali Raza, Honeywell Process Solutions

2 © 2015 Honeywell International All Rights Reserved

HPI | An Industry in Change

It is estimated that 40 exabytes (4.0 x 1019)

of unique new informationwill be generated worldwide this year.

Shell…”Over 40 Pbyte (1015 or quadrillion) of data today but

growing by several factors in coming years”


Transformative Time

Cloud

Big DataPredictive Analytics Connectivity

IndustrialInternet of Things

Mobility

Gartner’s 2013 Predictions

“Key business transformation drivers”

Are we ready!

Industry 4.0?

© 2015 Honeywell International All Rights Reserved

Transformative Time

250 global process and manufacturing executives

Optimize

Data Alone has No Value

Data Analytics

1/3use

Data Analytics

2/3use

Identify Issues

Investing

2/3are

Gather Data


Digital Transformation


Advanced Solutions Software

Software Solutions for Better Safety, Reliability, Efficiency and Sustainability

Alarm &

Operations

Management

Solutions

Profit

Solutions

Simulation

&

Competency

Solutions

Product

Management,

Planning &

Scheduling

Solutions

Data,

Analytics &

Collaboration

Solutions

Industry

Vertical

Solutions

Digital

Transformation

• Advanced Process Control

• Blending & Movement

Management

• Process Design

• Operator Competency

• Corrosion

• Production Management

• Advanced Planning & Scheduling

• Enterprise Collaboration

• Uniformance (PHA)

• Uniformance Sentinel

• Sentinel Mine

• Digital Suites for Oil & Gas

• OptiVision

• DynAMo Alarm Management

• DynAMo Operations Management


Digital Transformation

Mobility 1. Connectivity

Easier integration to everything with fewer point to point interfaces and pervasive analytics

2. Real-time

Now and always up to date

3. Collaboration

People and things working together remotely

Powered by…

Mobility & Cloud

Alarm &

Operations

Management

Solutions

Profit

Solutions

Simulation

&

Competency

Solutions

Product

Management,

Planning &

Scheduling

Solutions

Data,

Analytics &

Collaboration

Solutions

Industry

Vertical

Solutions

Digital

Transformation

OPC Connectivity

Cloud


OPC UA – Paving the way for the IIoT

Sub-net

Cloud

OPC UA

OPC UA

OPC UA

OPC UAOPC UA


Driving Industrial Internet of Things

with OPC UA

Benefits

• Native Security

• Multi-platform implementation

• Scalability – from embedded

smart sensors to mainframes

• Easy engineering

• Connectivity with context

(value & timestamp)

“OPC UA is one of the most important modern standards for industrial facilities and many further scenarios in an intelligent and connected world. OPC UA is considered a central building block on the way towards Industrie 4.0. It is the first unified, worldwide recognized industrial protocol for a secure smart factory.”

Holger Junker, Federal Office for Information Security, (BSI), Head of Division



Advanced Solutions Software

Software Solutions for Better Safety, Reliability, Efficiency and Sustainability

Alarm &

Operations

Management

Solutions

Profit

Solutions

Simulation

&

Competency

Solutions

Product

Management,

Planning &

Scheduling

Solutions

Data,

Analytics &

Collaboration

Solutions

Industry

Vertical

Solutions

Digital

Transformation


• Comprehensive suite of UniSim branded products for creating

and managing operator competency

• Industry leader with over 30 years Operator Training Simulator

experience WITH complementary competency tools

• Solving a significant customer problem: How do I know with

confidence my operations team is competent?

Developing & Managing Operator Competency

Implementing

Proven Training

Process:

Build

Training Plan

Define

Required Tools

Measure

Skills Evolution

Moving Beyond Training Simulators to Managing Operator Competency


The Need for Competency Assurance

I want to start a new plant safely and operate the plant efficiently

with reduced incidents and maintenance costs

I want to know that Operator knowledge is captured and shared

in a continuous manner

I want to extend training beyond the control systems and better

represent the full operating environment of daily activities

I want to measure how well all my Operators compare to a best

Operator performance

Industry Leaders are Moving from OTS to Competency Assurance


UniSim® Competency Suite

UniSim 3D Connect

UniSim CurriculumASM Operator Competency Model

Plan Tools Results

UniSim TutorKnowledge Based Training

UniSim OperationsOperator Training Simulator

UniSim Field ViewField Operator Training

Competency Management is the Next Step in Training Simulators


https://youtu.be/JcnZmeo5jwg


• Access over a private secure network

• Continuous curriculum updates

• Very small footprint at customer site

• Easy enterprise deployment

• Remote Honeywell support access

• Subscription pricing model

Virtual OTS in the CloudHosted by Honeywell

Changing the Business Model with Honeywell-

maintained Training System


Alarm Management

#1 Award Winning Alarm Management Solution

Alarm Management Software

• Reporting, Metrics, Analysis and

Compliance

• Master Alarm Database

• Management of Change

• Predictive Alerting | Enforcement

• Smart Reports and Alerts

Advanced Alarm Management

Services

• Alarm Philosophy Document

• Improvement Plan (Alarm | ORCA)

• Asset Benchmarking and Assessment

• Alarm Rationalization Tools and Services

Turning Noise into Knowledge through Effective Alarm Management


Operations Management

World’s Largest Operations Management Install Base

Operations Monitoring

• Critical Limit Deviations

• Excursions from Production Envelopes

• Functional Limit Ownership

• Integrity Operating Window

Operations Logbook

• Secure Shift Handovers

• Auditable Document of Record

• Critical Limit Documentation

• Compliance and Approvals

Driving Informed Decisions and Operational Compliance through Safe and

Profitable Operating Windows


One Single, Vendor-Neutral Solution

DynAMo Alarm and Operations Management

“Delivering operations integrity through better plant safety, availability and

compliance across your entire enterprise”

DynAMo Unified Suite

Alarm

Management

Operations

Management

Mobile Enabled

Next Generation: One Platform, One User Interface, One Solution, Mobile-

Enabled to ANY Plant Alarm & Operations Management Problems


Alarm and Operations ManagementDynAMo® Alarm and Operations Management


Better Plant Safety, Availability and Compliance across your Entire Enterprise

Alarm Management

• Stale and Standing Alarm

• Safety Bypasses and Inhibits

• Critical Alarm Limits

• Boundaries and Constraints

Operations Logbook

• Secure Shift Handover Process

• Shift Log History Compliance

• Critical Alarm Limit Recording

Operations Monitoring

• Critical Limit Deviations

• Excursions from Production Envelopes

• Integrity Operating Windows

Next generation integrated Suite goes beyond the Operator and

enables new workflows to better manage Operations integrity

`

Business

Layer

Process

Automation/

Operations

Plant

Management/

Maintenance

Operator


Situational Awareness and Collaboration

Honeywell “Pulse”


Our Blending and Movements Experience

• Corporate Programs established

with companies including:

‒ Chevron

‒ ExxonMobil

‒ LUKOIL

‒ Phillips 66

‒ Saudi Aramco

220+ sites, 700+ applications

>25% of world refining capacity

Ins

talls

BP, BPCL, Caltex, Chevron, Citgo, ENAP,

ExxonMobil, HMEL, HPCL, IOCL, Lukoil,

Marathon Oil, MiRO, MOL, P66, PetroChina,

PetroIneos, Petronas, PetroVietnam, Preem,

Saudi Aramco, Sasol, Shell, Sinopec, S-Oil,

St1, Suncor Energy, TOTAL, Valero

Se

lec

t

Cu

sto

me

rsF

ac

t Blending and movement solutions

earned one refinery a cost savings

of almost $0.45 per barrel

Largest Customer Base, Engaged with Honeywell

http://www.phillips66.com/

http://www.phillips66.com/


• Improved plant safety – reduced overfilling, contamination

• Improved reliability – use available equipment only and execute efficiently

• Improved operator effectiveness through an integrated solution

• Measuring, monitoring and acting on blending and shipping KPIs‒ Savings of 5-50 ¢/bbl of gasoline ($3+ million annually)

• Reduced demurrage fees‒ Improved execution of orders – $M per year

• Reduced losses due to custody transfer errors‒ Better handling of receipts – $100K per year

• Reducing product inventory 2 days

(100 MBPD refinery)‒ Savings of approximately $200K per year in

maintenance costs

• Reducing incidents can save $Ms

• Trading components can make $Ms

Our Value Proposition

Integrated Solution Delivers Value in All Areas


• Access over a private secure network

• Hosted by Honeywell or customer

• Very small footprint at customer site

• Easy and rapid enterprise deployment to better meet new compliance

• Remote Honeywell support access

Blend Optimization and

Monitoring in the Cloud

Business Planning & LogisticsBusiness Management, Analysis, Scheduling…

Months, Weeks, Days

Manufacturing Operations & ControlDispatch, Operating Instructions, Optimization...

Days, Shifts, Hours, Minutes

Batch Control

Continuous Control

Discrete Control

Levels 0,1,2

Level 3

Level 4

BPM

PBC

LIMS Viewer

PMM(control, monitor)

PMM(logging)

BLEND

PBO BI

Other Blend Controls

Changing the Business Model with Enterprise

Cloud Deployment


Smart Operations

Enterprise Deployment of Key Initiatives

Translates into Faster Deployment and Higher ROI

• Reliability

• Safety

• Energy Management

• Production

• Optimization

• Supply Chain


Smart Operations is Unique to Honeywell

Value Driven Technology

Deployment

Proven proficiency delivering value through consulting-based approach to technology deployment.

HPS portfolio of technology, associated engineering services and on-going application support allows customers to drive ROI on technology and people investments.

Work Process Transformation

Enabling Enterprise Optimization ONLY with Honeywell

Operational knowledge allows HPS to drive the work process transformation required to integrate information from operating assets and processing plants to drive sound business decisions.


Smart Operations for the Enterprise

Reliability

Safety

Energy

Management

Production

Optimization

Supply

Chain

Competency

… Improves OPEX

Efficiency across the

Enterprise

• Drive operational

consistency to improve

staff efficiency –consistent

use of technology and

work processes.

• Improved decision

support system to

minimize unplanned

shutdown and reduce cost

of production

… Drives Superior

Safety and Reliability

Performance

• Real-time surveillance of

critical equipment and

early notification to drive

proactive reliability

practices

• Provide increased

situational awareness to

make the right decisions

… Improves

Operational Agility

• Provide the relevant

business and operational

information to the right

people at the right time to

make the right decisions.

Driving Best-in-Class Performance Consistently Across the Enterprise


Reliance Industries Ltd.


Operator

Competency

• Develop, implement & maintain

High Fidelity, Operator Training

Simulator for every plant, at all

sites

• Enhance Operator

Competency

• Increase productivity

Operations

Management

• Integrated limit repository

• Operating instructions

• Operations management

• Operations logbook

• Interlock bypass management

• Safe operations

• Standard work processes

• Improved situational

awareness & communication

KPI Performance

Management

• Information integration

• Role-based KPIs

• Dashboards

• Monitoring

• Collaboration

• Improved unit operations

• Energy savings

• Standardization

• Visibility

• Agility

Honeywell and Reliance Implementation

Programmatic Approach to Smart Operations


Reliance Industries Ltd.

• Enterprise Performance Management

– Real Time KPIs for 2000+ Users

– Connecting 80+ base systems and 14 sites

– 18 Functional Areas

• Drill down dashboards

• Transforms work practices

• Converts data into knowledge

• Drives collaboration

Digital Transformation driving Smart Operation


Shell Deepwater Production Surveillance

Well History:

• 3/03/05: Salt Plug in Choke

- Choke plugged with salt

• 1/07/06: HC Deposition

(paraffin)

• 4/08/06: Ramp Well Up

Soluble Salts….100%

Hydrocarbon……..0%

Carbonates………0%

Iron Compounds…0%

Acid Insolubles…..0%

Well History:

• 3/03/05: Salt Plug in Choke

- Choke plugged with salt

• 1/07/06: HC Deposition

(paraffin)

• 4/08/06: Ramp Well Up

Soluble Salts….100%

Hydrocarbon……..0%

Carbonates………0%

Iron Compounds…0%

Acid Insolubles…..0%

Action & Value Capture

Deepwater EBS Framework

Operating

Guidelines

Surveillance

Flowline

Surveillance

Process System

Surveillance

Sand

Management

Surveillance

Rate and

Phase

Surveillance

Annulus

Pressure

Surveillance

Collaborative

Work Events –

Well Reviews

Water

Injection

Surveillance

Compressor Optimization Surveillance

Rotating Equipment

Performance Surveillance

ESP

Surveillance

Multi-Phase

Flow Meter

Surveillance

Pump and Generator

Surveillance

Pod Electrical

and Hydraulic

Surveillance

Gas Lift

Surveillance

Chemical Performance Surveillance

Pressure

Build-Up

Surveillance

Intermittent

Wells

Water Separation

Surveillance

Compressor Reliability

Surveillance

coverage across the production system Service

Descriptions

No No

No

No No Service Defined

Service Selected

Automated

initiation of Base

Service(s)

Eng or VAT request

POMC to conduct

surveillance service

RAO or CRO

request

surveillance service

01

Complete & submit

web form to POMC

for service request

02

Review service

request

Are

requirements clear

03

Clarify request with

originator

04

Update request form

and resubmit

05

Review service request

against planned and

current Service activity

YesIs this

request a duplication

06

Communicate

Service is already

being conducted and

send relevant

Service out

Yes

Is there

need for further

action

No

08

Assess POMC resource

availability against

service request load

Are their sufficient

resources

07

Close work request

09

Advise requestor that

service can not be

performed at this time

10

Complete Service

Description and assign

within POMC

11

Confirm that Service

Description meets

requestors needs

Yes

12

Update service request

Does Service

Description

meet needs

22

Communicate service

initiation and log in

Activity Resolution Log

No

Yes

Sxx

Advanced Alarming

tool detects a

condition of interest

13

Record alarm in an

event log

14

Assess if the alarm

warrants further analysis

19

Verify with Ops / Eng the

need for additional

action

21

Ops / Eng provides

feedback on alarm to

POMC

20

Ops / Eng verifies need

for further action via

service request

Is further

Action

needed

Yes

Select Service

Further action

required

No

Sub-sea Flow Line Surveillance 070619

v1.vsd

Is data valid

16

Confirm PI data validity

against DAS or other PI

Tags

17

Flag suspect PI tag or

instrument to be

investigated

18

Assess if the alarm

initiates a standard

POMC Service

Is further

action still required

Yes

No

Yes

No

Yes

01

20

Yes15

Record action in Action

Resolution Log

39

Trigger Points Flow Assurance Model Tuning :

1) Automated quarterly request to collect model input data2) Requests as and when required by Engineering

3) Operating boarding pressure changes by +/- 20%

Trigger Points Flow Assurance Performance :1) dP versus Flow relationship varies by more than 10%

2) When Temperature / Pressure relationship indicates hydrate conditions

Reg

ulat

ory

Affa

irs

Func

tiona

l

Eng

inee

ring

Virt

ual A

sset

Team

(VA

T)

Ope

ratio

nsP

OM

C S

urve

illan

ce

Tec

hnic

ian

PO

MC

Sur

veill

ance

Eng

inee

r

PO

MC

Sys

tem

s

Adm

inis

trato

rP

OM

C M

anag

er

NoNo Service Defined

No

Yes

Yes

14

Assess if the alarm

warrants further analysis

18

Assess if the alarm

initiates a standard

POMC Service

19

Verify with Ops / Eng the

need for additional

action

Select Service

Is further

action still required

17

Flag suspect PI tag or

instrument to be

investigated Is data valid

Advanced Alarming

tool detects a

condition of interest

Is further

Action

needed

13

Record alarm in an

event log

16

Confirm PI data validity

against DAS or other PI

Tags

No

Yes

No

Yes

Service Selected

01

Further action

required

21

Ops / Eng provides

feedback on alarm to

POMC

20

Ops / Eng verifies need

for further action via

service request

22

Communicate service

initiation and log in

Activity Resolution Log

S01

Automated

initiation of Base

Service (s)

Sub-sea Flow Line Surveillance 070619

v1.vsd

I. Service Management

15

Record action in Action

Resolution log

39

Support Framew ork RACI Chart

PO

MC

Ma

na

ge

r

Sy

ste

ms

Ad

min

istr

ato

r

Su

rve

illa

nc

e

En

gin

ee

r

Su

rve

illa

nc

e

Te

ch

nic

ian

OIM

Re

lia

bil

ity

En

gin

ee

r

Pro

du

cti

on

Te

am

Le

ad

Pro

ce

ss

Sta

ff

As

so

cia

te

CR

O

RA

O

Op

era

tio

ns

Ma

na

ge

r

Fa

cil

itie

s

En

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ee

r

Pro

du

cti

on

En

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ee

r

Ch

em

ica

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En

gin

ee

r

Su

b-s

ea

En

gin

ee

r

Sp

ec

ialt

y

En

gin

ee

rin

g

Pro

ce

ss

En

gin

ee

rin

g

Su

b-s

ea

En

gin

ee

rin

g

Ch

em

ica

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En

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ee

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Re

se

rvo

ir

En

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ee

rin

g

Re

gu

lato

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Aff

air

s

1Com plete and subm it web form to POMC for

service requestC, I R, C A R R R A R, C, I R, C, I R, C, I R, C, I R, C, I

2 Review service request R, A C C

3 Clarify request with originator R, A C C R, C A R R R R, C, I R, C, I R, C, I R, C, I R, C, I

4 Update requst form R, A C C

5Review service request against planned and

current Service activityR, A C C

6Com m unicate if Service is already conducted and

send relevant Service outputR, A C C I I I I I I I I I I I

7 Close work request R, A

8Assess POMC resource availability against

service request loadR, A C C

9Advise requestor that service can not be

perform ed at this tim eR, A I I I I I I I I I I I

10Com plete Service Description and assign within

POMCA R, C R, C R, C

11Confirm that Service Description m eets

requestors needsR, A C C C C C C C C C C C

12 Update Service request R, A R, C R, C

13 Record alarm in event log I R

14 Assess if the alarm warrents further analysis C, I R, A

15 Record action in event log I R, A

16Confirm PI data validity against DAS or other PI

Tags A C, I R

17Flag suspect PI tag or instrum ent to be

investigated A R I I

18Assess if the alarm initiates a standard POMC

ServiceA C, I R

19 Verify with Ops Eng the need for additional action R, C R, A C C C C, I C, I A C, I C, I C, I C, I C, I

20 Ops / Eng provides feedback on alarm to POMC I C, I C, I R, C A R R R A R R R R, A R, A

21Ops / Eng verifies need for further action via

service requestC, I R, C A R R R A R, C, I R, C, I R, C, I R, C, I R, C, I

22Com m unicate service initiation with requestor,

VAT, and or EngineeringA I R I I I I I I I I

RA

C

I

- I am ACCOUNTABLE if this work does not get done or is of poor qualityNotes

1) Accountabile for running Sub-sea models to diagnose flow line issues

2) Accountabile for running Sub-sea models for quarterly tuning - I am CONSULTED on the approach or results but am not responsible for delivery

- I am INFORMED about the work but neither resposnsible nor accountable

OtherPOM C

Support Framew ork I - Service

Management

Virtual Asset Team Functional EngineeringOperations

- I am RESPONSIBLE for getting this work done

Service

Frameworks

Process

Swim

Lanes

Process

RACIs

Standard

Operating

Procedures

(SOPs)

Rigorous, Consistent and Effective SurveillanceLean Operating Model Alerts are Validated

Alert Console

Trend for Alert Validation

Valid Alerts Initiate a Workflow


Shell Deepwater Production Surveillance

New Orleans Based Surveillance Center for Deep Water

Assets in the Gulf of Mexico and off the Coast of Brazil

~300 Wells across 11 Floating Structures & 2 FPSOs

6000 Analytics covering over 2000 pieces of equipment

Benefits:

• Reliability and Safety

• Prevent Production Deferment

• Prevent Equipment Failure

• People Enablement – Increased Work Efficiency

Connected Assets and Analytics driving Smart Operations


Thank You!

Documents

Ali Raza, Honeywell Process Solutions · 2015 Japan Technology Summit Yokohama, September 9-10 Digital Transformation for Operations Excellence, Next Generation Advanced Solutions