Eliminate hardware obsolescence and enable infinite software lifespan

TABLE OF CONTENTS

Part 1: If it’s not broken, why fix it?Barriers to migration

Part 2: Why upgrade—and why now?Benefits of modernization

Part 3: Modernization in actionFour case studies

Part 4: Future-proof your operations Embracing digital acceleration

1

2

6

11

“Companies make a concerted effort to keep IT infrastructure current. The same level of emphasis is not yet common practice for plant automation.”

John Rudolph, PresidentHoneywell Process Solutions

THE CASE FOR MODERNIZATION

“If it’s not broken, why fix it?” A valid question, especially if your control system is still functioning. But like any piece of equipment that’s been working 24/7 for over 30 years, your legacy system can’t perform with the same degree of efficiency, safety, or reliability as when it was first installed. Even at its best, it wasn’t built to support the business demands, market pressures, and safety regulations of today—let alone the future.

Of course, none of this is news to you. As a process industry expert, you’re well aware of the risks of running your plant processes with aging hardware and software. And you understand the advantages of modernization. But without the full support of senior leadership and key stakeholders, you may not be able to move forward.

The purpose of this eBook is to give you the

information you need to overcome challenges to

modernization so you can usher operations into the

future—efficiently and cost-effectively.

1

Part 1

“Companies make a concerted effort to keep IT infrastructure current. The same level of emphasis is not yet common practice for plant automation.”

John Rudolph, PresidentHoneywell Process Solutions

Why upgrade—and why now?In the past, one of the biggest obstacles to modernization was downtime. Taking your operations offline to perform an upgrade was incredibly disruptive and costly—as much as $1 million a day at least by some estimates. In 2016, Honeywell eliminated this barrier with the launch of on-process migration, which enables companies to maintain workflow and save literally millions of dollars.

Another potential obstacle to modernization is total cost of ownership or TCO. You already own the hardware, the thinking goes, so why not just continue to amortize that expense over time?

Which brings us back to the question: why upgrade—and why now? At a high level, the answer is that modernization allows you to effectively manage the entire lifecycle of your plant. Let’s take a closer look at what that means for your operations.

“The migration from HPM to EHPM can almost be described as plug-and-play, with virtually no impact on unit operations.”

Gabriele Marchetti, Section Head, DCS

2

THE CASE FOR MODERNIZATIONPart 2

Lower total cost of ownershipEven the best technology needs a periodic upgrade to offset the risk of obsolescence and to keep you competitive in a rapidly changing market. Plants that rely on control systems that do not offer on process migrations need a complete rip-and-replace every 7-10 years, which requires a full shut down or a risk filled “hot cut over” to the upgrade. In contrast, Honeywell’s differentiated continuous evolution approach can accomplish this with a minimal hardware refresh and an on-process upgrade every 4-5 years, contributing to 40% lower installed cost and 75% lower average annual TCO.

3

THE CASE FOR MODERNIZATIONPart 2

Avoid hardware obsolescenceAs older electronic components are replaced by modern alternatives, these legacy systems will face a critical shortage of spare parts by 2025, if not before. Waiting it out nearly guarantees rip-and-replace at a cost of 4–12 times more than an upgrade, while providing no incremental benefit. The solution is modernization by leveraging virtualization technologies to upgrade your hardware to software. These technologies will:

• Eliminate hardware obsolescence• Extend system life indefinitely • Avoid costly rip-and-replace • Maximize the return on your equipment investment

Protect your intellectual property (IP) investmentUpgrading combines the best of two worlds: state-of-the-art technology without any loss of IP and no re-engineering required. You retain all graphics, control strategies, controllers, I/O processors, wiring, logic configurations, and native displays. At the same time, you benefit from standards-based functionality, regulatory support capabilities, and integrated operations.

4

THE CASE FOR MODERNIZATION

Leverage data analytics The new software provides access to data analytics that improve operator effectiveness, including the ability to identify potential safety issues, differentiate between alarms, run processes closer to operating limits, perform routine procedures more efficiently and reliably, respond quickly to abnormal situations, and optimize plant processes.

Expand system capabilitiesModernization extends capacity and performance, optimizes your graphics, controls, and I/O as well as adding new high value features and capabilities. The control system’s common Human Machine Interface (HMI) and unified physical control network make it easy for control devices to integrate and expand with the latest generation of Experion PKS controllers and safety systems. Bottom line: Modernization expands your capabilities while removing the risk to obsolescence.

“ELCN essentially resets the odometer on your TDC 3000 investment.”

David Patin, Distinguished Engineering AssociateExxonMobil Research & Engineering

View article Honeywell rises to ExxonMobil challenge

Part 2

Eliminate coax infrastructure issues Coaxial cables have always been vulnerable to damage—from water, heat, torque, oxidation—and aging only adds to that risk. FTE eliminates coax-associated problems while supporting uninterrupted peer-to-peer communication. It also eliminates the need to have a hardware connection for every TPS node. Just one redundant ELCN bridge pair enables virtualization.

Part 2

5

THE CASE FOR MODERNIZATION

Advance your entire operations If that’s not enough to convince the decision-makers, consider these value-added benefits of modernizing your infrastructure:

Space Upgrading transforms hardware into software which significantly reduces your storage space footprint. It also centralizes your operations, so you can do more with fewer consoles and operators.

Traffic By shifting communications to Fault Tolerant Ethernet (FTE), you increase your network bandwidth by 20 times (5MB to 100MB). But that’s not all. Modernization digitizes your physical assets, emulating hardware with software and eliminating LCN boxes and bottlenecks.

Training Modernization simplifies the process of training workers to full competence. You can continue using your existing legacy graphics or migrate to Experion Orion HMI, an intuitive, efficient, and easy-to-learn interface that offers advanced visualizations, faster navigation and process changes, and advanced alarm management.

Recruitment The next generation of workers expects state-of-the-art technology. To attract, train, and retain younger workers, companies need to modernize their operations, from the physical environment to the graphical user interface to cyber security.

“A big advantage of upgrading from PM and APM to EHPM is significantly higher processor capacity and extended support.”

Lars Anderson, Automation ManagerPreem Refinery, Sweden

View video Honeywell’s Enhanced High Performance Process Manager at Preem Refinery in Lysekil

Part 2

MODERNIZATION IN ACTION

Part 3

6

THE CASE FOR MODERNIZATION

The following case studies illustrate why these companies chose to upgrade and how they’re benefiting from that decision.

Part 3

THE CASE FOR MODERNIZATION

Part 3ExxonMobil

BACK STORY

ExxonMobil was keenly aware that its installed base of Honeywell TDC 3000 systems was rapidly approaching a critical shortage of spare parts. Most notably, controller microprocessors and communications chips would reach end-of-life by 2025, and if the company didn’t take action, they’d face a massive rip-and-replace.

To avoid the immense cost of replacing the TDC 3000, ExxonMobil challenged Honeywell to develop an on-process migration solution that would provide rock-solid reliability and security. The two companies formed a joint task force and got to work.

SOLUTION

The result is Experion® LCN (ELCN) R501.1, a solution that emulates the entire TDC system as software, enabling infinite lifespan. In addition to avoiding downtime, the on-process migration to ELCN has eliminated future component issues, preserved all IP, unlocked the system from proprietary networks, and reduced the need for storage cabinets.

ADDITIONAL BENEFITS:

• LCN and UCN messages encapsulated in standard Internet protocol • FTE-connected safety system interfaces• Use of Honeywell’s cloud-based Open Virtual Engineering Platform to • • • engineer TDC solutions• Peer-to-peer integration of virtualized HPM controller nodes with current- • • generation C300/ACE nodes• Support for OneWireless (ISA 100 and WirelessHART) connectivity• Integration with ControlEdge and Unit Operations Controllers• Smaller, lower-cost operator training simulators

7Case study

THE CASE FOR MODERNIZATION

Part 3BioMCN

BACK STORY

BioMCN produces bio-methanol, a second-generation biofuel, at two methanol plants in the Netherlands. With an annual production capacity of 440K metric tons, M1 is the fourth largest plant in Europe. Although M2 is capable of producing 430K metric tons per year, it was mothballed more than a decade ago. In response to a surge in demand, BioMCN needed to increase capacity and optimize its plant operations.

SOLUTION

The on-process migration to Honeywell’s ELCN solution allows BioMCN to successfully and cost-effectively restart M2 production and increase its methanol plant capacity. The process preserved all graphics, control strategies, controllers, I/O processors, and wiring, while the upgrade to Fault Tolerant Ethernet (FTE) infrastructure prepared the plants for future growth.

ADDITIONAL BENEFITS:

• Updated cyber security and refurbished original control room using new desktop and IKB

• M1-M2 plants set up to run with same operators • Elimination of LCN coaxial cable • Virtualization to support future graphics

8Case study

THE CASE FOR MODERNIZATION

Part 3Total S.A.

BACK STORY

Total is a multinational integrated oil and gas company and large-scale chemicals manufacturer with a refinery capacity of 174,000 barrels per day. To stay viable in the face of global competition, Total has continued to invest in process automation technology, however, its older systems—those installed between 1982 and 1992—had reached max capacity. In addition, 18,000 active I/O that were on eight data Hiways and unit segregation had been lost.

SOLUTION

Total management undertook a major refinery expansion that extended its existing automaton assets while upgrading legacy TDC 2000 control systems to Experion® Process Knowledge System (PKS) technology. The new open automation architecture at the Port Arthur refinery allows multiple Experion systems installed on different operating units to communicate, exchange data, and work together seamlessly.

ADDITIONAL BENEFITS:

• Full and immediate access to critical data via direct connection to information and control networks

• Integration with human-machine interfaces (HMIs) throughout the facility • Improved plant operations, increased incident avoidance, and enhanced

workflows

9Case study

THE CASE FOR MODERNIZATION

Part 3Gunvor Ingolstadt Refinery

BACK STORY

Gunvor Ingolstadt Refinery produces 110,000 barrels per day of gasoline, diesel, heating oil and jet fuel. Recently, the refinery had recorded overruns on the UCNs and some HPMs, which caused system alarms and slowed display responses, impacting operational efficiency. To prevent interruptions in the coming years, Gunvor knew it would need to modernize its control system.

SOLUTION

Gunvor and Honeywell developed a step-wise plan to migrate 15+ HPMs to EHPM. The first step was to install FTE infrastructure into the system cabinets to support controller migration activities on-process or during plant turnaround. Within 24 hours, the first three HPMs were migrated to HPMs without disruption. During the turnaround, activities included replacement of operator consoles in the control room, renewal in the auxiliary room, and the migration of the remaining HPMs on two UCN networks to EHPMs.

ADDITIONAL BENEFITS:

• Preservation of all control functions and logic configurations • No changes to native displays • Increased capacity and FTE connectivity• Resolution of control network performance issues

10Case study

Part 4 THE CASE FOR MODERNIZATION

Future-proof your operationsThe benefits of modernization go far beyond today, beyond next year, beyond 2025. As the pace of digital transformation accelerates, it’s now more important than ever to bring your entire operations into the future—and it starts with asset digitization. From there, you can take full advantage of continuous innovation, artificial intelligence, and machine learning to compete on a whole new level.

Modernization is the key to managing the lifecycle of your plant, and in the process, increasing productivity, revenue, and profitability, now and in the future.

You’ve got this. We can help.

To learn more about Honeywell products and services, visit honeywellprocess.com or contact your Honeywell account manager.

Honeywell Process Solutions

Honeywell1250 West Sam Houston Parkway South Houston, TX 77042

Honeywell House, Arlington Business ParkBracknell, Berkshire, England RG12 1EB UK

Shanghai City Centre100 Zunyi Road Shanghai, China 20051