Intech200907 Honeywell

2009 Honeywell Users Group Americas Symposium Coverage and Insights
July 2009
Innovation today Wireless Security Applications New products
innovation today
Hard work yes, but innovation, imagination will trigger growth

By Gregory Hale
more. As all indicators point toward a long arduous sojourn out of the recession and into a more prosperous environment, that is where innovation and imagination come in, said Frank Whitsura, vice president general manager Americas for Honeywell Process Solutions. Albert Einstein once said imagination is more important than knowledge, Whitsura said during his kickoff presentation One thing every company discuss- at the Honeywell Uses in light of industry challenges is ers Group Americas Symposium in Phoebusiness optimization. But few are nix last month. That sentiment achieving the level theyre capable remained in place of. Urso throughout the entire meeting as leaders talked about possible ways to guide users through these turbulent times. It wont be easy, but it is possible. When it all comes down to it, getting through these times means understanding and controlling the massive amount of data hitting plant oors every day. It is estimated that 40 exabytes of data will be executed this year alone, said Honeywell Process Solutions President Norm Gilsdorf. That is more than the previous 5,000 years. How do you manage the information generated, and how will it be consumed? All this data and all this pressure, it is all about how we manage this (information), Gilsdorf said during his keynote address on opening day. It is about bringing the right data to the right person. One thing every company discusses in light of industry challenges is business optimization. But few are achieving the level theyre capable of, said Jason Urso, vice president of technology at Honeywell, during his technology update presentation. Best-in-class companies actually focus on three areas: process safety and security, operations excellence, and business agility. But they treat it as a technology problem, weaving together islands of automation to achieve a single solution. Yet when companies do this they have really created a complex solution, and the benets degrade, then go away entirely, Urso said. Then the cost of maintenance is higher, and overall youve created poor visibility when it comes to maintenance staff.
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he economy seems to be slowly creeping out of its downward slide, but to get a faster return, the same old solutions just wont cut it any
The time fearing the economy is over, business leaders and managers have to think and act as entrepreneurs. It is time to think of opportunities, not dwelling on what has happened. Gilsdorf outlined what he and his team see as the biggest challenges facing the process industries and the most important trends for which Honeywell is making plans. Trends now and moving forward include: Ubiquitous sensors: Sensors to me is one of the most exciting areas, declared Gilsdorf. MEMS (micro electromechanical systems), smart dust, analyzers on a chip, wearable sensors, GPS (global positioning system) tracking for equipment and employees, ying sensors for security, leak detection, video as a sensor, embedded sensors (as on a shelf in a distillation column), and others all fall into this slot. Wireless acting as a cost effective enabler that extends the control network and furthers sensing technologies and monitoring. This will enable us to address new regulations. We will monitor far away operations and applications. On a 3,000-kilometer pipeline in Kazakhstan, they have numerous breakins and diversions of oil, which they detect remotely using wireless pressure sensors. Convert data to actionable knowledge: This involves using online optimization models to invoke built-in procedures in the control system, to drive automated action and response by the control system. This slot includes soft sensors and the ability via simulation to provide the operator a way to work with what-if scenarios using real time data. The nal convergence of IT and process control will settle in embracing service oriented architecture (SOA) virtualization, cloud computing, and open systems. Unify the automation layers: This entails the interplay and communication from level one on the plant oor including eld devices to the top level where supply chain activities reside and will ensure there are role-based consoles displaying the information that the person at each level needs. There will be embedded batch systems. Well bring MES (manufacturing execution systems) into the clean room without dirty paper moving back and forth in that restricted zone. Going beyond the plant boundary: This trend would include an operation like one in India that webs, networks, and automates multiple wells, reneries, transportation, and retail outlets, Gilsdorf said.
We believe these six areas are the core of change in the future. I see a safer, more reliable enterprise to come, said Gilsdorf. One of the ways to grow is to remember the past, but keep moving forward. Innovation remains critical. One of the ways Honeywell is moving forward is also focusing on a venture called One Honeywell. One Honeywell looks to optimize all parts of systems from various Honeywell businesses for its customer. Everyone knows there is greater nancial instability and market volatility, or a rising need for improved safety and security, along with higher energy costs driving needs for improved energy efciency, and more stringent environmental standards regulated by EPA/ FERC and carbon tax regime. But the trick is to optimize. We need imagination more than ever. Economics are an issue, and some trends may lead to lifestyle changes, Whitsura said. One Honeywell goes beyond the plant. We have the technology and capability today. p Nicholas Sheble contributed to this report.
Inside...
ExCLuSIvE Q&A
Gilsdorf: Industry seeing little sparks of life

When it comes to the current economic situation, Honeywell Process Solutions President Norm Gilsdorf is seeing some signs of life around the world where some of the projects that had slowed or were postponed are starting to come back to life. Page 4
I N N O vat I O N tO d ay: Hard work yes, but innovation, imagination will trigger growth Knowledge management means saving time, money At one with integration Pushing operations excellence Operators learn to squeeze more out of system WIreleSS Wireless enables continued growth Plan ahead for wireless Wireless helps plant recover from disaster Wireless networking has more than one way to go Wireless keeps growing (Becker Q&A) ISA100 up and running SecUrIty Think security rst Security top of mind a p p l I c at I O N S An alarming situation: Get a plan and stick to it A remote monitoring partnership Genentech masters resource planning integration Roadmap to new technology South African renery gets face lift Reliability a total team effort HUG prOdUctS Saving energy from a dashboard OneWireless enables wireless process control Valve position sensor improves plant reliability Optimizing terminal operations Simulation software offers engineers greater range Touchscreen operator interface aids plant operators Honeywell to install re, gas detection system in Turkey Products on display
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video: Pushing operations excellence A mans got to know his limitations is a classic line from Clint Eastwoods Dirty Harry series, but the same can be said about a manufacturers operations teams. Honeywells Chris Stearns talks about how their operations excellence model allows end users to enhance their work processes to make the enterprise more competitive.
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INTECHS HONEYWELL E-ZINE
innovation today
Industry seeing little sparks of life

EDITORS NOTE: Honeywell Process Solutions President Norm Gilsdorf took some time during the Honeywell Users Group Americas Symposium in Phoenix and sat down with InTech Editor Gregory Hale to discuss some of the hot topics around the industry today.
Gilsdorf:
InTech : Since taking the helm at Honeywell Process Solutions in January, you have walked into a hornets nest of global economic issues affecting the industry. Do you see the recessionary times across the globe ending soon? Gilsdorf: I dont know if there is an end to it. I think we are seeing some signs of life around the world where some of the projects that Gilsdorf makes a point during his keynote address. had gotten slowed down or signicantly postponed; I see some signs a few of them are coming back to life. of keeping their systems doing the things they need. At the I think hopefully as the economic conditions continue to look a same time, we provide a lot of advanced applications that help bit positive, those will continue moving forward. I wouldnt call people further improve safety, reliability, or efciency, and there it an end to anything, but I would say we have got little sparks are a lot of things you can do without a signicant amount of capital investment today to get more value out of your enterof life coming back out there. prise. In tough times, a lot of those things you need to focus on. We actually have a lot of activity from our customers to put InTech : What areas seem to be coming back now? Gilsdorf: I think the oil and gas sector is coming back. And these in place or for those that had it in place kind of getting it really didnt go away. It quieted down for a while as people them tuned up to improve their operations. tried to assess the circumstances, and now that the price of oil has come back a bit and people have let the dust settle on the InTech : Do you see the U.S. coming out of this rst, or will crisis, they kind of feel a bit more stable about things. There the major economies across the globe all come out around the are several people that want to get back in now to get in some same time? Gilsdorf: I think actually some of emerging markets will come projects before it potentially gets overheated again. out of this rst. Today, when you look at China, that is one InTech : We have heard some experts say you should write off area where you see some more activity as the stimulus in China is having some quick effect. I think when demand recovers in this year and even some saying next year. What do you think? Gilsdorf: I dont consider this year a wash out at all. First of some markets, some of those emerging markets whether it is all, we have a very strong installed base, and those customers India, Brazil, or even Russia, which is driven by the price of oil, continue to have things we need to deliver to them in terms might recover faster than the U.S.
innovation today
InTech : What part of your customer segments are doing well at this point? Is it just oil and gas? Gilsdorf: I should have added earlier, the pharma side never really turned down that much. They continued through the downturn. They continued a fair amount of their investment plans. The oil and gas were there. Those were the primary two, though I would also add power continues to be a growing market because the emerging markets had such a demand for power. Those projects take many years to develop. Those had to continue despite the economic situation. Those three verticals had been fairly robust or at least not turned off. InTech : Keeping the economy discussion in mind, what do you see as the biggest issue keeping manufacturers up at night? Gilsdorf: I think it varies depending on where you are in the world and what industry. I think in some of the areas one of the big challenges is probably understanding the demand. A lot of industries, you look at the chemical industry or some of the rening segments, and they went from a period of high demand and good pricing to a signicant drop in demand and unpredictable pricing over night. So, now you might have to operate your unit at lower capacity or might have to operate at periods of time with the unit shut down and then back on again. And that is a shift in how you control and operate the unit to a strategic philosophy to pushing a unit to now running it at a lower speed. That is where we come in and look at the optimization and advanced process control looking at some of the things that are helping with supply chain software and help them to adapt to those changes and get the unit operating the best it can either through reduced output or in on/off mode. That is probably the biggest. I think one of the other things customers have to face is they have cut costs or staff are on furlough or are doing other things. They are operating staff just like the rest of us are faced with the distraction of this crisis, so again, you need to help them keep their people trained and up to speed and work very close to them to understand exactly how they are dealing with it and how you can help. p
Knowledge management means saving time, money

By Nicholas Sheble
efore this recession, we worried about folksthe boomersretiring with all their industry knowledge and knowhow walking out with them. Now were worried folks are going to be pushed out the door with the same intelligence, said Honeywells Sujeet Karna. Karna spoke during a technical session at the Honeywell Users Group Americas in Phoenix. Karna is a manager at Honeywell and works in lifecycle services. He addressed the knowledge management strategy during recessionary times. Knowledge management is an entity, an asset that industry must carefully Sujeet Karna makes a point during his take care of at all times. presentation on knowledge management What is the concept of knowledge strategy during recessionary times. we are talking about? Karna said there is knowledge acquisition, which consists of procedural knowledgerules, methods, procedures, and the like. Next, there is declarative knowledge, which entails facts, concepts, assertions, and so on. Karna amplied on the concept. Retention embraces explicit knowledge, which is articulated, codied, and stored in certain media. It is readily transmittable to others. Tacit knowledge cannot be transferred to another person as a result of it being written down or verbalized. Experts have the ability to access this information and a large portion of the information is tacit. Karna refers to tacit knowledge as tribal in nature. The critical success factor is access, said Karna. All too often explicit information is codied on inaccessible media like binders, individual hard drives, or on obscure le servers. This is not knowledge management because only individuals know to access this information. Thus as experts retire, explicit knowledge reverts to tacit or tribal knowledge. Karna introduced the technology that precludes losing this information and in fact collects and presents the information automatically. Further, it works with all major vendors DCS and PLC systems. It is the DOC4000. These are a few of the cases of the technology in action: A major rening company used the technology to recover mission critical control system information necessary to recover and rebuild their control system conguration after extensive hurricane damage. Another renery was able to resolve a persistent historian overrun issue using information gathered with the software. The technology saved signicant engineering time and effort on a multiple unit migration from one DCS to another at a large chemical plant. Similarly, another oil company reduced its budgeted time for documenting the as-is state by 28% during a system migration project. p
innovation today department name | The Department Description
At one with integration

By Ellen Fussell Policastro
manufacturer in these tough times needs to be able to get the most out of their systems to keep growing the business. One thing every company discusses in light of industry challenges is business optimization. But few are achieving the level theyre capable of, said Jason Urso, vice president of technology at Honeywell, during his technology update presentation at HUG in Phoenix. Urso emphasized the importance of onenessin integration solutions that is. Best-in-class companies actually focus on three areas: Process safety and security, operations excellence, and business agility. But they treat it as a technology problem, bringing together islands of automation for a single solution. Yet when companies do this, theyve really created a complex solution, and the benets degrade then go away entirely, Urso said. Then the cost of maintenance is higher, and overall youve created poor visibility when it comes to maintenance staff. Honeywells goal is to take a more holistic and integrated approach, to enable you to sustain business optimization over your lifecycle. It is called One Honeywell, and it offers the full breadth to treat a problem, not a series of point solutions. We help you get started by designing the
Jason Urso, vice president of technology at Honeywell, talks technology during his presentation at the Honeywell Users Group in Phoenix.
delivering on time and on budget. But we go one step beyond; we deliver with business readiness on day one, he said. Experion experience The Honeywell Experion Platform protects and preserves the install base and is designed to work with a wide variety of eld networks, he said. The PCBI function block is integrated with our C300 controller and can speak over Ethernet to any device
Honeywell designs out instabilities before you start putting steel in the ground, and you can use these models to train your operators as well as to check out your control and safety strategies and validate procedures before units come online. Urso
process up front with integrated DCS and re and gas solutions, to help you integrate throughout your lifecycle. Then you can improve your overall process throughput while driving down process incidents. Delivery of One Honeywell is through a main automation contractor program that builds on the traditional concept of
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modulesspeed input I/O module and accelerated cycle time, achieving increased efciency between boiler, controller, and process control at your facility. The C200 E controller platform enhances C200 to support additional memory, bringing batch manager to the C200 controller for faster batch execution to improve production. Other additions to the Experion experience are Experion HS and Experion LS tailored for smaller systems in specic markets. Experion HS provides a small typical SCADA solution, and Experion LS is for smaller batch and process systems. Process efciency As for process efciency, Weve generated $5 billion in terms of benets for our customers, Urso said. And a lot of these are from reduction in energy costs. Energy products include advanced energy solutions, packaged solutions for advanced control, and optimization algorithms. So users can optimize by your combustions, reduce ue gas emissions, monitor key energy indicators, and identify areas where you can improve efciency, he said.
that supports the ModBus TCP standard. Security is also one of the goals behind Experion. We built it [security] into the platform; we didnt add it in later, he said. The newest release for Experion includes the Series C steam turbine control, which allows us to achieve integration between DCS and steam turbine control with two
The Department Description | department innovation name today
A new energy dashboard will bring plant values into a single portal that keeps track of high level or unit level or equipment level. So you can identify chances to further increase energy efciency and keep track of energy efciency already created, Urso said. A great blend With blending and movement automation, the company last year introduced Experion BMA solutions (optimization for blend of property control and material transfer, optimal material path selection, integrated planning, execution, and reporting). Once your products are blended at the refinery theyre probably moved to a terminal, Urso said. Our terminal manager will be available before the end of this year.
and Callidus to improve their business in burners, are systems, thermal oxidizers, and vapor control systems. We can bring you a broad range of burner technology for best-in-class levels of efciency for process heaters, Urso said. As far as re and gas detection devices go, we can deliver ame, smoke, toxic gas, and a range of alarming devices. Urso described the importance of integrating re and gas detection with a hypothetical gas leak situation, whereby Honeywell gas detectors can pick up and alert re and gas platforms, which can communicate with emergency shutdown systems, which can isolate the toxic gas leak, then communicate directly to the Honeywell C300 controller (upstream or downstream). And all this is overseen by a single Experion interfaceanother testimony to one-
and reliable inventory control and custody transfer. Best of all, this exline radar level gauge is enabled for One Wireless so it can be deployed in your tank farms for safety issues, he said. People power And speaking of accuracy, human error accounts for almost half of the mistakes made in the process, so Honeywell has laid the foundation with Experion Human Interface, which is well integrated with ProtSuite for blending and movement automation solutions so you dont purchase a collection of point solutions. Once you have common human interface in place, the next place to improve is operator response; look at operator graphics and alarming display. In an abnormal situation, ASM graphics will help the operator respond faster and with more precision. We can help your operators respond 48% faster and more precisely, he said. Because startups and shutdowns are occurring less frequently these days, operators are out of practice. In our application called Procedural Operations, you can automate your procedures to reduce variables and move them closer to execution, even for the least experienced operator. p
Weve generated $5 billion in terms of benets for our customers. Urso

And all this works as part of one Honeywell solution: Petrochemcial transfer, loading, blending, and additive injection solutions. If a tanker truck driver badges in to a tanker ID control system, then theres an ID for the product trucker there to pick up. Hes requested to pull into a specic bay. At the same time a recipe is loaded which lowers the arm that lls the truck, carefully with blending, and additive injection systems, Urso said. Safety in integration To further qualify the importance of oneness, Urso described UniSim Lifecycle Solutions, which help users get started in overall plant design. Honeywell designs out instabilities before you start putting steel in the ground, he said, and you can use these models to train your operators as well as to check out your control and safety strategies and validate procedures before units come online. Honeywell has also acquired Maxon
ness. Thats the kind of integration you can expect with the Honeywell family, Urso said, to help you improve overall safety because you can respond faster and more accurately. As part of a litany of new products, Urso extended the oneness theme with a safety angle by announcing a manual gauge reader to wirelessly integrate manual gages at a low cost, a valve position sensor for remote valve position monitoring (ideal for people who have multiple video: Operators learn to squeeze more out of system valves in eld), and A manufacturer can have all the technology it wants, but it a exline radar level all comes down to an operators excellence on the plant oor. Honeywells Tom Williams talks about operator effectiveness. gauge for accurate
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wireless
Wireless enables continued growth

By Gregory Hale
hile most companies in the automation industry do the slow grind toward recovery, wireless is one technology that continues to grow, and potential applications just keep expanding every day. Wireless is gaining momentum throughout the industry, said Norm Gilsdorf, president of Honeywell Process Solutions during the Honeywell Users
Most project budgets are under heavy cost pressure, so wireless is a great mechanism to keep the same functionality and scope but at a lower price point. Becker
Group Americas Symposium in Phoenix. It is interesting. We are seeing the wireless kits and wireless mesh networks (selling) despite the economic conditions. Growth means it may be more cost effective these days to put in a wireless system that ts a bit easier into budgets. Wireless growth remains extremely strong this year, said Jeff Becker, Honeywell Process Solutions global wireless business director. Most project budgets are under heavy cost pressure, so wireless is a great mechanism to keep the same functionality and scope but at a lower price point. One of the reasons for the heightened interest in wireless may be because the ISA100 Standards Committee on Wireless Systems for Automation voted to approve the standard, ISA100.11a, Wireless Systems for Industrial Automation: Process Control and Related Applications. Now that the ISA draft has been accepted to establish as a standard, we think that will clear the
air and confusion and that will enable things, when that is nally adopted, to move forward at an even faster pace, Gilsdorf said. It is a big deal for the industry, Becker said. We as an industry nally have an open, exible, user-driven standard that meets all the requirements for eld instrument use in process plants. In a nutshell, the ISA100.11a standard will provide reliable and secure wireless operation for non-critical monitoring, alerting, supervisory control, open-loop control, and closed-loop control applications. The standard will dene the protocol suite, system management, gateway, and security specications for low-data-rate wireless connectivity with xed, portable, and moving devices supporting very limited power consumption requirements. The application focus is to address the performance needs of applications such as monitoring and process control where latencies of 100 milliseconds are acceptable. The standard assures operation in the presence of interference, harsh industrial environments, and with legacy non-ISA100 compliant wireless systems. The remaining steps include approval by the ISA Standards and Practices Board and ratication by the American National Standards Institute. The committee hopes to publish the standard in August. It is a future-proof standard that has the legs to last us for a long time, Becker said. It is one thing to talk about standards and the theory behind wireless, but it is quite another to have actual working products out in the market. Jason Urso, vice president of technology at Honeywell, unveiled, among the slew of wireless products, a manual gauge reader to wirelessly integrate manual gages at a low cost, a valve position sensor for remote valve position monitoring (for people who have multiple valves in eld), and a exline radar level gauge for accurate and reliable inventory control and custody transfer. This exline radar level gauge is enabled for OneWireless so it can be deployed in your tank farms for safety issues, Urso said. A simple case of wireless in action came to the forefront one year ago. One of the debates for
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wireless has always been about reliability, but Bryan McVicker does not have any doubt. McVicker, a Pyrolysis engineer at ExxonMobil, came to rely upon wireless after Hurricane Ike devastated his chemical plant in September 2008. His plant was ooded in 10 feet of water, and the entire electrical infrastructure was destroyed. (See related story on page 10.) We found ares remained in service, but DCS and controls were lost, McVicker said. We needed to make sure basic systems were in place to address potential hazards. I needed to make sure all core business units on site were adequately handling business preservation.
Plan ahead for wireless

efore Byron Lewis and his team decided to go wireless at the Alon renery in Big Spring, Tex., they had to ask themselves what would we do with wireless transmitters? The answer was easy: Use pressure transmitters to troubleshoot failed assets, and move it around as needed. They would also replace pressure gauges read during operator rounds (high value reading), and supply outside operators with several wireless transmitters. If the board operator needs an outside operator to monitor a gauge in the eld, they could replace it using a wireless transmitter. Of course this all sounds easy, but as Lewis found out, it was not as easy as it sounded. He shared his lessons learned with HUG attendees. The rst thing you need to do is dene a project that will leverage wireless transmitter technology. Lewis chose to measure the differential pressure across the reformer reactors. He installed XYR 5000 wireless pressure transmitters at reactors inlets and outlets, connected to an XYR 5000 base radio to HPM controller, congured a tagged point on the TPS system to calculate the differential pressure across the reactors. Before implementation though, there were several things to consider. We did a site assessment to decide where to locate the base radio, he said. Its important to take the time to gure out the location of the base radio to get maximum coverage. We chose to install at a location easy to get full coverage area. Lewis set up the demo unit at several locations, then took the transmitter and walked around the facility to decide the best location. We nally decided we could install at a central location that was easy to wire back to the central location system. The team set up a serial interface (SI) card using ModBus on a TPS system and connected the base radio to it. There are a couple of data point strategies in a bay station. We used the one where you could map the data points in order, so wed have one address and the data points would be
Wireless is almost always signicantly cheaper than doing the same thing via wire, and in many cases wireless allows them to do things that were just impossible to do in the past. Becker
McVicker turned to a wireless implementation to quickly help with recovery. Some of the challenges the company encountered included a weak infrastructure, no wiring, cabling, ber optics, or permanent power. Also they were limited in people because the instrument and electrician technicians and engineers all focused on rebuilding the plant. Within two days, Honeywell mobilized technicians and wireless stations came to the site. Within 12 days, there was an initial startup with risk-based security and controls review and instruments limited to critical services. While the hurricane situation was clearly an emergency, and wireless came through, the technology is also working in every day environments. Users typically want a wireless solution to improve safety, efciency, or reliability, Becker said. Wireless is almost always signicantly cheaper than doing the same thing via wire, and in many cases wireless allows them to do things that were just impossible to do in the past. p
sequential, he said. The gateway arranges ve oating points in order before it starts the next transmitter. With eight pressure transmitters for reformer reactors, two for the HDS reactor and one for the high-gain area, transmitters were mounted at the top, bottom of the reactor, and some were even mounted upside down and straight up from the reactor. When we did the conguration, we labeled all transmitters, put all 10 on the operators desk, and said, Go replace your pressure transmitters. Lessons learned The rst lesson Lewis learned in this project is to take the time to nd the best location for the gateway. Gateway antenna selection is important to get the desired coverage, he said. A high-gain antenna is a good option to add. A data concentrator may be required to adequately use the serial input. After describing several other applications and lessons learned, the most important to remember is to dene your coverage area; this understanding is crucial to set the correct expectation and acceptance, he said. Make sure it is hardware compatible; know the application and software will work together. Know security aspects, such as operator login, network security, and controllable assets denitions. You dont want to have a login name thats too long because its hard to type in with a stylus, he said. It is also important to involve and discuss with other department before dening needs. Dene short- and long-term wireless requirements to achieve maximum benets if you are unsure about wireless. Start small to achieve acceptance and knowledge.p
wireless department name | The Department Description
Wireless helps plant recover from disaster

ExxonMobils Bryan McVicker talks about the capabilities of wireless during his session.
ryan McVicker transferred to ExxonMobils Beaumont, Tex., chemical plant in July 2008, but he got more than he had bargained for when Hurricane Ike tore through in September. The massive storm left in its wake a broken levee, a plant ooded in 10 feet of water, and all electrical infrastructures destroyed. But after giving wireless a try (any port in a storm), McVicker and his team were sold on wireless benets.
We needed one vendor who provides everything from transmitters to operator interface. Routh
McVicker, a Pyrolysis engineer at ExxonMobil, and Ken Routh, from the core engineering group at ExxonMobil Chemical in Baytown, Tex., gave their version of how they depended on wireless in this dire situation at HUG. We were not allowed to go back to our ofces or retrieve anything, McVicker said. It was all trashed. While employees worked out of hotel ballroom for several weeks, the entire organization had to restructure. When we returned to work, we found ares remained in service, but
DCS and controls were lost. We were going to be in turnaround state for long time. We needed to make sure basic systems were in place to address potential hazards. I needed to make sure all core business units on site were adequately handling business preservation. Having no previous experience with wireless, McVicker was hoping to supplement operator rounds, not replace them, as key process parameters during recovery. Some of the challenges the company encountered included a weak infrastructure, no wiring, cabling, ber optics, or permanent power. Also, they were limited in people because the instrument and electrician technicians and engineers all focused on rebuilding the plant. So they contacted Honeywell to investigate wireless options. Within two days, the vendor had mobilized technicians, and wireless stations came to the site. Within 12 days, there was an initial startup with risk-based security and controls review and instruments limited to critical services. As an expert called in to help, Rouths role was to provide global support as a technical generalist. Some of the biggest specs we had were quick response, and we wanted a x that could provide
The Department Description | department name wireless
everything, Routh said. We needed one vendor who provides everything from transmitters to operator interface. We needed 802.11 Ethernet backbone wireless because we had no ber optic or cable. At least at that time, the vendor we could identify quickly was Honeywell. Technical answers The Beaumont team implemented XYR 600 frequency hopping spread spectrum transmitters with ve-second update rate. They initially installed nine transmitters, ve-second update rate, with17 transmitters ultimately installed. The x also included IEEE 802.11a wireless backbone mesh, four multinodes initially installed, with a nal total of ve, all powered with a solar panel (temporarily powered initially with generators). With an operator shelter 1100 feet away from the transmitters, the team used just a couple of PCs, with one seeing use as a OneWireless server that did all conguration and wireless networking setup. One of our security controls stipulation was this network had to be completely standalone, Routh said. The only place to view the data was in front of a table in this operator shelter; there was no Wi-Fi capability. The interface was Honeywell Experion HS on a desktop PC. The initial conguration had two
multinodes close together because of the tall structures in the plant and concern about interference, McVicker said. All in all, the wireless system made crucial device monitoring easier to use. It was staffed by console operators 24/7, with instrument monitoring and historization, are pilot thermocouples, cold are vaporizer TIs and LIs, and key utilities, such as rewater, potable water, natural gas, LP steam, and PIs. Once the system was in service, operators immediately began using the system. They were able to troubleshoot systems with a proactive response to pre-alarms and alarms. At the end of the outage, data was collected. The only thing we cared about was data appearing on ExxonMobil Chemicals Ken Routh gives his version of the screen, Routh said. We using wireless in the face of a dire situation. decided we needed technical data toward the end, so the Honeywell the system with errors or retries. During folks in the Houston area spent a lot of this time, one of the multinodes failed, time helping us congure and troublewhere there were two close together. shoot; we monitored seven key perforWe were worried about transmitters mance parameters for three weeks at being able to get to multinodes, Routh ve-second intervals. said. But we lost no data during that In the end, there was no problem in time.
Wireless networking has more than one way to go
he most useful analogy to portray what has become the future of wireless automation in the industrial space is cell phone technology with its grid of receivers and transmitting towers, said Soroush Amidi. It is a wireless web, a mesh network of signaling devices connecting one another and relaying intelligence hither and yon. So it is with this OneWireless technology, said Amidi, manager of wireless products at Honeywell. It is a unique technology in that the nodes handle three sorts of transmissions including WiFi, ISA100.11a, and eld I/Os. WiFi is in many products using IEEE 802.11 standards. Its certication warrants interoperability between different wireless devices. Most personal computer operating systems, many game consoles, laptops, smart phones, printers, and other peripherals support WiFi. The ISA100.11a is for industrial wireless users and operators. It provides for reliable and secure wireless operation for non-critical monitoring, alerting, supervisory control, open loop control,
and closed loop control applications. It sees to the performance needs of applications such as monitoring and process control where latencies on the order of 100 milliseconds are acceptable. The key benefits of this technology are that its ready for control applications, its easy to use, it lowers the cost of installation versus a hardwire network by 20-30%, it has the scalability to expand to 40 receivers, and its universal in that it embraces all the key existing wireless protocols, he said. Amidi also reported on the Wireless Compliance Institute. The ISA100 Wireless Compliance In- stitute, of which Honeywell is a part, works on the effective implementation and understanding of the planned ISA100 universal family of industrial wireless standards through: Compliance testing programs Associated market awareness Technical support to users and developers p
11
wireless department name | The Department Description
Wireless keeps growing

EDITORS NOTE: Jeff Becker, Honeywell Process Solutions global wireless business director, took some time during Honeywell Process Solutions Users Group Symposium to answer questions on the growth of wireless throughout the automation sector.
Honeywells Jeff Becker
InTech: How much growth do you see in the wireless market this year compared to last year? Becker: Wireless growth remains extremely strong this year. Most project budgets are under heavy cost pressure, so wireless is a great mechanism to keep the same functionality and scope but at a lower price point. InTech: What do you nd is the main reason users want to implement wireless? Becker: Customers typically want a wireless solution to improve safety, efciency, or reliability. Wireless is almost always signicantly cheaper than doing the same thing via wire, and in many cases wireless allows them to do things that were just impossible to do in the past.
Becker: Security and reliability have been the historic impediments, but I think time, experience, and data is changing that perception. The biggest step for most users is just getting a small pilot going. Once they try a OneWireless system and see how it performs, the conversation shifts to tell me how to do more with wireless. InTech: The ISA100 Standards Committee on Wireless Systems for Automation just voted to approve a major new industry standard, ISA100.11a, Wireless Systems for Industrial Automation: Process Control and Related Applications. What does that mean for the industry? Becker: It is a big deal for the industry. We as an industry nally have an open, exible, user-driven standard that meets all the requirements for eld instrument use in process plants. It is a future-proof standard that has the legs to last us for a long time. The best way to illustrate user sentiment toward the standard is in terms of how users voted; 96% of users on the committee voted in favor of the standard. InTech: What does that mean for Honeywell? Becker: We are certainly pleased. Honeywell has been an advocate for a single open industrial wireless standard for quite some time, and it is exciting to nally see that happening. InTech: Did you nd users were buying wireless solutions whether there was a standard or not? Becker: Yes. Its no secret that weve been the leading supplier of wireless systems in this market for years, and those customers weve helped with wireless systems achieved great benets from adopting wireless. However, it is important that our customers investments are protected, which is why having backward compatibility is so important. The very rst XYR5000 system we sold can be connected and transported over OneWireless. Our OneWireless systems all are software upgradeable. We started selling ISA100-ready systems a year ago, ensuring that customers that buy today can easily upgrade to the standard. All that said, we have noticed a surge in
We have noticed a surge in customer interest now that ISA100 was approved. I think some customers were waiting to be sure it passed before making a major commitment. Now that hurdle has passed, things are really accelerating. Becker
InTech: How long do you see the growth continuing? Becker: We are at the very beginning of wireless in the industrial market. One way to think about it is that somewhere between 30-60% of I/O in a plant is for indication purposes only. All of that could easily go wireless today. Of the remainder, many of those I/O points are for less critical control that may also be suitable for wireless. So the vast majority of I/O points are wireless-ready. However, well over 90% of the I/O being sold today is wired. In addition, wireless is enabling new types of I/O that never made sense using wireless. Add it all together, and the growth trend should continue for many years to come. InTech: What is the biggest impediment to wireless in users minds?
The Department Description | department wireless name
customer interest now that ISA100 was approved. I think some customers were waiting to be sure it passed before making a major commitment. Now that hurdle has passed, things are really accelerating. InTech: Do you ever see wireless becoming ubiquitous to the point where users think it is just another form of networking? Becker: I do think it will be ubiquitous, but it is difcult to predict when that will be. Attitudes toward different technology can take some time to change, but maybe not as long as we think. There was a time when Ethernet networking was considered a fringe technology not ready for the demands of industrial industry; look how that perception has changed.
. . . G U H t a ed t t po S
Jason Urso makes a grand entrance.
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We see wireless being used in almost every aspect of our customers business today. Becker
InTech: What do you see as the major use right now for wireless? Becker: We see wireless being used in almost every aspect of our customers business today. That said, the applications that seem to be most universal right now are tank farm automation, equipment health monitoring, and mobile worker enablement. The common theme of those applications is that they have a high ROI driven by dramatic wireless cost savings, but with low perceived risk of using wireless technology. InTech: Do you ever see wireless controlling a process? Becker: Customers use wireless to control processes today. We havent recommended this in the past, but the system is so reliable that many customers just go ahead and do it anyway. The new R120 release will change the game even more. We now have full hardware and RF path redundancy for the wireless system, coupled with speed, security, latency control, and reliability. We can nally say that we offer wired performance in a wireless world. p
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Eric De Groot addresses the crowd at HUG.
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Soroush Amidi introduces a slide to attendees.
Frank Whitsura makes a point during his presentation.
13
wireless
ISA100 up and running
he old fashioned way of running more and more wires is getting more and more painful and expensive. But the new way is wireless, and Dave Kaufman, director of business development of Honeywell Process Solutions and a board member of the ISA Wireless Compliance Institute, hosted a lunchand-learn session at the Honeywell Users Group in Phoenix, to teach attendees knew as much as they wanted to know about how the ISA100.11a wireless standard stacked up.
companys commitment to the standard. ExxonMobil views this standard important because it is where requirements can be vetted in an open forum. There is a risk to future security to rely on proprietary or consortia-based specs where we have no input or inuence, Schweitzer said. The whole idea is to have vendors get in there and roll up their sleeves, yell, and make a selection thats a consensus-based selec-
When we talked to customers three to four years ago, it was always, Ive got to be secure, reliable, and have good power management; but it was mostly security. We have kind of solved those things. Kaufman
ISA saw the burgeoning success of wireless coming down the pike and knew they needed to start a committee, Kaufman said. ISA100 is really trying to drive to that single network to meet all your needs. Its also a multiprotocol standard, and theres a workgroup centered on coexistence in ISA100. ISA100.11a was just approved, .15 on wireless backhaul backbone network is on the way, and the committee is working on .14 (trustworthy wireless), .21 (people and asset tracking and identication), and .12 (WirelesssHART and ISA100.11a converged network applications). One of the most signicant things about ISA100 is users are really involved in this committee, Kaufman said, and there are lots of supporting companies engaged in important discussions to make sure they get it right and end up with something users want to use, he said. Some of the companies include Shell, ExxonMobil, Dupont, Chevron, and Lilly. Customer testimonials Pat Schweitzer of ExxonMobil has been approved by his company to serve as cochair again this year, which shows the
14 INTECHS HONEYWELL E-ZINE
tion, Kaufman said. Dr. Abdelghani Daraiseh, an engineering specialist at Saudi Aramco, expects his company will wait on the ISA standard. Our direction is to use SP100 as a single wireless system for various plant applications, including Foundation Fieldbus, he said.
Honeywells Dave Kaufman, also a board member of the ISA Wireless Compliance Institute, hosted a lunch-and-learn session on how the ISA100.11a wireless standard stacks up.
User requirements When we talked to customers three to four years ago, it was always, Ive got to be secure, reliable, and have good power management; but it was mostly security, Kaufman said. We have kind of solved those things; people feel comfortable about security and reliability. Now people are realizing they have to own it, so they need investment protection. Investment protection means its been designed to accommodate all protocols. I want to make sure I can live with it. I dont want to be stuck living with Honeywell proprietary stuff forever, he said. Nonrouting nodes just means it can accommodate lick-and-stick sensors. A nonrouting device is cheap, so I can get information and start doing analysis
quicker, he said. The ISA100.11a standard can be more efcient by enabling more lick-and-stick sensors. The stack is independent of the radio. As radios turn over and technology turns over, you could have low-speed lick-and-stick monitoring something as well as high-speed below. ISA100.11a accommodates that. These radios are really powerful with a lot of functionality. You can pull that functionality out and put them in your stack, Kaufman said. ISA100 chose not to do that. They wanted to make it independent so you can choose your radios. Security With 128bit AES encryption, this means its tough for the bad guys to crack, Kaufman said. One attendee asked, Its
wireless
not always about keeping out bad guys, but keeping noise out. The answer was there is cooperation between ISA99, the standards group strictly focused on security, and ISA100 to bring in layers of security, from cyber layers to physical layers. ISA99 has set up a bunch of guidelines, and there is an ISA Security Compliance Institute (sister to the Wireless Compliance Institute) to deal with these issues. Reliability It is all about mesh, mesh, mesh, and multiple data paths across the plant. You can extend backbone routers out into the plant, they can be wired or wireless. Now I have more reliability, but I still have my sensor mesh, and I still have ability to have redundant gateways, system managers, and security managers, Kaufman said. The system manager is really God in the system network. It tells every device what it can do and when and what pattern it can talk in. The security manager is the keeper of the keys. And those two work together to keep security working throughout the network.
Interoperability You can have vendor A, B, and C working in vendor Ds cloud. It is an open standard that enables multivendor interoperability. Scalability You can extend backbone routers where you need to and get more sensors. Think of backbone routers like runways on an airport. These messages (planes) are ying through the air and landing on the runway (routers), he said. At some point, the runway cant handle any more planes. So you add more runways. Simple network management For your plant, you have one sensor network, one system manager, and one security manager. What is signicant about this is if you have multiple networks, sometimes it is hard to know what network that device is connected to, and that can be a maintenance nightmare coordinating keys and different networks. The beauty of .11a is you can have that one single system and leverage off the power of one. And with 2.4 GHz, you can use it anywhere in world.
The standard is developed in an open process, so anyone can contribute. It gets messy, but at the end of the day, you put a vote forward and you go for consensus. In that open process, theres a lot of venting as well as some good work, he said. And the result is some best-inclass designs from a lot of people. Wireless Compliance Institute The Wireless Compliance Institute is really a part of ISA as well as part of the American Standards Compliance Institute (ASCI). Its mission is to help reduce those times and costs and risks associated with standards for vendors and users. It ensures interoperability. It does that through compliance. It is all about interoperability in the device. It is a single forum for voicing your needs, and it provides technical support for deployment and configuration. There is application profile development to meet your wireless needs, time and cost savings for validation and verification, and certification assured interoperability. p Ellen Fussell Policastro
. . . G U H t a d e t t po S
Harold Engstrom makes a ne point.
Brendan Sheehan poses a question to the group.
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The audience listens intently at a breakfast session.
15
security
Think security rst

By Gregory Hale
he key to growing, whether it is in a bad economy or a robust environment, is squeezing as much out of the process as possible because increased productivity and lower production costs means a hike in protability. In most cases though, it really does not take much to hack into a system, and as quick as a jack rabbit in the hot Arizona desert, your prot goes out the window.
We are seeing a fundamental shift on who the decision makers are when it comes to security. Ultimately, it will become the IT manager or the CIO to make sure the systems are the appropriate enhancement to the IT platform. So, yes, these folks are starting to take an increased role. Wray
That concept has occurred more than most would like to think, and that is one reason why cyber security is becoming a hot topic in the corner ofces around the globe. Security has always been high on our minds, said Norm Gilsdorf, president of Honeywell Process Solutions at the Honeywell Users Group Symposium in Phoenix.
Video: Security top of mind Top automation executives today are nding security issues are weighing heavier on their minds. See what Honeywells security expert Andrew Wray says in this video interview.
We build a lot of security in the systems we put out there, and we continue to keep that an area of focus. This is headline front page issues we hear about every day, said Andrew Wray, senior global marketing manager for security at Honeywell Process Solutions. It goes beyond firewalls; this is an open society, so cyber security is top of mind. I dont know if (security) has changed focus in the industry, Gilsdorf said. I think if you look at security going forward, I think the broad issue of security will get some more thought and development going forward. This is where we as Honeywell Process Solutions combined with our brother companies at Honeywell will be able to help our customers with solutions. The foundation for a system has to be secure. Security should not be an after thought; rather it needs to be the rst thing a manufacturer has to think about before putting together their systems. For a user to become totally secure, in quite a few cases, they have to change their mindset and commit to ensure a secure environment. We are historically a reactive society, and (security) is about being proactive, Wray said. Some of our customers are becoming more aware of the challenges of implementing a complete security solution. Mindsets are changing though, as users are becoming more aware on what to ask to nd the right approach. I think some obviously are more aware, Gilsdorf said. I think others are trying to get up to speed and ask questions, and that is the role we need to play in talking to them and consulting with them to help them with what we know. I think this is an area that will have more discussion in the future. One other area becoming more dynamic is the plant oor working with IT. Some trends show IT is taking a stronger role in a plants cyber safety. We are seeing a fundamental shift on who the deci-
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security
. . . G U H t a d e t t po S
Manuel Hernandez presents at HUG.
sion makers are when it comes to security, Wray said. Ultimately, it will become the IT manager or the CIO to make sure the systems are the appropriate enhancement to the IT platform. So, yes, these folks are starting to take an increased role. Guarding against cyber attacks is obviously a key aspect to ensuring a secure environment, but so, too, is the physical side. That is why Honeywell was displaying at the users group their physical security systems that focus on ensuring against any intrusions at a plant. One product they were talking about centered on the TWIC system. TWIC stands for Transportation Workers Identification Credential. This card swipes through a reader, and the system then passes the ID along to the TSA, which then authenticates the card holder, said Michael Reinert, principle project specialist industrial security, Americas for Honeywell Process Solutions. The card also has an additional safety feature. If there is an incident at a plant, people can place their card in a muster point in case of an emergency, Reinert said. p
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Mike Long, Alan Autenrieth, and Jeff Becker discuss a topic during a lunch-andlearn session.
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The scene is set for another presentation at HUG.
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17
applications
An alarming situation:
Get a plan and stick to it

hen alarms are going off left and right, operators can turn a deaf ear because it is very easy to become overwhelmed. With no documented alarm management process, Gary Godfrey, senior staff engineer in the control systems department at Saudi Petrochemcial Company in Saudi Arabia, knew this was not a good way to keep the plant running safely. Operators ignore alarms because there are just too many to deal with. If youre being told 20 times a Gary Godfrey explains why his plant needed an alarm management process. minute somethings going wrong, you have no youre 80% of the way there. If theres no action think time to settle in and know what to do about for the operator, and there is nothing they can do that alarm, he said. about it, then dont tell them. You need a governing document, and you need If youre being told 20 times a minute somethings site-wide buy-in. An alarm philosophy is not one size ts all. It is going to be unique to your plant going wrong, you have no think time to settle in and practices. know what to do about that alarm. Godfrey and Incorporate industry guidelines. One thing we embraced was EEMUA, a U.K.-based organization One of the problems is a management system that has the industry standard for alarm managevia paper, and no alarm system performance mea- ment Godfrey said. Include basic denitions: What is an alarm? sures. Today if its not electronic, people dont do Be aware of alerts vs. alarms. Alarms you have to it, he said. You need a philosophy for your plant well docu- take quick action on. Alerts you may need to check mented and well written, or you cannot do alarm every 12 hours. Make sure you have alarm dead bands. This is management. Audible alarms must have operator action. key so you do not get chattering alarms. If it is just If your alarm philosophy contains that one line, going to sit there and go in and out, you need a
applications
dead band there. Set alarm priorities, such as emergency/ high/low. Only 5% of your alarms should have emergency priority. High should be 1%. For that, you probably have a minute to a ve-minute reaction time. Alarms that are low priority (i.e., the lter needs changing) can be attended to next shift. You dont have to get out there in the next two minutes. And remember; alarms are for the operators, not engineers. Pilot study incredible Godfrey and his team did a pilot study for six months, and the numbers were incredible, he said. There was an 83% reduction on one of the consoles in six months, and operators could respond in a timely fashion.
A remote monitoring partnership

By Gregory Hale
Youve got to walk before you run, so keep it simple. Godfrey

Information was kept in Excel with major columns including alarm description, reason for alarm, consequence of not alarming, expected operator action, response time denes priority), PVLO, PVHI, and other LCN parameters. Only look at bad actors, and consider the 80/20 rule, he said. We did a weekly bad actor review. Somebody has to own the alarm management. Empower someone to make decisions. Owners in this project were control system engineers, production/process engineers, and operations representatives. Team membership continuity is crucial. Justify all bad actors. Over time, youll build up a database of rationalized alarms online for operators in the future, he said. With one alarm per 10 minutes on average, Godfrey was pleased with the results of the study. But he cautioned alarm management is an ongoing process. Dont just do it once and walk away. Youve got to walk before you run, so keep it simple. Other pieces of advice included having management support for alarm management. In the future, were going to address standing alarms, reduce inhibited and disabled alarms, operator changes (top changed points and why), and operator changes per audible alarm, he said. p
rowth for a manufacturer is a great thing, and system issues resulting from that growth could be considered a nice problem to have. But a problem is still a problem, and Donald Acton needed to solve it. Acton, the DCS manager at MEMC Inc. at their Pasadena, Tex., ultra-pure granular polysilicon plant, really needed to nd some answers. His stafng was short, and the list of issues was long, so he decided remote monitoring was the way to go, and he decided to partner with Honeywell. We doubled the size of the plant where we went from two trains to four trains, Acton said during his presentation at the Honeywell Users Group. Starting from last June and until now, we have been doubling our amount of I/O. Part of the reason they went with Honeywell was because it was a known brand on the plant oor. We had the TDC3000 installed in the 1990s, so we decided to stick with (Honeywell) and go with Experion. We needed support for our legacy system, he said. Part of the migration plan allowed operators to have online access to a wide range of documentation, and Experion made it easy to incorporate third party systems, such as the alarm management system, Acton said. They also included a PHD system that allowed easier access to historical data. A lot of times people dont use their data historian, but I know people used this one because I would get calls about it, Acton said. With remote monitoring, Getting the system was one it would allow real time thing, but Acton said with his small staff, he wanted to partner with feedback at the plant. It Honeywell so he can concentrate also allowed us to tap into on his strengths. That is where the remote moniHoneywells expertise. This toring idea came in. With remote way we could focus on what monitoring, it would allow real time feedback at the plant. It also we do best and they could us to tap into Honeywells focus on what they do best. allowed expertise, Acton said. This way we could focus on Acton what we do best and they could focus on what they do best, he added. Once they started the remote monitoring process, they quickly found some issues to x: They had some miscongured switches. They were able to monitor operator reboots. They could determine CPU usage and memory. The whole part of partnering was so Acton and his team can focus on producing product. We are using the system to make silicon, Acton said. We dont want to monitor the system. It allows me to work on applications to help the business. My strength is building applications, not monitoring a system. Honeywell can monitor the system. Acton said remote monitoring is an effective way for smaller plants to leverage outside technical resources. Also, remote monitoring keeps problems small, so they dont grow into big problems. p
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applications department name | The Department Description
Genentech masters resource planning integration

att Krause and his engineering team at Genentech in South City (South San Francisco), Calif., were having a problem with their interface with ERP and MES; the challenge was the migration of a resource planning system and an operations management system and the fact they had to integrate them to enterprise resource planning system, SAP, used for process orders, genealogy, and inventory. The resource planning system, called BPCS, was for scheduling of process orders for tickets to make intermediate (stock solution of media) used in bioreactors to feed cell lines to grow faster. The material handling system Honeywell customized for Genetech was called gPOMS.
You might challenge the actual data, but its more important that subscriber systems have the same data, even if its wrong. Krause
Honeywell POMSnet was deployed in two waves. The rst wave deployment in the weigh and dispense area was integrated with BPCS, gPOMS (customized Level 4 system) and EDMS. The second wave deployment increased the MES footprint to intermediates and increased integration with LIMS and SAP while removing integration with BPCS and gPOMS. During the wave 2 deployment integration design, testing, and validation was re-scoped for SPA and LIMS as well as POMSnet integration processing updated to accommodate footprint expansion. The good news was SAP is a supported process, well known, and it involved functions such as nancial, HR, and operations. From a Genentech standpoint, SAP and POMSnet were able to replace BPCS and gPOMS. The end result was successful migration and over half a million transactions processed. But the integration process was not without challenges. We looked at the SAP Lifecycle trigger, Krause said. We loaded all Lifecycle values to get data as soon as it was dened in SAP. We removed Lifecycle changes from triggering transactions. We werent getting updates as they were moving through Lifecycle because there were no changes. SAP was triggering Material Master for early changes. The trigger for Material Master included changes to non-GMP data. There are ve attribute values shared between SAP and MES. SAP has 300 attribute values. We were nding changes outside ve points triggering another transaction, he said. We wanted to automatically update the latest specication version. If SAP is redened using measurement in kilograms, we wanted to stop that transaction. We wanted to revisit unit of measures. Krause and his team adopted the source system subscriber system ideology. Part of the lessons learned were, we wanted to stay in step with system of record. You might challenge the
actual data, but its more important that subscriber systems have the same data, even if its wrong. You should be making changes within the source system. Another challenge in the integration was each material master transaction required POMSnet material specication version to be approved. Some of the issues were POMSnet created material specication in editing, and material specication updates failed if the material was not approved. Failed updates must be reprocessed, which delayed recipe approval time and caused gaps in material master data. We were rewriting the master list twice, he said. We tried to adjust. We had 7,000 material master transactions in one day and 8,000 in August. It was an issue in terms of how SAP was managing the material triggering mechanism. From an MES perspective, we had to get those updates approved. We couldnt leave the highest material version not approved. It was pretty painful. But we estimate 10 hours per week in savings. Additional challenges involved a mix of paper ticket processing and MES integration and the impact on integration between POMSnet and Level 4 systems. We have a small handful of materials in paper that need to be consumed within MES. The issue is those products produced on paper were not triggering the lot master to the execution system. If it doesnt exist, there is no inventory; thats the largest headache, he said. Two resolutions The short-term resolution is whenever there is a paper ticket on something that needs to be consumed in the execution system, we scramble. From an inventory perspective, weve identied denite gaps between SAP and MES. A lot are attributed to MES. We have a buffer that can be formed later in a large tank. MES will identify each container. As production is created, a buffer is created, and inventory is summed up at lot level SAP, he said. Lessons learned At the end of the integration process, Krause and his teamed learned a few lessons. The system should be a system of record (complete, auditable, and accurate). If data in the target system is wrong, it should still match the source system so there is only one system to change. Data should be updated in SAP rst then propagated to MES. In order to maintain synchronization: Changes should be reected in source system and propagated to all target systems. Source systems should transact all data; the target system should parse, ignore, and transform as it needs. Minimize changes to legacy systems. Mixed MES (electronic and paper) complicates interfaces. Engage system expertise early. p
The Department Description | department name applications
Roadmap to new technology

By Nicholas Sheble
ystem obsolescence drives upgrades and We will keep existing scanners and improvements in the sensors in place. We will replace the old pulp and paper (P&P) industry where prot central processing units and the user margins are so thin interfaces. We will upgrade the signal that little money exists for any sort of processing. Garnett capital investment and the mantra of if it aint broke, dont x it thrives. Honeywell is on the verge of being unable to supply critical spare parts for some of our longtime customers in the P&P, said Brad Garnett at Honeywell Users Group. Garnett is a pulp, paper, and continuous web solutions director handling Honeywells Brad Garnett speaks on system obsolescence at Honeywell Users Group. global business out of Bangkok. Annual Return We should note some of these parts debuted Open Systems Integration in the 1970s and 1980s. To replace and repair Improved Visibility some operations, the company sometimes must Reduced Machine Breaks cannibalize several systems to make a single one Reduced Maintenance Costs live on. Reduced Unscheduled Downtime This is testimony to the industrys frugality and Honeywells devotion to old friends probaReduced Color Rejects bly, but the point of Garnetts talk was it is time Reduced Grade Change Losses to move on, and this is how it can happen given the P&Ps never ending protability and capital Increased Ash Levels crisis and the present recession. Upgrade Cost Honeywell listed between 10 and 15 units Reduced Break and Start-up Losses Quality Optimizer it will no longer support after 2010. Garnett Reduced Edge Control Losses Advanced Analysis Improved Alignment relayed the solution as he and the company Machine Sentinel Improved Resolution Color Control Upgrade see it. Faster Scanning MD Control Upgrade We will keep existing scanners and sensors CD Control Upgrade in place. We will replace the old central proReduced Spare Parts Usage PMP Signal Processing cessing units and the user interfaces. We will Scanner Upgrade Improved Reliability Base Da Vinci & Services upgrade the signal processing, Garnett said. He explained in detail how this strategy would improve the papermakers lives, products, and The Honeywell strategy would avoid a complete replacement of the quality margins. p control system but introduce a number of technical and quality upgrades.
Full Replacement Incremental Cost Incremental Installation Costs
www.honeywell.com/ps INTECHS HONEYWELL E-ZINE 21
applications department name | The Department Description
South African renery gets face lift

he Engen Petroleum renery was built between 1951 and 1954 and is surrounded by residential areas in Durhan, South Africa. You can imagine, we come under pressure from environmental groups, said Vikash Devray of Engen Petroleum Ltd., who gave a talk on how to improve operations and reduce costs with Prot Stepper at the Honeywell Users Group in Phoenix.
We wanted to allow for testing for the addition of new and existing independent variables while the current controller executed. To do this we needed to integrate and leverage current technology and reduce time and effort required for application revamp. Devray
Engen is now a global petroleum industry leader through its parent company Petronas, which has the largest market share in South Africa, and interests in over 20 African countries. Todays business is multifaceted, Devray said, rening crude oil, marketing,
t h g i s n I t Exper
and retailing primary rened petroleum products. Today, Engen renery in Durban produces more than 125,000 sbpd of oil (lead replacement, unleaded gasoline and low sulphur diesel, lubricants, and chemicals. Engen is a member of the Prot Customer Advisory Board. Its renery has a large Prot Suite installed base, and the renery has assisted on beta testing of early Prot Stepper products. The situation for Devray and his team was this: We had a successful Prot controller application at Durban FCCU complex. This covered reactor/regenerator sections, which were redone in 2004, and since then have had high acceptability with 93% uptime. The goal was to expand the application scope to include the main fractionation tower, which was previously excluded in the 2004 revamp. The FCCU is at the heart of plant operations, which are subject to frequent changes in feed rate, feed composition, and reactor severity, Devray said. The goal was to expand the application without decommissioning the controller. We wanted to allow for testing for the addition of new and existing independent variables while the current controller executed, he said. To do this we needed to integrate and leverage current technology and reduce time and effort required for application revamp. Traditional and competitive test methods were not feasible due to mixed closed-loop and open-loop structures. We needed an integrated tool to collect data, step test, and identify new models. We turned to Honeywell for help on this FCCU application revamp. Prot Stepper overview Devray described Honeywells Prot Stepper as an integrated tool providing data collection, automated testing, and real-time data visualization, with online identication of dynamic models for openand closed-loop. It also supports engineer and operator interfaces. It directly supports multiple testing modesthe initial controller/model development, model maintenance, and model expansion. The Prot Stepper tool reduced test time and supported online model identication and allowed testing as a mixed closed-loop and open-loop structure. It also automated identication of new process models and allowed existing Prot Controller applications to continue executing. The revamp caused little or no additional burden for operators in monitoring, Devray said. The existing Prot controller became the real-time monitor;
Video: Reliability a total team effort This economic environment is forcing manufacturers to stay on top of their games to ensure they get the most out of their systems. After all, downtime means lost revenue. Honeywells Bart Winters talks about how to make a system more reliable.
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The Department Description | department applications name
. . . G U H t a ed t t po S
it combined open- and closed-loop testing and identication, and provided active constraint management during plant testing. The true measurement of success though was in the real-time measurement of test progress. Some of the other benets included reduced implementation time. Process models were created automatically, manual data extraction was eliminated, and ofine identication testing automatically adapted to focus on model deciencies. Traditional testing could have put the renery at FCCU risk, Devray said. But the closed-loop identication and Prot Stepper maintained FCCU stability. Disturbances for operators were minimal. There was a 41% reduction in time to test and identify new FCCU models. And we estimated savings around $83,000. p
Tom Kindervater addresses the crowd.
>
Podcasts
One Honeywell solution Manufacturers can now take a holistic and integrated approach to sustain business optimization over a systems lifecycle. It starts from the design, and works all the way through the lifecycle. Honeywells Frank Whitsura discusses what the solution brings to the table. http://www.isa.org/brdcst/files/HUG Frank Whitsura Podcast.mp3 Prepare for the unexpected Are operators prepared when an abnormal situation arises at a manufacturing plant? The Abnormal Situation Management Consortium has the answers in this podcast. http://www.isa.org/brdcst/ les/061709_HUG_Podcast.mp3
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Shawn Kittle talks to HUG attendees.
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Audience members listen to presentation.
Paul Bird speaks to the crowd.
23
products
Saving energy with a dashboard
hen it comes to manufacturers today, one of the major issues they confront is how to improve upon energy performance. Honeywell says it has the solution. That solution is a customizable portfolio of new and existing hardware, software and services to help improve energy efciency and reduce greenhouse gas (GHG) emissions. These Energy Management Solutions target a wide range of energy-intensive process manufacturing facilities such as rening and petrochemical production. The new offering uses a Honeywell Energy Dashboard, which gathers information from various instruments and systems and tracks their energy consumption against dynamic energy targets. The Energy Dashboard allows the user to go to the most deviated targets, said Brendan Sheehan, senior marketing manager chemicals at Honeywell Process Solutions at a press conference at the Honeywell Users Group in Phoenix. You can look through the deviation page and nd common cause of deviations. This all could lead you to nd out about your energy performance and how to increase your performance. In and of themselves, the instruments are not new, but the concept of packaging them to get a better rate of return is, Sheehan said. Improving energy efciency is an effective way to reduce operating costs and CO2 emissions, Sheehan said. Working with Honeywells UOP in rening, energy
savings of 12-25% a year is possible. The reason this all came together now, Sheehan said, is because the Honeywell architecture now allows the company to bring in all the tools to offer a total solution. One application at a North American renery had a cost savings of $27 million a year and had a payback in less than two years, he said. At a pulp and paper plant, they were able to reduce the motor load by 53% and garnered a 2% reduction in energy, which reduced the total cost of operations. Capturing and analyzing data allows users to understand key energy indicators and how they affect overall energy consumption. The Energy Dashboard, which should be ready to hit the market in the fourth quarter, allows users to establish specic goals for reducing energy consumption, costs, and the associated GHG emissions, as well as to measure actual performance against those goals.
Improving energy efciency is an effective way to reduce operating costs and CO2 emissions. Energy savings of 1225% a year is possible. Sheehan
Once they are able to identify energy saving potential, they are then able to offer customizable hardware, software, and services to improve performance, including enhancements to measurement and monitoring, control and optimization, heat recovery, feedstock optimization, advanced process technology, utilities optimization and services to sustain and even improve results over time. p
OneWireless enables wireless process control

oneywell Process Solutions introduced the latest version of its OneWireless industrial mesh network solution for manufacturing facilitiesOneWireless R120 features the process industrys rst redundant wireless system gateway (WSG). The WSG manages data between wireless eld instrumentation and the plants process control network (PCN). It serves as a backup gateway to ensure data is delivered even if the main gateway malfunctions or fails. Paired with existing OneWireless redundancy features, this approach creates the rst industrial wire24 INTECHS HONEYWELL E-ZINE
less system with complete hardware and radio-frequency redundancy from the eld instrument to the PCN connection. Unique failure recovery features help prevent data loss, and the network can recover in less than two seconds from any eld hardware failure. Many plants today are only using wireless for non-critical applications, but that will undoubtedly change in the future as the trust in and adoption of wireless technology grows, said Jeff Becker, global wireless business director at Honeywell. Plants will control critical processes over
wireless networks, which must be as reliable as wired networks. OneWireless is ready for these new demands with built-in features that enhance data availability and system reliability. OneWireless R120 includes several other enhancements that improve the network scalability and reliability such as adaptive transmit power control for XYR 6000 eld instruments. This feature saves battery power and minimizes radio interference by enabling eld devices to use the least power possible to transmit signals to OneWireless multinodes, or access points. p
products
Valve position sensor improves plant reliability

he XYR 6000 Valve Position Sensor, the latest addition to Honeywells OneWireless industrial wireless portfolio, helps improve overall plant reliability by giving users the ability to remotely monitor a greater number of applications within their processing facilities. Based on the Honeywell MICRO SWITCH CX series hazardous location analog sensor, the new XYR 6000 Valve Position Sensor monitors the position of the valve when used in OneWireless systems, sending the signal from remote or potentially dangerous areas of the plant. The sensor carries all the appropriate hazardous location certications, which makes it ideal for various applications such as monitoring valve positioner status, manual process valve position, safety shower and eye bath notication, tank overow alarms, damper and louver position, door/gate position, or other applications where installing wires is inefcient,
This new sensor eliminates the need for manual monitoring, which can provide tangible benets for our customers.Becker
cost-prohibitive, or simply unsafe. MICRO SWITCH technology has been trusted for over seven decades in the process industries. Incorporating OneWireless connectivity helps our customers benet from increased safety and efciencies provided by these technologies, said Jeff Becker, global wireless business director for Honeywell Process Solutions. This new sensor eliminates the need for manual monitoring, which can provide tangible benets for our customers when they apply them in the plants most hazardous and remote areas.
The XYR 6000 Valve Position Sensor also simplies maintenance by electronically tagging each valve in the system, identifying valves that have degraded or been damaged. This reduces the need for eld technicians to manually inspect valves for maintenance. p
Optimizing terminal operations
oneywell released Terminal Manager, a distribution-automation system designed so process manufacturers can safely and efciently load and unload trucks, rail cars and ships in bulk-liquid terminals. The system links terminal operations into Honeywells Experion Process Knowledge System (PKS). Terminal Manager integrates with subsystems such as safety and security solutions, advanced control applications such as blending and movement, and most standard equipment found at terminals including weigh scales, ow computers, tank gauges, and automated valves. This integrated approach allows manufacturers to limit risks involved with lling large tanks with volatile products and to keep constant tabs on all products that come into and leave their terminals. Terminal Manager provides a secure database for information, including the custody-transfer transaction data from instrumentation, which provides legaltransfer points for billing and tax purposes; vehicle/driver data on each vehicle that enters the terminal to match orders to the right vehicles; and inventory man-
agement data that interfaces to pipeline and tank monitoring systems, providing detailed balance reports. The database houses order and shipment data from enterprise resource planning (ERP) systems, which helps support the invoicing and payment of products
before vehicles leave the terminal. The system also provides a secure audit trail that captures the minute-by-minute history of each event and activity in the terminal. This allows the renery to detect even the smallest product losses caused by incidents such as theft. p
Video: Products on display From wireless to safety and security and beyond, Honeywell had a plethora of products on display in its demonstration room at the Process Solutions Users Group Symposium.
25
products
Simulation software offers engineers greater range
niSim Design simulation software provides engineers a greater range of tools to build and test plant processes. The simulation and modeling software will include a are analyzer that enables process engineers to design, improve, and optimize industrial are systems. Additionally, UniSim Design will support XML-based case portability to allow users to share process design information with ASPEN HYSYS, HTFS, and HTFS+ offered by AspenTech. Both features should be available in early 2010. UniSim Designs interactive software
allows engineers to create and analyze both steady-state and dynamic models for plant design, performance monitoring, troubleshooting, operational improvement, business planning, and asset management. The addition of the are analyzer will allow users to create morecomplete models of their processes and further improve overall plant efciency. Flare systems are integral parts of many industrial processes where proper design and analysis is required to promote safe and efcient operations. Additionally, the new case-portability feature delivers
greater exibility by enabling Honeywell and AspenTech simulation users to access each others process models. These UniSim Design enhancements provide users with a more comprehensive simulation solution and provide for collaboration both in and outside their organizations, said Ashish Gaikwad, advanced solutions director for Honeywell Process Solutions. These enhancements fall in line with our approach of improving overall plant safety, reliability and efciency by giving personnel greater access to the most relevant information. p
Touchscreen operator interface aids plant operators

oneywell released a touchscreen operator interface that helps plant operators using Honeywell HC900 Control Systems more easily manage their processes. The Honeywell 900 Control Station is a panel-mounted interface available for all new HC900 installations. It also can be retrotted for existing, compatible systems. The new operator interface, featuring a 10.4-inch color display touchscreen, introduces enhanced graphic features designed to reduce set-up time and simplify operation while improving security and versatility in the eld. Preformatted displays, custom graphic tools, plus more
than 4,000 pre-built process graphic objects make it easy for system designers to create unique color graphic touchscreen displays that schematically symbolize the layout and functions of the process, facilitating operator acceptance. The interface also helps simplify process changeovers by allowing operators to select from previously stored recipe variables, setpoint programs, setpoint schedules and sequences. Efcient production means being able to focus on managing processes, said
Henri Tausch, vice president and general manager, Honeywell Field Solutions. The 900 Control Station enables customers to manage and optimize their applications by providing an easy-to-use system for application control, measurement and data acquisition. p
Honeywell to install re, gas detection system in Turkey
oneywell has been selected by Tekfen Construction & Installation Co., Inc. to design, congure, install, and initiate a new re and gas detection system at the BTC pipeline terminal in Ceyhan, Turkey. The BTC pipeline is a crude oil pipeline running from the Azeri-Chirag-Guneshli oil eld in the Caspian Sea to the Mediterranean Sea. It connects Baku, the capital of Azerbaijan; Tbilisi, the capital of Georgia; and the port of Ceyhan on the southeastern coast of Turkey, hence the name BTC pipeline. At 1,099 miles long, it is the second longest pipeline in the world. The project is funded by a consortium of 11 oil and gas companies and is led by BP Plc.
The new re and gas detection system will include Honeywells Safety Manager and Searchline Excel open path gas detectors, as well as closed-circuit television (CCTV) ame detectors. The system will cover the tank farm, metering and jetty areas at the Ceyhan terminal. Honeywells Experion Process Knowledge System (PKS) also will be installed in the terminals central control room and used to monitor all aspects of the system including alarming, event and video recording. In addition, the new re and gas detection system will be fully integrated with existing automation systems on the BTC pipeline, further increasing plant safety by providing opera-
tors with full insight into all gas levels and ame detection, allowing for better decision making. Enhancing the safety of a major pipeline requires the right technology and experience in order to keep the process safe and operations on track, said Naci Erakn, country leader, Honeywell Process Solutions, Turkey. Streamlined information, professional project management, and effective solutions for the customer all play major roles in addressing the pipelines safety. Our solution will help keep the plant operating safely and provide operators with additional information that will help improve the performance of the pipeline. p
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2009 Honeywell Users Group Americas Symposium Coverage and Insights

Innovation today Wireless Security Applications New products

Hard work yes, but innovation, imagination will trigger growth

Gilsdorf: Industry seeing little sparks of life

INTECHS HONEYWELL E-ZINE

Industry seeing little sparks of life

Knowledge management means saving time, money

INTECHS HONEYWELL E-ZINE

innovation today department name | The Department Description

At one with integration

The Department Description | department innovation name today

Weve generated $5 billion in terms of benets for our customers. Urso

INTECHS HONEYWELL E-ZINE

Wireless enables continued growth

Plan ahead for wireless

INTECHS HONEYWELL E-ZINE

wireless department name | The Department Description

Wireless helps plant recover from disaster

The Department Description | department name wireless

Wireless networking has more than one way to go

INTECHS HONEYWELL E-ZINE

wireless department name | The Department Description

Wireless keeps growing

Honeywells Jeff Becker

The Department Description | department wireless name

Eric De Groot addresses the crowd at HUG.

Soroush Amidi introduces a slide to attendees.

Frank Whitsura makes a point during his presentation.

INTECHS HONEYWELL E-ZINE

ISA100 up and running

Brendan Sheehan poses a question to the group.

The audience listens intently at a breakfast session.

INTECHS HONEYWELL E-ZINE

Think security rst

INTECHS HONEYWELL E-ZINE

INTECHS HONEYWELL E-ZINE

The scene is set for another presentation at HUG.

Get a plan and stick to it

A remote monitoring partnership

Youve got to walk before you run, so keep it simple. Godfrey

INTECHS HONEYWELL E-ZINE

applications department name | The Department Description

Genentech masters resource planning integration

The Department Description | department name applications

Roadmap to new technology

applications department name | The Department Description

South African renery gets face lift

INTECHS HONEYWELL E-ZINE

The Department Description | department applications name

Shawn Kittle talks to HUG attendees.

Audience members listen to presentation.

Paul Bird speaks to the crowd.

INTECHS HONEYWELL E-ZINE

Saving energy with a dashboard

OneWireless enables wireless process control

Valve position sensor improves plant reliability

Optimizing terminal operations

INTECHS HONEYWELL E-ZINE

Simulation software offers engineers greater range

Touchscreen operator interface aids plant operators

Honeywell to install re, gas detection system in Turkey

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