Achieving and Sustaining Peak Performance HONEYWELL FORGE FOR INDUSTRIAL Sandeep Chandran June 2019
Achieving and Sustaining Peak Performance
HONEYWELL FORGE FOR INDUSTRIALSandeep Chandran
June 2019
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
OPERATOR CHALLENGES
Longer, harsher operatingcycles between turnarounds, at peakperformance
• Demanding products, and quality commitments
• Older equipment stretched to meet demand
• Increasing safety, environmental compliance and stewardship
• Global competitive marketplace
Differing outcomes acrossshifts, units, plants andenterprise
• Knowledge Retention & Adoption
• Loss of expertise due to graying workforce
• Disconnected Solutions
• Inconsistent User created insights
Lack of Integrated insightsacross the operatingspectrum
• Rapid identification of Root Causes
• Access to alerts and actionable recommendations
• Closed-loop workflows
• Enterprise analytics for meaningful insights
Increasing
Operational
Complexity
Changing
Workforce
Demographics
Data Integration
to Intelligence
Integration
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PROCESS AUTOMATION INDUSTRY DIGITAL TRANSFORMATION
Digital Debt, Digital Dividend and Digital Penalty
ARE YOU READY for New Wave ?
20102000
• Industry adopted WINTEL
• Opened wider innovation opportunities
Va
lue
to
th
e C
us
tom
er
Innovations by Time Period
1975
DCS as Innovation
Industry 3.0
>2015
New Wave of Innovation
o Cloud
o IIoT
o Virtual Reality
o Machine Learning
o Digitization
Industry 4.0
The rate of change
ahead of us is steep
and accelerating
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Technology is now enabling us to truly understand
the interdependencies of the complete ecosystem
of people, assets and process
Co
st
of
Wa
itin
g
Time
Digital transformation late-
adopter curve
Previous late-
adopter curve
LATE ADOPTION COSTS WILL BE 2–3X GREATER THAN BEFORE
3
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HONEYWELL FORGE FOR INDUSTRIALENTERPRISE PERFORMANCE MANAGEMENT
Connected Plant Portal
Delivers actionable insights
for intelligent operations using real
time models, domain expertise and
visual analytics
• Role-based, comprehensive visual
analytics to optimize your process,
assets and people performance
• Identify process & asset equipment
issues and inter-relationships
• Actionable insights that improve ability
to collect, analyse and act on data -
highlights potential financial opportunity
• Deployment in a cloud environment
• Developed to meet industry’s highest
cyber security standards
Asset Alerts
OpportunitiesPerformance Metrics
Recommendations
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
BEFORE HONEYWELL FORGE FOR INDUSTRIAL
APC
Process engineer observes that APC
for the unit is not performing well
Trend analysis in Historian
Equipment analysis in
Reliability system (if exists)
Discuss with operations &
conduct other relevant
investigations
To further investigate, the engineer
conducts some of these actions
Manually assemble the insights, come up
with recommendations and action plan
Challenges:
1. Manual, time consuming and reactive
2. Difficult to uncover inter relationships
3. Determine actions
1 2 3
Analyze APC performance
OPPORTUNITY COST
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
AFTER HONEYWELL FORGE FOR INDUSTRIAL
Engineer accesses Honeywell Forge
✓ Digital Twins compares current process performance to optimal performance
✓ Analytics identifies areas where constraints prevent units from achieving optimal operations, providing recommended actions.
✓ Economic impact analysis is presented in dashboard to orient action plan to highest value issues
APC Digital Twin
Process Digital Twin
Asset Digital TwinRecommendations
Opportunities
Performance Metrics
1
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
Consumer Grade User Apps
Intuitive apps that enable user
adoption
API as a Service
Partner/OEM enablement; Ease
of integration & Migration
Intelligent Model Framework
Runs 3rd Party and Honeywell
models
Connectivity
Real-time for critical, near real-
time connections, ease of install,
single sign-on. Designed to to
meet industry’s highest cyber
security standards
Value Delivered
APIs extend the solution to
3rd party applications
Honeywell domain with
machine learning models
drive actionable insights
Minimize IT need to manage
connections across assets
Protect current investments
with an extensible solution
ModulesHoneywell Forge for Industrial
Clo
ud
Ind
ustr
ials
&
Ed
ge
HOW IT WORKS
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
First Principle Process Models (Process Simulation...)
Commonly used for process evaluation
Comprehensive representation of process and asset design
Empirical Models (Advanced Process Control..)
Commonly used for control & optimization
Represents process and equipment constraints that are fine
tuned using cause and effect
Knowledge Based, Statistical Models (Asset Performance
Management..)
Commonly used for equipment health monitoring
Uses operational knowledge and historical statistics to identify
abnormal operating conditions
Designed to quickly identify the best
path to peak performance
Model Libraries
Visual Analytics
Integrating Analytics and Recommendation
from Underlying Modules
INTELLIGENT MODEL FRAMEWORK
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
Process Reliability AdvisorUse real-time operating data to detect and
diagnose issues to improve unit performance
Leverage Honeywell UOP’s comprehensive
experience to assess process constraints and
proactively mitigate operational issues
Process Optimization AdvisorGain expert operational recommendations to utilize assets and derive maximum profitability from the complex
Provide an optimal set of operating conditions, based on customer economics, for the unit to run at minimal cost and waste
Improve throughput, yield, process & catalyst reliability through early event detection
Improve plant performance & increase profitability by over
$0.30-0.50/bbl in Refining
$10-20/MT in Petrochemicals
Underlying Intelligence
PROCESS PERFORMANCE
Extensions to Partner Units
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
Monitor
Real time APC performance accessible
at any time
... Prioritize
Visualization of APC performance in order of
economic impact
! Diagnose
Correlate economic performance of APC
towards process operations issues
Resolve
Detailed analysis identifies process
bottlenecks
$700,000
$750,000
$800,000
$850,000
$900,000
0 10 20 30W…
Profit Performance Monitor Identify degradation of unit performance and provide expert guidance through actionable instructions to
maintain unit profit performance
Provide visibility into the economic consequences of plant process performance as cost of lost
opportunity
Ensure sustainable benefits over varying operating conditions, visualizing real time unit profitability
Identify process, advanced control issues contributing to lost performance
Sustain throughput & yield for longer periods of time
Identify 10 to 20% lost benefits/year per APC application
CONTROL PERFORMANCE
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Data from controls &
edge devices1
SENSORS
CONTROL NETWORK
SECURED DATA
Asset digital twins & analytic models
2 3Metrics
Asset Alerts
Opportunities
Recommendations
4Asset Performance Management
• Predictive analytics deliver early insight to
impending issues
• Integrated process and asset data models
identify new levels of untapped
productivity
• Unified enterprise connectivity drives
common workflow across engineering,
maintenance, and operations
Cloud-based event/fault detection
Recurring annual savings of
$1M+ in small
$5-10M in larger deployments
ASSET PERFORMANCE
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
EMBEDDED ASSET TEMPLATES – DEPLOY
QUICKLY
12
The Honeywell Asset Performance Library
• Plug-n-play model creation
• Quickly create digital twins
• Models across asset and industry types
• Embedded expertiseCENTRIFUGAL PUMPS
HEAT EXCHANGERS
ELECTRIC MOTORS
VALVES
TURBO & RECIPROCATING
COMPRESSORS
FURNACES
GAS & STEAM TURBINES
FANS & BLOWERS
HAUL TRUCKS, EXCAVATORS,
SHOVELS
CRUSHERS, DRILLS, DOZERS
REACTOR COLUMNS
OXIDIZERS
ESP’s (ELECTRIC SUBMERSIBLE
PUMPS)
Refining & Petrochemicals
Oil & GasMining &
MetalsPower
Real-time Digital Twins
Head =3960*HP /
Flow
Performance CalculationsExchanger
Turbine
Compressor
Pump
Furnace
Asset
Library
Data Cleansing
Health Monitoring
Cloud Analytics
Sample equipment types available within the library (partial list)
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
Honeywell Forge for Inspection
Rounds
An end-to-end mobile solution for field
operations to manage daily operator rounds.
Standardized and automated processes,
connecting and orchestrating field operations
Works on any mobile device, or smart
wearable, – enabling maximization of existing
IT investments.
Safely and efficiently executing tasks and workflows
PEOPLE PERFORMANCE
Increase number
of closed-loop
workflows
Increase visibility
and transparency
Enhance process
and productivity
Reduce incidents
Reduce downtime
Reduce time spent
on root-cause
analysis
Reduce OPEX
Create operational
best practices, set standards
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
Combine digital twins of
process units & equipment
assets to generate insights
Augment intelligence from
underlying applications for
actionable insights
Shorten Ideation to Value
Delivery lifecycle
Increased profitability and
efficiency via integrated
and more accurate models
Visualizing analytical results
from multiple sources to
identify issues - leading to
action
Extensible and flexible platform
maximizing value generation
from a single interface
Integrating point solutions
to a single, common
persona-based solution
Deeper insights through
predictive analytics guidance
for faster decision making
HONEYWELL FORGE FOR INDUSTRIAL
Portable and extensible
platform to meet highest
cyber security standards
Identity Mgmt
API Gateway
Logging & Monitoring
App Hosting
Deployment
Platform Services/
Capabilities
Licensing
Access Mgmt
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
INTEGRATING DATA AND MODELS FOR AN ENTERPRISE VIEW
15
Make informed decisions by seeing the whole picture
Honeywell Forge for Industrial
Real-time data and visual intelligence to help
optimize production and increase profitability
Quickly spot opportunities, and provide
recommendations to improve processes,
equipment performance and automation.
Benchmark actual process and asset
performance against expected optimal
performance with digital twins
Quickly identify the best path to peak performance
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
HONEYWELL FORGE FOR INDUSTRIAL SESSIONS
• 11:30 AM – 12:15 PM Application of Process Reliability Advisor to Drive Operational ExcellenceKatherine Jones, Honeywell – MIRO Room
• 1:30 PM- 2:15 PMHoneywell Cloud Asset Performance Solution Helps Avoid Machinery Downtime within its PMT DivisionWilliam Olp, Honeywell PMT Orange – MIRO Room
• 2:30 PM – 3:15 PM Digitization of Operator Field Rounds at Reliance Pratik Naik, Reliance Industries Ltd – MIRO Room
• 3:45 PM – 4:30 PM Spotlight: Closing the Gap Between Planning & Control with Honeywell Profit Executive Perry Nord, Honeywell – Demo Center
• 4:45 PM – 5:30 PMHoneywell Forge for Inspection Rounds and other Technology EnablersSebastian Loeb and Veronica Turner – Honeywell – MIRO Room
© 2019 by Honeywell International Inc. All rights reserved.
Questions
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