Applying New Technologies to Reduce Project Risk LEAP™ - LEAN PROJECT EXECUTION Nigel Brockett 20 Oct 2016
Applying New Technologies to Reduce Project RiskLEAP™ - LEAN PROJECT EXECUTIONNigel Brockett
20 Oct 2016
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
Project Execution in the 21st Century
• What is different today?
- Over the last 7 to 10 years, projects have gotten
larger
- No one EPC, often no one owner will take full
ownership
- Scarcity of skilled people
• Implications
- Work is often done by multiple EPC’s or multiple
offices
- Work can be done under multiple owner
guidelines
- Some project deliverables impacted more
severely
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DATA will be late!
PROCESSES will change!
COST will be an
issue!
DATA will be late!
COST will be an issue!
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
The Challenge of a Traditional Project
Define Design Manuf Config Test Install
Start FinishPHYSICAL FUNCTIONAL
Hardware Definition
Marshalling Design
IO Assignment
Control Configuration
HMI Configuration
Alarm Configuration
System FAT
Site
Commission
I/O Counts, Locations
Instrument Index
Cable Designs
P&IDs, Narratives
Alarm Studies, Set Points
Configuration FAT
System
Configuration
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5
10
15
20
25
30
Traditional Project
Backend Loaded Managing Late Changes
3
Months
Traditional Project
Lab
or
FT
Es
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Repetitive Tasks Rework Redundant Tasks
Lean Execution Eliminates Waste
If “Time is Money”, Then “Wasting Time is Wasting Money?”
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Entering the same data
over and over again
Editing the same data
over and over again
Validating the same data
over and over again
Non-value Add Processes are Considered “Waste”
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Reduce Risk
Drive Effectiveness not Efficiency
To Efficiently Do What is Not Required is NOT Effective!
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Remove Custom Designs
Reduce Complexity
Reduce Travel
Reduce System
FAT
Reduce Cost
Reduce Schedule
ReduceHardwareFootprint
Remove Early
Hardware Order
Eliminate hardware Eliminate tasks
Eliminate travel Optimize execution
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Integrated solutions
increase value
of individual benefits!
LEAP Enabling Technologies
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Universal IO
VirtualizationCloud
Engineering
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Universal Channel Technology
Universal IO / RUSIO Units
Modules Shipped in last 18 months 3,600+
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Essentials PlatformTraditional Platform Premium Platform
Virtualization
Saves on Power, Weight and Cooling
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Design Independence with Virtualization
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Virtualized Controller IO Simulators
Delay deployment to hardware
Standardize supervisory
designs
Variable capacity
1 40+
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Cloud Engineering
SiteOffice
SSL VPN
Gateway
Honeywell VPN
Remote Office
Virtual
Engineering
Platform
Customer
Office
EPC
Office
Honeywell
Regional
Office
VEP Statistics (June 2015)
System Capacity 27,000 VMs
Current Usage 11,000 VMs
Total customer project systems 1640
Current active customer projects 842
WAN
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Virtual Acceptance Testing
Start Up New Pcs With the Longest Lifecycle!
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Honeywell Hosted ProjectTraditional
People and target equipment staged early in project in a
single location
Configuration checkout & FATs done
on large grained scope with travel
of critical resources for long periods
Project staged in data center; people distributed; equipment
not required until late in project
Customer, EPCs, HON all have secure
remote access to validate modular
increments – less travel & rework
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Global Project Delivery Model
Technical Standards + Project Methodology
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GPM (Global Project Methodology)
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Off theCritical Path
LEAP - Lean Project Execution
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Define Design Manuf Config Test Install
Start FinishPHYSICAL FUNCTIONAL
LateBinding
• Cloud Engineering enabled by Controller and IO Simulators in Virtual Machines
• Control Strategy Adaptability when you need it, during project execution
- No IO Module ID required for configuration
- No IO Channel ID required for configuration
- Functional configuration independent of physical design
• Late Binding matches the functional configuration to the physical design
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LEAP - Lean Project Execution
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Marshalling Design
HMI Configuration
Alarm Configuration
System FAT
Cable Designs
P&IDs,
Narratives
Alarm Studies,
Set points
LateBinding
Hardware Definition
IO Assignment
Control Configuration
Site
Commission
I/O Counts,
Locations
Instrument
IndexConfiguration
FAT
System
Configuration
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
Remote IO Cabinets
• Traditional design with field junction boxes and local equipment
rooms add engineering and construction cost
• Field mounted UIO eliminates significant cost, delivery lead times
and opportunities for error
Remote Instrument Enclosure
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Reducing project CAPEX
Component Cost
($ per I/O basis)
Convent’l
I/O Cards
UIO in
Cab
URMC Comments
Cost of I/O Hardware 100%
(Baseline)
110% 145% URMC adds more
cabinets, PSU, IOLE, etc.
Cost of Custom Marshalling
Panels
15%* - - Field terminals included in
UIO / URMC cab designs
Cost of Cabinet Staging and FAT 6%* - - Standard UIO cabs
shipped direct to site from
factory
RIE Footprint 56% 42% - Non-Blastproof RIE
Home Run Cables 30% 30% -
Field Junction Boxes 20% 20% - URMC replaces field JB
Fiber Optics and Power Cables - - 20% Redundant FO & power
Loop Wiring Testing 9% 9% 3%
Total Installed Cost (TIC) 236% 210% 169%
Relative Savings Baseline (11%) (28%) * Excludes impact of I/O
design changes
Relative Total Installed Cost Savings with Remote UIO Cabinets
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Support for Modular Construction
Technology to stay off the “Critical Path”
• Project early ships “standard” Universal Cabinet to Module Yards
- Ship sooner with less information
- Flexible location for installation
- Standard Factory testing
• At each Module Yard
- Terminate signals on any channel in Universal Remote Modular
Cabinets
- Full loop test prior to shipment
- Control and IO Configuration is done in a cloud
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What is Late Binding?
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Central Control Room
HMI
Control Configuration
Alarm Configuration
HMI Configuration
Configuration FAT
Alarm Studies, Set points
Sketches, Procedures
SIMACESIMC300
No physical channelassignments required
Universal Cabinet
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Late Binding Advances – Future
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Tagname 1
Tagname 2
Tagname 3
Tagname 4
Tagname n
FI101
Detect
Interrogate
Configure
Enable
Document
Central Control Room
HMI
Control Configuration
Alarm Configuration
HMI Configuration
Configuration FAT
Alarm Studies, Set points
Sketches, Procedures
SIMACESIMC300
No physical channelassignments required
Universal CabinetxxxxxxxxxxFI101xxxxxxxxxxxxxxxxxx
32 character tagname for HART 6/7
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LEAP Project Workflow
Work in Parallel, Virtual FAT, Ship to Site Earlier
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Minimal CheckoutEliminates big bang testing
with virtual FAT
FunctionalEPC
Honeywell
Honeywell Virtual Engineering
Platform
Customer
Direct to Site!
Physical
Standard Cabinets
Servers
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Case Study
• With Virtualization and Universal IO
• Reduce the MAC cabinets by 50%
• Reduce Marshalling cabinets by 90%
- $10K per cabinet is over $1M
• Reduce cabinet engineering, drawings and documentation
- ~40 hrs per cabinet means 5000 hours of work eliminated
- Depending on where that is done, saving from $500K to $1M
- 4 drawings per cabinet, typical, this eliminates 500 drawings
This represents 1000s of hours for the EPC to review, approve and cycle
to end user
• Reduce opportunities for marshalling mistakes by 66%
- Each loop can have up to 15 terminations between device and IO
Module
With Universal IO, there are 5
• Reduce capital cost by $16M
- In a normalized $50M MAC scope
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EPC Opportunities
• Potential EPC Benefits
• RIE Foundations and transport
- Engineering, Material and labor
• Home run cables and trays
- Engineering, Material and Labor
• Engineering drawings
- JB, wiring reports, routing plans, etc..
• Procurement Activity Reduction
- Supply chain reduction
• EPC FAT
- Time and Travel
• Commissioning savings
- Labor and travel
• Reduced Control Room and Equipment room
- Less footprint, power, HVAC, and weight
LEAP
Universal IO
Virtualiz-ation
Cloud Engineering
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End User Opportunities
• Reduced spares
- Universal Channel Technology adapting to signal mix
• Reduced OpEx
- RIE infrastructure, HVAC, Power, Fire and Gas, etc.
• Startup and Commissioning
- Reduced commissioning time and simplification
• Lifecycle cost reduction
- Tech refresh avoided
• Operations lifecycle simplicity
- Reduced marshalling, loop drawings made
simple, trouble-shooting and diagnostics
simplified
• Reduced project risk
- Reduced Cost and flexible schedule
- Keep automation off the critical path
LEAP
Universal IO
Virtualiz-ation
Cloud Engineering
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Traditional Waterfall Schedule
A Revolutionary New Schedule
LEAP Can Generate 25% of Schedule Flexibility or Compression!
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Traditional approach is often back end-loaded
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5
10
15
20
25
30
Months
LEAP Project vs. Traditional
Modular, Incremental Design – Avoid Backend Loading
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Traditional
LEAP Project
Lab
or
FT
Es
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A Universal Opportunity!
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LEAP delivers
a step change for Automation Projects!
Change Management
Schedule Management
Resource Management