Assuring Long-term Benefits from your Advanced Applications

2015 Honeywell Users Group

Europe, Middle East and Africa

Assuring Long-term Benefits from your Advanced Applications

Daren Lewis, Honeywell

2 © 2015 Honeywell International All Rights Reserved

• Advanced Solutions continue to be the largest

provider of Advanced Applications for the Process

Industry and established a wealth of experience

supporting these applications through the following

main service offerings:

‒ Benefits Guardianship Program (BGP) – entry level software

maintenance and support program designed to provide technical

assistance and free software updates

‒ BGP Plus – addition of scheduled engineering services designed

to maintain performance and extend the life of the applications

‒ BGP Performa – addition of proactive sustainment program via

secure remote service centers designed to maximize uptime and

performance at all times

Background

New

BGP Performa aligned with Assurance 360 Performa


The Sustainability Problem

Reduce Total Cost of Ownership

Knowledge

Management

Optimize or Sustain

Performance

Benefits from Advanced

Applications can quickly

decline without proper

maintenance effort

•Health monitoring

•Latest functionality

•Technology Refresh

•Address changes to people,

processes, plant, equipment

and operating conditions

Failure to address

support early will greatly

reduce long-term

benefits

•Dealing with scarce

resources

•Leverage Technology

•Consistent Asset Mgmt

strategies

•Avoid obsolescence

Skilled support resources are

difficult to find, train and

retain

•Awareness / training

•End user handover and acceptance

•Knowledge transfer & retention

•Consistency for multi-site installations


Typical Customer Benefits

Sustaining These Benefit Levels is the Real Challenge!

0

1

2

3

4

5

6

7

Operator Training & Simulation, Asset

Management

Production Management

Advanced Planning & Scheduling

Blending & Movement

Management

Operations Management

Advanced Process Control &

Optimization

An

nu

al B

en

efit

s: $

Mill

ion

s

2.0

1.5

1.0

0.5 Typ

ical

pay

bac

k p

eri

od

s (y

ear

s)

Typical Benefits Range from $10M - $50M Per Year Per Site (Actual Benefits Depend on Industry & Plant Scale)


20

40

60

80

100

120

0 6 12 18 24

Be

nef

its

(as

% o

f o

rigi

nal

)

Time (months)

No Maintenance

Basic Maintenance

Reactive Maintenance

Proactive Maintenance

Opportunity Assessment

Understanding the High Cost of Neglect

“…applications can quickly degrade to yield nominal benefits of <25% if they are not properly

monitored and maintained from point of installation” Customer, Honeywell Users Group Forum

• Good initial benefits

from Advanced

Applications

• Potential for rapid

degradation of benefits

without proper

monitoring and

maintenance

Position after circa 12 months

No Maintenance 50% loss

Basic Maintenance 20% loss

Reactive maintenance 10% loss

Proactive Maintenance 5% loss

Opportunity Assessment +5% gain

Related to sample data: Results will depend on

many factors, so indicative only.


BGP Optima

BGP Performa

BGPPlus

BGP

“On demand” services to provide technical

resources for non-periodic activities

Benefits Guardianship Tiered Services

Clear and Simple portfolio

In simple terms:

BGP Performa is a collaborative service

whereby Honeywell commits to jointly maintain

agreed plant / unit performance targets, with

regular progress reviews.

Honeywell will provide remote monitoring

and alerting to issues likely to impact on

Performance targets, with the recommended

(and prioritized) actions that the customer

should undertake.

Honeywell will work with the customer to

ensure their in-house resources are suitably

skilled to undertake the actions and tasks.


Sweating

Assets for longer

• How to see when our Advanced Applications are performing?

• How to increase uptime of our Advanced Applications?

Skilled Resources

• How to best deploy our limited in-house resources?

• How to ensure our in-house skills remain competent?

Operational Effectiveness

• How can we focus more on our core competencies?

• How to sustain increased benefits through proactive Performance management?

Cost of Ownership

• How to get faster incident responses and resolutions?

• How can we better manage change and technology upgrades?

Meeting needs with BGP Performa


Monitoring of System and Application health

provides a solid foundation to allow primary

focus on meeting Performance objectives

Foundations to deliver BGP Performa

To ensure the system is capable of running

the Advanced Application with no

impediments

To ensure the Application is working

correctly and is capable of delivering its

performance objectives

To ensure the Application is performing as

designed and continues to deliver

sustained benefits

BGP Performa: for business critical applications such as Advanced Process Control (APC), Process History & Analytics (PHD), OptiVision, Blending & Movements Automation (BMA), etc.


BGP Performa: Key responsibilities


The balanced scorecard

shows the top-level metrics

and targets that have been

agreed and adopted by the

BGP Performa teams.

Where possible, it also

shows the estimated $ value

that has been delivered

The KPI’s give confidence

that the system is robust

and performing more

effectively than ever before.

The scorecard is reviewed monthly and reflects the overall status and

trends of the collaborative program between Honeywell and the

customer.

Regular review of performance


Typical examples of

indicators and hierarchy

Low disk

space

System

Read time

System

Write time

Disk queue

length

Disk

Cache

Processor

load

Processor

interrupts

Processor

queue

length

Virtual

memory

Available

memory

Page files

Free page

tables

Page/ non

page bytes

Page per

second

Input bytes

/ second

Output

queue

length

Disk CPU Memory Network Disk Network CPU Memory

Quickly identify

trends and

thresholds Server

A

Server

B

Server

C

Monitoring System Health metrics


Typical examples of

indicators and hierarchy

OPC fail time /

frequency

TPN load read /

write

TPN interface

queue

TPN HCI client

connection

EPKS HCI client

connection

EPKS load read /

write

Controller

handle

count

Scheduling

overlaps

Disk

space

Handle

count

PHD handle

count

RDI handle

count

API handle

count

UDB handle

count

Security handle

count

PHD start

handle

RAPI handle

count

RDI state

Interface

state

Point age

Point

confidence

Ping time

Lost

connectio

n

Con store

failed

User count

Process

leaks

RDI

status

Server

status RDI Status Server StatusProcess Leaks

Application

health

Comms URT

platform Comms URT Platform App Health

Monitoring Application Health metrics


Performance monitoring with BGP Performa

• Increased efficiency and output across multiple plant & assets

• Control costs

• Make resourcing and management decisions

• Efficiently meet production plans

• Reduce unplanned downtime

• Identify bad actors

• Better deploy in-house resources

• Measure performance of Systems against key metrics and thresholds

• Proactive alerts

• Prioritized action list for intervention and improvement

Performance monitoring caters to needs of different stakeholders

Different Stakeholders


Plant

Crude Unit

CDU

APC Attainment

Usefulness

CV

Violation of hard limits

MV

Clamping

DATA

Reliability Acceptance Value Criticality

Objective Functionality

Inferential Attainment

Uptime

Historical trend

STAB SPLT

FCCU

MFRR DEBUT

Performance Monitoring: APC

•Performance KPI’s mapped into an aggregated Hierarchy across Enterprise

•Easy to see interactions and drilldown for better understanding of events

•“Icons” can reflect real data ( status, trends, thresholds and deviations)


Plant

Crude Unit

CDU

APC Attainment

Usefulness

CV


MV

Clamping

DATA




Uptime

Historical trend

STAB SPLT

FCCU

MFRR DEBUT


Example Commentary: “Overall performance is healthy but there are early

indications of performance drift in CDU Diesel and an ongoing instrumentation

issue with the Naphtha Splitter”

Example Recommendations (Prioritized To Do List)

1. Investigate increase in MV clamping on the FCCU debutanizer controller

63DEBUT.

2. Investigate loss of performance in CDU Diesel 95% inferential.

3. Recommend retuning furnace outlet temperature controller 51TIC002.


Plant

Crude Unit

CDU

APC Attainment

Usefulness

CV


MV

Clamping

DATA




Uptime

Historical trend

STAB SPLT

FCCU

MFRR DEBUT



Plant

Crude Unit

CDU

APC Attainment

Usefulness

CV


MV

Clamping

DATA




Uptime

Historical trend

STAB SPLT

FCCU

MFRR DEBUT




Plant

Crude Unit

CDU

APC Attainment

Usefulness

CV


MV

Clamping

DATA




Uptime

Historical trend

STAB SPLT

FCCU

MFRR DEBUT



Plant

Crude Unit

CDU

APC Attainment

Usefulness

CV


MV

Clamping

DATA




Uptime

Historical trend

STAB SPLT

FCCU

MFRR DEBUT

Including

Traditional

Profit Expert

Reports


DEDICATED PERFORMA SERVICE LEAD

OVERSIGHT OF KPIs AND OUTCOMES

LONG-TERM GUARDIANSHIP

LEVERAGE OF HONEYWELL’s EXPERTISE

ALERTING AND TRENDING

REMOTE PERFORMANCE MONITORING

SUSTAINED $ BENEFITS

BGP Performa on 1 slide

D

O

L

L

A

R

S


BGP Performa helps reduce the Total Cost of Ownership

• Honeywell provides faster incident response and resolutions

• Proactive service reduces number of incidents and increases uptime

• Effective planning and management of change and technology upgrades

• Cyber Security protection for remote connectivity

• Most effective deployment of in-house resources

BGP Performa helps to improve Operational Effectiveness

• Allows customers to focus on their core competency and Honeywell to take

responsibility for overall Performance of Advanced Applications.

• Honeywell guides the customer on most appropriate actions and priorities

• Honeywell helps to improve in-house skills and capabilities

Executive Summary


www.honeywellprocess.com

Questions


EMEA

Daren Lewis: Global Services Director

[email protected]

Matt Townley: Regional Service Leader (ENA)

[email protected]

Jayant Diwan: Regional Service Leader (ME)

[email protected]

Gerhard Kotze: Regional Business Leader (SSA)

[email protected]

Who to contact (in EMEA)

mailto:[email protected]




