Continuing coverage of this week’s Honeywell Process Virtual Technical Experience.
[Note: You can have these posts sent to you via email simply by signing up at the appropriate link. There is normally one post per day, however covering two conferences and a couple of press conferences this week necessitates a little extra coverage.]
Continuing the theme of “remote” and also support and services, Honeywell Process Solutions announced this week Enabled Services program powered by Honeywell Forge. This automation lifecycle services offering focuses on ensuring Industrial Control System (ICS) health, reliability and compliance.
- End-to-end solution enables remote preventive maintenance and support
- Plant operators can reduce number of incidents per year by 40% and improve total cost of ownership
“Honeywell developed the Enabled Services program as a subscription-based service for ICS users dealing with increasing system complexity, an aging industrial workforce and the constraints imposed on plant operations by global health concerns,” said Mark Dean, director of offering management, Honeywell Process Solutions. “Through this Enabled Services offering, Honeywell’s experts can conduct rapid analysis and make fast recommendations to solve the issues and be onsite only when necessary. Honeywell has created a powerful tool for customers to significantly improve maintenance efficiency and redirect expensive resources to high priority corrective maintenance.”
Honeywell estimates it’s Enabled Services solution can deliver increased value by reducing the number of incidents per year by 40%, with a net decrease in total cost of ownership of 15%. These capabilities not only help improve system health, performance and compliance, but also allow customers to redirect existing high skill resources to use more time to work on systems improvements and to focus on their core business.
Based on Honeywell’s step-change Lifecycle Solutions & Services delivery model, which responds to customer-driven feedback from around the world, the Enabled Services solution is designed around three key pillars:
- System health and performance – in other words, what is going wrong in the plant
- System compliance — why it is going wrong
- Prescriptive maintenance and remediation – how the issues can be resolved.
Honeywell’s program uses intuitive and consistent dashboards powered by Honeywell Forge technology, which provides users with real-time intelligence to enable peak performance. It also employs remote connection and/or local data collection, predictive and diagnostic tools, and global resource centers – all to support improved operational and business performance.
Enabled Services remote support capabilities were specifically developed with security in mind. The services employ protected network connections built on industry recognized standards, such as IEC 62443, to transfer data from the customer’s site to Honeywell’s global resource centers.
Through its proactive approach, Enabled Services offer improved efficiencies compared with ad hoc maintenance regimens, homegrown solutions that compromise migration readiness, and/or delaying service and repairs until assets fail. This comprehensive solution can help company executives, plant managers and control engineers to:
- Understand and improve operational effectiveness and risk profiles
- Leverage operational benefits from systems, applications and people
- Focus efforts on core competencies by deploying suitably skilled resources
- Improve the health, security and stability of control assets
Honeywell’s Enabled Services offering includes two levels of support to meet diverse customer requirements. Enabled Services Enhanced employs fully connected systems and offers continuous insights on system health, performance and compliance with actionable recommendations. Enabled Services Essential is intended for a non-connected system and offers less frequent updates.
One conference I’m attending from the comfort of my office this week is Honeywell Virtual Technology Experience. Thanks to the pandemic, no Honeywell User Group (HUG) this year.
This remote conference technology constantly improves. This is my fourth of the season. Technical glitches have been rare. Speakers overall have ranged from good to outstanding. Jason Urso, Honeywell Process Solutions Chief Technology Officer gave his usual great technology roundup even dialing in demos from Australia.
Interesting that I used the word remote, because that is the word of the year. Any of us who can work from home are. That includes process control where many engineers can work from home and avoid getting sick.
Urso pointed to disruptions in the economy including disturbances to supply chains, postponed maintenance checks, and restricted travel combining to increase operational risks for critical manufacturers. Simultaneously, demand for key products like toilet paper for hygiene, filter paper for purification products, and packaging materials for shipping is peaking, making reliable, high-quality production even more important.
“Living in this new reality, manufacturers are faced with having to find new ways of operating, balancing the need to keep critical processes and plants running while ensuring the safety of their employees,” noted Urso. ”Here are three critical steps manufacturers can take to navigate this unprecedented situation:
- Focus on essential work onsite to minimize the potential exposure of workers
- Adopt proven and secure remote solutions for operations
- Receive aid remotely through collaboration with on-call experts”
The bulk of the keynote reviewed three remote solutions Honeywell Process has developed for situations just like this.
Remote Project Engineering
Honeywell is continuing project operations by using software and digital twin technology. Project engineers from around the world continue working on Honeywell projects from home or in locations where offices are still operating with social distancing.
“We do so by utilizing digital twin technology that makes a digital replica of the customer’s equipment and processes which allows our project engineers to work on the ‘digital copy’ of the project versus on the actual equipment itself,” says Urso. “Critical infrastructure projects in oil and gas, pharmaceuticals, and power can proceed without interruption.”
Customers increasingly have fewer individuals working onsite to follow stay-at-home orders. In some cases, quarantines of key individuals are also affecting the availability of skilled resources at the site. In response, Honeywell has issued new software that enables process operations to be monitored or even executed from remote locations outside of the facility. Remote support staff in other facilities or at home can be utilized as if they are working directly at the process location.
We recently deployed remote operations solutions to one of our own specialty additives plants in Orange, Texas, that produces polyethylenes, allowing us to operate and ensure business continuity even with reduced onsite staffing. A virtual remote-control workstation duplicates the operator’s distributed control system stations in the main control room and can fully take over in case of further restrictions or illness. Our engineers can now support operations and execute essential tasks from remote locations, maintaining social distancing while keeping the same number of eyes on the plant.
According to Urso, “software was up and running in less than two hours and is protected by the highest levels of cybersecurity protocols and best practices.”
Remote Services and Support
Our customers are also looking for Honeywell to provide remote support in light of restrictions on personnel traveling and entering a site. Honeywell has deployed multiple remote service options to continue providing expert support via remote connectivity to our equipment. These remote options also use the power of Honeywell Forge offerings to proactively detect issues and bring them to the attention of both the customer and Honeywell experts.
Because our remote offerings help our customers in essential industries maintain critical activities in a safe manner during this crisis, Honeywell Process Solutions has trained all service technicians to build awareness of this capability and collaborate with our customers through this challenging time.
Suddenly the wireless networking side of IoT connectivity is hitting my radar. Since the culmination of the “wireless wars” of 10 years ago, this technology/market area has settled into supplying usable products. This information came from Honeywell—In short, by supplying ISA100 Wireless and WirelessHART connectivity to Cisco’s next-generation Wi-Fi Access Point, Honeywell’s OneWireless IoT Module can help users increase industrial plant productivity, worker safety, and digital transformation readiness.
Honeywell is developing a OneWireless IoT Module for the next-generation of Cisco’s industrial access points, the Cisco Catalyst IW6300 Heavy Duty Series Access Point. The Honeywell and Cisco technologies will form the backbone of Honeywell’s OneWireless Network.
The joint wireless solution enables Honeywell customers to quickly and easily deploy wireless technologies as an extension of their Experion Process Knowledge System (PKS). Combining the leading IT network technology by from Cisco and the leading Honeywell OneWireless multi-protocol technology provides customers with a single infrastructure that meets all their industrial wireless needs.
“For the past decade, Cisco and Honeywell have worked together to deliver secure, wireless solutions to connect mobile workers and field instrumentation in the most challenging process manufacturing environments,” said Liz Centoni, senior vice president and general manager, Cisco IoT. “We’ve had great success in bringing IT and operational teams together to reduce complexity and improve efficiency. Now, we are building on that foundation to extend the power of intent-based networking to the IoT edge.”
When combined with the Honeywell OneWireless IoT Module, the Cisco Catalyst IW6300 Heavy Duty Series Access Point offers the security, speed, and network performance needed to allow the seamless extension of the process control network into the field.
“The OneWireless IoT Module is Honeywell’s latest innovation as a leader in wireless technology,” said Diederik Mols, business director Industrial Wireless, Honeywell Process Solutions. “Our customers will benefit from OneWireless functioning as a seamless extension of Experion PKS and simplified deployment made possible by integrating the IoT module and aerials into a single unit.”
Years ago I dabbled in machine vision integration. It was fun and creative. My customers and I did some pretty cool quality control applications. So I maintain a liking for the technology even though the price of the hardware plummeted and ease-of-use skyrocketed. So, I bring you this interesting news.
Honeywell is collaborating with Papertech to develop and market TotalVision, a connected, camera-based detection system for the flat sheet industries. The system enables customers to identify and resolve defects on the production line, improving quality and efficiency. The fully integrated total quality control solution is designed for flat sheet and film processes in which surface detection and production break monitoring capabilities are critical for competitive success. This new solution is designed for paper, pulp, tissue, board, extruded film, calendaring, lithium-ion battery, copper and aluminium foil producers.
Combining Honeywell’s ExperionMX technology with market-leading Papertech’s TotalVision defect detection and event capturing capabilities, the solution provides a single-window operating environment for all aspects of process and quality control. Customers benefit from faster root cause determination of runnability and quality problems, thereby saving significant time in lost or downgraded production. When integrated with connected offerings such as Honeywell QCS 4.0, system data and analytics can be accessed anytime, anywhere, from any device.
“Honeywell represents an ideal collaborator for Papertech as our industry-leading WebInspector WIS and our WebVision web monitoring system (WMS) single platform TotalVision camera system seamlessly integrate with Honeywell’s quality control systems for a range of industries,” said Kari Hilden, CEO of Papertech Inc. “We look forward to working with the global Honeywell team and their customers.”
Honeywell will continue to support existing camera system users with parts and services, while offering an easy migration path to the new solution. Given the collaborative nature of the agreement, customers can choose to take a single party, single-window approach or to engage with Honeywell and Papertech separately.
“As the world moves from plastic to biomaterial-based packaging, and from hydrocarbon-based transportation to electric vehicles, flat sheet producers are under increased pressure to ensure output consistently meets a variety of performance and safety requirements,” said Michael Kennelly, global business leader for sheet, film and foil industries, Honeywell Process Solutions. “By bringing together Honeywell’s core strengths of measurement, control, connected applications and services in flat sheet production with Papertech’s leadership in web monitoring and inspection systems, we uniquely provide customers with that capability along with industry-beating lifecycle costs.”
Papertech is the global industry-leading machine vision system supplier for a range of web-based production lines with more than 1200 TotalVision installations in 42 countries. It is part of the IBS Paper Performance Group, a company with a more than 50-year history in delivering papermakers a full range of proven machine efficiency and product quality optimization solutions.
For more information visit Honeywell Quality Control Systems and Papertech TotalVision solutions.
My wife’s family took me off for a week-long vacation to the beach last week. Eight days of much needed rest after a bunch of travel and a hectic (meaning wet) spring soccer season.
Last week was also Rockwell Automation TechED. That conference was once open only to distributer and integrator tech people. Several years ago it opened to media and became quite a thing for a few years. Last year I received an invitation to attend but they said that there was no media program. The timing was bad for me, so I passed. This year, there was no word at all. And I saw no news.
There are several industrial automation user conferences this week. PTC invited me to its conference in Boston. Then I was invited to Honeywell User Group (HUG). Then there were other invitations. Busy week. I initially told PTC I would attend, then putting it in my calendar, I realized that the week included my wedding anniversary. It’s big number (as in large). My better sense prevailed and I’m watching both of those conferences from afar.
So far this week, Honeywell Process Solutions has made a big announcement with some innovative product releases. Rockwell Automation, which owns about 8% of PTC and is banking on the partnership to bring its software into the new age, also issued a release. I’m still figuring that one out.
Honeywell Proclaims New Approach to Engineering
• Experion PKS Highly Integrated Virtual Environment (HIVE) significantly simplifies control system design, implementation and lifecycle management while reducing cost
• Market-first solution uniquely decouples the assignment of input/output (IO) modules and control strategies from specific controllers, and leverages IT capabilities in customers’ own data centers
My take on this announcement considers the HIVE product suite part of the growing trend under the umbrella of “digital twin.” Other companies have some somewhat similar products, but what I’ve found is that each company moves the ball forward a little more in a seemingly endless cycle of innovation. Honeywell labels it an evolution of the company’s flagship Experion Process Knowledge System (PKS).
Experion PKS HIVE uses Honeywell’s LEAP project execution principles, software, and networking to unchain control applications from physical equipment, and controllers from physical IO. This enables control systems to be engineered and implemented in less time, at lower cost and risk, and with simpler, modular builds. The solution also transforms the way control systems are maintained over their lifecycle, shifting day-to-day management of servers to a centralized data center, where experts and established protocols mitigate cybersecurity risk, allowing plant engineers to focus more proactively on optimization of their control systems.
Experion PKS HIVE incorporates three elements – IT HIVE, IO HIVE and Control HIVE – which can be used individually or collectively, in tandem with customers’ existing systems and infrastructure:
• Experion PKS IT HIVE centralizes up to 80% of the IT infrastructure traditionally used in project engineering to lower project delivery and lifecycle costs, better leverage skills, and drive consistent physical and cybersecurity management across an enterprise.
• Experion PKS IO HIVE provides flexible IO and control distribution enabling the control system to become a natural extension of process equipment and to facilitate modular and parallel project execution.
• Experion PKS Control HIVE uniquely applies control containers to provide flexibility and standardization of control hardware platform, control location, and control engineering. With multiple physically controllers operating as part of a Experion PKS Control HIVE, control engineering is dramatically simplified through automated load balancing.
“In developing Experion PKS HIVE, Honeywell worked closely with customers across the chemical, refining and oil and gas industries,” said Jason Urso, chief technology officer, Honeywell Process Solutions. “Many of these organizations want a more efficient approach to control system engineering, yet one that can be adopted incrementally and used interchangeably with their existing systems and infrastructure. Experion PKS HIVE provides these benefits and is truly a distributed control as it applies and geographically distributes technology to where it is needed.”
Experion PKS HIVE shifts IO to the field and makes it fully accessible to any controller, taking individual physical controllers and distributing the load so that they appear as a single controller to eliminate complexity. The solution distributes IT compute from onsite to offsite providing a seamless operations experience.
The Experion PKS IT HIVE and IO HIVE can be ordered now, with deliveries beginning Q1 2020. Experion PKS Control HIVE will be available in the second half of 2020.
Rockwell Automation Emphasizes PTC Partnership
Rockwell Automation announces its “unique combination of IT and OT software accelerates customers’ Digital Transformation Initiatives.” It says its solutions-oriented approach simplifies how manufacturers achieve business outcomes that transform operational processes, workforce productivity and efficiency.
Showcasing solutions during LiveWorx this week the company highlights:
Enterprise Operational Intelligence – cuts manufacturing costs and increases flexibility and agility of manufacturing networks by providing real-time manufacturing performance management across the industrial enterprise.
Digital Workforce Productivity – heightens productivity, improves quality, and avoids safety and compliance risk by equipping workers with actionable, augmented intelligence.
Intelligent Asset Optimization – reduces downtime and maximizes asset utilization through real-time monitoring, diagnostics, and predictive and prescriptive analytics into asset capacity, performance, and health status.
Scalable Production Management – lowers cost of inventory, improves quality, and compliance and accelerates time to market with effective planning and control of production processes.