Process Solutions Evolving
Did Honeywell Process Solutions (HPS) short-circuit the Open Process Automation work? Inquiring minds wonder. Once again, some news and analysis of a conference that I couldn’t attend—three of these the same week in June.
HPS and ExxonMobil sent this release. Subsequently, I talked with some sources at competitor companies who broached the question to me—did this news short-circuit the ExxonMobil-led effort for a new process control solution? An interesting caveat is that there is more than one group within ExxonMobil—and they don’t necessarily agree.
From the first release:
The Open Process Automation group was initiated by ExxonMobil who was trying to find a better (less expensive) upgrade path for its control systems that had fallen behind that of its competitors. The oil & gas supermajor still has in operation a significant number of older systems installed as far back as the 1980s—systems that have served the company well for more than 30 years, but as older electronic components have been replaced by more modern alternatives, spare-parts shortages and looming obsolescence put ExxonMobil and other owner operators in a difficult place.
When facing obsolescence, rip-and-replace is clearly the option of last resort—incurring high costs, protracted downtime and the loss of all the intellectual property invested in developing a system’s displays, databases, control strategies and third-party interfaces, according to David Patin, distinguished engineering associate – control systems, ExxonMobil Research & Engineering.
The company’s installed base of Honeywell TDC 3000 systems, in particular, looked to be facing a critical shortage of spare parts in the year 2025, Patin explained. “So in 2011 we met with Honeywell regarding the future of TDC 3000,” Patin began, addressing a plenary session of the Honeywell Users Group Americas 2018 conference this week in San Antonio.
Challenge issued
Unwilling to settle for rip-and-replace, “We challenged Honeywell to develop and prove a method to migrate TDC forward,” Patin said. The two companies established a joint task team to investigate the problem.
ExxonMobil’s wish list of deliverables included avoiding wholesale system replacement (especially the I/O); preserving the company’s intellectual property investment; allowing for on-process migration of system components (meaning without shutting down the process); enabling new capabilities not currently possible with TDC; and unifying TDC with Honeywell’s current state-of-the-art Experion platform.
This last item encapsulated a desire for a solution that would “be usable by a younger workforce, yet stand the test of time,” Patin said. “I picture a third-grader who’s also a future TDC engineer,” he said. “They just don’t know it yet.”
Also implicit in ExxonMobil’s requirements were continued “rock solid” reliability and security, Patin added.
Solution identified
Since the technical obstacles to bringing TDC forward hinged on hardware obsolescence, notably controller microprocessors and communications chips that would no longer be available, the team settled on an emulation approach that would effectively abstract TDC system functionality from the specifics of the older hardware.
And in February 2018, seven years after that first meeting of the minds—and two years ahead of schedule—Honeywell answered ExxonMobil’s challenge with the release of Experion LCN R501.1. The Experion LCN, or ELCN, effectively emulates the TDC system as software. “It’s 100% binary compatible and interoperable with the old system,” Patin explained. “Current TDC code runs unmodified in this virtual environment, greatly reducing the technical risks. Intellectual property such as application code, databases and displays are preserved.”
In the end, the Experion Station, Server, ACE and APP nodes can take the shape of Windows-based “physical” applications or virtual machines. Application Modules, Network Gateway and Network Interface Module functionality is redeployed on Universal Embedded Appliances or as virtual appliances. Only the Enhanced PLC Gateway cannot be readily virtualized because the emulation of serial network connectivity is not well behaved, Patin explained. “This means you can build an almost 100% virtualized or 100% physical system—or somewhere in between.”
With the new solution, LCN and UCN messages are now encapsulated in standard Internet Protocol. “All the old networks now exist as logical constructs on Fault Tolerant Ethernet,” Patin said. “We’re no longer locked into proprietary networks.”
And to address the challenge of on-process migration, Honeywell has also introduced several bridge devices that effectively facilitate the virtualization of TDC system node functionality—without the need to interrupt the process under control.
Benefits achieved
Virtualization of the TDC environment has come with some added benefits, including the ability to use Honeywell’s cloud-based Open Virtual Engineering Platform to engineer TDC solutions; lower cost, smaller footprint training simulators; peer-to-peer integration of virtualized HPM controller nodes with current-generation C300/ACE nodes; support for OneWireless (ISA 100 and WirelessHART) connectivity; and integration with ControlEdge and Unit
Operations Controllers.
“It’ll be a game-changer,” said Patin. “We don’t know all that’s possible as yet.”
Other benefits include a drastic reduction—or elimination—of spare parts, as well as reductions in cabinet space requirements. “We’ve gone from two nodes to six in a single cabinet,” Patin said. “We’ve not fully realized unification with Experion, but that process has begun.”
Overall, Patin gave high marks to the Honeywell team for its response to ExxonMobil’s needs. “The challenge was met, and expectations exceeded,” he said. “The need to replace an entire system is eliminated, future component issues are virtually eliminated (pun intended), intellectual property is preserved and on
process migration is supported.
“ELCN technology essentially resets the odometer on your TDC 3000 investment,” Patin added. “It’s the best example of Honeywell’s commitment to continuous evolution that I’ve ever seen. And if it were a final exam, I’d give Honeywell an A on this one.”
<End of release>
Safety Manager
HPS also announced Safety Manager SC, the next generation of its flagship Safety Manager platform. Its modular, scalable design enables it to function as a single platform for all enterprise safety applications, allowing customers – who are often using four or five different safety systems – to consolidate and reduce their training and engineering costs, and spare parts inventories.
Safety Manager SC incorporates a new Series C-based controller and Honeywell technologies such as LEAP, Universal Safety IO, offline simulation and Experion integration, which collectively simplify safety system engineering, development and testing.
“Our customers increasingly want integrated safety and control solutions and the simplicity of partnering with one supplier for all their needs,” said Tim LeFevre, global customer marketing manager for safety systems, HPS. “We deliver exactly that by combining unrivaled expertise in distributed control systems (DCS) and safety systems with deep integration know-how. Honeywell is one of the few vendors that can support the full safety lifecycle.”
HUG
The ability of Honeywell Connected Plant’s offerings to deliver higher levels of safety, reliability, efficiency and profitability will continue to be the primary discussion point at the 43rdHoneywell Users Group (HUG) Americas symposium. More than 1,300 delegates from across the oil and gas, chemical, pulp and paper, and metals and mining sectors are attending the event, which features numerous displays of the newest technologies along with dozens of Honeywell- and customer-led sessions and technical discussions.
Throughout the conference, Honeywell will showcase how turning data into actionable insight requires more than just upgrading technology; it requires a system for capturing, retaining and sharing knowledge that allows both the plant and its workers to perform at their best every day.
“Digital transformation has to be about more than just moving data into the cloud,” said John Rudolph, president of Honeywell Process Solutions (HPS). “It ultimately has to be about the outcomes, including driving increased productivity and savings for our customers while allowing them to increase knowledge capture, knowledge sharing and knowledge retention among their employees.”
Rudolph was named president of HPS on May 31, 2018, succeeding Vimal Kapur, who was named president and CEO of Honeywell Building Technologies. Rudolph led the Projects and Automation Solutions, and Lifecycle Solutions and Services businesses for HPS over the past six years, driving significant growth. Rudolph also has held leadership roles with TAS Energy, General Electric and Ingersoll Rand.
Here is a revealing comment from the press release about HPS’s strategy and direction—something we’ve all been wondering about. “HUG attendees will be able to see and experience the Company’s ongoing transformation into a software-industrial provider.”
Announcements in brief:
- Thermal IQ – Enables maintenance engineers and plant managers to more effectively monitor and manage their thermal process equipment, minimizing unplanned downtime and maximizing uptime.
- Uniformance Cloud Historian – This software-as-a-service cloud hosting solution for enterprise-wide data capture, visualization and analysis helps customers improve asset availability, optimize processes and increase plant uptime.
- Asset Performance Management – Integrates asset and process data for actionable insights to improve asset performance and plant profitability.
- Immersive Competency – This cloud-based simulation offering uses a combination of augmented reality (AR) and virtual reality (VR) to train plant personnel on critical industrial work activities, empowering them to directly improve plant performance, uptime, reliability and safety.
- Personal Gas Safety – This solution integrates with Honeywell’s leading plant control system to protect workers and speed emergency response in case of hazardous leaks or worker injury.
- Intelligent Wearables – This hands-free, wearable technology allows industrial workers to more safely, reliably and efficiently accomplish their tasks in the plant or the field. It uses a head-mounted visual display that responds to voice and brings live data, documents, work procedures, as well as health and safety information into view and can connect field workers with remote experts in real time.
- Experion Batch – Combines Experion distributed control, batch automation, and new visualization technology for improved efficiency, quality and throughput.
- Measurement IQ for Gas – Provides measurement under control by transforming metering operations with 24/7 real-time condition-based monitoring.
