Return on Imagination - Honeywell User Group (HUG) 2009

Return on Imagination - Honeywell User Group (HUG) 2009

 
By Bill Lydon - Contributing Editor
 
June 15-19, 2009  Phoenix, AZ
 
Honeywell Process Solutions continues to grow in a number of dimensions including: additional products, wireless, energy, PLCs, independent system integrator initiatives, and Integrated Master Automation Contractor (IMAC) focus.
 
This year’s attendance was lower than previous years, but David Wade, Honeywell Users Group Americas Chairman, officially opened the HUG 2009 conference commenting that there were more than 50% new attendees.
 
Frank Whitsura, vice-president and general manager for the Americas, was the first Honeywell executive to speak.  Whitsura discussed the theme of the conference, return on imagination. In addition to the learning opportunities at the conference, he suggested attendees can gain a great deal by interacting with others and sharing ideas. Whitsura observed that ideas can come from some unusual places citing Coca Cola was invented by a doctor and the snowmobile by a 15 year old boy. 
 
Whitsura’s point was that knowledge and technology alone are not enough, we need to have the creativity and imagination to use them in novel ways to address the issues we are facing today. Whitsura cited four major issues to consider:
 
Economics
Greater financial instability and the need to run as efficiently as possible.
 
Safety & Security
Rising need for improved safety and security with regulations including CFATS (Chemical Facility Anti-Terrorism Standards), MTSA (Maritime Transportation Security Act), TWIC (Transportation Worker Identification Credential), ISPS (International Ship and Port Facility Security), and cyber security.
 
Energy
Higher energy costs are driving the need for improved energy efficiency at utilities and industrial plants.
 
Environmental Regulations
More stringent environmental standards driving emissions monitoring, combustion optimization, and zero flare requirements.
 
One Honeywell Theme
The theme, “One Honeywell,” was described as the idea that Honeywell has a wide range of products and services that can benefit customers. There was also an emphasis on “Integrated Field to ERP Connectivity.” Whitsura made the point in this way, “You all know Honeywell in the control room…you may not realize it, but in the last several years Honeywell and our sister companies touch facilities in ways you probably haven’t recognized or realized.” Areas include tank farms, terminal automation, process optimization, process licensing, process design, facilities management, fire alarm, building energy management, wireless, supply chain management, and physical plant security. There was a strong implication that the Honeywell Building Services group is working closer with the industrial group to deliver more value on projects. 
 
Innovative Process Automation in 2010
Norm Gilsdorf, President of Honeywell Process Solutions, discussed the information overload. To emphasize the scale of the problem, Gilsdorf noted that 40 exabytes (one quintillion bytes) of unique new information is estimated to be generated worldwide this year. More information than in the previous 5,000 years combined. Capturing data is much easier in control systems today so it easy to create too much information. Maybe we should think through the value of information before deciding to bring it into our systems.
 
Gilsdorf cited six technology trends to address industry challenges with fewer skilled people that must respond faster, handle more complex processes, and make better decisions.
 
Ubiquitous Sensors
The lower cost of sensors coupled with wireless will lead to data collected across the entire plant and enterprise. Sensor innovations will make new applications possible with intelligence onboard, such as analyzers on a chip. Other ideas include wearable sensors for fire and gas detection, and GPS tracking of equipment.  Video capabilities are expanding as a new process input for things like measurement of flow, level, temperature, pressure, leak detection, and hot spots.
 
Wireless
Wireless enables us to cost-effectively bring in data and push out the right information to a mobile worker, extending the control room to mobile operators for improved efficiency.
 
The Experion Mobile Station is a portable control room extension.
 
Convert Data to Knowledge
Advanced applications can convert data to knowledge and provide early event detection. Soft sensors provide advanced measurements using system information to quantify process data in new ways.
 
Converge IT and Process Control
Technology is making it possible to collect and process data through remote central locations, allowing leaner staffs at plants to handle the shrinking workforce. Data can be linked across the global enterprise and managed with proven IT technologies such as Service Oriented Architecture’s (SOA) that deliver common services enabling collaboration between manufacturers and partners. 
 
Unify Automation Layers
Data can be better refined and routed directly to the appropriate person (production, operations; maintenance) at the point of use.
 
Go Beyond the Plant Boundaries
Manage data at an enterprise level for enterprise-wide optimization and reliability from production to supply chain.
 
Holistic Systems Approach
Jason Urso, Vice President of Technology at Honeywell, described how many companies treat control system integration as a technology problem. These users buy point solutions hoping to weave them together to create a single integrated solution. Urso commented that this often delivers initial benefits but what they have created is a very complex solution with islands of automation that do not work together, and over time have increasingly higher maintenance costs. Honeywell is promoting a “holistic and integrated” approach named One Honeywell to deliver a single extensible solution. One Honeywell delivers tight integration by designing a system up front to create a seamless solution. Urso noted that the One Honeywell approach is delivered though the Integrated Main Automation Contractor program.
 
OneWireless
In an interview with Jeff Becker, Honeywell Process Solutions' Global Wireless Business Director, Becker affirmed that OneWireless is Honeywell’s wireless platform that includes 802.15.4, 802.11, and their older frequency hopping, spread spectrum product. Honeywell guarantees users will be ISA 100 compatible with the wireless products they buy today from Honeywell. According to Becker, OneWireless supports hardwired HART at the gateway and there are “no plans” to support WirelessHART.
 
Becker indicated that users are accepting wireless and are generally past asking if wireless is reliable and really available. Changing batteries is a common user question and Honeywell has designed OneWireless for long and consistent battery life. Honeywell recommends doing a five year change out of batteries as a preventive maintenance task to keep it simple. Becker mentioned a new service contract offering called, “the no worry battery guarantee,” where Honeywell will maintain the batteries for you. He also noted the average number of wireless nodes per application has grown into 100s per application.  More information.
 
Energy Conservation and Optimization
At the conference, Honeywell announced Energy Management Solutions - a suite of new and existing hardware, software, and services to help improve energy efficiency and reduce greenhouse gas (GHG) emissions.  The solution is targeted to a wide range of energy-intensive process manufacturing facilities. In the area of refining and petrochemical production, this solution additionally leverages expertise from Honeywell’s UOP subsidiary. Honeywell provided an estimated savings for selected applications:
 
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Don Morrison, Product Manager for Profit Suite Solutions, discussed Honeywell’s energy conservation and optimization offerings. Morrison indicated that Honeywell offerings are model-based control and economic optimization solutions. Offerings can be configured by the user to optimize for desired parameters. When production demand is high, optimization is generally configured to optimize production output; when business is down, optimizing for highest efficiency.
 
The keystone of the offering is Honeywell’s new Energy Dashboard which provides users information about their energy consumption against dynamic energy targets. Capturing and analyzing Key Energy Indicators (KEI) provide users an understanding about the drivers that affect energy consumption. This is used to determine where in the plant to focus energy optimization efforts. There are a number of different views available in the Energy Dashboard from high level to detailed.
 
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MasterLogic PLC
Honeywell demonstrated the MasterLogic PLC offering that provides high-speed, compact programmable logic controllers (PLCs) programmed with standard IEC-61131-3 programming languages. It also can be used with Honeywell’s Experion Process Knowledge System architecture and is compatible with Honeywell’s process control system software, including the recently released Experion LS.  This offering expands Honeywell’s reach into PLC applications and provides the basis for an offering that independent system integrators can sell. Honeywell recently joined the Control Systems Integrator Association in a move to work with independents. More Information
 
 
System Migration
The demonstration area featured ways to migrate from an existing system to the Honeywell Experion, with various methods that avoid immediate replacement of controllers, I/O, programming, or graphics.   Honeywell has methods for migration from:
  • Bailey
  • Fisher
  • Foxboro
  • Honeywell – QCS
  • Honeywell - TDC 2000 Data Hiway
  • Honeywell - TPS/TDC 3000
  • Moore
  • Rockwell ProcessLogix
  • Rosemount
  • Siemens
  • Yokogawa