2013 Honeywell Users Group Americas

1

Rob Crain Ole Kristensen

Improve Asset Reliability and Compliance with DOC4000

Configuration Management and Documentation

2

Agenda

• Current State, Problems we face

• What DOC4000 Enables

• Major Elements and Asset Models

• Benefits of:

– Better Decision Making

– Protection of Intellectual Property

– Cost Effective Flexible Delivery

• What is New?

– RECON

– iMOC

– Project Use

– Software as a Service

• Demo

• Q & A

Is your intellectual property

retiring with him?

Is your intellectual property

retiring with him?

DOC4000

CL Apps

Standard

Graphics

GUS

Graphics

TDC3000

Sub

Pictures

Button

Configs

Controllers

Logic Blocks Indicators

Discrete

TAGS

Alarms Others

MV

CV

I/O

MVC

MV

CV

I/O

MVC

MV

CV

I/O

MVC

CL Apps

Standard

Graphics

Graphics

Sub

Pictures

Button

Configs

Controllers

Logic Blocks Indicators

Discrete

TAGS

Alarms Others

PLC Instrument Shutdown

CL Apps

Standard

Graphics

Graphics

Experion

Sub

Pictures

Button

Configs

Controllers

Logic Blocks Indicators

Discrete

TAGS

Alarms Others

PLC Instrument Shutdown PLC Instrument Shutdown

MV

CV

I/O

MVC

MV

CV

I/O

MVC

Tags

Applications

I/O

Historian

Calculations

History

Graphics

Emerson Delta V

Is Your Documentation Up to Date?

4

Plant wide, Systems are becoming more complex

5

DOC4000 Enables

• Single place to look

– PLC & DCS

– Historian & APC

– Honeywell & ____________

• Management of Change

• Context

– Documents

– Notes

• Knowledge Retention

Build on What you Know

6

Mapping Connections

7

DOC4000 : Current Asset Model Compatibility

Distributed Control System (DCS) – ABB Process Portal B

– ABB 800xA*

– ABB Harmony

– Emerson Ovation

– Emerson DeltaV

– Emerson RS3*

– Emerson WDPF*

– Honeywell Experion Process Knowledge System

– Honeywell TotalPlant Solution

– Invensys Foxboro I/A Series

– Invensys InFusion

– Metso Max DNA*

– Yamatake DEO

– Yokogawa Centum CS*

– Yokogawa CENTUM CS3000

– Yokogawa CENTUM VigilantPlant (VP)

Safety Instrumented System (SIS) – Honeywell Fail Safe Controller

– Honeywell Safety Manager

– ICS Triplex*

– Invensys Triconex (MSW)

– Invensys Triconex (TS1131)

– HIMA*

– Yokogawa ProSafe*

Process Historian – AspenTech InfoPlus.21

– VSCalc*

– AspenTech InfoPlus*

– Honeywell PHD

– OSIsoft PI

– Invensys AIMstar

7

8

DOC4000 : Current Asset Model Compatibility

Programmable Logic Controller (PLC)

– GE Fanuc 90*

– GE Mark Series*

– Honeywell Logic Manager (LM/IPC620)

– Modicon ProWORX+*

– Modicon ProWORX32*

– Rockwell Allen-Bradley PLC 2*

– Rockwell Allen-Bradley PLC 3*

– Rockwell Allen-Bradley PLC 5

– Rockwell Allen-Bradley SLC 150*

– Rockwell Allen-Bradley SLC 500

– Rockwell Allen-Bradley Control Logix

– Siemens S7-400*

Advanced Process Control (APC) – AspenTech Dynamic Matrix Control

(DMCPlus)

– Honeywell Profit Controller/Robust Multivariable Predictive Control Technology (RMPCT)

Instrumentation – Bentley Nevada 3500

– Bentley Rebis*

– Emerson AMS*

– Intergraph SmartPlant Instrumentation (SPI/InTools)

Networks – PC

– Network*

HMI and Visualization – Invensys CTS

– Matrikon ProcessNet*

– Wonderware InTouch*

9

DOC4000

• Documentation for better

decision making

• Protect and optimize

intellectual property

• Cost effective, flexible

solution delivery

10

Better Decision Making

• Know what

interdependencies exist to

decide what changes can

be/should be made

• Manage spare capacity

with accurate configuration

data

• Find Defects

Avoid disruptions, optimize with confidence

11

Protect and Optimize Intellectual Property

• Capture tacit knowledge

• Aggregate and

contextualize critical data

• Visualize and access key

information

20-50% Productivity Improvement for Automation Professionals

12

Cost Effective, Flexible Solution Delivery

• Traditional Software

Purchase

– Purchase software

– Host at site

– Annual support

• Software as a Service

(SaaS)

– Requires no infrastructure

– Reduced implementation

– Access Anywhere Anytime

Easy to use, easy to buy

13

Introducing DOC4000 Service!

• Now Available!

• For Customers Who Need Solutions that Provide: – Productivity Enhancement

– Safety and reliability

– Incident prevention

– Disaster recovery

– Knowledge retention

– Project cost savings

• What’s New and Different? – Access to DOC4000 tools via browser

• NO NEED to buy host server, software licenses!

– Flexibility!

• One time snapshot (for customers who make few changes to their systems)

• Affordable, unlimited use (for customers whose budgets cannot withstand the cost of

purchasing outright)

• Access can be provided to various internal or 3rd party users

• Little or no administration (backups, software upgrades, patches,…)

14

Deliverables of DOC4000 Service

• Software tool to automate file

collection – HON provides link to extraction sw tool

and instructions

• Dedicated FTP Site for posting

files to be imported – TAC will coordinate telephone support

to customers needing help with data

gathering and posting if needed

• Browser Link to Access DOC4000

tools for their system(s) – If purchased as spot or service project,

browser link is available for 30 days

– If purchased as periodic agreement,

browser link is always available and

service allows for unlimited analysis

• Executive Summary with

Vulnerability Report – Included with each data analysis event

15

DOC4000 – What’s New?

• New Released Modules

– RECON

• Introduced 2011/2012

• Configuration Management for IT Assets on the process Control

network

– iMOC

• Workflow engine introduced Q2-2012

• Provides reconciliation of change

• Facilitates authorization to make the change

• New Applications

– DOC4000 Project Use

– DOC4000 Service

16

DOC4000 - RECON

Monitors computers and networks, including their:

– Hardware

– Operating system information

– Files Systems

– Installed Software

– Networking Devices

– Peripheral Devices

– Domains

– Groups and Users

17

DOC4000 Recon and COE Compliance

• Integrity Recon manages multiple COEs simultaneously

• It interrogates systems for COE compliance and reports on discrepancies from the spec

• It maintains individual change histories for each server, workstation, and desktop

• In addition to COE compliance, DOC4000 Recon reports other key information including:

– Serial numbers

– Correct operation of active directories

– Compliance to available drive capacity guidelines

– Disabled and stale user accounts

– Application and operating system services status, start mode, and state

18

Licensing and Vendor Compliance

• Licenses – Sometimes distributed using the honor system

– Can be difficult to track

– IT is responsible for licensing enforcement enterprise wide, but they have limited visibility into the automation networks

• Automation systems warranties – Some software installations and updates can inadvertently void the

manufacturer’s warranty

• Recon helps: – Track the number of licenses

– Optimally distribute licenses

– Verify software and components are vendor compliant

– Simplify audits

19

Introducing iMOC™

• Requirements for MOC for changes “Not in Kind”

• 3rd Generation MOC workflow application – Designed specifically for automation systems

– Built upon DOC4000 framework

• Intelligent platform for MOC – Graphical environment

– Enhances the design processes

– Embeds checklists

– Routes MOC package for approval

– Provides links to critical information

• Automatically reconciles changes

• Integrates with existing MOC processes

20

iMOC: Simple Graphical Workflow

• Workflow process definition

• Checklists

• Transitions

• Auto reconcile with DOC4000 – DOC4000 Detects all automation

changes

– Reconciles MOC cases to changes in

automation system

– Automatically generates reports of un-

reconciled changes

Profibus

DeviceNet

Other Buses

OPC

Production Management

APIs

PAC

Discrete ControlProcess Control

Common Information Infrastructure

FT (Option)

Wireless

Process

Visualization

Ethernet

Firewall

Business

Systems

FOUNDATIONfieldbus

OM OM

Application Specific Appliances

21

iMOC Addresses Critical Issues

• Undocumented/Unauthorized Changes

– Safety, production, and quality issues

– Cyber attacks

– Safety hazards

• Regulatory Compliance

– Controls and traceability

• Onerous MOC Processes

– Time consuming

– Error prone

– Lack of change reconciliation

– Discourage implementing changes

22

DOC4000 for Project Use

• Intergraph InTools is the defacto standard, used by EPC for designing Instrumentation and for building the control database

• During a project life cycle, there are many revisions made to the InTools and control databases

• During several stages in the project, manual work process are used to reconcile these divergent databases

• DOC4000 automatically identifies mismatches between the databases – I/O Slot locations

– Tag names

– Engineering units

– Descriptions

– Device manufacturer for smart devices

– Ranges

– Etc.

24

Typical Effort for Reconciliation

• 1 DCS with 10,000 I/O, 4 SIS with 1000 I/O each

– 7 man weeks

– 3 weeks calendar time

• Reconciliation typically done 3 to 4 times during the

project

– Detailed Design

– Pre FAT

– Post FAT

– Post SAT

• Total Effort

– 28 Man Weeks

– 12 weeks calendar time

25

Benefits of DOC4000 – Project Use

Example: 14,000 i/o project • Shorten FAT and SAT

– Less time spent identifying discrepancies, determining “who is right”

– Faster startup (less time tracking down errors)

– Errors found and remediated in the engineering offices, not at FAT or onsite

– Savings in the millions of dollars by shortening FAT and SAT by several weeks

• Reduction in costs - Manpower – 28 Weeks Without DOC4000, 4 Weeks With DOC4000

– 24 Weeks (86% Savings) Reduction in I&E engineering effort ($170,000)

• Database validation continually occurs, finding errors quickly and improving project quality

DOC4000 saves millions of dollars by decreasing cost and risk associated

with systems integration

26

Use DOC4000 Software to

• Minimize research time

• Provide Simple,

common

visualization

• Map

connections/references

• Find internal and

external dependencies

• Find configuration

defects

• Facilitate collaborative

Engineering

Prevent Problems

27

Reference Materials at Honeywellprocess.com

• Customer Facing Tools:

– Search for; DOC4000 Service for Configuration

Management

• Flyer

• Presentation

• Mini-Recorded Demonstrations

29

Thank You