Honeywell Pulp & Paper DCS Technology · PDF file2015 Japan Technology Summit Yokohama, September 9-10 Honeywell Pulp & Paper DCS Technology Fredrik Westerberg, HPS, Asia Pacific

2015 Japan Technology Summit

Yokohama, September 9-10

Honeywell Pulp & Paper DCS Technology

Fredrik Westerberg, HPS, Asia Pacific

2 © 2015 Honeywell International All Rights Reserved

• Markets & environment changing

• Necessity to reduce cost and streamline operations‒ Simpler to operate & maintain BUT

‒ Automation needs to “do more” to sustain impact over time

‒ Service approach also transforming

‒ Industry 4.0 Smart Factory ready

Papermaking Business is Changing


Industry 4.0 – Key Elements to Smart Factory

Big data and

analytics

Augmented

reality

Collaborative

manufacturing

Cyber

security

Horizontal and

Vertical

Integration

Vision of Industrial Production of the Future

With Experion PKS Honeywell is ready to help customers take advantage

of the coming technology transformation

Cloud

computing

Internet and

Wireless

Everywhere

Optimization

and SimulationAutonomous RobotsSource: Boston Consulting Group


Pulp & Paper Manufacturing 4.0 Vision

MV

APC

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APC

MV

APC

MV

APC

MV

APC

MV

AP

C

OM EHM

AM

PHD

UPS

SIS

OSIS

OSIS

O

SIS

O

SIS

O

SIS

O

SIS

O

SIS

OSIS

O

SIS

O

SIS

O

CPM

CPMCPM

CPM

CPM

CPM

CPMCPM

CPM

CPM

CPM

PROD PLAN

MCT

TRIM/FG/

WIP

MATERIALS

MGMT

LOGISTICS

QO

CREPE

PROD

TRACKING


Total integration is seen and experienced

in the control room and available wirelessly everywhere

The Control Room of the Future


Collaborative Manufacturing

A new way to unite information

• Process Control Information‒ Vital process information

‒ Design and maintenance & tools

‒ Process and event history

‒ CCTV, process and surveillance

cameras

• Business Planning and

Monitoring‒ Production and Logistic Planning

‒ Quality Management

‒ Maintenance Planning

‒ Daily Meetings

• Company and Corporation

Communication‒ Occupational health and safety

‒ Audio and video conferencing

‒ Kaizen & SixSigma processes

CROTF.wmv

CROTF.wmv


Native QCS and DCS Integration

• Experion MX R611 supports

interoperability with R410 and R430

versions of Experion PKS control

platform

• Common HMI

• Common Alarms

• Virtualization ready

• Distributed Server Architecture

• Native C300 peer to peer

communication

Experion PKS

Servers

Experion MX Server

Process Control

Network

Thin Client User

Interface

C300

Experion Console

or Flex Stations


Integrated Profit Loop is a model predictive single input, single output

(SISO) control algorithm that is derived from Honeywell’s “Patented and

Proven” Profit Suite control technology.

• PID Replacement Features:‒ Range Control Algorithm (RCA) w/Minimum OP

‒ Single Handle Tuning

‒ Improved Anti-Windup Handling

‒ Insensitivity to Process Noise

• Advanced Control Features:‒ Non-linear Level Control

‒ Inverse Response Control

‒ Asynchronous PV Inputs

‒ Smith Predictor Control

‒ Predictive Alarming

DCS with Embedded Advanced Control

19.8

20

20.2

20.4

20.6

20.8

21

21.2

21.4

21.6

21.8

1

30

8

61

5

92

2

12

29

15

36

18

43

21

50

24

57

27

64

30

71

33

78

36

85

39

92

42

99

46

06

49

13

52

20

55

27

58

34

61

41

64

48

67

55

70

62

73

69

76

76

79

83

82

90

85

97

Time

PV

an

d S

P V

alu

e

34.5

35

35.5

36

36.5

37

37.5

38

38.5

39

OP

Va

lue

120PIC731.PV

120PIC731.SP

120PIC731.OP


CPM: KPI Driven Control Improvement Activities


Single Window Integration for Smart Field

Devices

Series C

HART I/O

Experion

PKS

Series C

FIM

Series C

PGM

OneWireless

FDAP


Reduces Project Cost and Risk

Universal IO Channel Technology

New UIO – Any Channel can be DI/DO/AI/AO

Simpler project design

Shorter cut-over time

Reduced hardware

Proven

redundancy

Field-mountable

or standard-40C to +70C

HART 7 and FDM

support


• Mobile Productivity Solution for execution and tracking of

operator field tasks‒ Developed from Shell Global Solutions (OTTER program)

‒ Supports maintenance excellence initiatives

‒ Digitize field operations, quality, HSE, maintenance

‒ Integrated with historian, DCS, and MES

• Currently deployed at 25+ sites‒ Estimate over 1000 handheld computers deployed

‒ Temperature, vibration, RFID and barcode scanners

Field Advisor for Mobile Productivity

Locations

and Routes

AssetsBest

Practices

Tasks/Task

Lists

Round


Industrial Internet – Wireless Enabled Mill

Mobile Station

CCTV Cameras

IEEE 802.11 Backhaul

ISA100 Wireless

Wi-Fi

Field Device

Access Points

Cisco Wireless

Controller

Cisco Switch

Wireless Device

Manager

Business/Process Control

Network

ISA100 Wireless

Field Instruments

Wireless Portable

Gas Detectors

Cisco 1552S

Access Points

ISA100 Wireless Field Instruments Network• Battery-powered mesh routing or non-routing

• Line powered ISA100 Wireless access points for highest

speed, reliability, scalability, and maximum battery life

Multi-Application Plant-wide Network• Single network for Wi-Fi, ISA100, Ethernet

• Line powered multi-application access points for

the highest automation network performance,

reliability and scalability


Honeywell’s Holistic Approach to Physical

Security

Command Ctr.

PTZ Camera

1

2

3

4

5

COMMAND AND CONTROL

Control center that brings all

systems together at a central

point's) on a single platform

for event reporting and

response.

ACCESS CONTROL (ACS)

Systems used to secure the

access to a facility or an area.

Includes locks, card readers,

visitor/contractor badging,

biometric readers, and software

used for access authentication,

asset tracking, mustering and site

lockdown.

EXTENDED PERIMETER

Systems used to detect or protect

approaching threats.

Includes RVS and barriers for use

near waterways and open areas

beyond the perimeter.

VIDEO SURVEILLANCE (CCTV)

Systems used to watch a facility.

Includes cameras, housings,

mounts, monitors and software used

for

security and process control.

1

4Water Barrier3

Fence Sensors5

PE Beams5

Command Ctr.1

Fixed Camera4

Fixed Camera 4

PTZ Camera4

Fixed Camera 4

Auto Barrier 3

Lift Barrier 3 Card Reader2

Muster Reader 2

Muster Reader2

PERIMETER INTRUSION

DETECTION (PIDS)

Systems used to secure the

perimeter of a facility or an area.

Includes fence detection, PE beams

tied back to a panel and reported

through the software.


Complete Industrial Cyber Security Solutions

• Security Assessments

• Network & Wireless Assessments

• Security Audits

• Firewall

• Intrusion Prevention

• Access Control

• Policy Development

• Patching & Anti-Virus

• Application Whitelisting

• End Node Hardening

• Portable Media & Device Security

• Continuous Monitoring

• Compliance &Reporting

• Security Analytics

• Security Information& Event Management (SIEM)

• Security Awareness Training

• Current State Analysis

• Design & Optimization

• Zones & Conduits• Backup and Restore

• Incident Response


Easy to Use Dashboard Interface

Easy to use interface

Translates complex

cyber security

indicators into simple

measurements

Prioritize and focus

efforts on managing risks

Immediate information

for ongoing situational

awareness

A real-time assessment

of information from

devices throughout the

process control network

Developed specifically

for industrial

environments


On-Call

Regional Field

Service

Technician

Internet of Everything – Services & Support

• Fast diagnostic support

• Regional & global expert access

• Mill engineers

• Secure access via hardware key

• “Over the shoulder” remote measurement

and control optimization

Field Expert

CRM

Extended

Knowledge

Network

Process Control Network

Service Node

DMZ

Honeywell

Service Center(Secure Extranet)

Local IT

Local IT

TAC

VPN

Corporate Proxy

Server

Relay

Server


PHD

Collector

PF1

PHD

Shadow

Server Switch connecting to all

PHD collectors, Shadow

server and Service Node

Corporate

Firewall

DMZ

To Internet

PHD

Collector

Waste

Plant

PHD

Collector

PF2 - 2

PHD

Collector

PF3-1

PHD

Collector

PF3-2

PIMS

Server

Service

Node

Relay

Server

PHD

Collector

PF3-3

PM12 QCS

Server

PM12 PKT

Tools

Deinking DCS

Server

OMC2 QCS

Server

PM10 QCS

Server

PM3 DCS

Server

PM3 QCS

Server

PM2 WIS

Server

PM1 WIS

Server

PM3 WIS

Server

PM7 WIS

OPC Server

Reference of Remote Services Architecture

More than 20 Honeywell QCS / DCS / CD / Cognex WIS systems available

online 24x7 from anywhere in the world…

OMC3 DCS

Server

PM11 QCS

Server

PM8 QCS

Server

PM2 QCS

ServerPM1&2 DCS

ServerOMC3 QCS

Server

PM10 DCS

Server

PM11 DCS

Server

PM1 QCS

Server

PM1&2

Engineering


Cloud Computing – Honeywell is Virtualization

ready

Customer is locked

into the Hardware,

OS and Application

Open to malware

threat

Reduce PC

Hardware

Requirements

Simplify overall system

management

Reduce the Impact

and Frequency of

OS and hardware

change

Improve

availability,

reliability and

disaster

recovery


Cloud Engineering : Virtual Project Execution

Many People in

One Staging Location

Project Staged In Cloud;

People Distributed

Virtual Project Engineering and Staging


Customers who are using Virtualization today

API Raffineria Ancona SpA Göteborg Energi AB Phillips66

Ashland Specialty IngredientsGraphic Packaging International

IncProcter and Gamble

ASML Taiwan Ltd Imperial Oil Ltd Progress Energy Inc

Australia Pacific LNG Pty Ltd INEOS USA LLC Rohm and Haas

BASF Antwerpen N.V. Invista Sappi Fine Paper NA

BHP Jemena SCA Tissue North America LLC

Boardwalk Louisiana Midstream KAO Specialties Americas LLC Shell Oil Company

BPKEMYA Al Jubail Petrochemical

CompanySovcomflot Limited

Cenovus Energy LLC Kimberly-Clark Corp Suncor Energy

CEPSA Compania Espanola de

Petroleos SAKuwait Petroleum Europoort B.V. Syncrude

China Petrochemical Development

Corporation

Longview Fibre Paper and

Packaging IncTonenGeneral

ConocoPhillips Canada MacKay Operating Corp Total

DuPont Nova Chemicals Total Petrochemicals

Exxon Mobil OSUM Oil Sands TransCanada PipeLines

Georgia Pacific Petronas UOP

GB Biosciences Corp


• Stora Enso's and Arauco's joint-venture project Montes del Plata is building a new state-of-the-art 1.3 M tons

per year pulp mill in Uruguay. Start-up planned early 2014

• Biggest industrial investment in Uruguay ever, around $ 1.9 Billion

• Mill wide Honeywell Experion PKS covers entire pulp mill:

• Mill’s Process Information System by Honeywell’s:

• Drying machines equipped with Honeywell’s Experion MX QCS, profiling actuators Devronizer XP10 and

ProFlow, and web monitoring systems ProWeb 4G

• Entire mill covered by Honeywell Fire Protection System with EBI and XLS3000

“This mill will have a significant impact not only on the region’s pulp production capabilities,

but also on the local economy. It will employ 6,000 construction and 500 once in operation,”

said Carlos Pastrana, Project Director at Montes del Plata. “It’s important that this state-

of-the-art mill be outfitted with the best process and quality control systems supported by

experienced organization, and Honeywell’s track record of implementing mega-

projects speaks for itself.”

Greenfield Example : Montes del Plata

‒ 20 + 4 Operator Stations

‒ 3 System Clusters

‒ 44 C300 controllers

‒ 3500 Instrument loops (HART)

‒ 2100 ProfiBus motor controls (66 PGMs)

‒ 100+ remote cabinets

‒ Uniformance Process Studio

‒ WorkCenter PKS

‒ Operations Logbook

‒ Operations Monitoring

‒ BizCalc Manager

‒ Quality OptiMiser

‒ OptiVision Production Management for

Bale Tracking

‒ OptiVision Planning & Scheduling

‒ OptiVision Warehouse Management &

Container Loading

‒ Advanced Alarm Management


Expected Results from Technology

Transformation

Improve Customer retention

and satisfaction

Increase throughput by 10%

Reduce Raw Material Costs up

to 2%

Eliminate 5% of Quality Losses

Improve Finishing/ Converting

Losses by 10%

Reduce Inventory by 20%

Fewer Customer Quality issues

Savings on Logistics ~$2 per

ton

25% Reduction in Total Cost of

Ownership


Summary

• Maximum Benefits with measurement, control and operational excellence‒ Simple to operate & maintain

‒ Automation achieves bigger sustainable impact over time

‒ Transformed service approach

‒ Industry 4.0 Smart Factory ready

• All adds up to Reduced Costs and Streamlined operations for maximum

profitability


Thank You!

Documents

Honeywell Pulp & Paper DCS Technology · PDF file2015 Japan Technology Summit Yokohama, September 9-10 Honeywell Pulp & Paper DCS Technology Fredrik Westerberg, HPS, Asia Pacific