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Applying New Technologies to Reduce Project RiskLEAP™ - LEAN PROJECT EXECUTIONNigel Brockett

20 Oct 2016

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.

Project Execution in the 21st Century

• What is different today?

- Over the last 7 to 10 years, projects have gotten

larger

- No one EPC, often no one owner will take full

ownership

- Scarcity of skilled people

• Implications

- Work is often done by multiple EPC’s or multiple

offices

- Work can be done under multiple owner

guidelines

- Some project deliverables impacted more

severely

1

DATA will be late!

PROCESSES will change!

COST will be an

issue!

DATA will be late!

COST will be an issue!


The Challenge of a Traditional Project

Define Design Manuf Config Test Install

Start FinishPHYSICAL FUNCTIONAL

Hardware Definition

Marshalling Design

IO Assignment

Control Configuration

HMI Configuration

Alarm Configuration

System FAT

Site

Commission

I/O Counts, Locations

Instrument Index

Cable Designs

P&IDs, Narratives

Alarm Studies, Set Points

Configuration FAT

System

Configuration


0

5

10

15

20

25

30

Traditional Project

Backend Loaded Managing Late Changes

3

Months

Traditional Project

Lab

or

FT

Es


Repetitive Tasks Rework Redundant Tasks

Lean Execution Eliminates Waste

If “Time is Money”, Then “Wasting Time is Wasting Money?”

4

Entering the same data

over and over again

Editing the same data

over and over again

Validating the same data

over and over again

Non-value Add Processes are Considered “Waste”


Reduce Risk

Drive Effectiveness not Efficiency

To Efficiently Do What is Not Required is NOT Effective!

5

Remove Custom Designs

Reduce Complexity

Reduce Travel

Reduce System

FAT

Reduce Cost

Reduce Schedule

ReduceHardwareFootprint

Remove Early

Hardware Order

Eliminate hardware Eliminate tasks

Eliminate travel Optimize execution


Integrated solutions

increase value

of individual benefits!

LEAP Enabling Technologies

6

Universal IO

VirtualizationCloud

Engineering


Universal Channel Technology

Universal IO / RUSIO Units

Modules Shipped in last 18 months 3,600+

7


Essentials PlatformTraditional Platform Premium Platform

Virtualization

Saves on Power, Weight and Cooling

8


Design Independence with Virtualization

9

Virtualized Controller IO Simulators

Delay deployment to hardware

Standardize supervisory

designs

Variable capacity

1 40+


Cloud Engineering

SiteOffice

SSL VPN

Gateway

Honeywell VPN

Remote Office

Virtual

Engineering

Platform

Customer

Office

EPC

Office

Honeywell

Regional

Office

VEP Statistics (June 2015)

System Capacity 27,000 VMs

Current Usage 11,000 VMs

Total customer project systems 1640

Current active customer projects 842

WAN

10


Virtual Acceptance Testing

Start Up New Pcs With the Longest Lifecycle!

11

Honeywell Hosted ProjectTraditional

People and target equipment staged early in project in a

single location

Configuration checkout & FATs done

on large grained scope with travel

of critical resources for long periods

Project staged in data center; people distributed; equipment

not required until late in project

Customer, EPCs, HON all have secure

remote access to validate modular

increments – less travel & rework


Global Project Delivery Model

Technical Standards + Project Methodology

12

GPM (Global Project Methodology)


Off theCritical Path

LEAP - Lean Project Execution

13

Define Design Manuf Config Test Install

Start FinishPHYSICAL FUNCTIONAL

LateBinding

• Cloud Engineering enabled by Controller and IO Simulators in Virtual Machines

• Control Strategy Adaptability when you need it, during project execution

- No IO Module ID required for configuration

- No IO Channel ID required for configuration

- Functional configuration independent of physical design

• Late Binding matches the functional configuration to the physical design


LEAP - Lean Project Execution

14

Marshalling Design

HMI Configuration

Alarm Configuration

System FAT

Cable Designs

P&IDs,

Narratives

Alarm Studies,

Set points

LateBinding

Hardware Definition

IO Assignment


Site

Commission

I/O Counts,

Locations

Instrument

IndexConfiguration

FAT

System

Configuration


Remote IO Cabinets

• Traditional design with field junction boxes and local equipment

rooms add engineering and construction cost

• Field mounted UIO eliminates significant cost, delivery lead times

and opportunities for error

Remote Instrument Enclosure

15


Reducing project CAPEX

Component Cost

($ per I/O basis)

Convent’l

I/O Cards

UIO in

Cab

URMC Comments

Cost of I/O Hardware 100%

(Baseline)

110% 145% URMC adds more

cabinets, PSU, IOLE, etc.

Cost of Custom Marshalling

Panels

15%* - - Field terminals included in

UIO / URMC cab designs

Cost of Cabinet Staging and FAT 6%* - - Standard UIO cabs

shipped direct to site from

factory

RIE Footprint 56% 42% - Non-Blastproof RIE

Home Run Cables 30% 30% -

Field Junction Boxes 20% 20% - URMC replaces field JB

Fiber Optics and Power Cables - - 20% Redundant FO & power

Loop Wiring Testing 9% 9% 3%

Total Installed Cost (TIC) 236% 210% 169%

Relative Savings Baseline (11%) (28%) * Excludes impact of I/O

design changes

Relative Total Installed Cost Savings with Remote UIO Cabinets

16


Support for Modular Construction

Technology to stay off the “Critical Path”

• Project early ships “standard” Universal Cabinet to Module Yards

- Ship sooner with less information

- Flexible location for installation

- Standard Factory testing

• At each Module Yard

- Terminate signals on any channel in Universal Remote Modular

Cabinets

- Full loop test prior to shipment

- Control and IO Configuration is done in a cloud

17


What is Late Binding?

18

Central Control Room

HMI


Alarm Configuration

HMI Configuration

Configuration FAT

Alarm Studies, Set points

Sketches, Procedures

SIMACESIMC300

No physical channelassignments required

Universal Cabinet


Late Binding Advances – Future

19

Tagname 1

Tagname 2

Tagname 3

Tagname 4

Tagname n

FI101

Detect

Interrogate

Configure

Enable

Document

Central Control Room

HMI


Alarm Configuration

HMI Configuration

Configuration FAT

Alarm Studies, Set points

Sketches, Procedures

SIMACESIMC300

No physical channelassignments required

Universal CabinetxxxxxxxxxxFI101xxxxxxxxxxxxxxxxxx

32 character tagname for HART 6/7


LEAP Project Workflow

Work in Parallel, Virtual FAT, Ship to Site Earlier

20

Minimal CheckoutEliminates big bang testing

with virtual FAT

FunctionalEPC

Honeywell

Honeywell Virtual Engineering

Platform

Customer

Direct to Site!

Physical

Standard Cabinets

Servers


Case Study

• With Virtualization and Universal IO

• Reduce the MAC cabinets by 50%

• Reduce Marshalling cabinets by 90%

- $10K per cabinet is over $1M

• Reduce cabinet engineering, drawings and documentation

- ~40 hrs per cabinet means 5000 hours of work eliminated

- Depending on where that is done, saving from $500K to $1M

- 4 drawings per cabinet, typical, this eliminates 500 drawings

This represents 1000s of hours for the EPC to review, approve and cycle

to end user

• Reduce opportunities for marshalling mistakes by 66%

- Each loop can have up to 15 terminations between device and IO

Module

With Universal IO, there are 5

• Reduce capital cost by $16M

- In a normalized $50M MAC scope

21


EPC Opportunities

• Potential EPC Benefits

• RIE Foundations and transport

- Engineering, Material and labor

• Home run cables and trays

- Engineering, Material and Labor

• Engineering drawings

- JB, wiring reports, routing plans, etc..

• Procurement Activity Reduction

- Supply chain reduction

• EPC FAT

- Time and Travel

• Commissioning savings

- Labor and travel

• Reduced Control Room and Equipment room

- Less footprint, power, HVAC, and weight

LEAP

Universal IO

Virtualiz-ation

Cloud Engineering

22


End User Opportunities

• Reduced spares

- Universal Channel Technology adapting to signal mix

• Reduced OpEx

- RIE infrastructure, HVAC, Power, Fire and Gas, etc.

• Startup and Commissioning

- Reduced commissioning time and simplification

• Lifecycle cost reduction

- Tech refresh avoided

• Operations lifecycle simplicity

- Reduced marshalling, loop drawings made

simple, trouble-shooting and diagnostics

simplified

• Reduced project risk

- Reduced Cost and flexible schedule

- Keep automation off the critical path

LEAP

Universal IO

Virtualiz-ation

Cloud Engineering

23


Traditional Waterfall Schedule

A Revolutionary New Schedule

LEAP Can Generate 25% of Schedule Flexibility or Compression!

24


Traditional approach is often back end-loaded

0

5

10

15

20

25

30

Months

LEAP Project vs. Traditional

Modular, Incremental Design – Avoid Backend Loading

25

Traditional

LEAP Project

Lab

or

FT

Es


A Universal Opportunity!

26

LEAP delivers

a step change for Automation Projects!

Change Management

Schedule Management

Resource Management

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