Process automation has historically been an afterthought until after the process design and detailed engineering phases of a project. This can result in the vision of the process licensor not being accurately implemented in the control system and costly startup delays due to last minute changes. Honeywell UOP (UOP) in collaboration with Honeywell Process Solutions (HPS) is able to deliver faster, more sustainable value throughout the facility’s lifecycle by ensuring that UOP knowhow is fully utilized across the process automation portfolio.
Efficiently and effectively transferring process knowledge and experience from UOP to the customer is the goal of every project engagement. Combining the potential of process licensor expertise, advanced sensors, automation, modeling, and optimization has opened many exciting possibilities for the development of new solutions. As part of the same strategic business unit in Honeywell, UOP and HPS have been able to accomplish this by establishing the Honeywell UOP Applied Process Excellence (APEX) Center. The APEX Center provides:
- Rich knowledge base of both process technology design and automation knowhow to craft unique combined solutions driving customer profitability
- Continuous joint innovation between both portfolios to meet customer needs
- Simplified customer procurement process by providing a combined effective proposal for all Honeywell solutions
The Honeywell Advantage solution includes:
UniSim Competency Management:
HPS and UOP provide a holistic solution to the challenges faced by our customers in starting up and operating a Greenfield or Brownfield expansion. The solution includes curriculum development, candidate screening and assessment, training program development and implementation and certification of all technical staff in the refinery. This program includes the training courses from both UOP and HPS and the UOP Training Simulators for key process units.
These UOP Training Simulators capture UOP know-how in the form of reactor models, pre-built scenarios, exercises and workbooks based on UOP’s experience in starting up and supporting units around the world. Training simulators are available in the cloud enabling access to valuable training without the need for dedicated hardware.
UOP Critical Control Applications:
UOP Process Information and Control (PIC) applications provide critical control functions for UOP process units. Implementing the PIC applications on Honeywell platforms provides the following benefits:
- Points, alarms and events are available natively on the Experion® System without any need for cross-database configuration and alignment
- Smooth coordination between the Distributed Control System (DCS), Emergency Shutdown system (ESD) and PIC applications
- Procedural Operations in Experion can coordinate with the logic in the PIC application as appropriate
- Common hardware platform for PIC Apps and DCS or ESD and Fire and Gas systems reduces the number of platforms on site, eliminates black boxes and reduces training and maintenance costs
Experion Solution Suites (ESS):
The Experion Solution Suites, which are built for the Experion Orion console, are pre-engineered DCS and safety system graphics and control configuration specifically for UOP process technologies. These configurable templates include:
- Operators’ HMI graphics displays built to Abnormal Situation Management Consortium® standards
- Pre-engineered interfaces for UOP control systems
- Integrated alarm help (DynAMo® Solution Suites)
- Embedded procedures for critical unit operations
- Safety System configuration which captures UOP’s cause and effect matrix
Experion Solution Suites (ESS) when implemented on Honeywell’s Experion PKS Distributed Control System (DCS) allow customers to reduce project risk and start up new facilities sooner by embedding UOP process knowledge and expertise into the automation solution. During plant start-up, operating companies may face unforeseen challenges such as: non-functional DCS interfaces; poorly designed graphics causing operator confusion; displays based on piping and instrumentation diagram (P&ID) information only with no consideration for operator interaction and multi-unit operations; poorly designed alarm systems leading to alarm flooding; and operators unfamiliar with unit procedures missing critical steps.
ESS templates solve these problems by providing KPIs defined by UOP experts, PFD level graphics to allow the operators to visualize the right pieces of equipment, rationalized alarm help for critical alarms and contextual operating procedures to help the operators to operate the plant reliably.
UOP Modular Solutions:
UOP Modular Refining Solutions provide single-source project management, quick construction in challenging environments and superior quality control for reliable and cost-effective operations. We’ve delivered more than 1,400 fully-engineered and pre-fabricated modular process units delivered to customers around the world. Our expertise and project execution experience can help you manage and monetize resources more effectively.
For these modular units, UOP and HPS have pre-installed a suite of automation solutions to reduce site work and skilled labor requirements. In addition to the solutions described above, modular automation packages can include:
DynAMo Solution Suites (DSS):
The advanced user interface coupled with a well-managed alarm system actively reduces the frequency and severity of operator error. This can reduce expensive and potentially dangerous abnormal situations. However, in the event that an abnormal situation does occur, the control room operator still remains the primary line of defense. At this critical time, the operator is tasked with providing the right response, to the right situation, at the right time.
To assist operators in responding to alarms, UOP has collaborated with Honeywell Process Solutions to provide a suite of operator alarm guidance modules for UOP licensed units. These modules provide alarm help documentation leveraging UOP’s design intent and vast process experience. This guidance is pre-engineered and available for operators to start training before the automation system is live. This early training ensures competent and confident operators enabling smoother startups, improved safety, and higher reliability operations. Following startup, this advanced alarm guidance remains at the operator’s fingertips throughout operation embedded in the Experion Solution Suites on the Experion PKS DCS console.
Advanced Process Control with UOP toolkits:
Well-designed advanced process control is like having your best operator running the plant 24/7. It typically results in increased yield and throughput and a reduction in product variability. Implementation of APC can also lead to more stable operations improving reliability and overall equipment effectiveness.
UOP and HPS have pre-engineered APC configurations for UOP Process Units. This allows APC to be implemented earlier (up to 6 months) with consistent efficacy leading to millions of dollars of additional revenue to the customer. HPS has developed toolkits capturing UOP’s design correlations. These toolkits calculate variables that are difficult to measure directly allowing the APC application to safely maximize profitability.