ARC VIEW. Leveraging New Automation Approaches Across the Plant Lifecycle. Keywords. Summary. By Larry O Brien

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1 ARC VIEW JUNE 22, 2017 Leveraging New Automation Approaches Across the Plant Lifecycle By Larry O Brien Keywords Operational Excellence, Cloud, Virtualization, Operations Management, Field Commissioning, Lean Execution, Automation Projects, LEAP, Cybersecurity, Honeywell Summary Many of the new technologies offered by the process automation suppliers focus on reducing the cost and complexity of automation projects. Technologies like intelligent, single-point I/O; virtualization; cloud-based engineering; and integration of Many of the new technologies for process automation systems, such as intelligent, single-point I/O, have automation systems with power and energy management systems can have a huge impact on focused on reducing cost and complexity in automation projects. Automation reducing the upfront project costs. But what about suppliers are beginning to expand the ongoing lifecycle costs and operational excellence? value proposition by incorporating new technologies like the cloud, Many end users view the basic process automation virtualization, and intelligent sensors. system as a necessary commodity, rather than a value-adding asset that can provide significant return on investment after installation. But, in fact, while new forms of I/O and system engineering can greatly reduce the cost and complexity of a project, the new generation of systems can also offer significant return throughout the plant lifecycle. Honeywell recently briefed ARC Advisory Group on the company s new LEAP for Operations solution, which takes many of the new technologies and features developed for LEAP and extends their value across the plant lifecycle. Honeywell s three-pronged approach for LEAP for Operations includes: cloud-enabled execution of many level 2 and 3 applications, edge device integration, and integration of connected assets such as SCADA system RTUs and electrical assets via the IEC standard. VISION, EXPERIENCE, ANSWERS FOR INDUSTRY

2 ARC View, Page 2 From Project Solutions to Operational Solutions Driven by end user demand to reduce project cycle times and get automation off the critical path, Honeywell s original lean execution for automation projects strategy, LEAP, combined three key elements: cloud-based engineering, virtualization, and universal technology. The latter element refers to Honeywell s new universal configurable I/O and standard control cabinets. This helped shave up to six months off automation projects according to Honeywell. Engineers can work concurrently on a project in the engineering cloud and design a system that can be created virtually, then loaded into the physical system infrastructure right before deployment. ARC refers to this concept as late binding. Certainly, significant benefits can be had during the project phase and through system startup. But what about the much longer operational phases of the plant and the system? ARC s rule of thumb is that the operational cost of a process automation can be three times (or more) of its installed cost. ARC feels strongly that the process automation system should be viewed as an enabler for operational excellence; one that provides a platform for risk management, avoiding unplanned downtime, and reducing maintenance and other operational costs. Network Security Control Firewall Third Party Network Firewalls Corporate Network Firewalls IEC Cyber secure conformity Designed-in Security ISASecure Level1 Certified Development Process Security Reviews from 70+ Experts Access Control Configure Scope of Responsibility Optional Risk Manager for enhanced security Easily evaluate Risk Factors Continuous monitoring Detect threats Cybersecurity Is Pervasive Across all LEAP Elements Lifecycle Focus Honeywell s LEAP for Operations strategy leverages many of the same newer technologies in process automation, but with a focus on reducing lifecycle costs and increasing reliability. Cybersecurity is pervasive throughout LEAP for Operations and Honeywell employs secure-by-design concepts as well as layers of protection (including industrial-strength firewalls). In addition to cybersecurity, LEAP for Operations rests on cloud-based execution, edge device integration, and integration of what Honeywell calls Universal Connected Assets, which

3 ARC View, Page 3 include other subsystems and assets in the plant like electrical products, SCADA RTUs, and skid-mounted, OEM equipment. Cybersecurity by Design With Honeywell s secure-by-design approach, many cybersecurity-related features and functions are built in. LEAP for Operations focuses on four primary domains of network security: conformance to cybersecurity standards (like ISA 99 and IEC 62443), access control, and its Risk Manager application. Network security includes Honeywell s own Control Firewall product, a standard Experion system offering. The company also supports third-party and corporate network firewalls. Conformance to Cybersecurity Standards The ISA Security Compliance Institute (ISCI), a neutral, not-for-profit consortium manages the ISASecure certification process. Honeywell Experion C300, Safety Manager, and FIM controllers are certified ISASecure Level I. In January of 2017, Honeywell also received ISASecure SDLA lifecycle certification, which independently confirms that Honeywell s development processes comply with the security development lifecycle requirements of the ISASecure Security Development Lifecycle Assurance (SDLA) certification, which is based upon the IEC industrial cybersecurity standard. Risk Manager: A Single Portal for Cybersecurity with Contextual Dashboards Honeywell s Industrial Cyber Security Risk Manager application addresses some of the biggest roadblocks to effective cybersecurity management. It ensures that operators are always aware of their cyber risks and can direct cyber resources to areas that require immediate attention. Risk Manager collects information in a similar manner to traditional security information and event management (SIEM) products, but then converts this information into something that s easy for operators to understand and act upon. This includes notifications and alerts whenever security risk issues arise, plus a dashboard that helps operators understand the extent of these risks and the actions required. Drill down capabilities help operators and cybersecurity personnel quickly isolate risks to specific devices.

4 ARC View, Page 4 Cloud-Enabled Execution Environment ARC research indicates that an increasing number of end users are deploying their level 3 (MES) applications in the cloud. Compare to solutions deployed on site, cloud-based solutions can reduce the risk and cost of deploying and maintaining applications. End users are using various flavors of the cloud to implement these solutions today. Most prefer private clouds (remote or on-site), rather than the public cloud, since these offer deeper security. LEAP for Operations cloud enabled execution environment is available in these various cloud configurations. The Honeywell LEAP for Operations cloud environment, called Experion Elevate, is based on Microsoft Azure. The first tier of the cloud-based execution environment supports locally hosted visualization platforms and local clouds, also known as a fog computing approach. Virtualized Servers in Public Cloud controlling Tier 2 geographically dispersed assets supplements this approach while On-Process - Secured Public Cloud accommodating Virtualized servers in Eng Room with connection to Off-Process VEP for testing virtualization on a wider scale with Honeywell s nextgeneration Off-Process, Private\Public VEP Virtual Engineering Platform Physical Servers in Eng Room of Large Industrial Complex (Open VEP), originally developed for internal Honeywell Offers Multi-Tiered Cloud Execution Environment use at Honeywell, but now also offered commercially. This allows end users to build and test control strategies, display, alarms, and more in a virtual, cloud-hosted environment to enable concurrent engineering and virtual factory acceptance testing (FAT). Tier 3 supports virtualized servers in a public cloud, with no physical hardware on site. This configuration is good for controlling geographically dispersed assets and can be a useful and cost-effective configuration for oil and gas, SCADA, and other remote applications.

5 ARC View, Page 5 Edge Device Integration LEAP for Operations edge device integration includes advanced functions for automated device commissioning, support of multiple wireless networks for process field devices, integration of fire and gas systems, and integration of skid-mounted devices. Automated Device Commissioning Honeywell offers SmartLine transmitters for a variety of standard industrial field networks including both HART and FOUNDATION fieldbus. For wireless devices, Honeywell OneWireless devices now offer full support for both WirelessHART and ISA wireless protocols. What s more, the same late binding approaches mentioned previously, in which the software aspects of a process automation system can be merged with its actual physical hardware at the latest possible moment, allows end users to install and commission field devices before the actual control system software is deployed. Honeywell has taken additional steps to automate both intelligent field device commissioning and the subsequent testing and documentation stages, which appear to be unique capabilities for device configuration solutions today. Virtual Engineering Platform Customer System Instrument Index Build Devices Test CMs / HMI / etc. Build CMs / HMI / etc. Configuration Acceptance Test Interrogate Detect FT101 Match FT100 FT101 FT102 Test Document Universal Process Cabinet Configure Automated Device Commissioning Features Include Automated Testing and Documentation Experion I/O automatically queries all I/O channels to determine if a device is connected. Intelligent transmitters are recognized automatically by the I/O. The software configuration of the system is matched up to the in-

6 ARC View, Page 6 telligent device automatically and the configuration updated automatically. Other information resident in the system software configuration, such as transmitter range, alarm setting, and so forth can be updated to the intelligent transmitter in the field. With the Experion R500 release, Honeywell is introducing new testing and documentation capabilities for intelligent devices. These eliminate the need for paper-based tests, allowing for automated or guided testing procedures. For example, different percentages of range can be calibrated automatically using HART commands. In R500, all test results are also automatically documented and a total cabinet printout report is available, which can eliminate the need for a device loop sheet. In an automated device commissioning scenario with devices recognized automatically and their configurations updated remotely, the entire device commissioning process can be reduced to a couple of minutes, versus a couple of hours. Map 100 variables Create channel and controller Configure & validate points Diagnostics configuration TOTAL 1 hr 15 min 5 hrs 6 hrs 12+ hrs Universal Connected Assets LEAP FOR OPERATIONS provides better connectivity to assets in the plant outside of the process automation system. These include electrical systems, SCADA RTUs, third-party PLCs, and skid-mounted OEM equipment. Central BEFORE AFTER to this strategy is the Integrated ControlEdge Configure controller 5 min PLC / RTU2020 Automatically generate and Ethernet Interface Module (EIM), which 10 min review points Diagnostics configuration 0 min 15 (Ready out of the box) HOURS MIN TOTAL 15 min provides connectivity to a wide range of Ethernetbased networks, from BEFORE AFTER IEC for electrical Integrated ControlEdge Automatically generate and 2 min PLC / RTU2020 review 5 points Download points 1 min products and energy 3 TOTAL 3 min management systems to MIN MIN devices like Rockwell Automation PLCs on Ethernet/IP networks. Ethernet/IP integration also greatly eases the task of integrating skid-mounted equipment, which is predominantly controlled by PLCs and can represent up to 50 percent of the I/O in a process plant. 3 rd party PLC / RTU 12 For Updating a Control Strategy in either the RTU2020 or the PLC Map 5 variables Configure & validate points Download points TOTAL 5 min 10 min 2 min 17 min 3 rd party PLC / RTU 17 Automated Configuration Capabilities for ControlEdge PLCs and RTUs Reduce Time Required for Initial Configuration or Updating Control Strategies Honeywell also has its own ControlEdge PLCs and ControlEdge RTUs (formerly known as RTU 2020). Both products have autorecognition fea-

7 ARC View, Page 7 tures that can significantly reduce the amount of time required to configure these devices or update their control strategies. ControlEdge devices can automatically populate relevant associated diagnostic points into the HMI graphics of the overall system. Conclusion While new forms of I/O and new ways of completing automation projects have already proven to help reduce overall project cost and complexity, suppliers are expanding these new approaches to provide a better value throughout the system lifecycle, greatly reducing maintenance costs and total cost of ownership. Honeywell s LEAP for Operations approach, for example, features an expanded focus on cybersecurity, cloud-based execution, better integration with intelligent field devices and other edge devices, and better integration of subsystems and Ethernet-based networks. In ARC s view, this is a good strategy that will benefit both end users and Honeywell. LEAP for Operations is also an example of Honeywell s successful transition from a traditional controls and automation supplier to one that is focused on next generation software and services for industry. ARC also expects a lot of this thinking to go into the company s other businesses, such as infrastructure and smart cities. For further information or to provide feedback on this article, please contact your account manager or the author at lobrien@arcweb.com. ARC Views are published and copyrighted by ARC Advisory Group. The information is proprietary to ARC and no part of it may be reproduced without prior permission from ARC.