smart integration of offsite automation with epks

2015 Honeywell Users Group

Europe, Middle East and Africa

Smart Integration of Offsite Automation with EPKS

Jayaprakash R, Honeywell

© 2015 Honeywell International All Rights Reserved

Introduction

• Loading and un-loading

product are key activities in

off-sites operations

• Profitability depends on

success of these activities

• Many challenges exist that

need to be addressed

Our Goal:

Demonstrate how to address the

challenges in Storage,

movement, loading and un-

loading products and optimize

operations through improved

safety, reliability and efficiency

Intelligent Business Decisions leads to improved margins


Safety & Security

Protect People, Assets and

Environment

Reduce Spills &

Dangerous Mixing

Reliability

Improve Availability

Reduce Downtime

Reduce Demurrage

Efficiency

Improve Productivity Reduce Cost

Easy accounting,

Unified Ops

Terminal Operations Management Goals

Accuracy

Accurate Measurement, Better Control

Reduce loss, improve visibility


Current Challenges

• Seamless dataflow between

sub-systems

• Lack of Unified operating

systems in off-sites

• Manual intervention

between product movement

and loading systems

• Manual intervention during

reconciliations

• Downtime and Demurrages

True integrated systems in

off-sites

Will improve safety and

margins

Honeywell provides you with a comprehensive solution


Holistic approach:

Integrated solution, single view

Non-Integrated Approach:

Each supplier has a different view

Planning &

Scheduling

Safety

Accounting

Terminal

Mgt

Loading

Control

Solution attributes:

Single solution view

Common design philosophy

Integrated “out of the box”

Less expensive to implement &

manage (by as much as half)

Multiple solution providers

Only focus on subsystem

Plant staff becomes the integrators

More expensive to implement &

manage

Gauging

Customs

Security

How to Beat the Challenge ?

Point Solutions are Pointless...hence…we Integrate and not Interface


Terminal Manager – Smart TAS solution

• Advanced Configurable

workflow engine

• Transport modes - Road,

Rail, Marine, Pipeline

• Product Allocation,

Reconciliation, Email & SMS

notifications

• Integrated working with

Movement Automation

• Common SESP programs

and migrations

• VM and EBR Qualified

Built on Experion platform

“Experience a truly integrated TAS”


Benefits of Domain Expertise

Domain knowledge means ability to apply best practices

9 Honeywell Confidential

Terminal Manager - Powered by Experion

Experion (More than

SCADA/DCS)

Server, network

redundancy PLC /

Controller, Wireless

Typical SCADA

functions

Network, Cyber

security, anti-virus

Remote monitoring

Virtualization of server &

clients Backup control center

(Disaster Recovery)

System Status,

Diagnostics

Safety shutdown controller

Backup and restore

Motor Operated

Valves

Tank Gauging

Digital Video

Pump control, MOV, Interlocks,

wireless sensors and network

Alarms, trends, graphic

displays, history, reports

Firewall, preventing

cyber /virus attacks.

SIL3 controller for safety

shutdown e.g. LPG

Ghost image of server

for emergency restore

Control tank farm

valves, alarms,

interlocks

Monitor tank parameters,

alarms, interlocks,

regulate movements

Live video and playback

(e-Server) remote

monitoring, trends

Powered by VMware.

Reducing investment

and lifecycle costs


System Architecture – Smart Form

TAS Server & StationControl Room / Office

- Product Level

- Average Temperature

- Pressure (optional)

- Water bottom (optional)

Radar Servo

Experion - Real time

monitoring (DSA to

EPKS servers )

TM - Shipment handling

& workflow

- Flow Control Valves

- Shutoff Valves

- Flow Meters

- Additive Injection

- Blending Control

(optional)

- Pump Demand

(optional)

Flow Controller

& Local HMI

Field - Loading Bay Field – Tank Farm

Tank

Gauging

Tank Gauging

Interface

Comms

Interface /

terminal Server

- ENbus comms

- Inventory calcs- Serial RS485/422

- TCP/IP

- FO

LAN

Entis Pro

- Tank monitoring

- Tank gauge calibration

CIU Plus and

CIU PrimeCIU 888

MSC-L (Load Computer)

MSC-L


System Architecture – Ultimate Form (Scalable)

Process

Controller

C200

TGI

- Gauging field bus

- ASTM/API Calcs

- W&M Approved

DVM Server

Experion DVM

Web Server

Experion eServer

TM UI Web services

Engineering Portal Server

Fusion4 Portal

ENgauge

Local or Remote

I/O

Series A Chassis

Pump

Drives

PowerFlex

Tank Gauging

BPM ENbus

Process

Controller

C300

I.S. Local or

Remote I/O

Series H Rail

I.S. I/O

Series C Chassis

Terminal Servers

Serial Comms Gateway

Serial Devices

- Flow Controllers

- Access ID Readers

- Message Boards

- Third Party PLCs

I/O I/O

I.S. I/OI.S. I/O

F&G Controller

- Hydrocarbon sensors

- Vapour sensors

Fire & Gas Related

I/O

Hybrid

Controller

HC900

Local or

Remote I/O

HC900

ESD Controller

Safety Manager

SIL3

Safety Related

I/O

MOV Field bus

Ring network

MOV

Controller

Pakscan

TAS Server Pair

Experion PKS

Terminal Manager

A

B

Flex Stations

- Tank farm monitoring

- Movements control

- Loading bay monitoring

- Jetty control & monitoring

- Pipeline monitoring

- Schematic displays with DVM

- Alarm & Events Summery disp.

- TM UI

Printers

- BOL / BOD

- Reconciliation reports

- Cross reference reports

L1/L2 FTE

L2 FTE

L3 LAN

L4 WAN

Domain Controller

System Admin & Security

Terminal Services

ERP Relay Interface

OPC Gateway

Consol Stations

- Tank farm monitoring

- Movements control

- Loading bay monitoring

- Jetty control & monitoring

- Pipeline monitoring

- Schematic displays with DVM

- Alarm & Events Summery disp.

- TM UI

PHD Server

Uniformance PHD

EBR Server

Backup & Restore

EBI Server

Site Security

L3 EBI/DVM

Flex Station

- Operations Displays

- Engineering Tasks

DVM / EBI Stations CCTV Cameras

RES Server

Remote Engineering Services

Maintenance & Support

Wide Area Network

- ERP Interface

- PHD Clients

- Remote Alarm Paging

- Remote Event Archiving

- Remote Support

Back Office

- Contract Admin

- Shipment handling

- Ops./DVM graphics (web)

- TM UI (web)

- TM Database admin

- Electronic reports

Site Access

Control

Weighbridge

Interface

Weigh

Bridge

L3.5 DMZ

Redundancy

in server

Redundancy in

serial comms

Redundancy in

Ethernet

Ergonomic

console with 4

touch screens


Off-sites Movements Challenges

• Line-up errors

• High workload of off-sites operators

• Increasing demand for data integration

(i.e. for data reconciliation)

• Loss of expertise

• Low off-sites automation

• Manual co-ordinations

• Lack of interlocks between movement

and loading/unloading

If not addressed, challenges result in incidents, reduced profitability and delays


Overcoming the Challenges

• Requires an

appropriate

workflow:

Plan

Perform

Perfect


Integrated off site Management Helps Close the Loop

From Planning to Final Accounting

ORDER MANAGEMENT

Movement Task Management Loading and un loading Management

The order which is ready for execution is

validated and interlocks verified

Loading control and monitoring with alarms and safety interlocks

Integrate ERP order with loading and

movement system

Movement monitoring and

management with alarming

Task creation, line up and hand shake signals verified

The ERP orders are in sync with all the off sites

sub system

ERP

Terminal Manager

Movement Automation

Create activity

EXECUTION PREPERATION

EXECUTION MANAGEMENT

System readiness

Interlocks verified

Product, line up verifications and readiness


System Detail Mapping

Operation

Movement

Automation

Terminal

Automation

MIS / ERP Order Download Process P

Order Activation Monitoring Control

Loading arm assignment & permissive M C

Lineup C M

Loading Start C C

Flow Monitoring M M

Custody Transfer Meter Proving C C

Tank Swing (Source) C M

Real-time Volume Reconciliation C M

Tank Dynamics C M

Stop On-demand C C

Batch completion M C

Closeout C C

Movement report to MIS/ERP C -

Loading report and Invoicing - C

P: Process C: Control M: Monitoring


Experion in Action

Physical Security and Video

Common View Across Facility

Integrated Blending & Terminal

Automation

ERP Integration

Planning and Scheduling

Process Management

Common Platform across facility wide operations

https://www.cita.ie/meetings/0411flyer_files/sap.jpg


Safety and Security

Integration with Honeywell safety manager

Application role based security

Access card based authentication

Tamper proof Audit Trails

Defense-in-depth security

Windows Integrated Security

Integrated System

Integration with Honeywell EPKS and Devices to provide unified approach

Interface to ERP systems such as SAP

Control custody transfer to multiple transportation types from one system

Product inventory and common validations available across all transportation modes

High Availability & Reliability

Provides decentralized design that enables each loading bay to be controlled independently so that the failure of one bay will not impact operations on other bays and ensures 99.9% availability

VALUE PROPOSITION DIFFERENTIATING FACTORS

Configurable Workflow

Terminal Manager includes a host of configurable

options to enable project engineers (not just

software engineers) to truly “engineer” a workflow

solution according to the operational

requirements of the site. Irrespective of the

number of locations, make and model of batch

controllers, transaction planning options, mode of

transport & so on, the configurable workflow

offers a solution to meet the needs of every TAS

deployment under consideration.

Extensibility & Customization

Extensibility feature allows users to customize

workflows to suit specific needs. This allows the

site system to migrate to a newer version of

Terminal Manager Software with limited

disruption to terminal operations. It also makes

maintenance and trouble-shooting easier.

Value Propositions


Intelligent Business Decisions leads to

• Minimize ALL types of giveaway

– Unified approach to blending, movement and loading can

reduce giveaway significantly and reap tremendous benefits

Improve Refinery Margins


• Demo Room

• Consulting Corner

THANKS

Let’s continue in the...

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