“The Honeywell team went the extra mile on this project and worked very well with our team. The long-term vision for the plant is to fully migrate to Experion and integrate TotalPlant Batch over the next few years.”

Controls and Information Systems Manager

One of the world’s largest producers of consumer goods installed Honeywell’s Experion® Process Knowledge System (PKS) and TotalPlant® Batch at its plant near Mexico City. Leveraging Honeywell’s project expertise, the installation was completed in three months and resulted in several benefits:

• Investment protection in existing technology
• Increased process capability
• Minimal downtime
• Reduced operator training time

This customer was a past Honeywell customer and was using Honeywell’s TDC3000 control system integrated with Honeywell’s legacy batch software solution for process control at the site. The customer was not able to upgrade the existing systems during the initial project and requested that any new systems and software be able to integrate seamlessly with the existing making systems.

The customer wanted to increase efficiency and productivity at its plant while protecting its nvestment in its TDC 3000 system and third-party systems and controllers. The Experion platform was installed to control a new making train and to lay the foundation for future migrations. In addition to TDC 3000, the plant has multiple systems, platforms, and Programmable Logic Controllers (PLCs) from different suppliers. The customer turned to Honeywell to overcome the time constraints for this project which included a minimal window for downtime and an extremely aggressive project schedule. Training operators and transitioning them to a new system was also a concern for the customer.

Honeywell was selected for this project for a variety of reasons:

• Minimal downtime to integrate EPKS with existing systems
• Integration capabilities with TDC 3000, the existing batch system and third-party controllers
• Project execution capability
• Ability to leverage standards within the Experion environment
• Desire to take advantage of new features within Experion and TotalPlant Batch. Honeywell installed the system at the plant. The new system includes an Experion Station and Server, C300 controllers and TotalPlant Batch. Part of the Experion unified architecture, Honeywell’s TotalPlant Batch provides flexible and secure batch management for increasing plant performance and throughput.

In addition to integrating multiple systems and preserving the customer’s investment in existing technology, Honeywell was able to meet the plant’s need for minimal downtime. Only 6-8 hours of downtime was required for interfacing Eperion PKS with TDC3000, which was the only process interruption during the three-month project.

Another benefit of installing Experion was that it was easy for operators to use as they were already accustomed to working with Honeywell systems, significantly reducing training time.

With the installation complete, TDC 3000 still controls 90 percent of the plant with the remaining 10 percent now controlled by Experion to add process capability. “TotalPlant Batch, TDC and Experion work seamlessly together,” said the Controls and Information Systems Manager at the site.

The customer team worked closely with Honeywell in the execution and support of this project. Standards were developed and used in this project based on the tools and capabilities within the Experion PKS environment. These standards not only helped the customer meet the aggressive timing of this project, but are also being used on other projects within the company. “The Honeywell team went the extra mile on this project and worked very well with our team,” said the Controls and Information Systems Manager. “The long-term vision for the plant is to fully migrate to Experion and integrate TotalPlant Batch over the next few years.”

Experion® and TotalPlant® are registered trademarks of Honeywell International Inc.