Connected Plant

EXPERION® AND CONTROLEDGETM PLC: REDEFINING

PLANT-WIDE INTEGRATION
Honeywell’s Experion® platform when combined with ControlEdgeTM PLC provides an integrated
control solution through all levels of process and business for optimized operations and
maintenance efficiencies

White Paper
Introduction

Since their introduction, PLCs have evolved from simple

on-off controllers to advanced processor-based systems
that execute complex control algorithms. The demand for
added features, precision, and seamless connectivity
across plant floor has driven an increasing need for PLCs to
integrate with other control systems.

Honeywell’s new PLC, part of the ControlEdge family of

next generation controllers, provides unprecedented
connectivity through all levels of process and business
operations.

ControlEdge PLC, when combined with Experion® reduces

integration costs for balance of plant through dramatically
improved startup and commissioning time and decreased
cyber-attack risks with embedded secure communication,
thereby providing lower total cost of ownership and a more
reliable and consistent plant-wide operations.

Honeywell can serve as your single vendor for all

automation needs, including the DCS, PLC, SCADA, Field
Device Manager for asset management, and a Panel PC-all
with seamless integration and support.

This whitepaper describes key integration features of

Experion and ControlEdge PLC that enables a more
Standardized, Flexible, Connected and Cyber Secure
solution experience.

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Table of Contents

Introduction ................................................................................................................................................................................2

Fast and Lean Integration...................................................................................................................................................4

Integration challenges due to aging PLCs .................................................................................................................4

Consistent, Plant-wide HMI Integration ......................................................................................................................5

Simplified Asset Management..........................................................................................................................................6

Greater Engineering Flexibility .........................................................................................................................................7

Improved Connectivity ..........................................................................................................................................................7

Robust Cyber Security ...........................................................................................................................................................8

Honeywell- Your Right Partner for Automation........................................................................................................8

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 Integration challenges due to aging PLCs

Your challenge
“Connect the PLC to my
control system… with
less effort”

“Integrate my control
system with PLC over a
Secure interface”

“Operate from the

equipment or the
control room… more For any plant, lack of modern age PLCs and Designed to work with any SCADA system and
easily without learning robust connectivity infrastructure leads to over variety of interfaces, ControlEdge PLC
different sub-systems” various issues which accumulates and result into unlocks a superior experience when used with
high cost of ownership of systems. These issues Experion DCS/SCADA and Experion Panel PC
include over OPC UA. This integration provides an
unprecedented connectivity through all levels of
Our solution - High maintenance cost due to complex/ process and business for optimized operations
loose integration of systems, and maintenance efficiencies that release
IIoT ready controller
provides seamless interoperability issues personnel from manual processes.
integration - No single point of ownership leading to
higher troubleshooting time/cost The Industrial Ethernet enabled connectivity thru
Universal IO for lean
- Project schedule impact due to lesser OPC UA provides a dedicated data flow model
project execution
adaptability to last minute project which simplifies the integration architecture and
Cyber-Security across changes reduces maintenance overheads and need for
all levels - Poor connectivity leading to delayed specialized hardware such as network gears,
service and downtime communication gateways etc. Also, equipment
OPC UA based
communication - Higher risk to plant safety and serviceability and performance monitoring is
availability due to cyber security threats improved through use of optional features like
- Complex operator workflow and decision OEM cloud connectivity. Such improved
making due to lack of standard HMI connectivity comes with robust cyber security as
solution across control room and field well. Features like Secure boot, built-in firewall,
ISA 99 ready modelling helps reduce system
ControlEdge PLC, a modern age controller vulnerabilities to cyber threats.
supporting Honeywell’s IIoT-ready initiative
along with proven Experion HMI/SCADA provides
Fast and Lean Integration
an integrated and standard solution across the
plant. This provides an easy to use, lean and
Experion systems take the controller integration
flexible engineering environment for improved
paradigm to the next level with Honeywell’s new
startup, commissioning and change
management.

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ControlEdge PLC Integration over OPC UA point parameters of the ControlEdge PLC to
interface. Experion control system. This improves the
configuration time by up to 90% compared to
Enhanced ControlEdge PLC and Experion
conventional interfaces like Modbus and DNP3.
integration over OPC UA interface comes with
This huge savings in configuration time, efforts
pre-built PLC diagnostics in the Experion
and avoiding mapping complexities significantly
system, an Integrated alarm summary for C300 Fast and Lean
improves the plant startup time.
controller and PLC, and integrated history, trend Integration
and reporting - resulting in fast and easy
integration with significant cost savings and
Consistent, Plant-wide HMI - Easy configuration
and change
ease of plant operations. Integration management
- Seamless
Honeywell’s new Experion PPC (Panel PC) Touch operability and ease
panel provides a single HMI for PLC diagnostics of operations
- Avoiding traditional
and Experion system displays. The touch user
PLC point mapping
interface allows you to operate from the complexities in
equipment or from the control room easily control system
without learning disparate systems. Along with a
consistent Experion User Interface, the Experion
PPC shares common set of engineering and HMI
tools with Experion system including faceplates,
system and detail displays, HMI web solution
packs and more. This ensures seamless plant-
ControlEdge PLC, Experion and Experion PPC wide PLC configuration and operation flexibility
Integration and consistent Experion integration at machine,
Plant-wide HMI
process and system level for better plant startup
This integration is fast and lean where the PLC
efficiencies.
Solution
configuration tool can be directly launched from
Experion engineering environment either from - Honeywell’s new
Depending on the system availability needs, the
Experion Panel PC
local Panel HMI or from the control room Experion PPC can perform as a remote Experion for field operations
desktop station. This provides easy operability as station, as an Experion server with station or as a - Common HMI and
well as flexibility for doing the initial PLC remote thin client connecting to any of the tools
configuration, or changes during the operation engineering station or other nodes. These flexible - Flexible operations,
and maintenance. improved data flow
operation modes help meet different architecture
and decision
needs, greatly improves startup and making
The engineered ControlEdge PLC variables are
commissioning time and reduces data - Reduced
automatically configured in the Experion point
integration costs. engineering efforts,
database which helps eliminate the need to build training and
your PLC variables again in control system. Also, maintenance
the Experion Analog and Status points are overheads
generated directly from PLC Program therefore
avoiding double entry of configuration in PLC
and control system.

With ControlEdge PLC and Experion, the

configuration of any new control strategy or
updating an existing one is performed in Asset
minutes, thanks to its automated and efficient Experion Panel PC for Field Operations Management
workflow and use of OPC UA interface. The
An Experion based consistent operator view and - Onboard HART UIO
‘Named Variable Access’ feature of OPC UA
control for local operations provides a seamless with HART-IP
interface allows direct mapping of the critical protocol based
integration with
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Honeywell’s FDM
 data flow and exchange across the plant. A
combination of ControlEdge PLC, Experion PPC
and central Experion DCS or SCADA system
provides works on Common HMI tools extended
across the plants and helps plants with
Universal I/O o Significantly lowered total cost of ownership
with reduced engineering efforts, design
- Lean project flexibility and optimized training and
execution maintenance overheads
- Easily executed late
o Improved operator interactions and the
assignment Fast and Easy Prebuilt PLC Diagnostics
changes process workflow where the local operator
- Remote can now interact with other related plant The Experion HMI incorporates features
configuration processes, therefore better operator developed from extensive consideration of
- Reduced spares emergency response human factors by the Abnormal Situation
o Improved lifecycle support by providing ease Management consortium. Operators’ situational
of system maintenance and change awareness is optimized, fatigue minimized, and
management quick identification and response to abnormal
situations promoted. These features are available
Experion HMIWeb Display Builder is the object both in standard system displays and user built
oriented tool for building and maintaining PLC displays using the HMIWeb Solution Pack library.
HMI displays. It includes an object browser to
OPC UA Protocol easily navigate and make changes, a property
Simplified Asset Management
window to enter and view parameters, and a
- Smooth device structured list of shapes. Shapes can be dragged
integration ControlEdge PLC offers onboard HART support
and dropped to quickly engineer new displays
- Easy configuration on any of 16 Universal IO channels and HART-IP
- Cloud friendly open and modify existing ones.
protocol support. Honeywell’s Field Device
yet secure
Manager (FDM) provides fast and accurate
communication
commissioning of HART field devices. Rapid
maintenance decisions are afforded through
simplified diagnostics and fewer site trips. The
combination of FDM and HART-IP protocol
offers design flexibility using the HART-IP open
standard and investment protection through use

Integrated Cyber
Security

- Security built into

PLC and Experion
- Preserve safety and
availability
- Industrial cyber
security solutions
and managed
services

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of existing plant network infrastructure. Finally, While generating Experion IO points directly from
FDM conveniently co-exists on the ControlEdge ControlEdge PLC program, the Experion
Builder workstation and is scalable to large sized engineering environment allows users to
projects. optionally deselect and override PLC IO tags and
create own mapping for setting PLC point
The ControlEdge PLC and FDM can access both
properties. Also, the comparison tools in
the HART device’s digitally accurate secondary
Experion help track the changes made to an
variable and its diagnostic data. The operator can Lifecycle
existing PLC program with user friendly options
use Honeywell’s Field Device Manager to
to regenerate and/or override. Together these
benefits through
connect through to the HART device using HART Honeywell
features and tools provide engineering
IP.
flexibilities for optimizing efforts and adjust to
engineering changes. - Single vendor for
Greater Engineering Flexibility DCS, PLC, SCADA,
asset management
and HMI panel
Honeywell’s automation experience and
- Preserve safety and
innovative LEAP methodology are the key to availability
increased flexibility – allowing industrial firms to
- Easy upgrade paths
optimize project execution. With LEAP,
- Comprehensive
companies can realize significant capital savings Support and
on the total installed automation costs of a Services
Experion’s UDSP Feature
project, reduce rework costs, and minimize
schedule delays.
Improved Connectivity
Essential to the LEAP approach is the Built on a proven and capable platform,
implementation of 16- channel Universal I/O ControlEdge provides an IIoT-ready open
modules (UIO) supporting HART signals, which platform that enables users to better leverage
offer flexibility in I/O type, eliminating the need data across their assets. Use of the OPC UA
for custom PLC hardware alignment with protocol offers smooth integration to a broad
different I/O configurations and enabling range of instruments, equipment and software
simplified field device configuration and from multiple vendors while providing built-in
maintenance. Any field signal can be connected cyber security. Interoperable multi-level and
to any I/O channel. Deployment of UIO provides multiplatform open communication provides
greater flexibility for late stage changes, such as flexible and scalable design, enabling
configuration and design changes on a typical standardization with less hardware.
automation project.
An IIoT-ready platform enables more direct
The User Defined Scanned Parameters (UDSP) access to cloud- based applications for
feature of Experion allows mapping structured visualization and analytics. With direct access
data types and function blocks of the and reduced gateways, ControlEdge provides
ControlEdge PLC under a single Experion IO investment protection and easier maintenance,
point. It helps reducing the cost of data and therefore reduced cost and risk.
ownership by accumulating all the related data
at one place and make it available for operators Experion platform offers an Integrated alarm
for further analysis. These additional parameters summary for C300 controller and PLC, and
can be set as dynamically scanned in order to integrated history, trend and reporting - resulting
optimize the communication network bandwidth in fast and easy integration with significant cost
utilization as necessary. savings and ease of plant operations.

Native Peer to Peer communication between

ControlEdge PLC and Experion C300 using CDA

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protocol eliminates protocol mapping errors and reduces integration Choosing Honeywell provides distinct support
time. advantages as well as access to our broad
portfolio. Honeywell helps customers cost-
Robust Cyber Security effectively manage their control and safety
infrastructure in the face of constantly evolving
Honeywell’s embedded cyber security supports compliance, reduced technology with extended lifecycle support,
risk, and availability. Ours is the first PLC that is ISASecure Level 2 flexible and easy migration paths, and virtualized
certified. Features include secure boot to prevent uploading of upgrade capabilities.
unauthorized software, and a built-in firewall to reduce exposure to
Honeywell has continually guarded customer
denial-of-service attacks and message flooding, and a certified
investments by providing easy upgrade paths to
secure development lifecycle to ensure security is built-in from the
the latest control system technology. Honeywell
start.
continues to evolve and innovate to bring
In addition, PLC communication is secured using IPSec. This significant advances in automation technology,
prevents man-in-the-middle attacks and protects ControlEdge PLC while also providing a smooth migration path to
from unauthorized access. Encryption for critical data employs NSA today’s technology when the time is right for you.
Suite B recommended algorithms. This supports easy configuration We have a wealth of experience in migrating
and provides certificate-based authentication. legacy control and safety systems, no matter who
the manufacturer.
At the forefront of industrial safety and security, Honeywell offers
Industrial Cyber Security Solutions and Managed Services that help Every Modular Control System installation is
protect the availability, safety and reliability of industrial control backed by Honeywell’s comprehensive one year
systems and site operations. Honeywell improves business Warranty Support through our global Technical
performance by reducing the risk of incidents, faults and failures Assistance Centers (TAC). From installation and
that disrupt normal operations. This means customers can have commissioning to start-up and ongoing
greater confidence in the security of their PLC installation. operations, TAC has you covered with timely and
expert local support. Factory trained and
experienced TAC engineers provide telephone
technical support, prompt answers to questions
regarding procedures, documentation, operation,
service, training and system enhancements. TAC
support also includes a review of operational
PLC Communication with Experion- Secured with IPSec procedures, software analysis, and diagnostic
evaluations when required. For support services,
Honeywell- Your Right Partner for ask for Total Care Services for Modular Systems.
Extended support of installed assets has proven
Automation to be key to improved control system reliability,
reduced downtime, increased plant availability,
With Honeywell technology, industrial sites have a flexible way to and lower operating costs.
efficiently access data in a seamless manner, ensuring easy
configuration and maintenance. Honeywell can serve as a single
vendor for all automation needs, including the DCS, PLC, SCADA,
asset management with Field Device Manager, and an HMI panel.

ControlEdge PLCs are tightly integrated with the Experion control

system architecture. By partnering with an automation vendor
offering both DCS and PLC solutions, users have a single point of
contact from project inception to support, substantially reducing
CAPEX and OPEX.

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For More Information

To learn more about how Honeywell Experion Experion® and ControlEdgeTM are trademarks of
and ControlEdge can optimize your operations, Honeywell International Inc. All other trademarks are
the property of their respective owners.
visit our website www.honeywellprocess.com or
contact your Honeywell account manager.

Honeywell Process Solutions

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April 2019
www.honeywellprocess.com © 2019 Honeywell International Inc.