ability to migrate tdc and yokogawa systems - … to migrate tdc and yokogawa systems bhaskar...

2015 Japan Technology Summit

Yokohama, September 9-10

Ability to Migrate TDC and Yokogawa Systems

Bhaskar Shetty, Global Discipline Lead – Solutions

2 © 2015 Honeywell International All Rights Reserved

Today’s Agenda

Introduction

Why Consider Migration?

Migration Options

Benefits of Migration

Migration Tools and Kits

Competitive System Migration to Experion

Case Studies

Summary

Introduction


Introduction

• Ageing systems driving concerns:

reliability, obsolescence, loss of skills to maintain

• Growing pressure from global market to achieve

operational excellence

Delivers

• Phased approach to minimize risks while offering

lowest TCO

• Functional and operational benefits of a modern,

sustainable platform with Experion PKS

• Ability to integrate DCS with Safety and Security system

seamlessly

• Long lifecycle product hence reduced TCO

• Less disruptive migration due to evolution based

technology

Unsustainable

Current Situation

Honeywell

Modernization

Program

Why Honeywell


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary

Introduction



Why Should You Consider Migration?

Challenge #1

When obsolescence becomes an issue?

High maintenance cost due to parts obsolescence, high cost of spares ?

Is process knowledge lost due to experienced workforce retiring?

Inadequate support from current vendor

Parts & People

Are You Facing Obsolescence and Losing Process Knowledge?


• Unplanned shutdown

• Production loss

• Safety incident

• Environmental liability

• Inadequate System response


May result in

Challenge #2 Decreased Reliability

Loss of Control

Loss of View


Challenge #3 Increasing Competitive Pressure


New technology delivering

improved integration with

mission-critical Safety System:

• Meet product demand & specifications at lowest raw material cost

• Reduce energy consumption

• Operator effectiveness

Improved collaboration features and

advanced visualization to drive:

• Increased productivitythrough greater span of control

• Improved operator effectiveness through advanced alarming

• Use Advanced Solutions


Justification Process – Cost of Doing Nothing

Decreased Reliability

causes Unplanned

Shutdown

PROVOX system caused 3 unplanned shutdowns in

1 year-Petrobras

High Maintenance Cost

due to Parts

obsolescence, High Cost

of Spares

“SKC had various issues with the service provided

by Emerson since our old RS3 system was archaic

and the price of spare parts was not realistic,” said

Hyun Cho, General Manager, SKC Chemicals.

Inadequate Response Experion alarm system identifies process

conditions that the Moore system was too slow to

capture – HSM Metropolis

Increase Capacity Customer want to expand the system

http://hpsweb.honeywell.com/NR/rdonlyres/938BF993-61C3-48B6-BE98-FE5DFCBB0395/14860/Fazio_2005HUGPPT2.pdf

http://hpsweb.honeywell.com/Cultures/en-US/NewsEvents/SuccessStories/success_SKC.htm

http://hpsweb.honeywell.com/HPSWEBII/DownloadDocument.axd?DocumentUrl=/NR/rdonlyres/99D14B13-0A1F-441F-927D-201C6BDAFB74/16502/MigrateMooreAPACStoExperion.pdf

http://hpsweb.honeywell.com/HPSWEBII/DownloadDocument.axd?DocumentUrl=/NR/rdonlyres/99D14B13-0A1F-441F-927D-201C6BDAFB74/16502/MigrateMooreAPACStoExperion.pdf


Justification Process – Increased Benefits

Benefits of moving from Stagnant Technology

Migration to Experion = Increased Revenue,

Increased Production, Lower Cost of ownership

Operator Effectiveness Irving Oil - 45% decrease Daily Alarm Rate

Abnormal Situation Management

Sasol - $500,000 saved by increased situational awareness and improved consistent operation

Better Process Control Konya Sugar – 17 % Increase in Quality

Safety Standards Safety Embedded into DCS when changed to Safety Manager and Experion

http://hpsweb.honeywell.com/HPSWEBII/DownloadDocument.axd?DocumentUrl=/NR/rdonlyres/2E1AF2F7-E274-42EC-B299-37751FD6631B/54567/generalvaluecalculation_Rev2.xls

http://hpsweb.honeywell.com/NR/rdonlyres/D1FDC908-236F-4095-BE8E-30C2283E2798/50641/SuccessStory_IrvingOil_AlarmManagement.pdf

http://hpsweb.honeywell.com/Cultures/en-US/NewsEvents/SuccessStories/Successstory_Sasol_Experion_ROI.htm

http://hpsweb.honeywell.com/Cultures/en-US/NewsEvents/SuccessStories/success_konyasugar.htm

http://hpsweb.honeywell.com/Cultures/en-US/NewsEvents/SuccessStories/success_konyasugar.htm


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary


Migration Options


Options to Consider When Modernizing

Short-Term Life Extension (HMI Migration)

Phased Migration

Rip and Replace

Customer’s Intellectual Property is Retained and Translated


Honeywell HMI Migration

“We needed a solution that would improve process performance while still leveraging our

investment in the Bailey and Foxboro controllers.” - Alexandre Gershberg, Head of

Instrumentation and DCS, Kirishi Refinery.

Key

Differentiator

Key

Differentiator

Transition To Experion, Minimize Risk

http://hpsweb.honeywell.com/Cultures/en-US/NewsEvents/SuccessStories/SuccessStory_Kirishi_Experion.htm


Honeywell Controller Migration

Key

Differentiator

Key

Differentiator


Why Rip and Replace?

Key

Differentiator


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary

Migration Options



System

Modernization

Investment Linearity

Maintenance and Support

Phased Migration

Proactive Tech Refresh

Benefits of Modernization Program

Less Investment, Better Technology, More Benefits … Better ROI


How Does it Work?

“System Modernization” Proposition

1

2

Assess your

Automation

• Benefits Analysis

• Cost Analysis

• Automation Plan

Phased

Migration

• HMI

• Controllers

Technology

Refresh on

regular schedule

• Servers

• PC elements

• Screens

• FTE Switches

Support Services

• Solution Enhancement Support Program (SESP)

• Parts Management

• Standby/Call out

• Preventive Maintenance

• Corrective Service

• Open System Services

• Customer trainings

Predictable

cash outlay

• Investment Linearity

• Staged & Incremental


Honeywell has a longstanding record of delivering a phased

approach to platform modernization that delivers:

• Low-risk / low disruption to operations

• Lowest total cost of ownership

Why Honeywell?

Delivering a sustainable outcome. Honeywell is committed to the continued long-term support of our customers in the Japanese market by investing in:

• The continuous evolution of our flagship Experion®

PKS platform

• In-country project management, engineering and

support capabilities

Year 40+ Year 20 Year 10

Honeywell delivers a continuous evolution pathway to TDCS

modernization without rip and replace.


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary




• Graphics Match is used for migrating custom graphic

files from the following systems.‒ US/GUS/Plantscape Graphics

‒ Foxboro Graphics

‒ Provox-Emerson

‒ Siemens Teleperm (In development for current projects)

‒ Yokogawa (In development for current projects)

‒ Yamatake

Graphic Migration – Graphic Match tool

Experion HMIWeb


Migrate Graphics

using tool

Graphic Migration – Graphic Match tool (cont.)


Graphics Improvement


Controller DB Migration – Control Match tool

Honeywell TDC System includes

• TDC 2000 family Hiway Boxes‒ Basic Controller (CB)

‒ Extended Controller (EC)

‒ Multi Function Controller (MC)

‒ Advanced Multi Function Controller

(AMC)

‒ HLPIU, LLPIU, LEPIU (High/Low Level,

Low Energy Process Interface Units)

• TDC 3000 family UCN Nodes ‒ Process Manager (PM)

‒ Advanced Process Manager (APM)

‒ High Performance Process Manager

(HPM)

‒ Application Module (AM)

Legacy Competitor System includes

• Bailey

• Provox

• Foxboro

• RS3 (Emerson)

• ABB MOD300

• Siemens Teleperm

• Yokogawa (In development for

current projects)

• Toshiba

• Yamatake

Controller Database Migration Solution


Controller DB Migration – Control Match tool

Control Match tool helps to retain the Customer IP

Migrate DB

using tool


Third-party database to Experion Example


• Rewiring Tasks -for 16 point I/O card‒ Disconnect of old terminations

‒ Removal of old terminations

‒ Install new Series C I/O

‒ Rewire from new terminal blocks to Experion

‒ Documentation

• Using Wiring Kits –16 point I/O card‒ Install intermediate panels and New Series C I/O

‒ Connect cables

‒ Documentation

Retain Wiring Investment and Simplify Migration

• PROVOX Series 10, Series 20

• Bailey Infi90, NET90

• GSE Quantum

• Yokogawa

• All Others


AI MIGRATION CABLE

DI MIGRATION CABLES

DO MIGRATION CABLES

AO MIGRATION CABLE

Yokogawa Honeywell

AI

AO

DO

DI

Analog

Input TU

Analog

Output TU

Digital Input(24, 120, 240)

Digital Output(24 VDC, relay)

Digital Input (24, 120, 240)

Digital Output(24 VDC , relay)

TCA to Series C Migration Hardware

Preserve the

wiring


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary




• Flexible migration solution for old legacy Yamatake system to

the Experion PKS.

• Replace Yamatake LCN with Honeywell LCN and Integrate with

Experion using ES-T/ESVT

• Choice of Honeywell controllers either HPM or C300 with wiring-

kit solutions

• Phased approach hence minimum shutdown time.

• Interoperability between old controllers and new controllers.

• Embedded batch functionality

• Advanced control, and field network communications such as

HART, FOUNDATION Fieldbus, DeviceNet and Profibus support

• Wiring kit solution saves time and money.

Yamatake Migration


Database Conversion

Server

C300

FTE

Experion System

Name FC101Unit GRDesc FlowKey CntrlTuning 1.0T1 .5EU bbls/hr

Wiring Terminations

Yamatake HoneywellSystem

ACE

Series C IO’s

Phase by phase

Migration

Yamatake system Migration to Experion


Yokogawa System Migration to Experion

GSGW

PLC

ENG

FFCS-L

CS3000 on Vnet

CS

OPC Server

CS 1000

Ethernet

Vnet

HISStation

Experion System

FTE

Server

Fault Tolerant Ethernet

Matrikon Centum

VP OPC Server

XL


Toshiba Tosdic system Migration to Experion

Better method to

extract the IP by

Virtualizing

Toshiba PC

• Migration solution for old legacy Yamatake system to the Experion PKS

• Virtualized old Toshiba DOS PC helps to capture IP

• VM is loaded to VEP (Virtual Engg Platform) for easy access by Project Engg.

• Extract the configurations to electronic format for translating IP


Proven Support – Not Just Promises!

Honeywell is the only automation vendor that continues to

support 40+ year-old control systems


TDC/EPKS System – End of 2013

LCNFTE

UCN

C300

NIM

HM/AM

ACE

ESV-T

PM/APM/HPM

FSC

Triconex

LM

US

PCUS

GUS

ES-T

ENIM

EHPM

EUCN

SM

EUCN

Enhanced Universal Control

Network

EHPM

Enhanced High-performance

Process Manager

ENIM

Enhanced Network Interface

Module

Hiway

HG

CB/EC/PIU

MFC/AMC

The First Evolution Step – Unified Control


Hiway Migration Solutions – End of 2015

LCNFTE

C300

HM/AM

ACE

ESV-T

US

PCUS

GUS

ES-T

ENIM

EHPM

EUCNEHB

SM

SM

Hiway

HG

CB/EC/PIU

MFC/AMC

Hiway

CB/EC/PIU

MFC/AMC

The Evolution in Progress


TPN Migration Solutions – End of 2016

LCNFTE

UCN

C300

NIM

HM/AM

ACE

ESV-T

PM/APM/HPM

FSC

Triconex

LM

US

PCUS

GUS

ES-T

ENIM

EHPM

EUCN

ELMM

TCMI

SM

SM

The Evolution in Progress


TDC/EPKS System – After Modernization

LCNFTE

C300

HM/AM

ACE

ESV-T

ES-T

ENIM

EHPM

EUCN

ELMM

TCMI

SM

SM

Unified HMI and Unified Control


Strategy for TPS Modernization

Avoid Obsolescence with Modern Technology


Elevator Pitch for Honeywell Value proposition

To overcome current risks associated with obsolescence

of your old TDCS system, lower risk / disruption to your

operations, minimize overall expense and maximize benefits

from upgrade / migration…

Our Honeywell TDCS Modernization program

provides lowest risks to on-going operations,

lowest Total Cost of Ownership and

better Return on Investment.

We do this by phased migrations, on-going system support

to ensure reliability and uptime with our continued commitment

to significant on-going investment in DCS technologies.

Unlike the Life Extension Program, or a complete system

Rip-and-Replace

We have done this successfully for about 40 Yamatake

TDC migrations in Asia over the past 14+ years.

Mr. Customer*–

“

”*i.e., TDCS customer in Japan


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary


Case Studies


Feedback from TDC Customers

Samsung Total:

To express our deepest appreciation for your excellent technical support and quality management of NCC, CB & OCU plant DCS migration in the plant turn-around time. Hereby present this plaque to Honeywell as a token of our appreciation for your contribution.

SamYang Kasei:

We have impressed by successful migration of S3 plant despite of the limited shutdown time. Appreciate your effort and look forward to your continued support in the future.

SK Energy:

Thanks to the devotional support by Honeywell, the NAC Utility DCS was successfully changed without any problem.

Honeywell’s Support and trust had enabled Our Company to achieve accomplishment of this Project.

“

“

“ ”

”

”


Major Migration Project Delivered In Japan

• Yokogawa migration to Tonen General (System delivery

only) (2007- 2015)

• TDC2000 to Experion TPS migration to TG Sakai (2007)

• TDC to Experion TPS migration to A-Company (2012)

• Toshiba (TOSDIC/CIEMAC) migration to B-Company

(2014-2016)

• TDC to EPKS C300 migration to B-Company (2014)

• TDC to EPKS C300 migration for A-Company

• Yokogawa CENTUM XL migration for C-Company


Migrated Foxboro IA, Rosemount RS3,

Delta V, PLCs, and Hiway

Multi-System Migration to Experion Success

Used Wiring Kit and ControlMatch tool

Benefits

• Flexible, Reliable and Efficient Platform

• Centralized control room with common operator

interface for improved effectiveness and operator

confidence

• More accurate information for faster decision

making

• Human Machine Interface HMI to help operators

perform their jobs more efficiently and effectively

Borregaard Sarpsborg, Norway

5 Year Phased Migration


Yokogawa Micro-XL to Experion Success Story

• Client: MMG Rosebery Mine

• Location: Rosebery, Tasmania, Australia

• Application: Mining of Zinc, Lead and Copper concentrate and

Gold ore with onsite crushing, grinding and flotation processes

• Project: Complete replacement of Yokogawa Micro-XL System

• Scope:

– Experion PKS, C200 Controller, eServer, Rockwell Allen

Bradley PLC and DeviceNet Integration, Pi Historian

Integration

– Engineering Services, Project Management, Construction,

Staging with FAT, Onsite Installation, Commissioning and

Testing

• DCS and I/O:

– DCS – 4 x C200 Controllers, Redundant Servers

– 2000 x SCADA (direct PLC) points

– 1200 x Process (DCS style controller) points

– 8 x SCADA controller interfaces

– DeviceNet Integration for Motor Control from C200

– Approx 400 x Field Instruments in the processing plant

MMG Rosebery Mine

Replacement Project with Enhanced Supportability


Yokogawa Migration to Experion Success Story

Replacement Project with Enhanced Supportability

• Client: Tonen General

• Location: Kawasaki, Japan

• Application: Refining & petrochemical products.

• Project: Complete replacement of IBM(ACS) &

Yokogawa(CENTUM).

• Background and Strategy• ACS and Yokogawa CENTUM were installed in Kawasaki

& Wakayama Refineries through 1982-1988

• Yokogawa CENTUM-V at on-site(process units) will be end

of support(EOS) in 2015

• TG selected EPKS C300 of Honeywell as the most suitable

product of on-site for technical and S&C strategy.

• TG started ACS/CENTUM migration with EPKS at

Kawasaki Refinery from 2006

• Scope: DCS platform (Hardware & Software),

Engineering services, FAT and SAT

• Key competition: Total lifecycle cost & long term

support.


Yamatake Migration Success at Bangchak

Petroleum

“We were very pleased with Honeywell’s team and the successful completion

of our DCS migration. Their enthusiasm, even under a very tight schedule, and

ability to deliver on a challenging project was impressive. With a cutover that

met a short shutdown period of just seven days, we were delivered a proven,

reliable and very stable system.”Pratuang Nokkat, Project Manager, The Bangchak Petroleum Public Company Limited


Today’s Agenda

Introduction


Migration Options




Case Studies

Summary

Case Studies

Summary


Summary

• Front End Engineering and Design

• Incremental Upgrades

• Help customer justify a migration project

• Improve Operator Effectiveness

• Increase Scope of Automation

• Long Term Automation Plan

Improve Your

Business

Performance


[email protected]

ability to migrate tdc and yokogawa systems - … to migrate tdc and yokogawa systems bhaskar...

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