how to get the most out of your existing dcs
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Welcome!
How To Get The Most Out Of Your Existing DCSemphasizing a flexible approach to migration that leverages your
existing assets and minimizes your risk of downtime or disruption.
© Invensys 12 November, 2013Invensys proprietary & confidential1
Presented by:
Nasir Mundh, Global Modernization Director
Michael Rhodes, Global Migration Practice Director
Agenda
1. Housekeeping
2. Introductions
3. Why Migrate?
4. What Should You Consider?
5. Selecting A Migration Approach
6. Solutions
7. Why Invensys
8. Wrap Up/Questions
© Invensys 12 November 2013Invensys proprietary & confidential
Why Migrate?
4
According to ARC:
• $65 billion worth of obsolete technology is still in use
today
• Although these systems are still performing well beyond
original life expectancy, this introduces appreciable risk
for manufacturing organizations
Why change what you are doing today?
Justifiers to MigrateTwo primary reasons to migrate:
Financial opportunities
• Improved efficiencies
• Reduced downtime
The unknown
• Fear of previously reliable equipment
failing
• Risk of downtime and safety
Justifiers to Migrate
Fears and risks:
Can’t get support from OEM when you need it
• Limited technical or service support
• Parts not available
• Training not available
Aging workforce
• How do you train new operators on older equipment?
• How do you train technicians/engineers?
Compliance and cyber concerns
• System doesn’t support cyber program
• System not compliant with governmental requirements
Justifiers to MigrateFinancial opportunities:System downtime
• Higher rate of failure
• Materials not readily available
• Inefficient troubleshooting
Improved operator interaction
• Alarm scheming not operator friendly
• Graphics overwhelming
• System navigation inefficient
• Situational training
Justifiers to Migrate
Financial opportunities:
Improved control
• Improved DCS control schemes
• Multivariable control
• Business decision making
Maintenance management
• Improved diagnostics
• Workflow
• Mobile solutions
• Downtime tracking
• Reporting and analysis
Justifiers to Migrate
Financial opportunities:
High maintenance costs
• Materials cost more
• Services cost escalated
• Need third party consultant
• Have to go to “gray” market for
parts of questionable reliability
© Invensys 12 November 2013Invensys proprietary & confidential
What Should You Consider?
What To Consider
• Technology
• Experience
• Total automation vision
• Value add features
• Justifying return on investment
Evaluating Technology
• Fault tolerant hardware
• Control network interfaces
• Intelligent marshaling
• Virtualization and thin client
• Engineer anywhere
• Open standards
• Application integration
• Lifecycle approach
• Contextualized graphics
Experience
Engineering Expertise:
• Training
• Experience
• Global resources
• Service
Migration Experience:
• Consultant approach
• Audit processes
• Delivery processes
• Total projects
• Cutover experience
• What industries
• What equipment
• Minimum downtime
Total VisionControl
• DCS
• APC
• Business management
Service Support
• Technical support
• Remote monitoring
• Field service support
Operations
• Alarm management
• High performance graphics
• Report analysis
• Situational training
Compliance and security
• Consulting services
• Product architecture
• Knowledge of practices
• Knowledge of current & future
regulations
Maintenance
• Training
• Equipment DiagnosticsLife Cycle Support
• Philosophy
• Track record
Corporate
• Business visibility
• Business planning
Advanced Applications
Value Additions
Workflow Analytics, KPIs & Dashboards
Process Flowsheet
Design
Mass & Energy Balance
Data Reconciliation & Material Balance
Advanced Process Control
Real-Time Optimization
Real-Time Process
Performance Modeling
Operator Training
Simulator
Dynamic Simulation &
Studies
Enterprise Asset Management
System
Instrument Asset Management
System
Condition Monitoring
Predictive Measurement &
Analysis
Manufacturing Execution
System
Alarm Analysis Alarm Rationalization Alarm Shelving Advanced
Alarming Many Others
Lifecycle approach to ROI:
• Reduced workload & risk• Reduced unplanned downtime• Improved response & productivity• Safe, available, secure• Lowest total cost of ownership
Return On Investment
Example: Potential Business Benefits
BenefitImpact
Min Max
1Improve heat rate by reducing excess air and distributing oxygen and CO uniformly
0.30% 0.50%
2
Reduce maintenance and operations cost by: providing predictive and diagnostic asset management systems; improving data collection and analysis; and replacing obsolete systems (paper based notes).
1.0% 2.0%
3Reduce duration of planned shutdowns by eliminating need for overspeed testing
1.5% 2.5%
4Reduce auxiliary power requirement through advanced controls and simulation
70% 80%
Millions of dollars in benefits identified by implementing solutions.
Benefits
DCS U
pgra
de
Ass
et M
gmt
-D
iagn
ostic
s &
Ale
rts
(FD
M)
Ass
et M
gmt
-D
iagn
ostic
s &
Ale
rts
(CM
)
Turb
ine
Ove
rspe
ed T
rip
Com
bust
ion
Opt
imiz
atio
n
Sm
art
Firing
Wor
kflo
w
Ente
rprise
M
anuf
actu
ring
In
telli
genc
e
Mob
ile
Sol
utio
ns
OTS
1
Improve heat rate by reducing excess air and distributing O2 and CO uniformly
80% 15% 5%
2Reduce maintenance and operations cost
20% 20% 25% 15% 5% 10% 5%
3Reduce duration of planned shutdowns
10% 70%10%
10%
4Reduce auxiliary power requirement
80% 15% 5%
Payback (months) 23 6 11 20 7 3 9 7 5 7
Example: Solutions To Address Issues
© Invensys 12 November 2013Invensys proprietary & confidential
Selecting A Migration Approach
Migration Strategies
Bulldoze Cable Solution
HMI/Gateway I/O Replacement
© Invensys 00/00/00
Bulldoze Solutions
Bulldoze
Bulldoze is a total system replacement• Rip out & replace all hardware
• Most comprehensive way to migrate to a new system
• New controls with modern strategies
• Highest cost
• High risk
• Most disruptive solution• Most process downtime
• Requires the most planning
• Typically the most difficult to justify
© Invensys 00/00/00Invensys proprietary & confidential
Cable Solutions
Cable Solutions
• Comprehensive way to migrate to a new system
• Replace all electronics and power supplies
• New controls with modern strategies
• Leaves minimal equipment• Field wiring stays in place
• TA’s/TU’s remain
• Less downtime than bulldoze
• Disruptive to control cabinets• Removal of power supplies
• Removal of existing card racks
• Install new card racks and power supplies
© Invensys 00/00/00
I/O Plug-In Solutions
I/O modules are designed to plug-in to existing legacy system racks
I/O Replacement
• Reuse existing cabinets, racks, termination assemblies & field wiring
• Automated conversion tools & processes
• New controls with modern strategies
• New workstations, controllers & I/O modules
• No I/O mapping issues - exact match
• Automated database & I/O porting tools
• Least amount of process downtime
• Least amount of risk
• Reversible
© Invensys 00/00/00Invensys proprietary & confidential
HMI/Gateway SolutionsHMI is designed to interface with legacy DCS, PLC, and other automation systems
• Reuse existing controls and strategies
• Minimal or no process downtime with side-by-side installation &
checkout
• Automated conversion tools and processes
• Incremental or phased migration approach
• Should be a gateway enabling older technology
to be interfaced to applications with higher
return on investmentHMI/Gateway
Which Migration Approach Is Best?
No one approach will fit every facility
• Only you know the business drivers
• Most system architectures are unique
• Total automation installed base is unique
• Most corporate policies and how they are deployed at each plant is unique
Which Vendor Approach Is Best?Flexibility in approach:
• Multiple migration approaches
• Phased approach to fit your business drivers, not modifying your business
to fit migration options
Extensive experience:
• Demonstrated past projects with each approach
• Procedures, utilities, and process specifically pertaining to migration
• Ability to adjust to evolving requirements
Return on investment:
• Company focused on delivering value, not products
• Holistic approach to modernization
• Migration as a gateway to other value added applications
Solutions
© Invensys 12 November 2013Invensys proprietary & confidential
Best Practices - Plan• Carefully consider objectives and timeframe
• Use existing company standards or define new
• Include representatives from operations early
– Include your company standards and policies
– Include operational, maintenance, engineering, and
management requirements
Best Practices - Prepare
• Timeframe for project
• Project window is shorter than outage period
• Consider warm up/cool down and testing
• Prepare infrastructure
• Network switches, data highway, controllers, etc
• Ship controllers in simulation mode
• Everything in place and ready for shutdown
• Training
• Simulation to train operators
Best Practices - Document
• Document status of equipment in field
• Accurate list of all devices whether or not in service
• Third party devices – emulate if necessary
• Record all alarm points and values
• Note critical loops prior to cut-over
Best Practices - Optimize
• Control logic
• Functional replacement not a copy
• Apply current industry application knowledge
• Graphics
• Look to high performance graphics
• Improve navigational strategy
• Take advantage newest technology
• Alarms
• Reducing alarm density
• Removing ‘toothpick’ mentality
Project Execution Approaches
Hot Cutover• No process downtime required• Must identify critical loops and
equipment that can shutdown process or cause safety hazard
• Does not easily allow for marshaling alternatives
• Highest cutover cost
Hot and Cold Combination• Minimal process downtime• Identify critical loops and
equipment cut them hot• More easily allows for
marshaling alternatives• Higher cost than cold cutover• Safer than hot cutover• Allows for phased approach
Cold Cutover• Requires process downtime• Allows for marshaling alternatives• Forgiving of errors or poorly
documented installations• Most cost effective cutover
Foxboro Configuration Tools
•Simple change management of sequence code/block connections
•Advanced troubleshooting techniques
•SQL views, high performance querying and reporting of all control configurations
•Superior predictive maintenance and asset management
•Bulk engineering
•Automated install procedure
Slide 34
Legacy DCS vs. Foxboro Evo Comparison
Automatically transforms data to Foxboro format
Preserves:• tag names• tuning parameters• alarm parameters• descriptions, etc
Foxboro Taglist (prelim)Foxboro Taglist (prelim)
All usable info captured
LoopViewEditorLoopViewEditor
Assign loops, templates, hardware
Foxboro Taglist(final)Foxboro Taglist(final)
Ready for Foxboro ConfigurationTools import
Legacy ControlDatabase
ExistingDatabase
ExistingDatabase
• Honeywell• Emerson• Westinghouse• Bailey• Moore• Spectrum• other
Automated Database Conversion Process
FoxMacroFoxMacro
Top to Bottom Fault Tolerance
• Every bus
• Every I/O module
• Every control processor
• Every network connection
• No bad outputs
• No undetected failures
• Bumpless switchover to shadow module
• Highest Availability
© Invensys 00/00/00Invensys proprietary & confidential
I/O plug-in Migration SolutionI/O modules are manufactured to plug-in to existing legacy system racks.
• Reuse existing cabinets, racks, termination assemblies & field wiring
• No I/O mapping issues - exact match
• Minimum process downtime
• New workstations, controllers and I/O modules
•Automated database porting tools
Unique Plug-In Solution
Workstations
Controllers
Form fit replacement
modules
Legacy rackStep 1: Install new workstations& controllers
Step 2: Shut down the processStep 3: Replace I/O modules &
attach network connectorsStep 4: Loop checkStep 5: Start up processStep 6: Making product & saving
money - day 1!
And It’s Reversible !!!
•Bailey Net90
•Bailey Infi90
•Fisher Provox
•Honeywell TDC2000
•Honeywell TDC3000
•Moore APACS
•Westinghouse WDPF
WorkstationsControllers
Form fit modules
Legacy Racks
I/O plug-in Migration Solution
HMI SolutionHMI is designed to interface with legacy DCS, PLC, and other automation systems
• Based on industry leading HMI
• Reuse existing controls
• Minimum process downtime with side-by-side installation & checkout
• Automated conversion tools and processes
• Enables operational improvement applications
• Situational awareness library included
Integrated HMI Solutions
© Invensys 11/12/2013Invensys proprietary & confidential
Integrated HMI Solutions
• Bi-directional data link
• Automatic database configuration
• Integrated faceplate
• Integrated system status displays and
alerts
• Alarm and events integrated with blocks
• Tested side-by-side operation
• Tested and verified time synchronization
• Tested peer-to-peer communication
• Benchmark
OPC Solutions
• Bi-directional data link
Integrated Solutions
• Bailey Net90
• Bailey Infi90
• Honeywell TDC2000
• Honeywell TDC3000
• Moore APACS
• AB PLC
• Siemens PLC
OPC Solutions
• Fisher Provox
• DeltaV
• Westinghouse WDPF
• and more
Workstations
Legacy HMI
Legacy Controls
HMI Migration Solution
HMI Migration Solution
© Invensys 11/12/2013Invensys proprietary & confidential43
1970’s 1980’s 1990’s Present
Situational Awareness Graphic
Operator Impact• Increased monitoring load• Lack of understanding• More data to manage• Lost in the details• Operators become disengaged• Role is reduced to dealing with upsets• Loss of direct awareness
Trend• Plants are larger, more complex• Increased levels of
instrumentation• Increased levels of automation• Centralized operations
HMI Migration Solution
© Invensys 11/12/2013Invensys proprietary & confidential44
Maintenance
PLC
Company LAN
Management
Internet
Server
www
Plant Any locationDCS
Information & Intelligence
Operations & Execution
Control & Supervisory
• Intelligence Applications & Content• Workflow and Collaboration• Process Modeling • Reporting & Analysis
• Quality Management • Mobility• System Connectivity• Advanced Simulation, Optimization
• Performance, Scalability• Technology Modernization• Security and Simplification• Enable Common Control and Safety platform
HMI Migration Solution
Why Invensys
© Invensys 12 November 2013Invensys proprietary & confidential
Flexible solutions to fit your needs, options to fit your plant
• Top down with HMI/Gateway solutions
• Bottom up with I/O replacement solutions
• Complete replacement solutions
Holistic approach with proven expertise
• Migration engineering processes (conversion, commissioning & optimization)
• Global migration consultants, engineering, delivery & service teams
• Best practices planning, from design to support
More than a migration
• Extends existing investments to add ‘intelligence’
• Improvements to process efficiency & business performance
Experience
• Bulldoze migration
• I/O solution migration
• HMI migration
Why Invensys?
Thousands Of Projects: FOXBORO SPEC200 & SPECTRUM
FISHER SERIES 10&20
HONEYWELL TDC 2000 / 3000
Series 10Aracruz)BCIT Teck Yara Norway BP Kitiwake
Series 20Hawaii Sugar ExxonMobilPPGSterling Chem.Potash Co Boralex Total
Duke (M landing)Kentucky UtilNRGErcoProctor GambleAmerican ref. CorpNfld HydroIndeck (Corrinth)Chanute Sanyo (Batch)Keadby (UK)Boralex StrattonHercules (US)Indeck (orleans)Brazos (Turbine
TDC2KAgriumAlcanDofascoLanxess(Bayer)Teck Mexicana de CananeaDakota GasTotal (Elf Atochem)HuntsmanNipscoTXUUnion CarbideSan MiguelKraton PolymersCorporation Nacional del Cobre
TDC3KBASF AKKaucukKoch RefiningShell UKCMPCDakota GasBASF AntwerpValeroSRP Coronado
BordenIOCUPMBC HydroFirst EnergyAmbitCromptonGreat LakesKarachanganak PetrOhio EdisonLoma LindaTesoro Refinery HIERG Sircusa ItaliaCleveland Thermal
Freeport (PhelpsDodge) Linn Western Operating IncIOGEN
Mod300 SC series
BAILEY NET/INFI90
WESTINGHOUSE (WDPF)
MOORE APACS
100’s of sites
Bowater (GE TRIO)LT Automation
Invensys Minimizes Process Downtime
© Invensys 11/12/2013Invensys proprietary & confidential50
Michael Rhodes, Global Migration Practice Directormichael.rhodes@invensys.com +1 949 421 8068
Nasir Mundh, Global Modernization Directornasir.mundh@invensys.com +1 519 381 0411
Questions?
For more valuable DCS migration resources:www.real-time-answers.com/migration
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