how to get the most out of your existing dcs

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


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


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


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


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


• 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 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


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


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

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


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


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


© 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



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


Why Invensys


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


Michael Rhodes, Global Migration Practice [email protected] +1 949 421 8068

Nasir Mundh, Global Modernization [email protected] +1 519 381 0411

Questions?

For more valuable DCS migration resources:www.real-time-answers.com/migration

how to get the most out of your existing dcs

Technology

migration approach

migration experience

financial opportunities

equipment minimum downtime

investmentlifecycle

flexible approach

service supportparts

older equipment