no slide title · scada devices (rtu, plc) security ... •invensys foxboro ia, ... migrated...
TRANSCRIPT
Sustain.Ability.
2012 Honeywell Users’ Group EMEA
Satnam Bhogal
3rd Party Migration to Experion
Sustainable and Flexible Solutions
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Purpose
• Thinking about upgrading your DCS
legacy system?
– This session is about the best upgrade
approach options
• If your going to do it we want to
make sure you improve control and
not just replicate
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Reasons to consider upgrading
• Increased operational efficiency.
– You believe more can be achieved from
your current automation system
– Existing Legacy System has occasional
failures or not operator friendly
– Lack of Existing Technical Expertise
Makes it hard to upgrade.
• Increased reliability and availability.
– Downtime and plant failures happen.
• Maintenance issues because your legacy
system cannot be supported any longer with
spare parts
• No available technical knowledge
Efficiency
Improve Productivity Reduce
Cost
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More reasons to consider upgrading
• Increased sustainability.
– You may have an existing plant
that does runs effectively, the
legacy system you have does not
offer cost-effective control and
optimization solutions.
– Expand your Plant and
Modernize your System
Sustainability
Maximize Return on
Investment
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Why migrate to Experion PKS
• Unified architecture, with embedded
application technologies, collects and
integrates process and business data across
the entire facility.
• Process knowledge available where and
when it is needed
• Improves process performance, asset and
people effectiveness and business agility.
• Experion provides investment protection
– Allowing the functionality of third-party
systems, to be fully maximized when migrating
to the Experion system.
– Integration results in a single system with one
database.
• Providing single system for process,
business and asset management.
• Lowest TCO over 30 year Life Cycle
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One Experion HMI Across Platform and Apps
Improve Visibility and Awareness, Reduce Complexity
Experion HMI
Experion
C300/C200
Basic Controller Hiway
HPM TDC 3000
Safety Manager
40% of process safety incidents are related to human error – ASM Consortium
Digital Video Manager
SCADA Devices (RTU, PLC)
Security
QCS
APPS: Profit Suite, BMA, PHD
Third Party
Controller
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Careful Planning, Resource Allocation and Goal Alignment
Comprehensive Migration Services
•Evaluate Current System • Plan Operation requirements •Migration strategy and planning •Functional specification •Hot/Colds Cutover Plan •Phased Transitions •Implementation and staging •Commissioning •Network and control system architecture •HMI replacement /Configuration •Integrate Historians and Manufacturing info •DCS migration tools •Life Cycle Management
Successful and
Profitable
Migrations
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Migration Options
• Goals
– Extend the life of your current
controls
– Replicate existing capabilities
– Expand capabilities in a
supportable system
– Complete replacement by a
supportable system
• Options
– Incremental HMI migration
– Incremental controller
migration
– Rip and replace
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Efficient Legacy Termination Replacement
• Specifically made for Experion Series C I/O
• DIN Rail Mounted
• Cable plugs into unit and into C300 IOTA
• Field Cables terminated on orange terminal block
• Options for fusing, disconnects & test points
• Lowers risk of wiring issues during the system conversion
• Multiple Vendors
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I/O Bus Migrations – ABB TRIO to C300
FTE
CF9 Firewall
C300 Controller
Experion PKS Servers Process & SCADA
Experion
Stations
FTE
FTE
FTE
FTE
Redundant
Modbus/TCP
PCDI Interface
• Utilize a third party device
(Mynah) for redundant
Modbus/TCP comminations
from C300 to Genius I/O
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Some New Experion Offerings with Migration Impact
• Server Peer Responder
– Simplifies Connectivity
between Different Systems
• Virtualization
– Hardware Refresh
Optimization
• Universal IO
– Flexible Options to Match
Legacy IO
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Global Expertise
• Invensys Foxboro IA, Triconex
• ABB Bailey, F&P, MOD 300, H&B
• Emerson Fisher PROVOX, R/S3, Westinghouse,
Bristol Babcock, Delta V
• Siemens Teleperm M, S5, S7, Moore APACS
• Rockwell
• GE
• Toshiba
• Yokogawa
• More
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Bailey HMI Migration Success
• PCS Rehabilitation Project of
replacing legacy Bailey Infi 90
• Scope of project covers engineering,
installation, commissioning of Experion
PKS, Safety Manager and FI
• I-Mac responsibility for full scope
• Control Network design and
configuration
• Integration of plant and 4 remote sites •Relocation of PCC
Compagnie de Bauxite Guinee
Phased Migration with HMI First
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Multi-System Migration to Experion Success
Migrated Foxboro IA, Rosemount RS3, Delta V,
PLCs, and Hiway
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
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Bailey and Foxboro HMI Migration Success
• Improved decision making with better and faster access to process information
• Simplified work through one common interface and graphical displays between different process units
• Retained investment in Bailey controllers
Raised performance levels through greater process
reliability and stability
Kirishi Refinery - Russia
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Integrated DCS and Safety Migration Success
•Migrated to Experion and Safety Manager from Siemens and
Rosemount •Increased safety, reliability and maximum operability with integrated Safety Manager solution •Improved ability to gather and share business-critical information
“Honeywell’s best-in-class technology and elite team of experts have supported IRPC to continuously benefit from overall improved operations. This seamlessly delivered Experion …integrated with Safety Manager is proving to be highly reliable.”
Sompas Samnianglam, Instrument Section Manager, IRPC
IRPC Rayong, Thailand.
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Teleperm M Total Replacement Success
• More than 15 percent increase in sugar production
• Return on investment in less than one year, saving more than €300,000
Significant Product Quality Improvement Results in Increased Sales
Konya Sugar – Turkey
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Bailey HMI Migration Success
• Zero production down-time
• Higher uptime
• Increased productivity
• Faster, more effective decision
making
• Greater flexibility
• Improved safety
• Investment protection
• Seamless integration
• Ease of use
• Improved throughput
Wintershall - Netherlands
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Moore APACS Migration Success
Advanced application software tools that enabled the
plant to make better use of their current infrastructure
and equipment.
• Experion identified process conditions that Moore
was too slow to capture
• Complete investment protection • Improved uptime and reduced costs.
• Quick payback • Optimized valve movement.
• Installed and operating in 5 days.
• Ability to trend data
Raised performance levels through greater process reliability and stability
Honeywell Specialty Materials – Metropolis, IL
“The decision came down to repair old technology or put in a new system,” said Jon
Price, Process Engineer, “Part of the decision factor rested on the robust software
needed to provide quick payback and optimized valve movement, something we weren’t
getting from our current solution.”
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Summary
• Significant cost savings and productivity benefits can be gained
from an intelligently designed and properly implemented system
modernization strategy
• Honeywell can help you establish a secure path forward to
current technology
– Knowledgeable and Experienced Global Resources
– Flexible and Comprehensive Migration methods, planning, implementation
and support
– Document, Replicate , Enhance and Extend Life of Your Automation System
– Your best resource for migrating your plant to modern controls because
when it comes to solutions, we put client needs and objectives ahead rather
than a platform or approach first and we have the resources, attitude and
systems to get projects done
Achieve Your Goals and Requirements