Migration Solutions for Non-Honeywell SystemsSatnam Bhogal

October 4th, 2018

Challenges of Legacy Systems

Demand that IT provides economic advantage

cannot be met

Inflexibility affects response time to

shifting customer demands

Unable to expand cost-effectively to meet capacity

requirements

Difficulties harnessing new

business opportunities with current

limitations of system

Insufficient ability to predict abnormal situations and

equipment breakdown

Pending threat of outage or incident

Low availability of spare parts means costly

maintenance

Customer’s Vision

Workshops

with Customers &

Owners

Business/

Domain

Consulting Project Team Project Team

Initial Scope

Definition

Phase I Deliverables :1.High level business req.

2.Technology map

3.Expected outcomes

Phase II Deliverables: 1.Budgetary proposal

2.Master Technology Plan

3.Opportunity assessment

4.System architecture

5.Deployment Schedule

Budgetary Proposal

Opportunity Assessment

Phase III Deliverables: 1.Firm proposal

2.FEED

3.Business process Models

4.Detailed Soln. Analysis

Final Scope and

Firm Proposal

Phase IV Deliverables: 1.Project kick off

2.Design

3.Implement

4.Test

5.Commission

Project Deployment

Continous Innovation:1.After market support

2.Value audits

Fine Tuning

Phase 1

Vision &

Concept/

Demand

Studies

Phase 2Discovery

Process /

Master

Technology

Plan

Phase 3

Business Process

Modeling (BPM) /

Front End

Engineering

(FEED)

Phase 4

Project

Execution

Phase 5

Value

Sustenance

Program Engagement & Lifecycle Execution

"Honeywell helped us develop a plan to migrate our product and supplied both

the justification and economic benefit analysis for us to do so,”- RVA

FEED & Pre-FEED Activities

Conceptual Design

• Philosophy Documents

• Vision Documents

• Guideline Documents

• Design Studies and

Recommendations

Front-End Engineering & Design

• Philosophies and the visions developed during

conceptual design are transformed into actual

designs

• Project standards are critical in ensuring

consistency across the facility

• Project execution strategies

4

Competitor Legacy System | How Honeywell Addresses It

Proven Long Term Support Equals Customer Confidence

Needs/Challenges

• Doing nothing causes unplanned Shutdowns

• Parts & Service not available

• System not capable

• Need for More

• Safety, Reliability & Efficiency

• Need for Better Life Cycle Support

Our Capability

• Proven Long term Support

• Incremental HMI and Controller

Migration

• Tools that share Competitor

systems knowledge

• Experion with Series C300

Key

Differentiator

Value Proposition

For Honeywell customers with 3rd Party DCS Systems in addition to Experion or TPS/TDC;

Who need to replace the obsolete 3rd party System Honeywell’s 3rd Party Migration solution

Provides Low Risk, Cost effective Migration to Experion by providing consulting, tools, kits

and long term support

5

Control

Logix

Legacy Competitor System Landscape

Master

Advant

Freelance

Contronic /

Melody

DCI

System 6

Infi 90/

Harmony

Teleperm

APACS

- Quadlog

Provox

RS/3

Delta V

WDPF /

Ovation

Spectrum /

Spec 200

IA Series

Process

Logix

MOD 300

MOD V

Simatic

S5/S7

Modicon

PLC’s

Centum CS

Centum XL

Centum

CS1000/3000

Centum VPTriconex

ICS Triplex

ProSafe -RS

Distributed Control System

PLC Type Application

Safety System

Key

6

LEAP for

Operations

Cloud Enabled

Execution

Universal &Connected

Assets

Edge Device

Integration

Cyber Secure Conformity

(IEC62443-3-3)

Engineer and Operate Efficiently

• Advanced Operator Solutions (Orion with

Embedded APC & Alarm Management)

• Next Gen Virtualization Solutions

• Cloud Engineering with Smart Test

• Auto Document & MOC (TRACE)

Integrated Controls & Subsystems

• Universal Channel Technology (DCS, Safety

& PLC) & Integrated RTU

• Electrical & Ethernet (EIM; EIP & IEC 61850)

Edge Device Integration Simplified

• Automated Device Commissioning

• Smartline & Wireless Advantage

• Fire & Gas Integration

• Skid Integration

Options to Consider When Modernizing

Customer’s Intellectual Property is Retained and Translated

* HMI Migration solution need to be evaluated with site specific feasibility study before proposal

Short-Term Life Extension(HMI Migration)*

Phased Migration

Rip andReplace

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Honeywell HMI Migration

Evaluate Based on System Requirements

"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 &

DCS - Kirishi Refinery

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Honeywell Controller Migration

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Why Rip and Replace?

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Competitor System Migration Tools

❖ Controller DB Migration tools- ABB MOD 300

- Emerson RS3

- Yokogawa Centum-CS3000

- Yokogawa Centum-CS

- Invensys Foxboro-I/A

- Yamatake PM100

- ABB Bailey (Prelim)

- Emerson PROVOX (Prelim)

Competitor Displacement -Tools

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❖ Inventory/Parser tools- Invensys Foxboro-I/A

- Siemens Teleperm M

- Yokogawa Centum-CS3000 (P)

- Yokogawa Centum-CS

- Yokogawa Centum-XL (P)

- ABB MOD 300 (P)

- Emerson RS3 (P)

- Emerson PROVOX (P)

- Moore APACS (P)

❖ Graphics Migration tools- Emerson Provox

- Invensys Foxboro-I/A

- ABB Bailey

❖ PLC DB Migration Tools- PLC 5/SLC500 PLC to Control Edge PLC

❖ SCADA DB Migration Tools- Citect to Experion SCADA

Controller DB Migration – Control Match Tool

Control Match tool helps to retain the Customer IP

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Supports Following system

types:

❖ ABB MOD 300

❖ Emerson RS3

❖ Yokogawa Centum-CS,

❖ Yokogawa Centum-CS3000

❖ Invensys Foxboro-I/A

❖ Yamatake PM100

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Foxboro Controller Data Migration

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Graphic Migration – Graphic Match Tool

Supports Following

system types:

❖ Emerson Provox

❖ Invensys Foxboro-I/A

❖ ABB Bailey

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Graphics Improvement

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Migration Concept Foxboro I/A 100 Series

Term connector

FBM

Cable

Term Connector + cable + either (1) connection block or (2) plug

connector block or (3) discrete wire block = Termination Cable

Assembly (TCA) Rear of FTB

Mounting post

Interconnects to

Foxboro card

Side view of FTB

Connection options “Nosecone” interface detail

The FBM connector is commonly referred to as a

“nosecone”

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Foxboro System Migration to Experion

Database

Foxboro System

Wiring Terminations

AW, AP, or WP

Foxboro IA Nodebus

CP

Server

C300

FTE

Experion System

ACE

Series C IO’s

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

Phase by phase

Migration

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Traditional Hot Cut-Over

•Typically used at Refineries and some Chemical facilities

•Process never goes down (hopefully) but runs in manual for durations

•Takes a LONG time to complete the system conversion

•Plant Personnel required for every conversion

•Field work required during Hot Cutover

•Requires substantial planning

•Risk to operations

•Requires changing of configuration to support cutover

A new Methodology to Migrate Control Systems

• Individual modules linked together

•Aligns with marshalling terminals

•Unlimited number of stacks

•Parallel Migration of:

- PLC, DCS, Remote I/O in

parallel

- Different manufacturers

- Great Solution for Older

Honeywell Systems

Automated Hot Cut-over

•Process interruption limited to running PID function in manual for a few seconds

•No field work required – bypass valves, signal generation, manual valve control

•Limited Plant Personnel required

•Some planning required

•Configuration verified during hot-cut over

•System Conversion anytime

•Competitive Systems or Older TDC Systems

Why Honeywell?

Honeywell delivers a continuous evolution pathway to System

modernization without rip and replace.

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

Year 40+ Year 20 Year 10

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

• The continuous evolution of our flagship Experion® PKS platform

• In-country project management, engineering and support capabilities

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• Turn Key Contract - Total Replacement with Initial HMI Migration

• 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 Process Control Centre

ECS1

1

S2

2

S3

3

SE

4

PC

5

CH

13

CA

14 1

CT

17

BR

19

MP

20

MG

22

SO

31 1

Serv-cl.

BA

Batafong

RS232

Coax

12

6362

LOOP 1 Principale

LOOP 10

SONGOLONLOOP 11 CITE

Noeuds

01 à 30 : PCU

31 à 40 : Serveur

41 à 60 : Communication

61 à 70 : EWS

01 : Principale

02 : Broyage et Parcs

03 : Sécheurs et Calc.

04 : Expédition

05 : Centrale Elec.

06-09 : Réserves

10 : Songolon

11 : Cité

Réseau

Infinet

PCV - Ethernet

01 à 10 : Serveurs

11 à 30 : Clients Usine

31 à 40 : Clients Aux.

41 à 50 : Clients Adm.

Coax

Serv-cl.

RS232

PompesFiltres

CICI

Pompes

- Pompes

- Dosage

LOOP 2 PARCS

Broyage

PA

21

Parcs

RadioTelephone

PCC

SS3

LOOP 3 SECHEURS

Calcina-

tion

ABR5 PCC PCC

S

S

3

FUTURE

PCC

LOOP 5 LOOP 4

CHARGEMENT

Manut.

Poussiere

ABR5

50

50

51

51

42

42

45

45

44

44

43

43

30

ABR5ABR5

Centrale

PCC

IS-50NX-CT

125-220 MHz - 375W

220-700 MHz - 125W

700-1000MHz - 50 W

Antenna

Equipment

CYLINK-19MP

PCL

Dryers

3534

PCC

CIU at

DRYERS

Centrale

6 7 8

B

M

S

1

B

M

S

2

B

M

S

3

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T

0

3

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T

0

3

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0

2

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0

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POND

23

ClientClientClient

Client

Client Client

IP Address 172.20.18.31

Agglomeration

172.20.18.21 172.20.18.22 172.20.18.23

FiberOptic

converter to RJ45

FiberOptic

converter to RJ45

CAT 5

cables

RTD and RTD redundant

servers at PCC room

SCSI Cables

FiberOptic

converter to RJ45

Switch

Hub

Fiber Optic Hub

PCL Fure

172.20.18.11 172.20.18.12

Agglo PCL Central

172.20.18.3 172.20.18.2

Client Client

PCL Central

Fiber Optic Hub

Switch

FiberOptic/ RJ45 converter

FiberOptic/

RJ45 converter

172.20.18.41 172.20.18.42

Bailey to Experion Success Story

Compagnie des Bauxite de Guinee

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• Total ABB Bailey with Delta V HMI Replacement

INFI90/Delta V to Experion Success Story

Client: Groupement Berkine Anadarko/Sonatrach JV

Location: HBNS Block 404, Berkine Basin, Algeria

Application: Oil production facility through four-trains at

285,000 b/d

Project: CPF Automation Upgrade Replacement of legacy ABB Bailey Infi90/Delta V

Scope: Experion PKS, Safety Manager, OTS, FDM

Eng Services, PM, Staging/Checkout & Site Work

I/O: DCS – 3,648

SS – 4812

FGS – 3,216

I/F’s – 28,800

Hassi Berkine (HBNS) CPF

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Foxboro I/A to Experion Success Story

Replacement of Installed System Less than 12 years Old

• Client: Middle East Oil Refinery (Midor)

• Location: Alexandria

• Application: Oil refinery with 100,000 b/d capacity (18 process units

with utilities and offsites)

• Project: Automation Rehabilitation and Upgrade replacement of

legacy Invensys I/A system (Ver. 6.1.2 and 8.4.3 (CR5)

• Scope: Experion PKS, FDM, HIMA u/g , MUX u/g ,Eng Services,

PM, Staging/Checkout & Site Work

• DCS and I/O:

DCS – 17,944

I/F’s links - 40 devices

Midor

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QAFAC to Experion Success Story

Replacement Project with Enhanced Supportability

• Location: Mesaieed Industrial City, Qatar

• Application: Production of methanol and methyl

tertiary butyl ether (MTBE)

• Project: DCS Control System Upgrade/Replacement

Replacement of legacy Invensys I/A system ver

8.4.3 (u/g’d 2009), add in of CO2 Project and

Boiler Integration. Change-over April 2014.

Scope increase with F&G System and Control

Room Refurbishment.

• Scope:

Experion PKS, Universal I/O, PHD, FDM, Safety

Manager, Engineering Services, PM,

Staging/Checkout & Site Work

• DCS and I/O:

– DCS – 3883 IO

– SCADA Points - 28800

– Sequences-96

QAFAC

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Multi-System Migration to Experion Success story

Phased Migration over 5 years

Migrated Hiway system, Foxboro IA, Rosemount RS3,

Delta V and PLCs.

Used Wiring Kit and Control Match 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

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• Raised Performance Levels Through Greater Process Reliability and Stability

Foxboro and Bailey HMI Migration Success

Kirishi Refinery - Russia

• 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 Foxboro/Bailey controllers until point of obsolescence

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