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Migrate Your Legacy Control Systems to Foxboro IA Series. Invensys Enterprise Control Offerings. Corporate Systems. Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem. Corporate. Software Applications

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Invensys enterprise control offerings
Invensys Enterprise Control Offerings

Corporate Systems

Industry Solutions

Services:

Consulting, Project

Execution,

Learning,

Operational Improvement, Maintenance & Support

Partner Ecosystem

Corporate

Software Applications

Invensys and Third Party

Manufacturing / Production Operations

Automation

Invensys and Third Party

Enterprise Control System

IT

Platform

Integration and

Collaboration Platform


Where the offerings we will discuss fit within the infusion enterprise control system
Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System


Pillars of operational excellence and focus of this discussion
Pillars of Operational Excellence and Focus of This Discussion

Operational

Excellence

Level 3

(Multi-plant/Multi-site)

Environment

And Safety

People

Level 2

(Plant Floor/Area)

Asset

Level 1

(Resource/Asset)

Control


Today s agenda
Today’s Agenda: Discussion

  • Why Migrate?

  • Selection Criteria to Consider

  • Critical Implementation guidelines

  • Project examples

  • Q&A


Why migrate
Why Migrate Discussion?

  • Unscheduled downtime leads to loss of production

  • Older technology offers no competitive edge

  • Suppliers offer little support making spares and repairs more difficult

  • Maintenance costs exceed value of existing system

  • Aging workforce and dwindling expertise

$65 Billion:

Automation Systems facing End of Life


Today s agenda1
Today’s Agenda: Discussion

  • Why Migrate?

  • Selection Criteria to Consider

  • Critical Implementation guidelines

  • Project Examples

  • Q&A


Selection Criteria to Consider: Discussion

  • Are you taking advantage of new technology?

  • Does the supplier offer solid path to future (long-term support)?

  • Does the platform accommodate advanced applications?

  • Have you done Migration Site Audit?

    • Are you able to preserve your existing investments?

    • Are you replacing hardware assets that offer no value?

    • Is this solution a standard or custom interface?

    • Does this solution minimize costs , risk & process impact?


Take advantage of new technology Discussion

  • Open platform

  • Superior integration

  • Simplicity – ease of use

  • Flexibility, expandability

  • Performance & reliability

    • Fault tolerance at all level

  • Cyber Secure compliance

Mesh Network


Selection Criteria to Consider: Discussion

  • Are you taking advantage of new technology?

  • Does the supplier offer solid path to future (long-term support)?

  • Does the platform accommodate advanced applications?

  • Have you done Migration Site Audit?

    • Are you able to preserve your existing investments?

    • Are you replacing hardware assets that offer no value?

    • Is this solution a standard or custom interface?

    • Does this solution minimize costs , risk & process impact?


An enterprise control system
An Enterprise Control System Discussion

Corporate Systems

Corporate

Operations Management

Performance

Web Portal

Application

Services

Optimization

ERP

Governance

Supply and

Demand Chain

Execution

Safety

Control

Measurement

and

Instrumentation

Manufacturing / Production Operations

Automation/Production

Enterprise

Integration

Historian

Open Device

Integration

BPM

Workflow

Integration and

Collaboration Platform

IT

Platform


Selection Criteria to Consider: Discussion

  • Are you taking advantage of new technology?

  • Does the supplier offer solid path to future (long-term support)?

  • Does the platform accommodate advanced applications?

  • Have you done Migration Site Audit?

    • Are you able to preserve your existing investments?

    • Are you replacing hardware assets that offer no value?

    • Is this solution a standard or custom interface?

    • Does this solution minimize costs , risk & process impact?


Does the Discussionsupplier offer solid path to future?

1 I/A Series, 25 Years of Continuous Investment & Innovation

Today

1980s

1990s

2000s

2 msec logic in I/O

Redundant fieldbus

1st embedded digital fieldbus

1st Windows NT-based control

Adaptive feed forward control

1st expert controller tuning

1st distributed software

1st open industrial system

1st Ethernet control bus

1st object software

1st standard UNIX

Legacy DCS plug-in migration

All digital instrument bus

Self-healing 1gb Mesh Network

Anybus fieldbus integration

1st on Windows XP & Solaris 8

1st Redundant, secure, high speed, Ethernet remote I/O

FDSI Superior integration to third parties

1st InFusion Enterprise Control

Intrinsically safe I/O

Cyber Security Enhancements

100 Series Upgrade Program

ArchestrA on I/A

Intelligent Marshalling

CS 3000

Stardom

Centum V

Micro XL

Master

XL

Net90

Infi 90

Master

Advant

800x

Centum VP

Freelance

PlantScape

APACS

Ovation

Delta V

PCS 7

IndustrialIT

Provox S10

WDPF

TDC 3000

WDPF II

Teleperm

Experion

Micro

TDC 2000

Provox S20

RS3


Selection Criteria to Consider Discussion:

  • Are you taking advantage of new technology?

  • Does the supplier offer solid path to future (long-term support)?

  • Does the platform accommodate advanced applications?

  • Have you done a Migration Site Audit?

    • Are you able to preserve your existing investments?

    • Are you replacing hardware assets that offer no value?

    • Is this solution a standard or custom interface?

    • Does this solution minimize costs, risk & process impact?


Typical approaches to dcs migration
Typical Approaches to DCS Migration Discussion

Bulldoze

Cable Solution

Transition Solutions

I/O Replacement


Bulldoze
Bulldoze Discussion


Cabling solutions
Cabling Solutions Discussion



I o replacement
I/O DiscussionReplacement


Designed to minimize cost risk downtime
Designed to Minimize Cost, Risk & Downtime Discussion

  • Reuse existing cabinets, racks, termination assemblies & field wiring

  • No I/O mapping issues - exact match

  • Minimum process downtime

  • 100% new system (workstations, controllers and I/O modules)

  • Reversible – no risk!

  • Full system warranty

  • Automated database porting tools


Today s agenda2
Today’s Agenda: Discussion

  • Why Migrate?

  • Selection Criteria to Consider

  • Critical Implementation guidelines

  • Project Examples

  • Q&A


Plan Discussion

  • Approach

    • Carefully consider objectives and timeframe

  • Standards

    • Use existing company standards or define new

  • Team

    • Include representatives from Operations early


  • Prepare
    Prepare Discussion

    • 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


    Document
    Document Discussion

    • 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


  • Optimize
    Optimize Discussion

    • Control logic

      • Functional replacement not a copy

      • Apply current industry application knowledge

  • Graphics

  • Take advantage newest technology

  • Alarms

    • Reducing alarm density

    • Removing stir stick mentality


  • 5 DiscussionSteps to Plug-In a New System

    A complete DCS replacement that won’t put your process at risk


    Today s agenda3
    Today’s Agenda: Discussion

    • Why Migrate?

    • Selection Criteria to Consider

    • Critical Implementation guidelines

    • Project Examples

    • Q&A


    500 global migration projects
    500+ DiscussionGlobal Migration Projects:

    HONEYWELL TDC 2000 / 3000

    FOXBORO

    SPEC200 & SPECTRUM

    MOORE APACS

    TDC2K

    Agrium

    Alcan

    Dofasco

    Lanxess(Bayer)

    Teck

    Mexicana de Cananea

    Dakota Gas

    Total (Elf Atochem)

    Huntsman

    Nipsco

    TXU

    Union Carbide

    San Miguel

    Kraton Polymers

    Corporation Nacional del Cobre

    Exxon Mobil Italy

    TDC3K

    BASF AK

    Kaucuk

    Koch Refining

    Shell UK

    CMPC

    Dakota Gas

    BASF Antwerp

    Valero

    SRP Coronado

    Freeport (Phelps

    Dodge)

    Linn Western Operating Inc

    IOGEN

    100’s of sites

    BAILEY NET/INFI90

    FISHER SERIES 10&20

    Borden

    IOC

    UPM

    BC Hydro

    First Energy

    Ambit

    Crompton

    Great Lakes

    Karachanganak Petr

    Ohio Edison

    Loma Linda

    Tesoro Refinery HI

    ERG Sircusa Italia

    Cleveland Thermal

    Series 10

    Aracruz)

    BCIT

    Teck

    Yara Norway

    BP Kitiwake

    Series 20

    Hawaii Sugar ExxonMobil

    PPG

    Sterling Chem.

    Potash Co Boralex

    Total

    WESTINGHOUSE (WDPF)

    Duke (M landing)

    Kentucky Util

    NRG

    Erco

    Proctor Gamble

    American ref. Corp

    Nfld Hydro

    Indeck (Corrinth)

    Chanute

    Sanyo (Batch)

    Keadby (UK)

    Boralex Stratton

    Hercules (US)

    Indeck (orleans)

    Brazos (Turbine

    Mod300 SC series

    Bowater (GE TRIO)

    LT Automation


    Refinery - UK Discussion

    • Legacy Systems: Honeywell TDC3000 & Foxboro Spectrum

    • Challenge:

    • Upgrade control systems in 5 production units as part of control room centralization project

    • Upgrade needed to be completed quickly

    • Project needed to be conducted without requiring the systems to be shut down

  • Selection Criteria:

    • Sound technical solution

    • Strong engineering resources available locally

    • Previous experience with bidding vendors

  • Results:

    • £10,000,000 savings in production downtime

    • Enhanced operator communication

    • Temporarily reverted back to existing control system during project to correct a minor software problem; successfully repeated cutover while preventing disruption to process unit


  • Legacy System Discussion: Westinghouse WDPF

    Challenge:

    Informed by Vendor - no support after 2005

    Hardware Failures becoming more frequent.

    Island power system dictated fast, reliable upgrade –2 weeks!

    Selection Criteria:

    Needed a cost effective, low risk migration solution with minimum process downtime.

    Partner that provides ongoing service & support – locally

    Proven experience

    New system must be better, not just a functional replacement

    Results:

    100% new DCS for $75k on $4M project

    Minimum downtime – installation & commissioning to completion - 1 week!

    No more end-of-life issues, with backwards compatibility guaranteed

    Power Station - Canada


    Offshore platform
    Offshore DiscussionPlatform

    • Legacy Systems: Fisher Provox

    • Challenge:

    • Continued failures of aging control system, threatening production

    • Implement new system quickly and cost-effectively

    • Upgrade with no adverse affect on gas production operations

  • Selection Criteria:

    • system switchover downtime / production must not exceed ten days

    • Maintain footprint of existing control system infrastructure

  • Results:

    • First migration in less than 7 days; second under 5 days

    • Minimized installation cost

    • Advanced DCS on offshore platforms

    • Reduced maintenance costs

    • Lower cost of ownership


  • Chemical Plant - USA Discussion

    • Legacy System: Fisher Provox

    • Challenge:

    • Received obsolescence notification from vendor : no support after 2012

    • Shrinking Provox knowledge base

    • Costly spare parts and availability

    • Expensive to add I/O, especially for remote field instruments

  • Selection Criteria:

    • Minimal production downtime

    • Open architecture with ease of expansion and flexibility; ability to integrate to MES/ERP

    • Good support infrastructure and expertise

    • Low life cycle costs

    • Results:

    • Well executed migration project that met schedule and budget

    • Control system performance

    • Improved software and hardware maintenance


  • In Summary: Discussion

    • Consider all your options during selection:

      • Do your research on suppliers, platforms, and track records

      • Develop a migration cost/benefit analysis

      • Determine functional versus value-added replacement

      • Do strive to minimize process impact during system changeover

      • Do require a Migration site audit

  • Plan, plan, and plan some more:

    • Engage all relevant stakeholders early

    • Identify all standards and optimize control applications

    • Plan your schedule carefully relevant to outage period

    • Do as much up front infrastructure preparation as possible

    • Document status of online and offline equipment, alarms, loops

    • Use simulation for checkout and training


  • Today s agenda4
    Today’s Agenda: Discussion

    • Why Migrate?

    • Selection Criteria to Consider

    • Critical Implementation guidelines

    • Project Examples

    • Q&A


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