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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

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:
  • Why Migrate?
  • Selection Criteria to Consider
  • Critical Implementation guidelines
  • Project examples
  • Q&A
why migrate
Why Migrate?
  • 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:
  • Why Migrate?
  • Selection Criteria to Consider
  • Critical Implementation guidelines
  • Project Examples
  • Q&A
slide9
Selection Criteria to Consider:
  • 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?
slide10
Take advantage of new technology
  • Open platform
  • Superior integration
  • Simplicity – ease of use
  • Flexibility, expandability
  • Performance & reliability
    • Fault tolerance at all level
  • Cyber Secure compliance

Mesh Network

slide11
Selection Criteria to Consider:
  • 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

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

slide13
Selection Criteria to Consider:
  • 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?
slide14
Does the supplier 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

slide15
Selection Criteria to Consider:
  • 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

Bulldoze

Cable Solution

Transition Solutions

I/O Replacement

designed to minimize cost risk downtime
Designed to Minimize Cost, Risk & Downtime
  • 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:
  • Why Migrate?
  • Selection Criteria to Consider
  • Critical Implementation guidelines
  • Project Examples
  • Q&A
slide23
Plan
  • Approach
      • Carefully consider objectives and timeframe
  • Standards
      • Use existing company standards or define new
  • Team
      • Include representatives from Operations early
prepare
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
document
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
optimize
Optimize
  • 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
slide27
5Steps to Plug-In a New System

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

today s agenda3
Today’s Agenda:
  • Why Migrate?
  • Selection Criteria to Consider
  • Critical Implementation guidelines
  • Project Examples
  • Q&A
500 global migration projects
500+ Global 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

slide30
Refinery - UK
    • 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
slide31
Legacy System: 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 Platform
    • 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
slide33
Chemical Plant - USA
    • 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
slide34
In Summary:
  • 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:
  • Why Migrate?
  • Selection Criteria to Consider
  • Critical Implementation guidelines
  • Project Examples
  • Q&A
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