Migrate Your Legacy Control Systems to Foxboro IA Series

2. Migrate Your Legacy Control Systems to Foxboro IA Series

3. 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

4. Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System

5. 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

6. Today’s Agenda: • Why Migrate? • Selection Criteria to Consider • Critical Implementation guidelines • Project examples • Q&A

7. 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

8. Today’s Agenda: • Why Migrate? • Selection Criteria to Consider • Critical Implementation guidelines • Project Examples • Q&A

9. 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?

10. 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

11. 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?

12. 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

13. 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?

14. 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

15. 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?

16. Typical Approaches to DCS Migration Bulldoze Cable Solution Transition Solutions I/O Replacement

17. Bulldoze

18. Cabling Solutions

19. Transition Solutions

20. I/O Replacement

21. 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

22. Today’s Agenda: • Why Migrate? • Selection Criteria to Consider • Critical Implementation guidelines • Project Examples • Q&A

23. Plan • Approach • Carefully consider objectives and timeframe • Standards • Use existing company standards or define new • Team • Include representatives from Operations early

24. 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

25. 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

26. 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

27. 5Steps to Plug-In a New System A complete DCS replacement that won’t put your process at risk

28. Today’s Agenda: • Why Migrate? • Selection Criteria to Consider • Critical Implementation guidelines • Project Examples • Q&A

29. 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

30. 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

31. 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

32. 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

33. 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

34. 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

35. Today’s Agenda: • Why Migrate? • Selection Criteria to Consider • Critical Implementation guidelines • Project Examples • Q&A