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Best practices in dcs migration webcast

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  • 1. Best Practice DCS Migrationhttp://www.real-time-answers.com/migration/ Graham Bennett Senior Migration Technical Consultant 42 years in Automation Industry© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All thirdparty trademarks and service marks are the proprietary marks of their respective owners. © Invensys 00/00/00 Invensys proprietary & confidential
  • 2. Today’s Agenda: 1. Why Migrate? 2. Selection Criteria to Consider 3. Critical Implementation guidelines 4. Project examples 5. Q&ASlide 2
  • 3. 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 $65 Billion:• Maintenance costs exceed value of existing Automation system Systems facing End of Life• Aging workforce and dwindling expertise
  • 4. Today’s Agenda: 1. Why Migrate? 2. Selection Criteria to Consider 3. Critical Implementation guidelines 4. Project Examples 5. Q&ASlide 4
  • 5. 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?
  • 6. Take advantage of new technology • Open platform • Superior integration Mesh Network • Simplicity – ease of use • Flexibility, expandability • Performance & reliability • Fault tolerance at all level • Cyber Secure compliance
  • 7. 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?
  • 8. Does the supplier offer solid path to future? 1 I/A Series, 25 Years of Continuous Investment & Innovation 1980s 1990s 2000s Today 1st distributed software 2 msec logic in I/O Legacy DCS plug-in migration FDSI Superior integration to third parties 1st open industrial system Redundant fieldbus All digital instrument bus 1st InFusion Enterprise Control 1st Ethernet control bus 1st embedded digital fieldbus Self-healing 1gb Mesh Network Intrinsically safe I/O 1st object software 1st Windows NT-based control Anybus fieldbus integration Cyber Security Enhancements 1st standard UNIX Adaptive feed forward control 1st on Windows XP & Solaris 8 100 Series Upgrade Program 1st expert controller tuning 1st Redundant, secure, high ArchestrA on I/A speed, Ethernet remote I/O Intelligent MarshallingSlide 8
  • 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. An Enterprise Control System Governance Platform Corporate BPM Corporate Systems IT ERP Supply and Enterprise Demand Chain Integration Manufacturing / Production Operations Collaboration Platform Optimization Workflow Integration and Open Device Operations Management Performance Integration Execution Web Portal Control Application Services Safety Automation/Production Historian Measurement and InstrumentationSlide 10
  • 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 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?
  • 12. Typical Approaches to DCS Migration Bulldoze Cable Solution Transition Solutions I/O Replacement
  • 13. Bulldoze Approach: Rip out & replace Benefits: Challenges: Most comprehensive Costly way to migrate to a new system More downtime
  • 14. Cabling Solutions Approach: Gut the original cabinet, cable over to a rack of new equipment, adjust for I/O re-mapping Benefits: Quick solution for Challenges: system Extra footprint Interoperability Low risk Costly implementation
  • 15. Transition Solutions Approach Replace the HMI, then controllers, then finally the I/O modules Challenges: Benefits: Much more costly Small investment over time – almost upfront double initial quote Incremental change Extra footprint
  • 16. I/O Replacement Approach: Plug-In to your existing legacy system racks Benefits: Challenges: Very cost effective Technology not solution available from most Reduced downtime suppliers Easily reversed if necessary
  • 17. 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
  • 18. Today’s Agenda: 1. Why Migrate? 2. Selection Criteria to Consider 3. Critical Implementation guidelines 4. Project Examples 5. Q&ASlide 18
  • 19. Plan • Approach – Carefully consider objectives and timeframe • Standards – Use existing company standards or define new • Team – Include representatives from Operations earlySlide 19
  • 20. 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 operatorsSlide 20
  • 21. 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-overSlide 21
  • 22. 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 mentalitySlide 22
  • 23. 5 Steps to Plug-In a New System • Install new workstations & controllers 1 • Put process in steady state 2 • Replace I/O modules & attach network connectors 3 • Cursory loop check 4 • Re-start process 5
  • 24. Today’s Agenda: 1. Why Migrate? 2. Selection Criteria to Consider 3. Critical Implementation guidelines 4. Project Examples 5. Q&ASlide 24
  • 25. 500+ Global Migration Projects: HONEYWELL TDC 2000 / 3000 FOXBORO MOORE APACS TDC2K SPEC200 & SPECTRUM Freeport  Agrium 100’s of sites (Phelps Alcan Dodge)  Dofasco Linn Western  Lanxess(Bayer) Operating Inc Teck  IOGEN Mexicana de Cananea FISHER SERIES 10&20 BAILEY NET/INFI90 Dakota Gas Total (Elf Atochem) Series 10 Borden Huntsman Aracruz) IOC Nipsco BCIT  UPM TXU Teck  BC Hydro Union Carbide Yara Norway  First Energy San MiguelWESTINGHOUSE (WDPF) BP Kitiwake Ambit Kraton Polymers Crompton Corporation Nacional   Duke (M landing) Series 20 Great Lakes del Cobre Kentucky Util Hawaii Sugar  Karachanganak Petr Exxon Mobil Italy NRG ExxonMobil Ohio Edison Erco PPG Loma Linda TDC3K Proctor Gamble Sterling Chem. Tesoro Refinery HI BASF AK American ref. Corp Potash Co Boralex  ERG Sircusa Italia Kaucuk Nfld Hydro Total Cleveland Thermal Koch Refining Indeck (Corrinth) Shell UK Chanute  Mod300 SC series CMPC Sanyo (Batch) Dakota Gas Bowater (GE  Keadby (UK) BASF Antwerp TRIO) Boralex Stratton Valero LT Automation Hercules (US) SRP Coronado Indeck (orleans) Brazos (Turbine
  • 26. Refinery - UKLegacy Systems: Honeywell TDC3000 & Foxboro SpectrumChallenge:• 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 downSelection Criteria:• Sound technical solution• Strong engineering resources available locally• Previous experience with bidding vendorsResults:• £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
  • 27. Power Station - CanadaLegacy System: Westinghouse WDPFChallenge:• 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 replacementResults:• 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
  • 28. Offshore PlatformLegacy Systems: Fisher ProvoxChallenge:• Continued failures of aging control system, threatening production• Implement new system quickly and cost-effectively• Upgrade with no adverse affect on gas production operationsSelection Criteria:• system switchover downtime / production must not exceed ten days• Maintain footprint of existing control system infrastructureResults:• 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
  • 29. Chemical Plant - USALegacy System: Fisher ProvoxChallenge:• 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 instrumentsSelection 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 costsResults:• Well executed migration project that met schedule and budget• Control system performance• Improved software and hardware maintenance
  • 30. 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
  • 31. Today’s Agenda: 1. Why Migrate? 2. Selection Criteria to Consider 3. Critical Implementation guidelines 4. Project Examples 5. Q&ASlide 31
  • 32. Next Steps:Request your FREE Migration site audit: – Migration consultation & step by step survey of existing legacy equipment – Can include demo trailer visit Any questions? Please contact: Amanda.Smith@invensys.com: 1-508-549-4905http://www.real-time-answers.com/migration/

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