Welcome!

HowToGetTheMostOutOfYourExistingDCS
emphasizing a flexible approach to migration that leverages your
existing assets and minimizes your risk of downtime or disruption.

Presented by:

Nasir Mundh, Global Modernization Director

Michael Rhodes, Global Migration Practice Director

1 Invensys proprietary & confidential Invensys 12 November, 2013

Agenda

1. Housekeeping
2. Introductions
3. Why Migrate?
4. What Should You Consider?
5. Selecting A Migration Approach
6. Solutions
7. Why Invensys
8. Wrap Up/Questions
Why Migrate?

Invensys proprietary & confidential Invensys 12 November 2013

 Why change what you are doing
today?
According to ARC:
$65 billion worth of obsolete technology is still in use
today
Although these systems are still performing well beyond
original life expectancy, this introduces appreciable risk
for manufacturing organizations

4
Justifiers to Migrate
Two primary reasons to migrate:

Financial opportunities
Improved efficiencies
Reduced downtime
The unknown
Fear of previously reliable equipment
failing
Risk of downtime and safety
Justifiers to Migrate

Fears and risks:

Cant get support from OEM when you need it
Limited technical or service support
Parts not available
Training not available
Aging workforce
How do you train new operators on older equipment?
How do you train technicians/engineers?
Compliance and cyber concerns
System doesnt support cyber program
System not compliant with governmental requirements
Justifiers to Migrate
Financial opportunities:
System downtime
Higher rate of failure
Materials not readily available
Inefficient troubleshooting
Improved operator interaction
Alarm scheming not operator friendly
Graphics overwhelming
System navigation inefficient
Situational training
Justifiers to Migrate
Financial opportunities:
Improved control
Improved DCS control schemes
Multivariable control
Business decision making
Maintenance management
Improved diagnostics
Workflow
Mobile solutions
Downtime tracking
Reporting and analysis
Justifiers to Migrate

Financial opportunities:
High maintenance costs
Materials cost more
Services cost escalated
Need third party consultant
Have to go to gray market for
parts of questionable reliability
What Should You
Consider?

Invensys proprietary & confidential Invensys 12 November 2013

What To Consider

Technology
Experience
Total automation vision
Value add features
Justifying return on investment
Evaluating Technology

Fault tolerant hardware

Control network interfaces
Intelligent marshaling
Virtualization and thin client
Engineer anywhere
Open standards
Application integration
Lifecycle approach
Contextualized graphics
Experience
Engineering Expertise: Migration Experience:

Training Consultant approach

Experience Audit processes

Global resources Delivery processes

Service Total projects

Cutover experience

What industries

What equipment

Minimum downtime
 Total Vision
Control Operations Maintenance

DCS Alarm management Training

APC Equipment Diagnostics

High performance graphics
Life Cycle Support
Business management
Report analysis
Philosophy
Service Support
Situational training Track record
Technical support Compliance and security
Corporate
Remote monitoring
Consulting services
Business visibility
Field service support
Product architecture Business planning

Knowledge of practices

Knowledge of current & future

regulations
 Value Additions

Process Data
Advanced Workflow
Analytics, KPIs
Flowsheet
Mass & Energy
Reconciliation &
Applications & Dashboards
Design
Balance
Material Balance

Real-Time
Operator Dynamic
Advanced Real-Time Process
Training Simulation &
Process Control Optimization Performance
Modeling Simulator Studies

Enterprise Asset Instrument Asset Predictive Manufacturing

Condition
Management Management Measurement & Execution
System Monitoring
System Analysis System

Alarm Advanced
Alarm Analysis Alarm Shelving Many Others
Rationalization Alarming
Return On Investment

Lifecycle approach to ROI:

Reduced workload & risk

Reduced unplanned downtime
Improved response & productivity
Safe, available, secure
Lowest total cost of ownership
Example: Potential Business
Benefits
Impact
Benefit
Min Max
Improve heat rate by reducing excess air and
1 0.30% 0.50%
distributing oxygen and CO uniformly

Reduce maintenance and operations cost by: providing

predictive and diagnostic asset management systems;
2 1.0% 2.0%
improving data collection and analysis; and replacing
obsolete systems (paper based notes).

Reduce duration of planned shutdowns by eliminating

3 1.5% 2.5%
need for overspeed testing
Reduce auxiliary power requirement through advanced
4 70% 80%
controls and simulation
Millions of dollars in benefits identified by implementing solutions.
Example: Solutions To Address Issues

Overspeed Trip

Manufacturing
Diagnostics &

Diagnostics &
DCS Upgrade

Asset Mgmt -

Asset Mgmt -

Optimization
Alerts (FDM)

Smart Firing
Combustion

Intelligence
Alerts (CM)

Enterprise

Solutions
Workflow
Turbine

Mobile

OTS
Benefits

Improve heat rate

by reducing
1 excess air and 80% 15% 5%
distributing O2 and
CO uniformly
Reduce
2 maintenance and 20% 20% 25% 15% 5% 10% 5%
operations cost
Reduce duration of
10
3 planned 10% 70% 10%
%
shutdowns
Reduce auxiliary
4 power 80% 15% 5%
requirement
Payback (months) 23 6 11 20 7 3 9 7 5 7
Selecting A
Migration Approach

Invensys proprietary & confidential Invensys 12 November 2013

Migration Strategies

Bulldoze Cable Solution

HMI/Gateway I/O Replacement

Bulldoze Solutions

Bulldoze is a total system replacement

Rip out & replace all hardware
Most comprehensive way to migrate to a new system
New controls with modern strategies
Highest cost
High risk
Most disruptive solution
Most process downtime
Requires the most planning
Typically the most difficult to justify Bulldoze

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 Cable Solutions
Comprehensive way to migrate to a new system
Replace all electronics and power supplies
New controls with modern strategies
Leaves minimal equipment
Field wiring stays in place
TAs/TUs remain
Less downtime than bulldoze
Disruptive to control cabinets
Removal of power supplies
Cable Solutions
Removal of existing card racks
Install new card racks and power supplies

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I/O Plug-In Solutions
I/O modules are designed to plug-in to existing legacy system racks

Reuse existing cabinets, racks, termination assemblies & field wiring

Automated conversion tools & processes
New controls with modern strategies
New workstations, controllers & I/O modules
No I/O mapping issues - exact match
Automated database & I/O porting tools
Least amount of process downtime
Least amount of risk
Reversible I/O Replacement

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HMI/Gateway Solutions
HMI is designed to interface with legacy DCS, PLC, and other
automation systems
Reuse existing controls and strategies
Minimal or no process downtime with side-by-side installation &
checkout
Automated conversion tools and processes
Incremental or phased migration approach
Should be a gateway enabling older technology
to be interfaced to applications with higher
return on investment
HMI/Gateway

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Which Migration Approach Is Best?

No one approach will fit every facility

Only you know the business drivers
Most system architectures are unique
Total automation installed base is unique
Most corporate policies and how they are
deployed at each plant is unique
Which Vendor Approach Is Best?
Flexibility in approach:

Multiple migration approaches

Phased approach to fit your business drivers, not modifying your business
to fit migration options

Extensive experience:

Demonstrated past projects with each approach

Procedures, utilities, and process specifically pertaining to migration

Ability to adjust to evolving requirements

Return on investment:

Company focused on delivering value, not products

Holistic approach to modernization

Migration as a gateway to other value added applications

 Solutions

Invensys proprietary & confidential Invensys 12 November 2013

 Best Practices - Plan
Carefully consider objectives and timeframe

Use existing company standards or define new

Include representatives from operations early

Include your company standards and policies

Include operational, maintenance, engineering, and

management requirements
Best Practices - 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
Best Practices - 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

Best Practices - Optimize
Control logic
Functional replacement not a copy
Apply current industry application knowledge

Graphics
Look to high performance graphics
Improve navigational strategy

Take advantage newest technology

Alarms
Reducing alarm density
Removing toothpick mentality
Project Execution Approaches
Cold Cutover
Requires process downtime
Allows for marshaling alternatives
Forgiving of errors or poorly Hot and Cold Combination
documented installations Minimal process downtime
Most cost effective cutover Identify critical loops and
equipment cut them hot
More easily allows for
Hot Cutover
marshaling alternatives
No process downtime required
Higher cost than cold cutover
Must identify critical loops and
Safer than hot cutover
equipment that can shutdown
Allows for phased approach
process or cause safety hazard
Does not easily allow for
marshaling alternatives
Highest cutover cost
Foxboro Configuration Tools
Simple change
management of sequence
code/block connections
Advanced troubleshooting
techniques
SQL views, high
performance querying and
reporting of all control
configurations
Superior predictive
maintenance and asset
management
Bulk engineering
Automated install
procedure
Legacy DCS vs. Foxboro Evo Comparison

Slide 34
 Automated Database Conversion Process
Honeywell
Emerson
Westinghouse Automatically transforms data to
Legacy Control Existing Bailey Foxboro format
Database Moore
FoxMacro Preserves:
Database
Spectrum tag names
other
tuning parameters
alarm parameters
descriptions, etc
Foxboro All usable info captured
Taglist (prelim)

LoopView Assign loops, templates, hardware

Editor

Foxboro Ready for Foxboro Configuration

Taglist(final) Tools import
Top to Bottom Fault Tolerance

Every bus
Every I/O module
Every control processor
Every network connection
No bad outputs
No undetected failures
Bumpless switchover to shadow
module
Highest Availability
I/O plug-in Migration Solution
I/O modules are manufactured to plug-in to existing legacy
system racks.

Reuse existing cabinets, racks, termination

assemblies & field wiring

No I/O mapping issues - exact match

Minimum process downtime

New workstations, controllers and I/O modules

Automated database porting tools

Invensys proprietary & confidential Invensys 00/00/00

Unique Plug-In Solution

Workstations

Step 1: Install new workstations

Legacy rack
& controllers
Step 2: Shut down the process
Step 3: Replace I/O modules &
attach network connectors Controllers
Step 4: Loop check
Step 5: Start up process
Step 6: Making product & saving
money - day 1!
Form fit
And Its Reversible !!! replacement
modules
I/O plug-in Migration Solution

Bailey Net90
Controllers Workstations

Bailey Infi90

Fisher Provox

Honeywell TDC2000

Honeywell TDC3000
Legacy Racks

Moore APACS
Formfit
modules
Westinghouse WDPF
 HMI Solution
HMI is designed to interface with legacy DCS, PLC, and other
automation systems

Based on industry leading HMI

Reuse existing controls
Minimum process downtime with side-by-side installation & checkout
Automated conversion tools and processes
Enables operational improvement applications
Situational awareness library included
Integrated HMI Solutions

Integrated HMI Solutions OPC Solutions

Bi-directional data link Bi-directional data link
Automatic database configuration
Integrated faceplate
Integrated system status displays and
alerts
Alarm and events integrated with blocks
Tested side-by-side operation
Tested and verified time synchronization
Tested peer-to-peer communication
Benchmark

Invensys proprietary & confidential Invensys 11/12/2013

HMI Migration Solution
Workstations Integrated Solutions

LegacyHMI
Bailey Net90
Bailey Infi90
Honeywell TDC2000
Honeywell TDC3000
Moore APACS
AB PLC
Legacy Controls
Siemens PLC

OPC Solutions
Fisher Provox
DeltaV
Westinghouse WDPF
and more
HMI Migration Solution

Trend Operator Impact

Plants are larger, more complex Increased monitoring load
Increased levels of Lack of understanding
instrumentation More data to manage
Increased levels of automation Lost in the details
Centralized operations Operators become disengaged
Role is reduced to dealing with upsets
Loss of direct awareness

1990s Present
1970s 1980s

Situational Awareness Graphic

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HMI Migration Solution
Management
Maintenance

Company LAN

Server

www

Internet

PLC
DCS

Plant Any location

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HMI Migration Solution
Information & Intelligence
IntelligenceApplications&Content
WorkflowandCollaboration
ProcessModeling
Reporting&Analysis

Operations & Execution

QualityManagement
Mobility
SystemConnectivity
AdvancedSimulation,Optimization

Control & Supervisory

Performance,Scalability
TechnologyModernization
SecurityandSimplification
EnableCommonControlandSafetyplatform
Why Invensys

Invensys proprietary & confidential Invensys 12 November 2013

Why Invensys?
Flexible solutions to fit your needs, options to fit your plant
Top down with HMI/Gateway solutions
Bottom up with I/O replacement solutions
Complete replacement solutions
Holistic approach with proven expertise
Migration engineering processes (conversion, commissioning & optimization)
Global migration consultants, engineering, delivery & service teams
Best practices planning, from design to support
More than a migration
Extends existing investments to add intelligence
Improvements to process efficiency & business performance
Experience
Bulldoze migration
I/O solution migration
HMI migration
Thousands Of Projects:
HONEYWELLTDC2000/3000
FOXBORO
MOOREAPACS TDC2K
SPEC200&SPECTRUM
Freeport Agrium
100sofsites
(Phelps Alcan
Dodge) Dofasco
LinnWestern Lanxess(Bayer)
OperatingInc Teck
IOGEN MexicanadeCananea
FISHERSERIES10&20 BAILEYNET/INFI90 DakotaGas
Total(ElfAtochem)
Series10 Borden Huntsman
Aracruz) IOC Nipsco
BCIT UPM TXU
Teck BCHydro UnionCarbide
YaraNorway FirstEnergy SanMiguel
WESTINGHOUSE(WDPF) BPKitiwake Ambit KratonPolymers
Crompton CorporationNacional
Duke(Mlanding) Series20 GreatLakes delCobre
KentuckyUtil HawaiiSugar KarachanganakPetr
NRG ExxonMobil OhioEdison TDC3K
Erco PPG LomaLinda BASFAK
ProctorGamble SterlingChem. TesoroRefineryHI Kaucuk
Americanref.Corp PotashCoBoralex ERGSircusaItalia KochRefining
NfldHydro Total ClevelandThermal ShellUK
Indeck(Corrinth) CMPC
Chanute Mod300SCseries DakotaGas
Sanyo(Batch) BASFAntwerp
Bowater(GE
Keadby(UK) Valero
TRIO)
BoralexStratton SRPCoronado
LTAutomation
Hercules(US)
Indeck(orleans)
Brazos(Turbine
Invensys Minimizes Process Downtime
 Questions?

Michael Rhodes, Global Migration Practice Director

michael.rhodes@invensys.com +1 949 421 8068

Nasir Mundh, Global Modernization Director

nasir.mundh@invensys.com +1 519 381 0411

For more valuable DCS migration resources:

www.real-time-answers.com/migration

50 Invensys proprietary & confidential Invensys 11/12/2013