March 31st and April 1st, 2009Mile High Industrial and Automation Conference Plug-In Migration – A Better Approach to DCS System Replacement Stephen Golemme,

March 31st and April 1st, 2009 Mile High Industrial and Automation Conference

Plug-In Migration – A Better Approach to DCS System Replacement

Stephen Golemme, Sr Technical Consultant, Invensys Process

Systems


When to Migrate?

Threat of unscheduled downtime

Emerging or new business needs are impossible to support without new system

No longer cost effective to support old system(s)

Old system(s) cannot support new technology

Old system is declared end-of-life


Issues Vendors Face

Keep pace with Technology - Need for a next generation system every 10 - 15 years Obsolescence of parts Costly to maintain and support Need for systems that will do more

Reluctance to compromise new system design to accommodate the past

Next generation system products have a different shape and size


Popular Migration Solutions

The Bulldoze – demolish and start again

Cable Solutions – gut the original cabinet, cable over to a rack of new equipment, adjust for I/O mapping

Transition Solutions – Replace the HMI, then controllers, then finally the I/O modules

Gateways – integration solution to share data between and old system and a new system


ARC Analysts Pros & ConsMigration Strategy Benefits Challenges

Bulldoze - Rip out and start again

(Originally only game in town)

Most comprehensive way to migrate to a new system

Costly, downtime issuesMost impractical solution

Cable Solutions - Gut the original cabinet, cable over to a rack of new equipment, adjust for I/O re-mapping

A quick solution for systeminteroperability. Low risk

Fails to address end of life and maintenance issues, temporary solution, can be costly

Transition Solutions - Replace the HMI, then controllers , then finally the I/O modules.

Small investment upfront, incremental change

Much more costly over time – almost double initial quote

Gateways - Integration solution to share data between and old system and a new system

Effective solution for migrating to different platform from different supplier

Increased footprint, time to install, I/O mapping issues

I/O Replacement - Plug-In to your existing legacy system racks.

Very cost effective solution with reduced downtime, easily reversed if necessary

Offered by small number of suppliers


Designed to minimize cost, risk & downtime

I/O modules are manufactured to Plug-In to your existing legacy system racks.

Reuse existing cabinets, racks, term. assemblies and field wiring

No I/O mapping issues - exact match

Minimum process downtime

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

Full system warranty


Plug-In DCS I/O Modules

One for one I/O board replacement

Meets or exceeds I/O capacity of legacy cards

Lines up exactly with I/O points

Manufactured using same components as traditional I/O modules

Automatic bootup on installation

Fully redundant I/O bus - no single point of failure


Unique Plug-In Solution

Step 1: pre-install new workstations & controllers

Step 2: set process in steady state mode

Step 3: replace I/O modules & attach network connectors

Step 4: loop check

Step 5: start up process

Step 6: making product & saving money - day 1 !!!

And It’s Reversible !!!

I/A SeriesWorkstations

I/A SeriesControllers

I/A SeriesForm fit

replacement modules


Lowest Installed Cost

0

200

400

600

800

1000

1200

Plugged-InMigration

Replacement(Bulldoze)

InstrumentEngineering

SystemEngineering

Install &Rewire

System Cost

Eliminated installation & rewiring costs


-$1,500,000.00

-$1,000,000.00

-$500,000.00

$0.00

$500,000.00

$1,000,000.00

$1,500,000.00

1 2 3 4 5 6

Days

Dolla

rs

Production $ Plug-In

Production $ Bulldoze

Lost Production due to downtime


Lowest Risk Solution Site Survey & audit

Hardware & application review

Requirements docs, design docs, test plans, validation plans, implementation plans

Automated tools for database conversion and full system documentation

Full system FAT off-site

Switchover done in hours, not days or weeks

Non-destructive, fully reversible

Migration Centers of Expertise


Protect your investment

Vendor should assume responsibility for the entire system – new & old

Future upgrade paths and plans should be clearly identified – years ahead of schedule

Ensure your investment is protected and you are supported for a lifetime!


A Case Study – WDPF Westinghouse Migration

NL Hydro – A Nalcor Energy Company, Holyrood, Newfoundland Hydro Migration of a 1990’s Vintage Westinghouse WDPF DCS Informed by Vendor - no support after 2005 Hardware Failures becoming more frequent. Island power system dictated fast, reliable upgrade –2 weeks!

Foxboro migration selected: 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 system leveraging IPS’ integrated portfolio of technology Brand new DCS for $75k on $4M project Minimum downtime – installation & commissioning to completion - 1 week! Localized & strong partnership with the IPS team – improved troubleshooting of process

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


Plug-In – A Better Approach to DCS System Replacement

30% - 40% below a bulldoze solution

Reuse the wiring, cabinets, nests, etc – things that don’t fail

No I/O mapping issues

No interim/throwaway solutions

Easily reversible

1 small outage (1 day) away from a new system

Check our references - please !!!


Plug-In To...

Foxboro Spectrum SPEC200

Honeywell TDC2000 & TDC3000

Bailey NET90 & INFI90

Fisher PROVOX S10 & S20

Westinghouse WDPF

Siemens Moore APACS

Taylor Mod300


Thank You!To learn more –

visit the Invensys booth www.ips.invensys.com/migration

March 31st and April 1st, 2009Mile High Industrial and Automation Conference Plug-In Migration – A Better Approach to DCS System Replacement Stephen Golemme,

Documents

new system slide

mile high industrial

new system costly

new system workstations

new system design

system warranty slide

new system effective

system documentation