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

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Presentation on theme: "March 31st and April 1st, 2009Mile High Industrial and Automation Conference Plug-In Migration – A Better Approach to DCS System Replacement Stephen Golemme,"— Presentation transcript:

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

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

3 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Issues Vendors Face Keep pace with Technology - Need for a next generation system every 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

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

5 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference ARC Analysts Pros & Cons Migration StrategyBenefitsChallenges Bulldoze - Rip out and start again (Originally only game in town) Most comprehensive way to migrate to a new system Costly, downtime issues Most 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 system interoperability. 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

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

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

8 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference 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 Its Reversible !!! I/A Series Workstations I/A Series Controllers I/A Series Form fit replacement modules

9 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Lowest Installed Cost Eliminated installation & rewiring costs

10 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Lost Production due to downtime

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

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

13 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference A Case Study – WDPF Westinghouse Migration NL Hydro – A Nalcor Energy Company, Holyrood, Newfoundland Hydro Migration of a 1990s 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

14 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Plug-In – A Better Approach to DCS System Replacement 30% - 40% below a bulldoze solution Reuse the wiring, cabinets, nests, etc – things that dont 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 !!!

15 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Plug-In To... Foxboro Spectrum SPEC200 Honeywell TDC2000 & TDC3000 BaileyNET90 & INFI90 FisherPROVOX S10 & S20 Westinghouse WDPF Siemens Moore APACS Taylor Mod300

16 March 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Thank You! To learn more – visit the Invensys booth


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