Honeywell Migration Strategies April 24, 2017

Honeywell TDC2000/3000 Migration Strategy Flexible Options for Investment Protection

Honeywell TDC Architecture 1986-1995 US PLNM AM HM Local Control Network (LCN) BOS CB/EC AMC Data Hiway PIU HG NIM TDC 2000 1975-1985 PM TRICON SM UCN

Abbreviations CB – Basic Controller MC – Multifunction Controller AMC – Advance Multifunction Controller EC – Extended Controller FTA – Field Termination Assembly RTP – Remote Terminal Panel PM – Process Manager APM – Advanced Process Manager HPM – High Performance Manager PKS – Process Knowledge System SOPL – Sequence Oriented Programming Language SEBOL – Sequence & Batch Oriented Language CL – Control Language

TDC Series Replacement References Yokogawa has experienced the following three major methods. Hot Cut Over During HCO process, two systems are simultaneously running. Monitoring / Trending is achieved by both Yokogawa HMI and Honeywell US/GUS loop by loop. System/Process alarm of TDC should be handled by US/GUS. Honeywell FTA utilization with Cold Cut Over This solution needs short duration shutdown, but control system totally replaced at one time. This solution is common in Asian users. Application conversion Yokogawa has developed several kinds of AP conversion tool. The powerful tools make engineering hours minimized.

TDC Replacement References Hot Cut Over ? Entire system replacement S Company (Wax) - South Africa PK (Olefins) - Saudi Arabia M Paper (Pulp preparation) – Japan Petro Chemical (LLPE) – Japan C Company (Gas) - USA Others (30 reference sites in worldwide) Entire system replacement by HCO S Company (Soda ash) - USA V Company (Refinery) - USA M Company (Refinery) - USA S Chemical (Ethylene, Olefins) - USA Replacement with FTA D Paper (KP) - Japan N Chemical (Fluid) - USA I Company (PVC) - Malaysia D Chemical (Utility) – Japan Replacement with FTA and HCO (None) Stay with FTA ? Indicates the uses of Application conversion tools

A paper mill replacement project A project study A paper mill replacement project 18 X MC, 1 X AMC Hardware and software have been delivered. Replacement work at site was March 2002. I/Os Analogue 400 points, Digital 1000 points (Existing) Analogue 200 points, Digital 500 points (New) Replacement work: 2.5 days Loop check 1.5 days, Interlock test 3 days Yokogawa creates application based on functional specification document. Cost study

Migration for Yokogawa Solutions High Speed bus direct connection Safety System Integration AOA (Advanced Operation Assistance) Field Digital bus integration PRM (Plant Resource Manager) as Fieldbus solution MES integration MES AOA (Exa) PRM MES TDC HMI CS3000 HMI LCN Vnet/IP(1Gbps) HG/NIM CS3000 Controller Safety System CS3000 FIO Safety FIO HW/UCN Fieldbus TDC Controller FTA Field Devices

Replacement with FTA Migration Experience

Experience - Replacement with HW FTA How to migrate total system ? Renew HMI, Controller, I/O node and I/O module. Minimum impact to terminals and field wirings. Maximum usage of existing TDC components. TDC2000/3000 CS3000 replace HMI HIS Control Network Vnet/IP PCS FCS Terminal Board . . . No Field-wiring change Field Devices

TDC System Configuration – Replacement with HW TB Replace by CS3000 Other systems US USx GUS AMx CM/CG HM AM LCN(5M bps) OS/EOS/EOS NIM PLCG HG PLCP HWY(250Kbps) UCN(5M bps) PIU CB LM MC EC A-MC PM/APM/HPM TCB TCB TCB PCTP RTP FTA PCTP PCTP Re-usage of terminal board Field

Controller migration overview AM/HM Vnet/IP CB A-MC/PM LL-PIU HL-PIU FCU I/O bus FIO FIO MB SC TB MB Field wiring Field wiring Field wiring Field wiring More than one existing controller(CB,MC,PM) can be replaced by an FCS. Change-over construction is made easy by using remote I/O node (FIO).

TDC(CB,EC,MC) replacement CS3000 Power Unit (CS3000 Power Unit can be used as well) Power Unit CB/MC FIO Point Card File Marshaling Board Terminal Panel From Field Existing filed wiring Cable by Yokogawa Cable TDC2000

Replacement with FTA TDC2000

CB replacement Existing Cabinet Existing power supply unit Reference Existing Cabinet Existing power supply unit CS3000 FIO node Cable Marshaling board TDC-I/F cable CB/MC terminal board I/O file terminal board Made by Yokogawa Existing TDC parts TDC2000

HL-PIU replacement TDC2000 TDC CS3000 Power Unit Power Unit (CENTUM Power Unit can be used as well) Power Unit Common Card File FIO Point Card File FIO and marshaling board are added Point Card File A marshaling board is added. Point Card File A marshaling board is added. Point Card File A marshaling board is added. Without any modifications to the existing field wiring TDC2000

HL-PIU replacement (point card file) Migration tool kit and FIO Cover Bracket Remove I/O cards and card cage. Through cards Marshalling Cards FIO Mounting Base Existing I/O cards and card cage (nest) from outside frame are removed. 8 x Signal through cards, Cover bracket, Marshalling card, FIO mounting metal base, and FIO are added TDC2000

Terminal board by Yokogawa LL-PIU replacement TDC CS3000 Power Unit (CENTUM Power Unit can be used as well) Power Unit Common Card File FIO Point Card File FIO Point Card File Point Card File Terminal board by Yokogawa Field connection is to be re-wired. Point Card File As the LL-PIU cold junction compensation system is not accurate, (TC input value deviates about 3 degrees when the door is opened) entire replacement of Point card files is strongly recommended. TDC2000

Yokogawa components for TDC migration Cable adapter Marshaling board TDC2000

Replacement with FTA TDC3000

PM, AMC replacement TDC3000 TDC CS3000 Power Unit Power Unit FIO can be used as well) Power Unit PM , AMC FIO PM , AMC Terminal Panel Cable by Yokogawa Cable Existing field wiring From Field TDC3000

Direct connection PM, AMC I/O interface An existing TDC terminal board and standard CS3000 FIO module is connected using dedicated “adapter & cable” and power distribution unit. CS3000 Standard FIO Dedicated adapter for TDC terminal board TDC Existing terminal board (FTA) Power distribution Unit Dedicated cable for TDC terminal board To Field 24VDC Power supply TDC3000

Installation example (1) Reference No field re-wiring is required. YOKOGAWA Cable connecting to FIO Before After TDC3000

Installation example (2) Reference In case of MUX RTD FTA, Compatible Board is provided by YOKOGAWA. Before After FTA Compatible Board TDC3000

Application Conversion Configuration information import & conversion Tag name with tuning parameters DDC loop Cascade loop Graphic static display data. Migration Experience

Application DB conversion/import TDC2000/3000 Graphics hardcopy Indicates AUTO conversion PRINTER CS3000 Data base Tag Information (imported from Printer port) CS3000 builder function Picture Source Graphics background File Conversion SOPL/CL -> SEBOL Retype Manual input SEBOL Text file Under Study Trend Pen assign Retype Manual input Trend pen CSV file Text file Tuning Parameter Yokogawa Eng. Tools CSV file Manual input (if required) DDC Drawing Step 1 Step 2 Step 3

Procedure of Picture Conversion Screen Image of Graphic Conversion Tool DS File Picture Editor on US DX File Yokogawa tool on PC DX.txt File Yokogawa tool on PC CS File Import to CS3000 Graphic Editor

Data is converted to CS3000 control drawing. EB file How To Convert DDC data .0 Reference Data is converted to CS3000 control drawing. EB file

Results of DDC Conversion CS3000 drawing. Reference

Conversion from SOPL(CL) to SEBOL global block SW AGTCRT alias %Z010101 global block SW REPSW alias %Z010102 global block SW STPBSW alias %Z010103 global block SW LAL alias %Z010104 global block BSETU FIQ001 global block SIO V001, V002 global integer FLG001 * if (REPSW.PV == ON and FLG001) then goto ST01 end if wait until(STPBSW.PV == ON and LAL.PV == ON) ST01: FIQ001.BSET = %.NNO1 [FIQ001.SW.MODE = 1, “AUT”] drive(V001 = OPEN) wait until(FIQ001.BSTS == “END”) drive(V001 = CLOSE) FLG001 = OFF ST02: FIQ001.BSET = %.NN01*4 Drive(V002 = OPEN) drive(V002 = CLOSE) dialogue;“CHARGE END %f6.1”, FIQ001.SUM; conform quit REAC: TIC002.MODE = “MAN” TIC002.MV = 100 drive(P001,P002 = ON, ON) wait until(TIC001.PV >= %.NN02) [TIC002.MODE,TIC001.MODE = “CAS”, “AUT”] Under Study Program Example * SEQ Polymer (101) DEF AGTCRT=DI0101,REPSW=DI0102 STPBSW=DI0103,LAL=DI0104 PHASE CHARGE CHRG IF REPSW AND FLG001,ST01 WAIT STPBSW AND LAL ST01 SET FIQ001.SH=NN01 ON FIQ001.ST OPEN V001 WAIT FIQ001.AT CLOSE V001 OFF FLG001,FIQ001.ST ST02 SET FIQ001.SH=NN01*4 OPEN V002 WAIT FIQ001.AH OFF FIQ001.ST CLOSE V002 (F) MESAG (2)CHARGE END (FIQ001.AV) KLT (F) PHASE Reaction REAC SET TIC002.MD=SMA SET TIC002.OV=100 ON P001,P002 WAIT TIC001.PVE>=NN02 SET TIC001.MD=AUT SET TIC001.MD=CAS SEBOL

Hot Cut Over (HCO) Migration Experience

TDC System Configuration – Entire Replacement by HCO Replace by CS3000 Other systems US USx GUS AMx CM/CG HM AM LCN(5M bps) OS/EOS/EOS NIM PLCG HG PLCP HWY(250Kbps) UCN(5M bps) PIU CB EC A-MC PM/APM/HPM LM MC TCB TCB TCB PCTP FTA RTP PCTP PCTP Field

Hot Cut Over execution process – under HCO CS3000 Cabinet CS3000 Marshalling Panel Vnet/IP A-MC/PM FCU I/O Cable AMC or PM FIO TB Terminal Panel Re-direct Field wiring Each TB connection is re-direct to Yokogawa terminal board. (“Point by point” or “loop by loop”) Cables between terminal boards and FIO modules are connected in advance.

HCO execution process – final stage CS3000 Cabinet CS3000 Marshalling Panel Vnet/IP A-MC/PM FCU I/O Cable AMC or PM FIO TB Terminal Panel Field wiring Operation & monitoring points are gradually shifted to CS3000 HIS. Finally, HW cabinet/US are removed!

To provide total IA production system Asset Management After Migration Merit To provide total IA production system Asset Management Safety system Integration Portal and Remote HMI

Yokogawa IA Systems Solutions Solution-based Packages Process Information Management Enterprise Systems Production Management Advanced Plant Operation Assets Management Safety Management Safety Instrumented System Device Asset Management Field Instruments Fieldbus technology

Integrated Plant Resource Management Plant Resource Manager Integrated database enables new maintenance style using fieldbus, minimizing maintenance costs and maximizing total value of ownership Advanced Features Integrated device database for both FOUNDATION Fieldbus and HART devices The Device Parameter window dramatically simplifies device configuration User configurable device event log facilitates audit trail management Quick access to electronic documents and chart

Prosafe RS Integration To provide tightly integration with Prosafe RS Ethernet CS 3000 HIS CS 3000 ENG ProSafe-RS ENG Control Bus ProSafe RS SCS FCS Safety Loop Standard Loop SCS: Safety Control Station

Portal and remote HMI Internet Portal Client Firewall for Internet Wireless Fidelity Office Network Portal Web Server Firewall Plant Network HIS Portal Application Server Control bus FCS

Yokogawa provides flexibility for your migration strategies Summary Yokogawa provides flexibility for your migration strategies Reduce Maintenance Cost Investment Protection Continuing Evolution Flexible Migration Plan More user friendly Operation and Engineering

Let us envision your plant VigilantPlant concept in anchored in the ideal plant as we see it, what we want our customers to achieve, or keep achieving. It is a plant where people are watchful and attentive, while the customers business responds to change quickly and efficiently. It is an operation that delivers non-stop production, while confidently expanding the customer’s capabilities into the future. This is the vision and promise behind VigilantPlant, the clear path to operational excellence.