1. Honeywell Migration Strategies
April 24, 2017

2. Honeywell TDC2000/3000 Migration Strategy
Flexible Options for Investment Protection

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

4. 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

5. 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.

6. 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

7. 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

8. 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

9. Replacement with FTA
Migration Experience

10. 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

11. 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

12. 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).

13. 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

14. Replacement with FTA
TDC2000

15. 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

16. 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

17. 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

18. 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

19. Yokogawa components for TDC migration
Cable adapter
Marshaling board
TDC2000

20. Replacement with FTA
TDC3000

21. 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

22. 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

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

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

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

26. 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

27. 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

28. 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

29. Results of DDC Conversion
CS3000 drawing.
Reference

30. 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

31. Hot Cut Over (HCO)
Migration Experience

32. 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

33. 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.

34. 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!

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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.