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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
March 31st and April 1st, 2009 Mile 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
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009 Mile 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
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009 Mile 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
March 31st and April 1st, 2009 Mile 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
March 31st and April 1st, 2009 Mile 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 It’s Reversible !!!
I/A SeriesWorkstations
I/A SeriesControllers
I/A SeriesForm fit
replacement modules
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Lowest Installed Cost
0
200
400
600
800
1000
1200
Plugged-InMigration
Replacement(Bulldoze)
InstrumentEngineering
SystemEngineering
Install &Rewire
System Cost
Eliminated installation & rewiring costs
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
-$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
March 31st and April 1st, 2009 Mile 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
March 31st and April 1st, 2009 Mile 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!
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009 Mile 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 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 !!!
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Plug-In To...
Foxboro Spectrum SPEC200
Honeywell TDC2000 & TDC3000
Bailey NET90 & INFI90
Fisher PROVOX S10 & S20
Westinghouse WDPF
Siemens Moore APACS
Taylor Mod300
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Thank You!To learn more –
visit the Invensys booth www.ips.invensys.com/migration