Sustain.Ability.

2012 Honeywell Users’ Group EMEA

Satnam Bhogal

3rd Party Migration to Experion

Sustainable and Flexible Solutions

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Purpose

• Thinking about upgrading your DCS

legacy system?

– This session is about the best upgrade

approach options

• If your going to do it we want to

make sure you improve control and

not just replicate

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Agenda

Migration Planning and Setup

Migration Solutions

Success Stories and Summary

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Reasons to consider upgrading

• Increased operational efficiency.

– You believe more can be achieved from

your current automation system

– Existing Legacy System has occasional

failures or not operator friendly

– Lack of Existing Technical Expertise

Makes it hard to upgrade.

• Increased reliability and availability.

– Downtime and plant failures happen.

• Maintenance issues because your legacy

system cannot be supported any longer with

spare parts

• No available technical knowledge

Efficiency

Improve Productivity Reduce

Cost

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More reasons to consider upgrading

• Increased sustainability.

– You may have an existing plant

that does runs effectively, the

legacy system you have does not

offer cost-effective control and

optimization solutions.

– Expand your Plant and

Modernize your System

Sustainability

Maximize Return on

Investment

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Why migrate to Experion PKS

• Unified architecture, with embedded

application technologies, collects and

integrates process and business data across

the entire facility.

• Process knowledge available where and

when it is needed

• Improves process performance, asset and

people effectiveness and business agility.

• Experion provides investment protection

– Allowing the functionality of third-party

systems, to be fully maximized when migrating

to the Experion system.

– Integration results in a single system with one

database.

• Providing single system for process,

business and asset management.

• Lowest TCO over 30 year Life Cycle

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One Experion HMI Across Platform and Apps

Improve Visibility and Awareness, Reduce Complexity

Experion HMI

Experion

C300/C200

Basic Controller Hiway

HPM TDC 3000

Safety Manager

40% of process safety incidents are related to human error – ASM Consortium

Digital Video Manager

SCADA Devices (RTU, PLC)

Security

QCS

APPS: Profit Suite, BMA, PHD

Third Party

Controller

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Careful Planning, Resource Allocation and Goal Alignment

Comprehensive Migration Services

•Evaluate Current System • Plan Operation requirements •Migration strategy and planning •Functional specification •Hot/Colds Cutover Plan •Phased Transitions •Implementation and staging •Commissioning •Network and control system architecture •HMI replacement /Configuration •Integrate Historians and Manufacturing info •DCS migration tools •Life Cycle Management

Successful and

Profitable

Migrations

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Agenda

Migration Planning and Setup

Migration Solutions

Success Stories and Summary

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Migration Options

• Goals

– Extend the life of your current

controls

– Replicate existing capabilities

– Expand capabilities in a

supportable system

– Complete replacement by a

supportable system

• Options

– Incremental HMI migration

– Incremental controller

migration

– Rip and replace

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Honeywell Migration Global Knowledge Repository

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Retain Wiring and Enable Stranded HART

• Bailey Infi 90/Net 90

• Yokogawa

• Foxboro

• PROVOX

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Efficient Legacy Termination Replacement

• Specifically made for Experion Series C I/O

• DIN Rail Mounted

• Cable plugs into unit and into C300 IOTA

• Field Cables terminated on orange terminal block

• Options for fusing, disconnects & test points

• Lowers risk of wiring issues during the system conversion

• Multiple Vendors

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I/O Bus Migrations – ABB TRIO to C300

FTE

CF9 Firewall

C300 Controller

Experion PKS Servers Process & SCADA

Experion

Stations

FTE

FTE

FTE

FTE

Redundant

Modbus/TCP

PCDI Interface

• Utilize a third party device

(Mynah) for redundant

Modbus/TCP comminations

from C300 to Genius I/O

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Some New Experion Offerings with Migration Impact

• Server Peer Responder

– Simplifies Connectivity

between Different Systems

• Virtualization

– Hardware Refresh

Optimization

• Universal IO

– Flexible Options to Match

Legacy IO

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Agenda

Migration Planning and Setup

Migration Solutions

Success Stories and Summary

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Global Expertise

• Invensys Foxboro IA, Triconex

• ABB Bailey, F&P, MOD 300, H&B

• Emerson Fisher PROVOX, R/S3, Westinghouse,

Bristol Babcock, Delta V

• Siemens Teleperm M, S5, S7, Moore APACS

• Rockwell

• GE

• Toshiba

• Yokogawa

• More

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Bailey HMI Migration Success

• PCS Rehabilitation Project of

replacing legacy Bailey Infi 90

• Scope of project covers engineering,

installation, commissioning of Experion

PKS, Safety Manager and FI

• I-Mac responsibility for full scope

• Control Network design and

configuration

• Integration of plant and 4 remote sites •Relocation of PCC

Compagnie de Bauxite Guinee

Phased Migration with HMI First

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Multi-System Migration to Experion Success

Migrated Foxboro IA, Rosemount RS3, Delta V,

PLCs, and Hiway

Benefits

• Flexible, Reliable and Efficient Platform

• Centralized control room with common operator

interface for improved effectiveness and

operator confidence

• More accurate information for faster decision

making

• Human Machine Interface HMI to help

operators perform their jobs more efficiently

and effectively

Borregaard Sarpsborg, Norway

5 year Phased Migration

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Bailey and Foxboro HMI Migration Success

• Improved decision making with better and faster access to process information

• Simplified work through one common interface and graphical displays between different process units

• Retained investment in Bailey controllers

Raised performance levels through greater process

reliability and stability

Kirishi Refinery - Russia

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Integrated DCS and Safety Migration Success

•Migrated to Experion and Safety Manager from Siemens and

Rosemount •Increased safety, reliability and maximum operability with integrated Safety Manager solution •Improved ability to gather and share business-critical information

“Honeywell’s best-in-class technology and elite team of experts have supported IRPC to continuously benefit from overall improved operations. This seamlessly delivered Experion …integrated with Safety Manager is proving to be highly reliable.”

Sompas Samnianglam, Instrument Section Manager, IRPC

IRPC Rayong, Thailand.

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Teleperm M Total Replacement Success

• More than 15 percent increase in sugar production

• Return on investment in less than one year, saving more than €300,000

Significant Product Quality Improvement Results in Increased Sales

Konya Sugar – Turkey

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Bailey HMI Migration Success

• Zero production down-time

• Higher uptime

• Increased productivity

• Faster, more effective decision

making

• Greater flexibility

• Improved safety

• Investment protection

• Seamless integration

• Ease of use

• Improved throughput

Wintershall - Netherlands

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Moore APACS Migration Success

Advanced application software tools that enabled the

plant to make better use of their current infrastructure

and equipment.

• Experion identified process conditions that Moore

was too slow to capture

• Complete investment protection • Improved uptime and reduced costs.

• Quick payback • Optimized valve movement.

• Installed and operating in 5 days.

• Ability to trend data

Raised performance levels through greater process reliability and stability

Honeywell Specialty Materials – Metropolis, IL

“The decision came down to repair old technology or put in a new system,” said Jon

Price, Process Engineer, “Part of the decision factor rested on the robust software

needed to provide quick payback and optimized valve movement, something we weren’t

getting from our current solution.”

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Summary

• Significant cost savings and productivity benefits can be gained

from an intelligently designed and properly implemented system

modernization strategy

• Honeywell can help you establish a secure path forward to

current technology

– Knowledgeable and Experienced Global Resources

– Flexible and Comprehensive Migration methods, planning, implementation

and support

– Document, Replicate , Enhance and Extend Life of Your Automation System

– Your best resource for migrating your plant to modern controls because

when it comes to solutions, we put client needs and objectives ahead rather

than a platform or approach first and we have the resources, attitude and

systems to get projects done

Achieve Your Goals and Requirements

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