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HowToGetTheMostOutOfYourExistingDCS
emphasizing a flexible approach to migration that leverages your
existing assets and minimizes your risk of downtime or disruption.
Presented by:
1. Housekeeping
2. Introductions
3. Why Migrate?
4. What Should You Consider?
5. Selecting A Migration Approach
6. Solutions
7. Why Invensys
8. Wrap Up/Questions
Why Migrate?
4
Justifiers to Migrate
Two primary reasons to migrate:
Financial opportunities
Improved efficiencies
Reduced downtime
The unknown
Fear of previously reliable equipment
failing
Risk of downtime and safety
Justifiers to Migrate
Financial opportunities:
High maintenance costs
Materials cost more
Services cost escalated
Need third party consultant
Have to go to gray market for
parts of questionable reliability
What Should You
Consider?
Technology
Experience
Total automation vision
Value add features
Justifying return on investment
Evaluating Technology
Cutover experience
What industries
What equipment
Minimum downtime
Total Vision
Control Operations Maintenance
Knowledge of practices
Process Data
Advanced Workflow
Analytics, KPIs
Flowsheet
Mass & Energy
Reconciliation &
Applications & Dashboards
Design
Balance
Material Balance
Real-Time
Operator Dynamic
Advanced Real-Time Process
Training Simulation &
Process Control Optimization Performance
Modeling Simulator Studies
Alarm Advanced
Alarm Analysis Alarm Shelving Many Others
Rationalization Alarming
Return On Investment
Overspeed Trip
Manufacturing
Diagnostics &
Diagnostics &
DCS Upgrade
Asset Mgmt -
Asset Mgmt -
Optimization
Alerts (FDM)
Smart Firing
Combustion
Intelligence
Alerts (CM)
Enterprise
Solutions
Workflow
Turbine
Mobile
OTS
Benefits
Invensys 00/00/00
Cable Solutions
Comprehensive way to migrate to a new system
Replace all electronics and power supplies
New controls with modern strategies
Leaves minimal equipment
Field wiring stays in place
TAs/TUs remain
Less downtime than bulldoze
Disruptive to control cabinets
Removal of power supplies
Cable Solutions
Removal of existing card racks
Install new card racks and power supplies
Invensys 00/00/00
HMI/Gateway Solutions
HMI is designed to interface with legacy DCS, PLC, and other
automation systems
Reuse existing controls and strategies
Minimal or no process downtime with side-by-side installation &
checkout
Automated conversion tools and processes
Incremental or phased migration approach
Should be a gateway enabling older technology
to be interfaced to applications with higher
return on investment
HMI/Gateway
Phased approach to fit your business drivers, not modifying your business
to fit migration options
Extensive experience:
Return on investment:
Graphics
Look to high performance graphics
Improve navigational strategy
Slide 34
Automated Database Conversion Process
Honeywell
Emerson
Westinghouse Automatically transforms data to
Legacy Control Existing Bailey Foxboro format
Database Moore
FoxMacro Preserves:
Database
Spectrum tag names
other
tuning parameters
alarm parameters
descriptions, etc
Foxboro All usable info captured
Taglist (prelim)
Every bus
Every I/O module
Every control processor
Every network connection
No bad outputs
No undetected failures
Bumpless switchover to shadow
module
Highest Availability
I/O plug-in Migration Solution
I/O modules are manufactured to plug-in to existing legacy
system racks.
Workstations
Bailey Net90
Controllers Workstations
Bailey Infi90
Fisher Provox
Honeywell TDC2000
Honeywell TDC3000
Legacy Racks
Moore APACS
Formfit
modules
Westinghouse WDPF
HMI Solution
HMI is designed to interface with legacy DCS, PLC, and other
automation systems
LegacyHMI
Bailey Net90
Bailey Infi90
Honeywell TDC2000
Honeywell TDC3000
Moore APACS
AB PLC
Legacy Controls
Siemens PLC
OPC Solutions
Fisher Provox
DeltaV
Westinghouse WDPF
and more
HMI Migration Solution
1990s Present
1970s 1980s
Company LAN
Server
www
Internet
PLC
DCS