Plug-In Migration

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Plug-In Migration A Better Approach to DCS
System Replacement

• Stephen Golemme, Sr Technical Consultant,
  Invensys Process Systems

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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

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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

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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

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ARC Analysts Pros Cons
Migration Strategy Migration 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 issues Most 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 system interoperability. 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
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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

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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

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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 Its Reversible !!!
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Lowest Installed Cost
Eliminated installation rewiring costs
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Lost Production due to downtime
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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
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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!

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A Case Study WDPF Westinghouse Migration

• NL Hydro A Nalcor Energy Company, Holyrood,
  Newfoundland Hydro
• Migration of a 1990s 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

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Plug-In A Better Approach to DCS System
Replacement

• 30 - 40 below a bulldoze solution
• Reuse the wiring, cabinets, nests, etc things
  that dont 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 !!!

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Plug-In To...

• Foxboro Spectrum SPEC200
• Honeywell TDC2000 TDC3000
• Bailey NET90 INFI90
• Fisher PROVOX S10 S20
• Westinghouse WDPF
• Siemens Moore APACS
• Taylor Mod300

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• Thank You!

To learn more visit the Invensys booth
www.ips.invensys.com/migration