Part 2 of Laurie Ben and John Dolenc modernization and migration session.

1. Modernizations & Migrations Lessons LearnedPart II Laurie R. Ben John Dolenc

2. Introduction Part I Modernization/Migration Projects Overview Choosing the Approach/Strategy Justification : Where’s the money coming from? ROI Cost Impacts: Where’s the money going? TICC Summary: Part I Part II Risk Mitigation & Best Practices Lessons Learned: What to watch for? Summary Part II

4. Scope of Work

5. Justification

6. Cost

7. Risk Mitigation

8. ScheduleLegacy DCS

9. Migration Project Risks Not restarting production on schedule after the cutover Will new control strategy work Poor control loop performance Communication issues Interfaces / Migration Products Between system and existing 3rd party devices Missing a key interface or action Schedule creep Cost escalation

10. Risk Mitigation Early Engineering and Planning Detailed site survey Operational functional specification Scope of Work Definition Freeze Maximize pre-cutover work Legacy System Data Mining Test plan preparation and thorough configuration testing prior to installation Experienced project team leadership Multi-project program management

11. Cost Influence 100% High Define Scope Cost Expenditure Process Development Ability to Influence Cost Ability to Influence Cost 50% Design Implementation Start-up Low 0% Time

13. Option Review

14. Justification

16. Performance Assessment

18. Engineering & Design

19. Project Management

20. Risk Mitigation7.5% increased project ROI 30% decrease in project duration 6% additional capacity

21. Initial Site Audits System life cycle audit Physical infrastructure Operational objectives

22. Example Detailed System Life Cycle Audit

23. Life Cycle Audit RS3 ‘GOTCHA’ Detailed review consists of analyzing all the I/O types, firmware, and software revision levels to ensure all the I/O is compatible with the transition solution In most cases, firmware can be upgraded using the RS3 System before the installation of transition solution Not doing this step could result in I/O not being compatible and/or I/O not at the correct revision level Startup is a little too late to find this out…

24. Modernization/Migration Project Planning Understand that the original process automation plan may have been designed to meet minimum requirements with no regards for future yield and energy optimization Original Project Criteria & Actions Energy was cheap Measurement technology was lacking I&C scope reduced for project budget reasons

25. Modernization/Migration Project Planning Understand the difference between process / operational requirements and legacy system methods to perform a task Process operational functional specification development based on operational KPI performance Define a detailed automation system design basis that best uses the features of the control system to meet the functional specification

26. Modernization/Migration Project Planning To get improved efficiencies, yield & energy consumption – NEED TO PUSH THE ENVELOP Run as close to constraints as possible Complex control strategies Constraint control MPC with Optimizer Need process measurements Need to remove variability in control loops Control valve performance Good tuning of control loops Early notification of possible abnormal operations

27. Modernization/Migration Project Planning Use control engineers to oversee or review the design of the control strategy Thoroughly test system configuration prior to commissioning Properly plan and staff the commissioning and start-up including the use of the system tools such as AMS and INSIGHT

29. Time for data collection of key variable trends, control reactions and loop interactions

30. Control Performance Consulting services to evaluate process trends and recommend strategy modifications and control tuningMAC SCOPE Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 APPRAISE SELECT DEFINE EXECUTE OPERATE VISION DEFINE OPTIMIZE IMPLEMENT REFINE FEED PHASE FEED PHASE CONSULTING (Concept/Study) MAC – Main Automation Contractor

31. Optimize Process Operations after Start-UP Once the process operation is at an optimum performance level, it is important to keep it there . Use the system’s tools Asset Management InSight

32. Avoid Replacement-in-Kind Be leery of copying code from the legacy system Dead code not removed Legacy code does not take advantage of new system configuration tools Legacy strategy created to overcome automation deficiencies may hinder performance in new system

33. Legacy Platform “Domain” Expertise IPA Aligned Deliverables Phase 1 – Determine the EXACT HW & SW Basics Phase 2 – Determine the EXACT Class & Custom Content Phase 3 – Develop controller based Design Work Package Phase 4 – Extract data in a form useful for project execution Phase 5 – Generate FAT/SAT documentation for pre and post start-up operations

34. Phase 1 Deliverables– Exact IO cont. IO from theSoftware Perspective

35. Phase 2 Deliverables “Class Content” Class Content is“Duplicated”

36. Phase 3 Deliverables“FEED Work Package” Controller derived Design Documents are marked up and hyperlinked to manuals so non-SME personnel can interpret data

37. Phase 4:Execute

38. What to Watch Out For

40. MOD300*

41. Infi90/Net90*

42. Standard Form PID Users

43. ABB Masterpiece, Advant

44. RS3, DeltaV*

45. VALMET Damatic Classic

46. Measurex Open, Vision 2000

47. Texas Instrument

48. Yokogawa

49. Honeywell*

50. Classical PID Forms Users

51. Honeywell *

52. PROVOX, DPR900, DeltaV*

53. FOX I/A, Spec 200

54. Bailey INFI90*

55. MOD300*

56. Fischer-Porter Micro DCI

58. Unit Conversions of Tuning Constants (Temperature Loop) …the units were really P=1.99 %out/%pv, I = 5.98 min/rep and D= 1.4 min for this loop Source: Standard PID P = 1.99 %out/%pv, I = 5.98 min/rep, D= 1.49 min. Destination: Standard PID P = 1.99 %out/%pv, I = 5.98 sec./rep, D= 1.49 sec.

60. MOD300*

61. Infi90/Net90*

62. Standard Form PID Users

63. ABB Masterpiece, Advant

64. RS3, DeltaV*

65. VALMET Damatic Classic

66. Measurex Open, Vision 2000

67. Texas Instrument

68. Yokogawa

69. Honeywell*

70. Classical PID Forms Users

71. Honeywell *

72. PROVOX, DPR900, DeltaV*

73. FOX I/A, Spec 200

74. Bailey INFI90*

75. MOD300*

76. Fischer-Porter Micro DCI

78. What if You Pick the Wrong Form?Series vs. Standard (Temperature) Source: Series PID: P = 1.04 %out/%pv, I = 0.323 rep/min, D= 2.88 min Destination: DeltaV Standard PID; Convert units but forgot to convert to Standard tuning: P = 1.04 %out/%pv, I = 186 sec/rep, D= 173 sec. (Incorrect!)

79. Avoiding the “Gotchas” Do investigate what new technology is available and examining ways to use it to improve the process Base automation system requirements on the system as a tool for operations to run the plant easier Troubleshoot equipment failures Optimize the process Future system expansion Specify the control system to meet operational requirements Don’t specify system component performance criteria, e.g. process speed & monitor pixel number.

80. Avoiding the “Gotchas” Look at Total Installed and Commissioned Cost versus lowest cost equipment Lower cost of engineering and installation Built-in versus custom design Base configuration on using capabilities in new system vs. legacy system Do not be afraid of using multiple field communication types to match specific application Make sure “Alarm Design” is a ‘process’ engineer design task/issue vs. control/automation engineer task/issue Identify alarm requirements based on process conditions Use of conditional alarming

81. Avoiding the “Gotchas” Power & Grounding Make sure I/O power requirements are defined May need interposing relays for Discrete Outputs Grounding efficiency may have changed since legacy system installation via additions to grounding grid Control Loop Strategy Understand that control loops need to work as a “SYSTEM” What loops need to be tuned aggressively and which need to allow natural process variability Legacy Configuration Conversion Data Mining ‘ keep the good, get rid of the bad’ Legacy Tuning conversions

82. Summary: Part II Risk Mitigation & Best Practices IPA Model & Industry Benchmarking Best Practices that Mitigate Risk & Improve Performance Mining the Legacy System Files Lessons Learned: What to watch for? Plan, Plan, and Plan: Revisit the Plan and adjust as needed Use New Technology to Improve Operations TICC vs Lowest System Cost Mix/Match Communication Protocol to Application Alarm Design: Who Benefits from Getting it Right? Power & Grounding Legacy Tuning Conversions: Impact of getting it wrong

83. Associated Workshops and Roadmaps

84. Exhibit Hall - Product Showcase Entrance Modernization Pavilion

85. Scott Ross Keith Bellville Alice Stewart Yassin Mobarak Mike French Laurie Ben John Dolenc Chris King Gordon Lawther Cody Long Zaidan Kazour