Migrating an automation system requires tremendous planning to avoid unpleasant outcomes. With decades of experience in hundreds of plants we’ve learned some important lessons that we will share with you in this next webinar.
We’ll emphasize a flexible approach to migration that leverages your existing assets and minimizes your risk of downtime or disruption.
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4. Why change what you are doing
today?
According to ARC:
•
$65 billion worth of obsolete technology is still in use
today
•
Although these systems are still performing well beyond
original life expectancy, this introduces appreciable risk
for manufacturing organizations
4
5. 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
6. Justifiers to Migrate
Fears and risks:
Can’t get support from OEM when you need it
•
Limited technical or service support
•
Parts not available
•
Training not available
Aging workforce
•
How do you train new operators on older equipment?
•
How do you train technicians/engineers?
Compliance and cyber concerns
•
System doesn’t support cyber program
•
System not compliant with governmental requirements
7. Justifiers to Migrate
Financial opportunities:
System downtime
•
Higher rate of failure
•
Materials not readily available
•
Inefficient troubleshooting
Improved operator interaction
•
Alarm scheming not operator friendly
•
Graphics overwhelming
•
System navigation inefficient
•
Situational training
8. Justifiers to Migrate
Financial opportunities:
Improved control
•
Improved DCS control schemes
•
Multivariable control
•
Business decision making
Maintenance management
•
Improved diagnostics
•
Workflow
•
Mobile solutions
•
Downtime tracking
•
Reporting and analysis
9. 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
13. Experience
Engineering Expertise:
Migration Experience:
• Training
• Consultant approach
• Experience
• Audit processes
• Global resources
• Delivery processes
• Service
• Total projects
• Cutover experience
• What industries
• What equipment
• Minimum downtime
14. Total Vision
Control
Operations
Maintenance
• DCS
• Alarm management
• Training
• APC
• High performance graphics
• Business management
Service Support
• Technical support
• Remote monitoring
• Field service support
• Report analysis
• Situational training
Compliance and security
• Consulting services
• Product architecture
• Knowledge of practices
• Knowledge of current & future
regulations
• Equipment Diagnostics
Life Cycle Support
• Philosophy
• Track record
Corporate
• Business visibility
• Business planning
15. Value Additions
Advanced
Applications
Workflow
Analytics, KPIs
& Dashboards
Process
Flowsheet
Design
Mass & Energy
Balance
Data
Reconciliation &
Material Balance
Advanced
Process Control
Real-Time
Optimization
Real-Time
Process
Performance
Modeling
Operator
Training
Simulator
Dynamic
Simulation &
Studies
Enterprise Asset
Management
System
Instrument Asset
Management
System
Condition
Monitoring
Predictive
Measurement &
Analysis
Manufacturing
Execution
System
Alarm Analysis
Alarm
Rationalization
Alarm Shelving
Advanced
Alarming
Many Others
16. Return On Investment
Lifecycle approach to ROI:
•
•
•
•
•
Reduced workload & risk
Reduced unplanned downtime
Improved response & productivity
Safe, available, secure
Lowest total cost of ownership
17. Example: Potential Business
Benefits
Benefit
Impact
Min
Max
0.30%
0.50%
1
Improve heat rate by reducing excess air and
distributing oxygen and CO uniformly
2
Reduce maintenance and operations cost by: providing
predictive and diagnostic asset management systems;
improving data collection and analysis; and replacing
obsolete systems (paper based notes).
1.0%
2.0%
3
Reduce duration of planned shutdowns by eliminating
need for overspeed testing
1.5%
2.5%
4
Reduce auxiliary power requirement through advanced
controls and simulation
70%
80%
Millions of dollars in benefits identified by implementing solutions.
18. Improve heat rate
by reducing
1 excess air and
distributing O2 and
CO uniformly
Reduce
2 maintenance and
operations cost
20% 20% 25% 15%
5%
5% 10%
10
%
70%
5%
10%
80% 15%
23
6
11
20
7
3
OTS
Mobile
Solutions
Enterprise
Manufacturing
Intelligence
Workflow
Smart Firing
80% 15%
Reduce duration of
3 planned
10%
shutdowns
Reduce auxiliary
4 power
requirement
Payback (months)
Combustion
Optimization
Turbine
Overspeed Trip
Asset Mgmt Diagnostics &
Alerts (CM)
Asset Mgmt Diagnostics &
Alerts (FDM)
Benefits
DCS Upgrade
Example: Solutions To Address Issues
5%
9
7
5
7
25. Which Migration Approach Is Best?
No one approach will fit every facility
• Only you know the business drivers
• Most system architectures are unique
• Total automation installed base is unique
• Most corporate policies and how they are
deployed at each plant is unique
26. Which Vendor Approach Is Best?
Flexibility in approach:
• Multiple migration approaches
• Phased approach to fit your business drivers, not modifying your business
to fit migration options
Extensive experience:
• Demonstrated past projects with each approach
• Procedures, utilities, and process specifically pertaining to migration
• Ability to adjust to evolving requirements
Return on investment:
• Company focused on delivering value, not products
• Holistic approach to modernization
• Migration as a gateway to other value added applications
28. Best Practices - Plan
• Carefully consider objectives and timeframe
• Use existing company standards or define new
• Include representatives from operations early
– Include your company standards and policies
– Include operational, maintenance, engineering, and
management requirements
29. Best Practices - Prepare
•
Timeframe for project
• Project window is shorter than outage period
• Consider warm up/cool down and testing
•
Prepare infrastructure
• Network switches, data highway, controllers, etc
• Ship controllers in simulation mode
• Everything in place and ready for shutdown
•
Training
• Simulation to train operators
30. Best Practices - Document
• Document status of equipment in field
• Accurate list of all devices whether or not in service
• Third party devices – emulate if necessary
• Record all alarm points and values
• Note critical loops prior to cut-over
31. Best Practices - Optimize
• Control logic
• Functional replacement not a copy
• Apply current industry application knowledge
• Graphics
• Look to high performance graphics
• Improve navigational strategy
• Take advantage newest technology
• Alarms
• Reducing alarm density
• Removing ‘toothpick’ mentality
32. Project Execution Approaches
Cold Cutover
•
Requires process downtime
•
Allows for marshaling alternatives
•
Forgiving of errors or poorly
documented installations
•
Most cost effective cutover
Hot Cutover
•
No process downtime required
•
Must identify critical loops and
equipment that can shutdown
process or cause safety hazard
•
Does not easily allow for
marshaling alternatives
•
Highest cutover cost
Hot and Cold Combination
•
Minimal process downtime
•
Identify critical loops and
equipment cut them hot
•
More easily allows for
marshaling alternatives
•
Higher cost than cold cutover
•
Safer than hot cutover
•
Allows for phased approach
33. Foxboro Configuration Tools
•Simple change
management of sequence
code/block connections
•Advanced troubleshooting
techniques
•SQL views, high
performance querying and
reporting of all control
configurations
•Superior predictive
maintenance and asset
management
•Bulk engineering
•Automated install
procedure
35. Automated Database Conversion Process
Legacy Control
Database
Existing
Database
• Honeywell
• Emerson
• Westinghouse
• Bailey
• Moore
• Spectrum
• other
FoxMacro
Foxboro
Taglist (prelim)
LoopView
Editor
Foxboro
Taglist(final)
Automatically transforms data to
Foxboro format
Preserves:
• tag names
• tuning parameters
• alarm parameters
• descriptions, etc
All usable info captured
Assign loops, templates, hardware
Ready for Foxboro Configuration
Tools import
36. Top to Bottom Fault Tolerance
• 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
40. HMI Solution
HMI is designed to interface with legacy DCS, PLC, and other
automation systems
• Based on industry leading HMI
• Reuse existing controls
• Minimum process downtime with side-by-side installation & checkout
• Automated conversion tools and processes
• Enables operational improvement applications
• Situational awareness library included
47. Why Invensys?
Flexible solutions to fit your needs, options to fit your plant
•
Top down with HMI/Gateway solutions
•
Bottom up with I/O replacement solutions
•
Complete replacement solutions
Holistic approach with proven expertise
•
Migration engineering processes (conversion, commissioning & optimization)
•
Global migration consultants, engineering, delivery & service teams
•
Best practices planning, from design to support
More than a migration
•
Extends existing investments to add ‘intelligence’
•
Improvements to process efficiency & business performance
Experience
•
Bulldoze migration
•
I/O solution migration
•
HMI migration