2012 Honeywell Users Group Americas Sustain.Ability. Ben Comtois Marjorie Ochsner 3rd Party Migration to Experion Sustainable and Flexible Solutions

Transcription

1 2012 Honeywell Users Group Americas Sustain.Ability. Ben Comtois Marjorie Ochsner 1 3 rd Party Migration to Experion Sustainable and Flexible Solutions

2 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 2

3 Agenda Migration Planning and Setup Migration Solutions Success Stories and Summary 3

4 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 4

5 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 5

6 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 6

7 One Experion HMI Across Platform and Apps 40% of process safety incidents are related to human error ASM Consortium Third Party Controller Experion C300/C200 Safety Manager Experion HMI QCS SCADA Devices (RTU, PLC) APPS: Profit Suite, BMA, PHD HPM TDC 3000 Security Basic Controller Hiway Digital Video Manager 7 Improve Visibility and Awareness, Reduce Complexity

8 Comprehensive Migration Services Careful Planning, Resource Allocation and Goal Alignment 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 8

9 Agenda Migration Planning and Setup Migration Solutions Success Stories and Summary 9

10 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 Migration Options 10

11 Honeywell Migration Global Knowledge Repository 11

12 Retain Wiring and Enable Stranded HART Bailey Infi 90/Net 90 Yokogawa GSE Foxboro PROVOX 12

13 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 13

14 I/O Bus Migrations ABB TRIO to C300 Experion PKS Servers Process & SCADA Experion Stations F T E F T E F T E F T E CF9 Firewall F T E C300 Controller Redundant Modbus/TCP PCDI Interface Utilize a third party device (Mynah) for redundant Modbus/TCP comminations from C300 to Genius I/O 14

15 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 15

16 Agenda Migration Planning and Setup Migration Solutions Success Stories and Summary 16

17 Global Expertise Invensys Foxboro IA, Triconex ABB Bailey, F&P, MOD 300, H&B Emerson Fisher PROVOX, RS3, RMV 9000, Westinghouse, Bristol Babcock, Delta V Siemens Teleperm M, S5, S7, Moore APACS Rockwell GE Toshiba Yamatake Yokogawa More 17

18 Multi-System Migration to Experion Success Borregaard Sarpsborg, Norway 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 18 5 year Phased Migration

19 Bailey and Foxboro HMI Migration Success Kirishi Refinery - Russia 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 19

20 Integrated DCS and Safety Migration Success IRPC Rayong, Thailand. 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 20

21 Teleperm M Total Replacement Success Konya Sugar Turkey 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 21

22 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 22 Achieve Your Goals and Requirements

23 What makes it UNIVERSAL? 32 Universal Channels Each channel SOFT configurable as DI, DO, AI & AO Fully Redundancy Extended Temp. Range (-40 to +70 Deg C) Local & Remote capability Digital Input Digital Output Environmentally Hardened Analog Input Analog Output Cabinet Mounted & DIN RAIL version Universal IO Experion s Multi-Tool 23

24 Server Peer Responder Robust controller peer-to-peer communication with other subsystems Direct point-parameter references in Control Builder Tight integration of Control and SCADA points TPN points Supports migrations to Experion Batch Manager Remote Experion Clusters Direct point.parameter references Eliminates need for OPC mailboxing Faster and simpler to implement Easier to troubleshoot 24 The Most Integrated System, Just Raised the Bar