Satnam Bhogal October 4th, Migration Solutions for Non-Honeywell Systems

Transcription

1 Satnam Bhogal October 4th, 2018 Migration Solutions for Non-Honeywell Systems

2 Challenges of Legacy Systems Pending threat of outage or incident Low availability of spare parts means costly maintenance Demand that IT provides economic advantage cannot be met Unable to expand cost-effectively to meet capacity requirements Insufficient ability to predict abnormal situations and equipment breakdown Inflexibility affects response time to shifting customer demands Difficulties harnessing new business opportunities with current limitations of system

3 Program Engagement & Lifecycle Execution Customer s Vision Workshops with Customers & Owners Business/ Domain Consulting Project Team Project Team Phase 1 Vision & Concept/ Demand Studies Phase 2 Discovery Process / Master Technology Plan Phase 3 Business Process Modeling (BPM) / Front End Engineering (FEED) Phase 4 Project Execution Phase 5 Value Sustenance Initial Scope Definition Budgetary Proposal Opportunity Assessment Final Scope and Firm Proposal Project Deployment Fine Tuning Phase I Deliverables : 1.High level business req. 2.Technology map 3.Expected outcomes Phase II Deliverables: 1.Budgetary proposal 2.Master Technology Plan 3.Opportunity assessment 4.System architecture 5.Deployment Schedule Phase III Deliverables: 1.Firm proposal 2.FEED 3.Business process Models 4.Detailed Soln. Analysis Phase IV Deliverables: 1.Project kick off 2.Design 3.Implement 4.Test 5.Commission Continous Innovation: 1.After market support 2.Value audits "Honeywell helped us develop a plan to migrate our product and supplied both the justification and economic benefit analysis for us to do so, - RVA

4 FEED & Pre-FEED Activities Conceptual Design Philosophy Documents Vision Documents Guideline Documents Design Studies and Recommendations Front-End Engineering & Design Philosophies and the visions developed during conceptual design are transformed into actual designs Project standards are critical in ensuring consistency across the facility Project execution strategies

5 Competitor Legacy System How Honeywell Addresses It 4 Needs/Challenges Doing nothing causes unplanned Shutdowns Parts & Service not available System not capable Need for More Safety, Reliability & Efficiency Need for Better Life Cycle Support Our Capability Proven Long term Support Incremental HMI and Controller Migration Tools that share Competitor systems knowledge Experion with Series C300 Key Differentiator Value Proposition For Honeywell customers with 3rd Party DCS Systems in addition to Experion or TPS/TDC; Who need to replace the obsolete 3rd party System Honeywell s 3rd Party Migration solution Provides Low Risk, Cost effective Migration to Experion by providing consulting, tools, kits and long term support Proven Long Term Support Equals Customer Confidence

6 Legacy Competitor System Landscape 5 Master Advant Freelance Contronic / Melody DCI System 6 Teleperm APACS - Quadlog Simatic S5/S7 Provox RS/3 Delta V WDPF / Ovation Spectrum / Spec 200 IA Series Modicon PLC s Triconex Process Logix Control Logix ICS Triplex Centum XL Centum CS Centum CS1000/3000 Centum VP ProSafe -RS MOD V MOD 300 Infi 90/ Harmony Key Distributed Control System Safety System PLC Type Application

7 Engineer and Operate Efficiently 6 LEAP for Operations Advanced Operator Solutions (Orion with Embedded APC & Alarm Management) Next Gen Virtualization Solutions Cloud Engineering with Smart Test Auto Document & MOC (TRACE) Edge Device Integration Simplified Automated Device Commissioning Smartline & Wireless Advantage Fire & Gas Integration Skid Integration Edge Device Integration Cloud Enabled Execution Universal & Connected Assets Integrated Controls & Subsystems Universal Channel Technology (DCS, Safety & PLC) & Integrated RTU Electrical & Ethernet (EIM; EIP & IEC 61850) Cyber Secure Conformity (IEC )

8 Options to Consider When Modernizing 7 Short-Term Life Extension (HMI Migration)* Phased Migration Rip and Replace * HMI Migration solution need to be evaluated with site specific feasibility study before proposal Customer s Intellectual Property is Retained and Translated

9 Honeywell HMI Migration 8 "We needed a solution that would improve process performance while still leveraging our investment in the Bailey and Foxboro controllers. Alexandre Gershberg Head of Instrumentation & DCS - Kirishi Refinery Evaluate Based on System Requirements

10 Honeywell Controller Migration 9

11 Why Rip and Replace? 10

12 Competitor System Migration Tools 11 Inventory/Parser tools Graphics Migration tools - Invensys Foxboro-I/A - Siemens Teleperm M - Yokogawa Centum-CS3000 (P) - Yokogawa Centum-CS - Emerson Provox - Invensys Foxboro-I/A - ABB Bailey - Yokogawa Centum-XL (P) - ABB MOD 300 (P) - Emerson RS3 (P) PLC DB Migration Tools - PLC 5/SLC500 PLC to Control Edge PLC - Emerson PROVOX (P) - Moore APACS (P) SCADA DB Migration Tools Controller DB Migration tools - Citect to Experion SCADA - ABB MOD Emerson RS3 - Yokogawa Centum-CS Yokogawa Centum-CS - Invensys Foxboro-I/A - Yamatake PM100 - ABB Bailey (Prelim) - Emerson PROVOX (Prelim) Competitor Displacement -Tools

13 Controller DB Migration Control Match Tool 20 Supports Following system types: ABB MOD 300 Emerson RS3 Yokogawa Centum-CS, Yokogawa Centum-CS3000 Invensys Foxboro-I/A Yamatake PM Control Match tool helps to retain the Customer IP

14 Foxboro Controller Data Migration 13

15 Graphic Migration Graphic Match Tool 14 Supports Following system types: Emerson Provox Invensys Foxboro-I/A ABB Bailey

16 Graphics Improvement 15

17 Migration Concept Foxboro I/A 100 Series 16 Connection options Nosecone interface detail FBM Cable Term connector Side view of FTB Term Connector + cable + either (1) connection block or (2) plug connector block or (3) discrete wire block = Termination Cable Assembly (TCA) The FBM connector is commonly referred to as a nosecone Rear of FTB Mounting post Interconnects to Foxboro card

18 Foxboro System Migration to Experion AW, AP, or WP Experion System 17 Foxboro IA Nodebus FTE CP Name FC101 Unit GR Desc Flow Key Cntrl Tuning 1.0 T1.5 EU bbls/hr Database C300 ACE Server Series C IO s Foxboro System Phase by phase Migration Wiring Terminations

19 Traditional Hot Cut-Over Typically used at Refineries and some Chemical facilities Process never goes down (hopefully) but runs in manual for durations Takes a LONG time to complete the system conversion Plant Personnel required for every conversion Field work required during Hot Cutover Requires substantial planning Risk to operations Requires changing of configuration to support cutover

20 A new Methodology to Migrate Control Systems Individual modules linked together Aligns with marshalling terminals Unlimited number of stacks Parallel Migration of: - PLC, DCS, Remote I/O in parallel - Different manufacturers - Great Solution for Older Honeywell Systems

21 Automated Hot Cut-over Process interruption limited to running PID function in manual for a few seconds No field work required bypass valves, signal generation, manual valve control Limited Plant Personnel required Some planning required Configuration verified during hot-cut over System Conversion anytime Competitive Systems or Older TDC Systems

22 Why Honeywell? Honeywell delivers a continuous evolution pathway to System modernization without rip and replace. 21 Honeywell has a longstanding record of delivering a phased approach to platform modernization that delivers: Low-risk / low disruption to operations Lowest total cost of ownership Year 40+ Year 20 Year 10 Delivering a sustainable outcome. Honeywell is committed to the continued long-term support of our customers by investing in: The continuous evolution of our flagship Experion PKS platform In-country project management, engineering and support capabilities

23 Client Client Client Client Calcination Manut. Poussiere POND PCC PCC ABR5 Coax Serv-cl. RS232 Client ABR5 Coax Radio CYLINK-19MP Client Antenna Equipment ABR5 IS-50NX-CT MHz - 375W MHz - 125W MHz - 50 W Telephone PCC SS3 FiberOptic/ RJ45 converter Fiber Optic Hub FiberOptic/ RJ45 converter PCC Client FUTURE Fiber Optic Hub Client Serv-cl. RS232 Bailey to Experion Success Story 22 Compagnie des Bauxite de Guinee PCS Rehabilitation Project of replacing legacy Bailey Infi 90 Scope of project covers engineering, installation, commissioning of Experion PKS, Safety Manager and FI I-Mac responsibility for full scope Control Network design and configuration Integration of plant and 4 remote sites Relocation of Process Control Centre CAT 5 cables FiberOptic converter to RJ45 Hub IP Address Agglomeration RTD and RTD redundant servers at PCC room Switch FiberOptic converter to RJ45 PCL Fure Agglo PCL Central Switch BA PCL Dryers FiberOptic converter to RJ45 SCSI Cables PCL Central - Pompes - Dosage Batafong CIU at DRYERS LOOP 3 SECHEURS LOOP 1 Principale ABR5 PCC PCC I I I I I I T T T I I T I I I I T T LOOP 4 LOOP 10 LOOP 11 CITE LOOP 2 PARCS SONGOLON LOOP 5 CHARGEMENT Centrale S1 S2 S3 SE B M S 1 B M S 2 B M S 3 CA MP MG EC CH SO CI CI Pompes PC BR PA S S 3 CT Filtres Pompes Broyage Parcs Centrale Infinet Réseau Noeuds PCV - Ethernet 01 : Principale 02 : Broyage et Parcs 03 : Sécheurs et Calc. 04 : Expédition 05 : Centrale Elec : Réserves 10 : Songolon 11 : Cité 01 à 30 : PCU 01 à 10 : Serveurs 31 à 40 : Serveur 11 à 30 : Clients Usine 41 à 60 : Communication 31 à 40 : Clients Aux. 61 à 70 : EWS 41 à 50 : Clients Adm. Turn Key Contract - Total Replacement with Initial HMI Migration

24 INFI90/Delta V to Experion Success Story 23 Hassi Berkine (HBNS) CPF Client: Groupement Berkine Anadarko/Sonatrach JV Location: HBNS Block 404, Berkine Basin, Algeria Application: Oil production facility through four-trains at 285,000 b/d Project: CPF Automation Upgrade Replacement of legacy ABB Bailey Infi90/Delta V Scope: Experion PKS, Safety Manager, OTS, FDM Eng Services, PM, Staging/Checkout & Site Work I/O: DCS 3,648 SS 4812 FGS 3,216 I/F s 28,800 Total ABB Bailey with Delta V HMI Replacement

25 Foxboro I/A to Experion Success Story 24 Client: Middle East Oil Refinery (Midor) Location: Alexandria Application: Oil refinery with 100,000 b/d capacity (18 process units with utilities and offsites) Project: Automation Rehabilitation and Upgrade replacement of legacy Invensys I/A system (Ver and (CR5) Scope: Experion PKS, FDM, HIMA u/g, MUX u/g,eng Services, PM, Staging/Checkout & Site Work DCS and I/O: DCS 17,944 I/F s links - 40 devices Midor Replacement of Installed System Less than 12 years Old

26 QAFAC to Experion Success Story QAFAC 25 Location: Mesaieed Industrial City, Qatar Application: Production of methanol and methyl tertiary butyl ether (MTBE) Project: DCS Control System Upgrade/Replacement Replacement of legacy Invensys I/A system ver (u/g d 2009), add in of CO2 Project and Boiler Integration. Change-over April Scope increase with F&G System and Control Room Refurbishment. Scope: Experion PKS, Universal I/O, PHD, FDM, Safety Manager, Engineering Services, PM, Staging/Checkout & Site Work DCS and I/O: DCS 3883 IO SCADA Points Sequences-96 Replacement Project with Enhanced Supportability

27 Multi-System Migration to Experion Success story 26 Borregaard Sarpsborg, Norway Migrated Hiway system, Foxboro IA, Rosemount RS3, Delta V and PLCs. Used Wiring Kit and Control Match tool 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 Phased Migration over 5 years

28 Foxboro and Bailey HMI Migration Success 27 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 Foxboro/Bailey controllers until point of obsolescence Raised Performance Levels Through Greater Process Reliability and Stability

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