2015 Japan Technology Summit
Yokohama, September 9-10
Ability to Migrate TDC and Yokogawa Systems
Bhaskar Shetty, Global Discipline Lead – Solutions
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Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Introduction
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Introduction
• Ageing systems driving concerns:
reliability, obsolescence, loss of skills to maintain
• Growing pressure from global market to achieve
operational excellence
Delivers
• Phased approach to minimize risks while offering
lowest TCO
• Functional and operational benefits of a modern,
sustainable platform with Experion PKS
• Ability to integrate DCS with Safety and Security system
seamlessly
• Long lifecycle product hence reduced TCO
• Less disruptive migration due to evolution based
technology
Unsustainable
Current Situation
Honeywell
Modernization
Program
Why Honeywell
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Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Introduction
Why Consider Migration?
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Why Should You Consider Migration?
Challenge #1
When obsolescence becomes an issue?
High maintenance cost due to parts obsolescence, high cost of spares ?
Is process knowledge lost due to experienced workforce retiring?
Inadequate support from current vendor
Parts & People
Are You Facing Obsolescence and Losing Process Knowledge?
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• Unplanned shutdown
• Production loss
• Safety incident
• Environmental liability
• Inadequate System response
Why Should You Consider Migration?
May result in
Challenge #2 Decreased Reliability
Loss of Control
Loss of View
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Challenge #3 Increasing Competitive Pressure
Why Should You Consider Migration?
New technology delivering
improved integration with
mission-critical Safety System:
• Meet product demand & specifications at lowest raw material cost
• Reduce energy consumption
• Operator effectiveness
Improved collaboration features and
advanced visualization to drive:
• Increased productivitythrough greater span of control
• Improved operator effectiveness through advanced alarming
• Use Advanced Solutions
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Justification Process – Cost of Doing Nothing
Decreased Reliability
causes Unplanned
Shutdown
PROVOX system caused 3 unplanned shutdowns in
1 year-Petrobras
High Maintenance Cost
due to Parts
obsolescence, High Cost
of Spares
“SKC had various issues with the service provided
by Emerson since our old RS3 system was archaic
and the price of spare parts was not realistic,” said
Hyun Cho, General Manager, SKC Chemicals.
Inadequate Response Experion alarm system identifies process
conditions that the Moore system was too slow to
capture – HSM Metropolis
Increase Capacity Customer want to expand the system
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Justification Process – Increased Benefits
Benefits of moving from Stagnant Technology
Migration to Experion = Increased Revenue,
Increased Production, Lower Cost of ownership
Operator Effectiveness Irving Oil - 45% decrease Daily Alarm Rate
Abnormal Situation Management
Sasol - $500,000 saved by increased situational awareness and improved consistent operation
Better Process Control Konya Sugar – 17 % Increase in Quality
Safety Standards Safety Embedded into DCS when changed to Safety Manager and Experion
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Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Why Consider Migration?
Migration Options
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Options to Consider When Modernizing
Short-Term Life Extension (HMI Migration)
Phased Migration
Rip and Replace
Customer’s Intellectual Property is Retained and Translated
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Honeywell HMI Migration
“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 and DCS, Kirishi Refinery.
Key
Differentiator
Key
Differentiator
Transition To Experion, Minimize Risk
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Honeywell Controller Migration
Key
Differentiator
Key
Differentiator
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Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Migration Options
Benefits of Migration
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System
Modernization
Investment Linearity
Maintenance and Support
Phased Migration
Proactive Tech Refresh
Benefits of Modernization Program
Less Investment, Better Technology, More Benefits … Better ROI
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How Does it Work?
“System Modernization” Proposition
1
2
Assess your
Automation
• Benefits Analysis
• Cost Analysis
• Automation Plan
Phased
Migration
• HMI
• Controllers
Technology
Refresh on
regular schedule
• Servers
• PC elements
• Screens
• FTE Switches
Support Services
• Solution Enhancement Support Program (SESP)
• Parts Management
• Standby/Call out
• Preventive Maintenance
• Corrective Service
• Open System Services
• Customer trainings
Predictable
cash outlay
• Investment Linearity
• Staged & Incremental
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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
Why Honeywell?
Delivering a sustainable outcome. Honeywell is committed to the continued long-term support of our customers in the Japanese market by investing in:
• The continuous evolution of our flagship Experion®
PKS platform
• In-country project management, engineering and
support capabilities
Year 40+ Year 20 Year 10
Honeywell delivers a continuous evolution pathway to TDCS
modernization without rip and replace.
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Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Benefits of Migration
Migration Tools and Kits
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• Graphics Match is used for migrating custom graphic
files from the following systems.‒ US/GUS/Plantscape Graphics
‒ Foxboro Graphics
‒ Provox-Emerson
‒ Siemens Teleperm (In development for current projects)
‒ Yokogawa (In development for current projects)
‒ Yamatake
Graphic Migration – Graphic Match tool
Experion HMIWeb
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Migrate Graphics
using tool
Graphic Migration – Graphic Match tool (cont.)
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Controller DB Migration – Control Match tool
Honeywell TDC System includes
• TDC 2000 family Hiway Boxes‒ Basic Controller (CB)
‒ Extended Controller (EC)
‒ Multi Function Controller (MC)
‒ Advanced Multi Function Controller
(AMC)
‒ HLPIU, LLPIU, LEPIU (High/Low Level,
Low Energy Process Interface Units)
• TDC 3000 family UCN Nodes ‒ Process Manager (PM)
‒ Advanced Process Manager (APM)
‒ High Performance Process Manager
(HPM)
‒ Application Module (AM)
Legacy Competitor System includes
• Bailey
• Provox
• Foxboro
• RS3 (Emerson)
• ABB MOD300
• Siemens Teleperm
• Yokogawa (In development for
current projects)
• Toshiba
• Yamatake
Controller Database Migration Solution
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Controller DB Migration – Control Match tool
Control Match tool helps to retain the Customer IP
Migrate DB
using tool
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• Rewiring Tasks -for 16 point I/O card‒ Disconnect of old terminations
‒ Removal of old terminations
‒ Install new Series C I/O
‒ Rewire from new terminal blocks to Experion
‒ Documentation
• Using Wiring Kits –16 point I/O card‒ Install intermediate panels and New Series C I/O
‒ Connect cables
‒ Documentation
Retain Wiring Investment and Simplify Migration
• PROVOX Series 10, Series 20
• Bailey Infi90, NET90
• GSE Quantum
• Yokogawa
• All Others
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AI MIGRATION CABLE
DI MIGRATION CABLES
DO MIGRATION CABLES
AO MIGRATION CABLE
Yokogawa Honeywell
AI
AO
DO
DI
Analog
Input TU
Analog
Output TU
Digital Input(24, 120, 240)
Digital Output(24 VDC, relay)
Digital Input (24, 120, 240)
Digital Output(24 VDC , relay)
TCA to Series C Migration Hardware
Preserve the
wiring
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Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Migration Tools and Kits
Competitive System Migration to Experion
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• Flexible migration solution for old legacy Yamatake system to
the Experion PKS.
• Replace Yamatake LCN with Honeywell LCN and Integrate with
Experion using ES-T/ESVT
• Choice of Honeywell controllers either HPM or C300 with wiring-
kit solutions
• Phased approach hence minimum shutdown time.
• Interoperability between old controllers and new controllers.
• Embedded batch functionality
• Advanced control, and field network communications such as
HART, FOUNDATION Fieldbus, DeviceNet and Profibus support
• Wiring kit solution saves time and money.
Yamatake Migration
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Database Conversion
Server
C300
FTE
Experion System
Name FC101Unit GRDesc FlowKey CntrlTuning 1.0T1 .5EU bbls/hr
Wiring Terminations
Yamatake HoneywellSystem
ACE
Series C IO’s
Phase by phase
Migration
Yamatake system Migration to Experion
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Yokogawa System Migration to Experion
GSGW
PLC
ENG
FFCS-L
CS3000 on Vnet
CS
OPC Server
CS 1000
Ethernet
Vnet
HISStation
Experion System
FTE
Server
Fault Tolerant Ethernet
Matrikon Centum
VP OPC Server
XL
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Toshiba Tosdic system Migration to Experion
Better method to
extract the IP by
Virtualizing
Toshiba PC
• Migration solution for old legacy Yamatake system to the Experion PKS
• Virtualized old Toshiba DOS PC helps to capture IP
• VM is loaded to VEP (Virtual Engg Platform) for easy access by Project Engg.
• Extract the configurations to electronic format for translating IP
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Proven Support – Not Just Promises!
Honeywell is the only automation vendor that continues to
support 40+ year-old control systems
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TDC/EPKS System – End of 2013
LCNFTE
UCN
C300
NIM
HM/AM
ACE
ESV-T
PM/APM/HPM
FSC
Triconex
LM
US
PCUS
GUS
ES-T
ENIM
EHPM
EUCN
SM
EUCN
Enhanced Universal Control
Network
EHPM
Enhanced High-performance
Process Manager
ENIM
Enhanced Network Interface
Module
Hiway
HG
CB/EC/PIU
MFC/AMC
The First Evolution Step – Unified Control
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Hiway Migration Solutions – End of 2015
LCNFTE
C300
HM/AM
ACE
ESV-T
US
PCUS
GUS
ES-T
ENIM
EHPM
EUCNEHB
SM
SM
Hiway
HG
CB/EC/PIU
MFC/AMC
Hiway
CB/EC/PIU
MFC/AMC
The Evolution in Progress
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TPN Migration Solutions – End of 2016
LCNFTE
UCN
C300
NIM
HM/AM
ACE
ESV-T
PM/APM/HPM
FSC
Triconex
LM
US
PCUS
GUS
ES-T
ENIM
EHPM
EUCN
ELMM
TCMI
SM
SM
The Evolution in Progress
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TDC/EPKS System – After Modernization
LCNFTE
C300
HM/AM
ACE
ESV-T
ES-T
ENIM
EHPM
EUCN
ELMM
TCMI
SM
SM
Unified HMI and Unified Control
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Strategy for TPS Modernization
Avoid Obsolescence with Modern Technology
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Elevator Pitch for Honeywell Value proposition
To overcome current risks associated with obsolescence
of your old TDCS system, lower risk / disruption to your
operations, minimize overall expense and maximize benefits
from upgrade / migration…
Our Honeywell TDCS Modernization program
provides lowest risks to on-going operations,
lowest Total Cost of Ownership and
better Return on Investment.
We do this by phased migrations, on-going system support
to ensure reliability and uptime with our continued commitment
to significant on-going investment in DCS technologies.
Unlike the Life Extension Program, or a complete system
Rip-and-Replace
We have done this successfully for about 40 Yamatake
TDC migrations in Asia over the past 14+ years.
Mr. Customer*–
“
”*i.e., TDCS customer in Japan
42 © 2015 Honeywell International All Rights Reserved
Today’s Agenda
Introduction
Why Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Competitive System Migration to Experion
Case Studies
43 © 2015 Honeywell International All Rights Reserved
Feedback from TDC Customers
Samsung Total:
To express our deepest appreciation for your excellent technical support and quality management of NCC, CB & OCU plant DCS migration in the plant turn-around time. Hereby present this plaque to Honeywell as a token of our appreciation for your contribution.
SamYang Kasei:
We have impressed by successful migration of S3 plant despite of the limited shutdown time. Appreciate your effort and look forward to your continued support in the future.
SK Energy:
Thanks to the devotional support by Honeywell, the NAC Utility DCS was successfully changed without any problem.
Honeywell’s Support and trust had enabled Our Company to achieve accomplishment of this Project.
“
“
“ ”
”
”
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Major Migration Project Delivered In Japan
• Yokogawa migration to Tonen General (System delivery
only) (2007- 2015)
• TDC2000 to Experion TPS migration to TG Sakai (2007)
• TDC to Experion TPS migration to A-Company (2012)
• Toshiba (TOSDIC/CIEMAC) migration to B-Company
(2014-2016)
• TDC to EPKS C300 migration to B-Company (2014)
• TDC to EPKS C300 migration for A-Company
• Yokogawa CENTUM XL migration for C-Company
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Migrated Foxboro IA, Rosemount RS3,
Delta V, PLCs, and Hiway
Multi-System Migration to Experion Success
Used Wiring Kit and ControlMatch 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
Borregaard Sarpsborg, Norway
5 Year Phased Migration
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Yokogawa Micro-XL to Experion Success Story
• Client: MMG Rosebery Mine
• Location: Rosebery, Tasmania, Australia
• Application: Mining of Zinc, Lead and Copper concentrate and
Gold ore with onsite crushing, grinding and flotation processes
• Project: Complete replacement of Yokogawa Micro-XL System
• Scope:
– Experion PKS, C200 Controller, eServer, Rockwell Allen
Bradley PLC and DeviceNet Integration, Pi Historian
Integration
– Engineering Services, Project Management, Construction,
Staging with FAT, Onsite Installation, Commissioning and
Testing
• DCS and I/O:
– DCS – 4 x C200 Controllers, Redundant Servers
– 2000 x SCADA (direct PLC) points
– 1200 x Process (DCS style controller) points
– 8 x SCADA controller interfaces
– DeviceNet Integration for Motor Control from C200
– Approx 400 x Field Instruments in the processing plant
MMG Rosebery Mine
Replacement Project with Enhanced Supportability
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Yokogawa Migration to Experion Success Story
Replacement Project with Enhanced Supportability
• Client: Tonen General
• Location: Kawasaki, Japan
• Application: Refining & petrochemical products.
• Project: Complete replacement of IBM(ACS) &
Yokogawa(CENTUM).
• Background and Strategy• ACS and Yokogawa CENTUM were installed in Kawasaki
& Wakayama Refineries through 1982-1988
• Yokogawa CENTUM-V at on-site(process units) will be end
of support(EOS) in 2015
• TG selected EPKS C300 of Honeywell as the most suitable
product of on-site for technical and S&C strategy.
• TG started ACS/CENTUM migration with EPKS at
Kawasaki Refinery from 2006
• Scope: DCS platform (Hardware & Software),
Engineering services, FAT and SAT
• Key competition: Total lifecycle cost & long term
support.
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Yamatake Migration Success at Bangchak
Petroleum
“We were very pleased with Honeywell’s team and the successful completion
of our DCS migration. Their enthusiasm, even under a very tight schedule, and
ability to deliver on a challenging project was impressive. With a cutover that
met a short shutdown period of just seven days, we were delivered a proven,
reliable and very stable system.”Pratuang Nokkat, Project Manager, The Bangchak Petroleum Public Company Limited
49 © 2015 Honeywell International All Rights Reserved
Today’s Agenda
Introduction
Why Should You Consider Migration?
Migration Options
Benefits of Migration
Migration Tools and Kits
Competitive System Migration to Experion
Case Studies
Summary
Case Studies
Summary
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Summary
• Front End Engineering and Design
• Incremental Upgrades
• Help customer justify a migration project
• Improve Operator Effectiveness
• Increase Scope of Automation
• Long Term Automation Plan
Improve Your
Business
Performance