Plug-In Migration – A Better Approach to DCS System Replacement

1. Plug-In Migration – A Better Approach to DCS System Replacement Stephen Golemme, Sr Technical Consultant, Invensys Process Systems Mile High Industrial and Automation Conference

2. When to Migrate? • Threat of unscheduled downtime • Emerging or new business needs are impossible to support without new system • No longer cost effective to support old system(s) • Old system(s) cannot support new technology • Old system is declared end-of-life Mile High Industrial and Automation Conference

3. Issues Vendors Face • Keep pace with Technology - Need for a next generation system every 10 - 15 years • Obsolescence of parts • Costly to maintain and support • Need for systems that will do more • Reluctance to compromise new system design to accommodate the past • Next generation system products have a different shape and size Mile High Industrial and Automation Conference

4. Popular Migration Solutions • The Bulldoze – demolish and start again • Cable Solutions – gut the original cabinet, cable over to a rack of new equipment, adjust for I/O mapping • Transition Solutions – Replace the HMI, then controllers, then finally the I/O modules • Gateways – integration solution to share data between and old system and a new system Mile High Industrial and Automation Conference

5. ARC Analysts Pros & Cons Mile High Industrial and Automation Conference

6. Designed to minimize cost, risk & downtime I/O modules are manufactured to Plug-In to your existing legacy system racks. • Reuse existing cabinets, racks, term. assemblies and field wiring • No I/O mapping issues - exact match • Minimum process downtime • 100% new system (workstations, controllers and I/O modules) • Full system warranty Mile High Industrial and Automation Conference

7. Plug-In DCS I/O Modules • One for one I/O board replacement • Meets or exceeds I/O capacity of legacy cards • Lines up exactly with I/O points • Manufactured using same components as traditional I/O modules • Automatic bootup on installation • Fully redundant I/O bus - no single point of failure Mile High Industrial and Automation Conference

8. I/A Series Workstations I/A Series Controllers I/A Series Form fit replacement modules Unique Plug-In Solution • Step 1: pre-install new workstations & controllers • Step 2: set process in steady state mode • Step 3: replace I/O modules & attach network connectors • Step 4: loop check • Step 5: start up process • Step 6: making product & saving money - day 1 !!! And It’s Reversible !!! Mile High Industrial and Automation Conference

9. Lowest Installed Cost Eliminated installation & rewiring costs Mile High Industrial and Automation Conference

10. Lost Production due to downtime Mile High Industrial and Automation Conference

11. Lowest Risk Solution • Site Survey & audit • Hardware & application review • Requirements docs, design docs, test plans, validation plans, implementation plans • Automated tools for database conversion and full system documentation • Full system FAT off-site • Switchover done in hours, not days or weeks • Non-destructive, fully reversible Migration Centers of Expertise Mile High Industrial and Automation Conference

12. Protect your investment • Vendor should assume responsibility for the entire system – new & old • Future upgrade paths and plans should be clearly identified – years ahead of schedule • Ensure your investment is protected and you are supported for a lifetime! Mile High Industrial and Automation Conference

13. A Case Study – WDPF Westinghouse Migration • NL Hydro – A Nalcor Energy Company, Holyrood, Newfoundland Hydro • Migration of a 1990’s Vintage Westinghouse WDPF DCS • Informed by Vendor - no support after 2005 • Hardware Failures becoming more frequent. • Island power system dictated fast, reliable upgrade –2 weeks! • Foxboro migration selected: • Needed a cost effective, low risk migration solution with minimum process downtime. • Partner that provides ongoing service & support – locally • Proven experience • New system must be better, not just a functional replacement • Results: • 100% new system leveraging IPS’ integrated portfolio of technology • Brand new DCS for $75k on $4M project • Minimum downtime – installation & commissioning to completion - 1 week! • Localized & strong partnership with the IPS team – improved troubleshooting of process problems. • No more end-of-life issues, with backwards compatibility guaranteed Mile High Industrial and Automation Conference

14. Plug-In – A Better Approach to DCS System Replacement • 30% - 40% below a bulldoze solution • Reuse the wiring, cabinets, nests, etc – things that don’t fail • No I/O mapping issues • No interim/throwaway solutions • Easily reversible • 1 small outage (1 day) away from a new system • Check our references - please !!! Mile High Industrial and Automation Conference

15. Plug-In To... Foxboro Spectrum SPEC200 Honeywell TDC2000 & TDC3000 Bailey NET90 & INFI90 Fisher PROVOX S10 & S20 Westinghouse WDPF Siemens Moore APACS Taylor Mod300 Mile High Industrial and Automation Conference

16. Thank You! • To learn more – • visit the Invensys booth • www.ips.invensys.com/migration Mile High Industrial and Automation Conference