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Power to PerformHoneywell Users Group 2008Power to Perform
Honeywell Users Group 2008
Marjorie OchsnerSenthil Balasundaram
Non-Honeywell System Migration to Experion
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Agenda
• Justifying a Modernization• Upfront Planning and
Assessment• HMI Migration Solutions• Controller Migration Solutions• Wrap up and General
Recommendations
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Why Migrate?Migration Justification = Cost of Doing Nothing + Increased Benefits
Improve Safety, Reliability and Efficiency
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Cost of Doing NothingDecreased 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
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Benefits of Moving from Stagnant Technology
Migration to Experion =Increased Revenue, Increased Production, Lower Cost
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
Integrated Safety “Honeywell… supported IRPC to continuously benefit from overall improved operations..”Sompas Samnianglam, Instrument Section Manager, IRPC
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Agenda
• Justifying a Modernization• Upfront Planning and
Assessment• HMI Migration Solutions• Controller Migration
Solutions• Wrap up and General
Recommendations
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Upfront System Assessment• Current Situation – Front End Engineering and Design
– Budgeting and justification• Constraints
– Hot cutover requirements– Turn around scheduling– Phased Approaches– Existing Instrumentation
• Goals– Increased safety– Operational improvements– Business improvements
• Financing options are available• Strawman plan based on constraints and goals
"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
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Benefits of Front End Engineering & Design
• Reduction in Project Risk • Design Consistency • Project Cost Savings • Operational Readiness • Business Readiness • Lifecycle Sustainability
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Global 3rd Party Migration Experience
Fisher PROVOX
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Foxboro IA, Spectrum, Spec 200
*** **** *
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Yokogawa Centum XL, CS
** *
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Rosemount RS/3, RMV 9000
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Hartman & Braun Contronics, Freelance
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Siemens Teleperm M, Moore APACS
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*******
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Rockwell Process Logix
** ** **Bailey
* * ***** * *
*
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Migration Options
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Risk and Benefit Profile
CostProject
Risk Benefit
Extend Life x Very Low Low
IncrementalUpgrades
5x Low Significant
Rip andReplace
30x High Significant
Opt
ion
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Investment Protection
CostProject
Risk Benefit
Extend Life x Very Low Low
IncrementalUpgrades
5x Low Significant
Rip andReplace
30x High Significant
Opt
ion
Extend Life Not Available for Many Systems
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Agenda
• Justifying a Modernization• Upfront Planning and
Assessment• HMI Migration Solutions• Controller Migration
Solutions• Wrap up and General
Recommendations
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Why Honeywell HMI Migration?
Transition To Experion, Minimize Risk
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Which Systems and When
• Legacy Network, Controller and I/O still supported• Used to Transition to Central Control Room in conjunction
with System Expansions• Intermediate step for Controller Migration• Successful in Bailey, PROVOX, Foxboro IA, Moore APACS,
Siemens Teleperm M, RMV, Process Logix
Transition to Experion
“We needed a solution that would improve process performance while still leveraging our investment in the Bailey controllers.” - Alexandre Gershberg, Head of Instrumentation and DCS, Kirishi Refinery.
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Bailey HMI Migration Success
• Zero production down-time • Higher uptime• Increased productivity• Faster, more effective decision making • Greater flexibility• Improved safety • Investment protection• Seamless integration• Ease of use• Improved throughput
Wintershall - Netherlands
We are very happy with the results, and with the passage of time and further integration efforts we expect to realize more and more benefits such as time efficiency, increased platform performance and reliability, ease of maintenance and cost reduction… - Hans Reijn, Facility Engineer, Wintershall”
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Robust Infrastructure - BaileyServer
Primary OPCServer
Backup OPCServer
Redundant Redundant Experion ServersExperion Servers
Robust Networks Robust Networks (FTE)(FTE)
Dual Active Dual Active RovisysRovisys Servers Servers
managed by managed by Redirection Redirection
Manger (RDM)Manger (RDM)
Dual SCSI Dual SCSI AdaptersAdapters
Dedicated SCSI Dedicated SCSI channelschannels
Multiple Multiple CIUCIU’’ssSupportedSupported
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Robust Infrastructure - PROVOXServer
Primary DataCollector
Backup DataCollector
Redundant Client Redundant Client Interfaces to Data Interfaces to Data
CollectorsCollectorsRedundant Redundant
Networks (FTE)Networks (FTE)
Dual Active Data Dual Active Data Servers Servers
Supported for Supported for seamless failoverseamless failover
ControllerIFC SRX
IFC-TRN
ControllerIFC SR90
`IFC-REV2
LocalTraffic
DirectorHighway
Data Links
2-13
HighwayData Links
2-14
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Transition to Experion
Parameter Mapping
TiPS OPC Parameter Data Type Access Description
IVP Real Read/Write Output Value
MODE Integer Read/Write Mode
QUESTDATA Boolean Read Questionable Data - Failure in PROVOX data
DDP
DDPPollTime Real Read/Write DDP poll time in seconds
EU 0% Real Read/Write Engineering Units 0%
EU 100% Real Read/Write Engineering Units 100%
FAILSAFE AO Real Read Only
OFCC0 Real Read Only Output File Card Channel - AO
INC CLO? Real Read/Write Increase Open, Increase Close
REM OFS? Real Read/Write Remote Out of Service
RESCATTR Real Read/Write Resource attribute
3rd Party Point Experion
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Efficient Database Conversion
SCADA points are created in QB, once it is copied from excel to QB
Database is analyzed and equivalent SCADA point
is generated
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Efficient PROVOX Database Conversion
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Efficient Bailey Database Conversion
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Transition to Experion
Bailey Detail Display
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PROVOX Detail Display
Transition to Experion
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Bailey Faceplates
Transition to Experion
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PROVOX Faceplates
Transition to Experion
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Graphics Improvement
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Agenda
• Justifying a Modernization• Upfront Planning and
Assessment• HMI Migration Solutions• Controller Migration
Solutions• Wrap up and General
Recommendations
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Why Honeywell Controller Migration?
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Which Systems and When
• Aging systems with poor or no support of legacy controller and I/O• Typically phased in or used in conjunction with HMI migration• Front end engineering and design are keys to success• Experienced with many systems including Bailey, PROVOX, Foxboro
IA, Spectrum, Spec 200, Moore APACS, Siemens Teleperm M, RS3, Hartman & Braun, Yokogawa, GSE, etc…
““We felt that we were at a dead end and needed a system that could grow with us and provide a clear migration path,” said Stacey Miller, Applications Engineer, USA Yeast
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Rosemont RS3 & Siemens PLC S5 Success
• 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 R300 platform integrated with Safety Manager is proving to be highly reliable.”Sompas Samnianglam, Instrument Section Manager, IRPC
IRPC Rayong, Thailand
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• PROVOX Series 10, Series 20• Bailey Infi90, NET90• GSE Quantum• Yokogawa• All Others Require Approval
Migration Kits Save Time and Money
Rewiring Tasks Using Migration Kits
• Disconnect old terminations• Remove old Bailey field termination unit (FTU)• Install new Series C I/O • Rewire
• Install migration kits and new Series C I/O• Connect cablesSave about 75% on labor
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Efficient Conversion of PROVOX Strategy
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Opportunity to Improve Process Control
Bailey Predictive ControlProfit Loop Solution
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Access HART
• Many plants have existing HART devices connected to Network 90 or Infi 90 as an Analog Input/Output
• Migration kit connection to Series C HART I/O reveals HART information
• Enables maintenance, operations and process improvements
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Leverage Upgraded Infrastructure
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PROVOX Wiring Kit Use Success
• Experienced several days of unscheduled lost production due to 3 separate DCS failure
• Used wiring migration kit to get on line in less than 24 hours
“The teamwork displayed by the Honeywell Process Solutions group and
our local team made the Experion installation a very successful project,
and allowed our facility to start up slightly ahead of schedule.”
—Ron Snell, Operations Manager
Honeywell Specialty Material – Geismar, LA
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Agenda
• Justifying a Modernization
• Upfront Planning and Assessment
• HMI Migration Solutions• Controller Migration
Solutions• Wrap up and General
Recommendations
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Recommendation #1: Front End Engineering & Design
• Reduction in Project Risk • Design Consistency • Project Cost Savings • Operational Readiness • Business Readiness • Lifecycle Sustainability
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CostProject
Risk
Enables New
Benefit Capture
Extend Life x Very Low Very Low
Incremental Upgrades 5x Low Significant
Rip and Replace 30x High Significant
Opt
ions
Recommendation #2: Incremental Upgrades When Possible
Life Extension Not Usually an Option; Minimize Risk
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Recommendation #3: Improve Operator Effectiveness
Be Aware of Changing Operator’s Role when Migrating
Reliability
Improved Throughput
and Operator Productivity
EfficiencySafety
Reduced Incidents
Effective Alarm System
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Recommendation #4: Leverage Upgraded Infrastructure
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Recommendation #5: Develop Long Term Automation Plan
Lifecycle Management
Improve Process Automation Lifecycle
Implement
Maintain
Plan
Upgrade
LCM
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Why Honeywell
• Experienced Engineering and Design
• Improve Process Control
• Improve Operator Effectiveness
• Leverage Increase Scope of Automation
• Long Term Automation Commitment Supports On-going Incremental Upgrades
Improve Your
Business Performance
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Come see us in the Demo Room www.honeywell.com
