PlugIn Migration A Better Approach to DCS System

Plug-In Migration – A Better Approach to DCS System Replacement Stephen Golemme, Sr Technical Consultant, Invensys Process Systems March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

When to Migrate? l Threat of unscheduled downtime l Emerging or new business needs are impossible to support without new system l No longer cost effective to support old system(s) l Old system(s) cannot support new technology l Old system is declared end-of-life March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Issues Vendors Face l Keep pace with Technology - Need for a next generation system every 10 - 15 years Obsolescence of parts l Costly to maintain and support l Need for systems that will do more l l Reluctance to compromise new system design to accommodate the past l Next generation system products have a different shape and size March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Popular Migration Solutions March 31 st and April 1 st, 2009 l The Bulldoze – demolish and start again l Cable Solutions – gut the original cabinet, cable over to a rack of new equipment, adjust for I/O mapping l Transition Solutions – Replace the HMI, then controllers, then finally the I/O modules l Gateways – integration solution to share data between and old system and a new system Mile High Industrial and Automation Conference

ARC Analysts Pros & Cons Migration Strategy Benefits Bulldoze - Rip out and start again (Originally only game in town) Most comprehensive way to migrate to a new system Costly, downtime issues Most impractical solution Cable Solutions - Gut the original cabinet, cable over to a rack of new equipment, adjust for I/O re-mapping A quick solution for system interoperability. Low risk Fails to address end of life and maintenance issues, temporary solution, can be costly Transition Solutions - Replace the HMI, then controllers , then finally the I/O modules. Small investment upfront, incremental change Much more costly over time – almost double initial quote Gateways - Integration solution to share data between and old system and a new system Effective solution for migrating to different platform from different supplier Increased footprint, time to install, I/O mapping issues I/O Replacement - Plug-In to your existing legacy system racks. Very cost effective solution with reduced downtime, easily reversed if necessary Offered by small number of suppliers March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference Challenges

Designed to minimize cost, risk & downtime I/O modules are manufactured to Plug-In to your existing legacy system racks. March 31 st and April 1 st, 2009 l Reuse existing cabinets, racks, term. assemblies and field wiring l No I/O mapping issues - exact match l Minimum process downtime l 100% new system (workstations, controllers and I/O modules) l Full system warranty Mile High Industrial and Automation Conference

Plug-In DCS I/O Modules March 31 st and April 1 st, 2009 l One for one I/O board replacement l Meets or exceeds I/O capacity of legacy cards l Lines up exactly with I/O points l Manufactured using same components as traditional I/O modules l Automatic bootup on installation l Fully redundant I/O bus - no single point of failure Mile High Industrial and Automation Conference

Unique Plug-In Solution l Step 1: pre-install new workstations & controllers l Step 2: set process in steady state mode l Step 3: replace I/O modules & attach network connectors l Step 4: loop check l Step 5: start up process l Step 6: making product & saving money - day 1 !!! I/A Series Workstations I/A Series Controllers March 31 It’s and April. Reversible 1 , 2009 Mile And !!!High Industrial and Automation Conference st st I/A Series Form fit replacement modules

Lowest Installed Cost Eliminated installation & rewiring costs March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Lost Production due to downtime March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Lowest Risk Solution Migration Centers of Expertise March 31 st and April 1 st, 2009 l Site Survey & audit l Hardware & application review l Requirements docs, design docs, test plans, validation plans, implementation plans l Automated tools for database conversion and full system documentation l Full system FAT off-site l Switchover done in hours, not days or weeks l Non-destructive, fully reversible Mile High Industrial and Automation Conference

Protect your investment l Vendor should assume responsibility for the entire system – new & old l Future upgrade paths and plans should be clearly identified – years ahead of schedule l Ensure your investment is protected and you are supported for a lifetime! March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

A Case Study – WDPF Westinghouse Migration l 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! l 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 l Results: ¡ 100% new system leveraging IPS’ integrated portfolio of technology ¡ Brand new DCS for $75 k on $4 M 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 March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Plug-In – A Better Approach to DCS System Replacement l 30% - 40% below a bulldoze solution l Reuse the wiring, cabinets, nests, etc – things that don’t fail l No I/O mapping issues l No interim/throwaway solutions l Easily reversible l 1 small outage (1 day) away from a new system l Check our references - please !!! March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Plug-In To. . . Foxboro Spectrum SPEC 200 Honeywell TDC 2000 & TDC 3000 Bailey NET 90 & INFI 90 Fisher PROVOX S 10 & S 20 Westinghouse WDPF Siemens Moore APACS Taylor Mod 300 March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference

Thank You! To learn more – visit the Invensys booth www. ips. invensys. com/migration March 31 st and April 1 st, 2009 Mile High Industrial and Automation Conference