1. Best Practice DCS Migration
http://www.real-time-answers.com/migration/
Graham Bennett
Senior Migration Technical Consultant
42 years in Automation Industry
© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third
party trademarks and service marks are the proprietary marks of their respective owners.
© Invensys 00/00/00 Invensys proprietary & confidential

2. Today’s Agenda:
1. Why Migrate?
2. Selection Criteria to Consider
3. Critical Implementation guidelines
4. Project examples
5. Q&A
Slide 2

3. Why Migrate?
• Unscheduled downtime leads to loss of
production
• Older technology offers no competitive edge
• Suppliers offer little support making spares
and repairs more difficult
$65 Billion:
• Maintenance costs exceed value of existing Automation
system Systems facing
End of Life
• Aging workforce and dwindling expertise

4. Today’s Agenda:
1. Why Migrate?
2. Selection Criteria to Consider
3. Critical Implementation guidelines
4. Project Examples
5. Q&A
Slide 4

5. Selection Criteria to Consider:
Are you taking advantage of new technology?
Does the supplier offer solid path to future (long-term support)?
Does the platform accommodate advanced applications?
Have you done Migration Site Audit?
Are you able to preserve your existing investments?
Are you replacing hardware assets that offer no value?
Is this solution a standard or custom interface?
Does this solution minimize costs , risk & process impact?

6. Take advantage of new technology
• Open platform
• Superior integration
Mesh Network • Simplicity – ease of use
• Flexibility, expandability
• Performance & reliability
• Fault tolerance at all level
• Cyber Secure compliance

7. Selection Criteria to Consider:
Are you taking advantage of new technology?
Does the supplier offer solid path to future (long-term
support)?
Does the platform accommodate advanced applications?
Have you done Migration Site Audit?
Are you able to preserve your existing investments?
Are you replacing hardware assets that offer no value?
Is this solution a standard or custom interface?
Does this solution minimize costs , risk & process impact?

8. Does the supplier offer solid path to
future?
1 I/A Series, 25 Years of Continuous Investment & Innovation
1980s 1990s 2000s Today
1st distributed software 2 msec logic in I/O Legacy DCS plug-in migration FDSI Superior integration to third parties
1st open industrial system Redundant fieldbus All digital instrument bus 1st InFusion Enterprise Control
1st Ethernet control bus 1st embedded digital fieldbus Self-healing 1gb Mesh Network Intrinsically safe I/O
1st object software 1st Windows NT-based control Anybus fieldbus integration Cyber Security Enhancements
1st standard UNIX Adaptive feed forward control 1st on Windows XP & Solaris 8 100 Series Upgrade Program
1st expert controller tuning 1st Redundant, secure, high ArchestrA on I/A
speed, Ethernet remote I/O Intelligent Marshalling
Slide 8

9. Selection Criteria to Consider:
Are you taking advantage of new technology?
Does the supplier offer solid path to future (long-term support)?
Does the platform accommodate advanced
applications?
Have you done Migration Site Audit?
Are you able to preserve your existing investments?
Are you replacing hardware assets that offer no value?
Is this solution a standard or custom interface?
Does this solution minimize costs , risk & process impact?

10. An Enterprise Control System
Governance
Platform
Corporate
BPM Corporate Systems
IT
ERP
Supply and
Enterprise Demand Chain
Integration
Manufacturing / Production Operations
Collaboration Platform
Optimization
Workflow Integration and
Open Device
Operations Management Performance
Integration
Execution
Web Portal
Control
Application
Services
Safety
Automation/Production
Historian
Measurement
and
Instrumentation
Slide 10

11. Selection Criteria to Consider:
Are you taking advantage of new technology?
Does the supplier offer solid path to future (long-term support)?
Does the platform accommodate advanced applications?
Have you done a Migration Site Audit?
Are you able to preserve your existing investments?
Are you replacing hardware assets that offer no value?
Is this solution a standard or custom interface?
Does this solution minimize costs, risk & process impact?

12. Typical Approaches to DCS Migration
Bulldoze
Cable Solution
Transition Solutions
I/O Replacement

13. Bulldoze
Approach:
Rip out & replace
Benefits: Challenges:
Most comprehensive Costly
way to migrate to a
new system More downtime

14. Cabling Solutions
Approach:
Gut the original cabinet, cable over to a rack
of new equipment, adjust for I/O re-mapping
Benefits:
Quick solution for Challenges:
system
Extra footprint
Interoperability
Low risk Costly implementation

15. Transition Solutions
Approach
Replace the HMI, then controllers, then finally
the I/O modules
Challenges:
Benefits:
Much more costly
Small investment
over time – almost
upfront
double initial quote
Incremental change
Extra footprint

16. I/O Replacement
Approach:
Plug-In to your existing legacy system racks
Benefits: Challenges:
Very cost effective Technology not
solution available from most
Reduced downtime suppliers
Easily reversed if
necessary

17. Designed to Minimize Cost, Risk & Downtime
• Reuse existing cabinets, racks, termination
assemblies & field wiring
• No I/O mapping issues - exact match
• Minimum process downtime
• 100% new system (workstations,
controllers and I/O modules)
• Reversible – no risk!
• Full system warranty
• Automated database porting tools

18. Today’s Agenda:
1. Why Migrate?
2. Selection Criteria to Consider
3. Critical Implementation guidelines
4. Project Examples
5. Q&A
Slide 18

19. Plan
• Approach
– Carefully consider objectives and timeframe
• Standards
– Use existing company standards or define new
• Team
– Include representatives from Operations early
Slide 19

20. Prepare
• Timeframe for project
– Project window is shorter than outage period
– Consider warm up/cool down and testing
• Prepare infrastructure
– Network switches, data highway, controllers, etc
– Ship controllers in simulation mode
– Everything in place and ready for shutdown
• Training
– Simulation to train operators
Slide 20

21. Document
• Document status of equipment in field
– Accurate list of all devices whether or not in service
– Third party devices – emulate if necessary
• Record all alarm points and values
• Note critical loops prior to cut-over
Slide 21

22. Optimize
• Control logic
– Functional replacement not a copy
– Apply current industry application knowledge
• Graphics
• Take advantage newest technology
• Alarms
– Reducing alarm density
– Removing stir stick mentality
Slide 22

23. 5 Steps to Plug-In a New System
• Install new workstations & controllers
1
• Put process in steady state
2
• Replace I/O modules & attach network connectors
3
• Cursory loop check
4
• Re-start process
5

24. Today’s Agenda:
1. Why Migrate?
2. Selection Criteria to Consider
3. Critical Implementation guidelines
4. Project Examples
5. Q&A
Slide 24

25. 500+ Global Migration Projects:
HONEYWELL TDC 2000 / 3000
FOXBORO
MOORE APACS TDC2K
SPEC200 & SPECTRUM
Freeport Agrium
100’s of sites
(Phelps Alcan
Dodge) Dofasco
Linn Western Lanxess(Bayer)
Operating Inc Teck
IOGEN Mexicana de Cananea
FISHER SERIES 10&20 BAILEY NET/INFI90 Dakota Gas
Total (Elf Atochem)
Series 10 Borden Huntsman
Aracruz) IOC Nipsco
BCIT UPM TXU
Teck BC Hydro Union Carbide
Yara Norway First Energy San Miguel
WESTINGHOUSE (WDPF) BP Kitiwake Ambit Kraton Polymers
Crompton Corporation Nacional
Duke (M landing) Series 20 Great Lakes del Cobre
Kentucky Util Hawaii Sugar Karachanganak Petr Exxon Mobil Italy
NRG ExxonMobil Ohio Edison
Erco PPG Loma Linda TDC3K
Proctor Gamble Sterling Chem. Tesoro Refinery HI BASF AK
American ref. Corp Potash Co Boralex ERG Sircusa Italia Kaucuk
Nfld Hydro Total Cleveland Thermal Koch Refining
Indeck (Corrinth) Shell UK
Chanute Mod300 SC series CMPC
Sanyo (Batch) Dakota Gas
Bowater (GE
Keadby (UK) BASF Antwerp
TRIO)
Boralex Stratton Valero
LT Automation
Hercules (US) SRP Coronado
Indeck (orleans)
Brazos (Turbine

26. Refinery - UK
Legacy Systems: Honeywell TDC3000 & Foxboro Spectrum
Challenge:
• Upgrade control systems in 5 production units as part of control room centralization project
• Upgrade needed to be completed quickly
• Project needed to be conducted without requiring the systems to be shut down
Selection Criteria:
• Sound technical solution
• Strong engineering resources available locally
• Previous experience with bidding vendors
Results:
• £10,000,000 savings in production downtime
• Enhanced operator communication
• Temporarily reverted back to existing control system during project to correct a minor
software problem; successfully repeated cutover while preventing disruption to process unit

27. Power Station - Canada
Legacy System: Westinghouse WDPF
Challenge:
• Informed by Vendor - no support after 2005
• Hardware Failures becoming more frequent.
• Island power system dictated fast, reliable upgrade –2 weeks!
Selection Criteria:
• 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 DCS for $75k on $4M project
• Minimum downtime – installation & commissioning to completion - 1 week!
• No more end-of-life issues, with backwards compatibility guaranteed

28. Offshore Platform
Legacy Systems: Fisher Provox
Challenge:
• Continued failures of aging control system, threatening production
• Implement new system quickly and cost-effectively
• Upgrade with no adverse affect on gas production operations
Selection Criteria:
• system switchover downtime / production must not exceed ten days
• Maintain footprint of existing control system infrastructure
Results:
• First migration in less than 7 days; second under 5 days
• Minimized installation cost
• Advanced DCS on offshore platforms
• Reduced maintenance costs
• Lower cost of ownership

29. Chemical Plant - USA
Legacy System: Fisher Provox
Challenge:
• Received obsolescence notification from vendor : no support after 2012
• Shrinking Provox knowledge base
• Costly spare parts and availability
• Expensive to add I/O, especially for remote field instruments
Selection Criteria:
• Minimal production downtime
• Open architecture with ease of expansion and flexibility; ability to integrate to MES/ERP
• Good support infrastructure and expertise
• Low life cycle costs
Results:
• Well executed migration project that met schedule and budget
• Control system performance
• Improved software and hardware maintenance

30. In Summary:
• Consider all your options during selection:
• Do your research on suppliers, platforms, and track records
• Develop a migration cost/benefit analysis
• Determine functional versus value-added replacement
• Do strive to minimize process impact during system changeover
• Do require a Migration site audit
• Plan, plan, and plan some more:
• Engage all relevant stakeholders early
• Identify all standards and optimize control applications
• Plan your schedule carefully relevant to outage period
• Do as much up front infrastructure preparation as possible
• Document status of online and offline equipment, alarms, loops
• Use simulation for checkout and training

31. Today’s Agenda:
1. Why Migrate?
2. Selection Criteria to Consider
3. Critical Implementation guidelines
4. Project Examples
5. Q&A
Slide 31

32. Next Steps:
Request your FREE Migration site audit:
– Migration consultation & step by step survey of existing legacy equipment
– Can include demo trailer visit
Any questions? Please contact:
Amanda.Smith@invensys.com:
1-508-549-4905
http://www.real-time-answers.com/migration/