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Emerson Legacy Emerson Legacy System Modernization System Modernization PhilosophyPhilosophy

Roel C. MulderRoel C. Mulder

Director Migrations & Director Migrations & Modernization EuropeModernization Europe

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WHY partner with Emerson early ?WHY partner with Emerson early ?WHY partner with Emerson early ?WHY partner with Emerson early ?– Match requirements to business

objectives

– Holistic approach

• Automation modernization and not just system migration

– Form a partnership

• Create a vision to sustain a competitive edge for the next 20 years

– Articulate the value of automation

• Develop a compelling business case to modernize

• Help to win over skeptical management

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Next ICSS (BPCS+SIS) architectureNext ICSS (BPCS+SIS) architectureNext ICSS (BPCS+SIS) architectureNext ICSS (BPCS+SIS) architecture

FullyFully integratedintegrated system, system, butbut separatedseparated accordingaccording to IEC 61511to IEC 61511

Separated Safety networkSeparated Safety networkOne system databaseOne system database

NONO serversserversNONO traffic controllerstraffic controllersIPIP communication between nodescommunication between nodes

Separated Safety networkSeparated Safety networkOne system databaseOne system database

NONO serversserversNONO traffic controllerstraffic controllersIPIP communication between nodescommunication between nodes

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Integration AdvantageIntegration AdvantageIntegration AdvantageIntegration Advantage

- Integrated Operation

– Any data from BPCS or SIS on graphics

- Integrated Engineering

- One tool with separate BPCS/SIS User profile

- Integrated Diagnostics

- Integrated Alarms and Events

– One system clock, one Event Chronicle

- Separated Control & Safety

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TRADITIONAL all TRADITIONAL all DiscretesDiscretes via SIS IOvia SIS IOTRADITIONAL all TRADITIONAL all DiscretesDiscretes via SIS IOvia SIS IO

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MODBUS comms

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MAXIMIZE BPCS MAXIMIZE BPCS –– SIS IntegrationSIS Integrationcreates Commercial Advantagecreates Commercial AdvantageMAXIMIZE BPCS MAXIMIZE BPCS –– SIS IntegrationSIS Integrationcreates Commercial Advantagecreates Commercial Advantage

SYSTEM comms

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Electronic Marshalling Solution Electronic Marshalling Solution Electronic Marshalling Solution Electronic Marshalling Solution - 22 channel types for BPCS, high voltage/low

voltage and Intrinsically Safe

- 20 channel types for SIS, high voltage/low voltage and Intrinsically Safe

- Marshalling requirement included

– fuse, knife disconnect, testing points, led status, signal conditioning, high current relay, (IS) isolation

42 types©©

Electronic Marshalling InstallationElectronic Marshalling InstallationElectronic Marshalling InstallationElectronic Marshalling Installation- Ex Zone 2 certified

- -40 to +70 degC

- ISA-S71.04-1985 Class G3

- Marine certification

- Only 20 cm build-in depth, DIN rail

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Electronic Marshalling 19inch Electronic Marshalling 19inch mounting for Migrations in cabinetsmounting for Migrations in cabinetsElectronic Marshalling 19inch Electronic Marshalling 19inch mounting for Migrations in cabinetsmounting for Migrations in cabinets

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BPCS Migrations SIS Migrations

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MigrationsMigrations in the Heavy in the Heavy ProcessProcess IndustryIndustryMigrationsMigrations in the Heavy in the Heavy ProcessProcess IndustryIndustry

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DCS Migration CriteriaDCS Migration CriteriaDCS Migration CriteriaDCS Migration Criteria

- Minimal process shutdown

- Smooth transition for operation personnel

- Save transition

- Spread of investment over multiple years

- Preserve the field cabling, avoid individual loop test

- Finally replacing all the operation consoles, the controllers and IO

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WHAT needs to be done?WHAT needs to be done?WHAT needs to be done?WHAT needs to be done?

Field DevicesField Devices

Plant AreasPlant AreasRack RoomRack Room

Control RoomControl RoomMaintenance ShopMaintenance Shop

Control NetworkControl Network

Plant NetworkPlant Network

Add Add // Replace Replace InstrumentsInstruments

Junction Box Junction Box LocationsLocations

Integrity of Integrity of CablesCables, , TraysTrays, , Conduit Conduit etc.etc.

Wiring Wiring PhilosophyPhilosophy

Application Application ComplexityComplexity

Network Network InfrastructureInfrastructure

Operating Operating StandardsStandards

Training Training RequirementsRequirements

Historians Historians & & 3rd 3rd party party

connectivityconnectivity

Production Production Management Management

& & ERP ERP IntegrationIntegration

UnderUnder--utilized utilized Smart InstrumentsSmart Instruments

AvailableAvailable && AccurateAccurateDocumentationDocumentation

“Clean” Areas“Clean” Areas

Leave PLCs in Leave PLCs in Place Place or or Move Move to to

New SystemNew System

Real Real Estate Estate CConstraintsonstraints

100% 100% Accurate Accurate I/O I/O

CountCount

FJBsFJBs

Maintenance Maintenance PracticesPractices

Power Power & & GroundingGrounding

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Emerson Emerson Modernization ProgramsModernization ProgramsEmerson Emerson Modernization ProgramsModernization Programs

- “Emerson has developed a flexible approach to the migration of their own and competitor legacy systems.”

- “One key advantage that Emerson has, which many of its competitors do not, is its expertise in field instrumentation, control valves, fieldbus implementation, and wireless implementation.”

- “This is especially crucial in hot cutover projects where not only the system, but also the instruments and valves were being changed over.”

www.emersonprocess.com/Modernizationwww.emersonprocess.com/Modernization HOW ??HOW ??

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Migration in 2 or 3 phasesMigration in 2 or 3 phasesMigration in 2 or 3 phasesMigration in 2 or 3 phases- System components have different life cycles

- Separate the risk for the application from the physical electrical connection risk over two steps

- Distribute the required process shutdown over several planned stops

- Financial spread over multiple years

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Emerson’s Migration ProgramEmerson’s Migration ProgramEmerson’s Migration ProgramEmerson’s Migration Program

- Phased migration

- Preserve investments

- Minimal process shutdown

- Avoiding obsolescence

- Include improvements

- Improved control will improve output

- Involve Emerson services to minimize risk

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Legacy DCS Migration MethodsLegacy DCS Migration MethodsLegacy DCS Migration MethodsLegacy DCS Migration Methods

- One step, all-at-once

- Horizontally, layer-by-layer

- Vertically, process unit-by-unit

- L shape, Horizontal + Vertical

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Horizontal Legacy DCS Migration method Horizontal Legacy DCS Migration method step 1 HMI replacementstep 1 HMI replacementHorizontal Legacy DCS Migration method Horizontal Legacy DCS Migration method step 1 HMI replacementstep 1 HMI replacement

IO cards

HMIStation

HMIStation

HMIStation

ConfigStation

TerminationPanel

IO cards

TerminationPanel

IO cards

TerminationPanel

DataServer

Controllers Controllers Controllers

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Horizontal MethodHorizontal MethodHorizontal MethodHorizontal MethodADVANTAGE

- Smooth method for Operators, no mix of two systems.

- Parallel and/or fall back operation

- One discipline per step, separate graphics, control language and electrical risks

- Short switchover times needed

DISADVANTAGE

- Intermediate equipment and services that are replaced in the next steps

- More equipment needed

- Hybrid system service needed for step 1

- Performance Legacy DataServer

- No improvements during step 1

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Vertical Legacy DCS Migration method Vertical Legacy DCS Migration method step 1 First process unit replacementstep 1 First process unit replacementVertical Legacy DCS Migration method Vertical Legacy DCS Migration method step 1 First process unit replacementstep 1 First process unit replacement

IO cards

HMIStation

HMIStation

HMIStation

ConfigStation

TerminationPanel

IO cards

TerminationPanel

IO cards

TerminationPanel

ConfigStation

Controllers Controllers Controllers

Vertical MethodVertical MethodVertical MethodVertical MethodADVANTAGE

- Limited risks per process unit only for graphics conversion, control language and electrical risks

- No extra project resources needed

- Direct improvements possible per unit

- Switchover at planned unit stops

DISADVANTAGE

- Two system HMIs in one control room, risk for operator mistakes

- System service needed for both systems

- Intermediate equipment for data exchange

- Only possible for non-interrelated units

- Detailed research needed for data interlocks ©©

WhatWhat is the Best is the Best MigrationMigration MethodMethod ??WhatWhat is the Best is the Best MigrationMigration MethodMethod ??

- Depends on planned shutdown period of the plant

- Depends on foreseen transition period

- Depends on acceptable risk

- Depends on resourses

- Depends on system size

- Depends on space for new cabinets and logistics

- Depends on need for improvements

ItIt all all dependsdepends

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DCS DCS MigrationsMigrations ProjectsProjectsDCS DCS MigrationsMigrations ProjectsProjectsEXISTING PROJECTSEXISTING PROJECTS RECENT PROJECTSRECENT PROJECTS

NewshamNewsham

Quad 204Quad 204Clair RidgeClair Ridge

SolanSolan

DagnyDagny

VisundVisund

ETAPETAP

Martin Martin LingeLinge

AndrewAndrew

CleetonCleeton

North North CormorantCormorant

Forties CharlieForties CharlieForties EchoForties Echo

NinianNinian Central/ North/ SouthCentral/ North/ SouthMurchisonMurchisonHeatherHeather

ThistleThistle

GryphonGryphon

BalmoralBalmoral

AlwynAlwynDunbarDunbar

West Sole AlphaWest Sole Alpha

North Sea Automation & Safety SystemNorth Sea Automation & Safety SystemNorth Sea Automation & Safety SystemNorth Sea Automation & Safety System

■■ AndrewAndrew■■ CleetonCleeton■■ NewshamNewsham■■ West Sole AlphaWest Sole Alpha

■■ SolanSolan

■■ Martin Martin LingeLinge

■■ North CormorantNorth Cormorant

■■ Forties CharlieForties Charlie■■ Forties EchoForties Echo

■■ Clair RidgeClair Ridge■■ ETAPETAP■■ QUAD 204QUAD 204

■■ DagnyDagny■■ VisundVisund

■■ NinianNinian Central/N/SCentral/N/S■■ MurchisonMurchison

■■ HeatherHeather■■ ThistleThistle

■■ Gryphon FPSOGryphon FPSO

■■ BalmoralBalmoral

■■ AlwynAlwyn■■ DunbarDunbar

Device Signal Tag (DST) = 140,000Device Signal Tag (DST) = 140,000

TOTAL $167MTOTAL $167M