WIB seminar
How to benefit from a migration
M+W Process Automation
A Company of the M+W Group
15 March 2012
Doc. Vers.: 14
Agenda
 Introduction
 The speaker, the company
 Migration psychology
 Automation Master Plan
 Migration opportunities
 Reduce production cost
 Reduce maintenance cost
 Improve reliability
 Increase efficiency & ease of operations
 Safety & Explosion Protection
 Documentation
 Types of migrations
 Alternatives
 Life-time extension
 Virtualization
 Smart wiring concepts
 Points of attention in migrations
 Risk assessment
 Risk mitigation
 Key items in a migration




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Ensuring desired functionality
Migration concepts
Planning & project phasing
FAT / loop testing / start-up
Training
 Typical Cost distribution
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© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 14
Introduction
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
About the Speaker
• Stephan Hoste
4
•
Background in Engineering, 20y of experience in engineering & project
management on process automation projects
•
History of international automation projects for major industries
•
Managing Director of M+W Process Automation BE+NL since 1999
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© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Our Industries
Advanced Technology
Facilities
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Semiconductor
Flat Panel Display
Photovoltaics
Battery Cells
Life Science &
Chemicals
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Pharma & Biotech
Food & Nutrition
Consumer Care
Chemicals
Energy & Environment
Technologies
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Renewable Energy
Waste to Energy
Power Plants
Oil & Gas
High Tech
Infrastructure

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Science & Research
IT & Telecom
Space & Security
General Industries
Process Automation
 Chemicals
 Pharma & Biotech
 Food & Nutrition
 Automotive
 Semiconductor
 Oil & Gas, Paper
Products & Services
 Cleanroom Products
 Air Handling Units
 Contracting
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 Controlled Environments
 Technology Center
 Operation & Maintenance
© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 19
M+W Process Automation
as a Total Automation Solution Supplier
 Our core business is to
deliver total automation
solutions via in-house
resources
Control
Cabinet
Mounting
EquipmentDelivery
MES and ERP
Supplier
Support
Hotline
Equipment- Development
- Manufacturing
 Independent
 Multi-discipline
 Focused on project
and customer needs
Field EquipmentManufacturer
Installation
Product
Development
Support
SAP
Hotline
Manufacturing
and Business
Integration
Project
Application
(Software, Design)
24/7 Service
&
Hotline
Specification
Supply Management
Validation
Project
Application
(Software, Design)
Start-Up
Training
Robot
Programming
Project
Application
(Software, Design)
FS-PLC
Delivery
Consulting
Design
Basic and detail
Engineering
FS-PLC
- Development
- Manufacturing
DCS
Delivery
Project
Application
(Software, Design)
Hotline
Hotline
Support
DCS
- Development
- Manufacturing
Support
FS-PLC Manufacturer
DCS Manufacturer
Total Solution Supplier
© M+W Process Automation – A Company of the M+W Group
Company Data and Locations
Founding:
1986
Headquarters:
Management:
Ludwigshafen am Rhein
Franz Greisberger,
Henning Hammerstaedt
M+W Group
Group:
 Automation for the process industry
 Automation for the automotive and
manufacturing industry
 EPCM
 19 locations in Germany
Hamburg
Warsaw
Hanover
Wittenberg
Breda
Antwerp
Wavre
Wroclaw
Schwarzheide
Monheim
Bornheim
Krakow
Leuna
Nünchritz
Zwickau
Prague
Frankfurt/M.
Brno
Ludwigshafen
Neckarsulm
Ingolstadt
Sindelfingen
Burghausen
Biberach
Teufel Software GmbH Balgheim
Penzberg
Basel
Bratislava
Linz
Kufstein
 14 further locations in Europe

2 locations in China
Locations in Russia
Locations in China
Moscow
Nanjing
Shanghai
© M+W Process Automation – A Company of the M+W Group
Migration Psychology
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Migration Psychology
• Lifecycle management – the female touch
T = T0
9
T = T0 + 3 months
T = T0 + 6 months
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© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Automation Master Plan
Collect
Current State
- Systems & subsystems
- Infrastructure
- Resources
External influences
-
Strategic Objectives
Long Term Objectives
Economic changes
Automation Trends
Plan
Execute
Master Plan (10-15y)
- Plans & options to meet the
objectives
- Preferred way to meet the plan
(performance/cost ratio)
- Staged Deployment plan
- Infrastructure impact
- Cost estimates
- Risk assessment & mitigation
plan
Mid-term action Plan (1-3y)
- Short- term Objectives and
goals
- Business Intelligence
Requirements
- Staged implementation plan
- Budget estimate & cash flow
plan
- Resource plan
- Integration plan
Initiate of Automation
Projects
-
Feasibility study
Requirements Specifications
Purchase specifications
Design specifications
Procurement
Doc.-Vers.: 1
10
© M+W Process Automation – A Company of the M+W Group
Migration opportunities
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Opportunities to look for during a migration
•
Reduce production costs
• Control Room consolidation
• Energy rationalization (VSD’s, …)
•
Reduce Maintenance costs
• Resolve old work-arounds / quick solutions / old system deficiencies
• Review use of library & typical requirements
• MCC’s for reducing downtime
•
Reliability enhancement
• I/O Segregations on card level / CPU level
• Redundancy concepts
• Power supply concepts & UPS
• Shorter MTTR, longer MTBF
•
Time to clean out the garage…
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1
© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Opportunities to look for during a migration
•
Increasing efficiency and ease-of-operation
• Operator effectiveness - High Performance HMI
• Alarm Management Philosophy
• Batch optimization
• Improve grade changes
•
Safety Related issues
• Zoning issues
• Ex(i) calculations
•
Documentation update
• P&ID’s
• E&I documentation
• Functional Design Specifications (C&E, Interlocks, SFC’s)
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1
© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Typical Cost distribution
of migration projects
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Cost distribution of a system migration
(w/o external field changes)
•
System migration to a new DCS platform, no field wiring changes, no Batch plant
Source: ARC, March 2010, The-Control-System-Migration-Survival-Manual
Reference Project 1
Func. Specs
4%
FAT
3%
Reference Project 2
PM
4%
Training
2%
E&I Eng
12%
IBN
15%
Training
2%
DCS
Hardware
39%
DCS Eng
12%
DCS Eng
13%
Func.
Specs
6%
FAT
4%
PM
3%
IBN
6%
DCS
Hardware
39%
E&I Eng
13%
Cab Constr
& Mounting
7%
Training
3%
FAT IBN
2% 4%
Func Specs
PM
8%
6%
Cab
Constr &
Mounting
16%
E&I Eng
16%
DCS Hardware
34%
DCS Eng
18%
Cost Estimate based on
specific customer history
C&C&M
9%
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1
© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Conclusions
 Total Hardware cost = DCS system (including I/O) + cabinet mounting + wiring +
terminal boards + construction
 Functional specifications < 10% of project cost
 highest impact on functionality & maintainability
 No specifications = no baseline for FAT
 FAT, DCS Engineering, Commissioning = f(Functional Specifications)
 DCS system cost from 25 to 40%
 Engineering Labor Cost from 30 to 50%
(no batch process)
Source: ARC, March 2010, The-Control-System-Migration-Survival-Manual
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© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 14
Types of Migrations
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Types of migrations
Same vendor DCS
Big Bang
Different vendor DCS
Approach
- Not common since no installed
base protection
Approach
- Smaller systems, typically up to
1000 I/O in 5 to 10 days
- Larger systems (smart wiring), up to
4000 I/O in 1 to 5 days
Pro’s
- No complex intermediate solutions
- No extra/hidden maintenance/license costs
- Effective yet disruptive (shutdown required)
- Most cost effective solution when addressing the engineering issues
- Full migration cost as well as TCO are visible (CAPEX)
Beware
- Fall-back strategy
- Risk assessment
- Migration Tooling
- Cost spread may prevail over TCO
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© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Types of migrations
Same vendor DCS
Phased
Step-wise
Staged
…
Approach
- Typically HMI / Controllers / I/O in
separate phases
Different vendor DCS
Approach
- Process unit based migration
scenario
Pro’s
- Smaller project phases, so more manageable
Beware
- Comparative Pricing on TCO ?
Beware
- Result = SCADA system ?
- Leave obsolete equipment in place?
- Support from old vendor?
Beware
- 2 systems running in parallel (operator , licenses, training…)
- Migration Tooling
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1
© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Types of migrations
Different DCS System
Approach
- Common for HPI, Oil & Gas, Water
Treatment facilities with next-to-no
downtime
- Detailed step-wise cut-over
scenario
Hot cut-over
Pro’s
- No downtime
Beware
- Cost
- Space
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1
© M+W Process Automation – A Company ofDoc.-Vers.:
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Group
Alternatives
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Life-time extension
•
•
22
Spare Parts Management
Refurbishing and redeployment of decommissioned parts
1
© M+W Process Automation – A Company ofDoc.-Vers.:
the M+W
Group
Virtual system architecture
26
Bedienst
ations
InTouch
V10.0
Konverte
rA
Anlage
Visualisie
nbus
rung
Konvert
er A
Datenser
ver
LA
N
Konverte
rB
Visualisie
rung
Konverte
rC
Visualisie
rung
Konvert
er B
Konverte
r A-C
Nebenanl
agen
Konvert
er C
VPL
Visualisie
rung
Nebena
nlagen
Engineeri
ng
VPL
26
Thin
Clients
InTouch
V10.0
Terminal
+ 1 ES
bus
Bladesystem
LA
N
Storagesy
stem
Anlagen
bus
Konvert
er A
Konvert
er B
Konvert
er C
Nebena
nlagen
VPL
© M+W Process Automation – A Company of the M+W Group
Virtual system example
© M+W Process Automation – A Company of the M+W Group
Smart wiring Concepts
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Example, migration of an old Teleperm System
Step-by step build-over to new system
Step 1:
Step-by-step rewiring from the
old Teleperm to a New I/O panel
board
Existing I/O distribution
with system cables
Step 2:
Fuses & Lterminal blocks
here
Temporary
racks
Decommission the existing
Teleperm-racks
Build new I/O racks from
temporary racks into the existing
cabinets.
New I/O
distribution panel
Pre-fab System
cable on I/O plug
© M+W Process Automation – A Company of the M+W Group
Typical Cut-over strategy
Rebuild I/O from PLS/SPS simplified representation
Step 1:
Unmount
wiring
I/O layer
DCS/SPS
Existing
I/O-connector
OLD System
Sensors
Actors
Step 3:
Exchange System
cabinets and Hardware
components
Every I/O signal from the
OLD System ALT is rebuild
on I/O of the NEW System.
CPU +
I/O layer
Step 2:
Mount
wiring
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NEW System
© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 1
Alternative cut-over „swift-replug“
Basic Idea: Prepare for a cut-over with a flexible interface to
obtain a quick System Swap with a built-in fall-back strategy
 Proven in use on multiple occasions and on various OLD system
X to NEW system Y
 Minimum cutover time required during the actual shutdown
 New System hardware can supplied almost completely pre-wired
and tested
 If problems occur with the new system, there is a real fall-back
scenario
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© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 1
Alternative cut over „swift-replug“
Cut-over principle „swift-replug“, simplified representation
Existing
I/O terminals
Sensors
Actors
I/O
DCS/SIS
Step 1: Preparation Phase
Cable side of I/O connector is
being made ‚pluggable‘
OLD System
Sensors
Actors
I/O
DCS/SIS
OLD System
Step 2: Cut-over phase with
new DCS System Cabinets
a) Swap system cabinets
b) Hook-up the system cables
from the old system to the new
system.
Use of special system cables,
pre-wired and pre-tested can
also acommodate swift
transitions
I/O
DCS/SIS
New System
29
© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 1
Alternative cut-over „swift-replug“
Step 1: Install cable plugs in the existing System cabinets
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© M+W Process Automation – A Company of the M+W Group
Doc. Vers.: 1
Alternative cut-over „swift-replug“
Build new system cabinet(s)
Step 2: Swap System cabinets
Terminal Blocks for
new I/O cards
Imagine your Brand
New System Here
Electr. Fuses
Imagine your Brand
New System Here
Install I/O
distribution panel
Fall-back Strategy
31
© M+W Process Automation GmbH – A Company of the M+W Group
Doc. Vers.: 1
Migration Points of attention
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14
Preparation for a good Migration
Where are the Risks?
 Exceeding deadlines / violate milestones
 Incorrect software specifications
 Failures in software
 Hardware failures
Prototype
 Exceeding deadlines for switch over
Design
copy
 Unavailability of key personnel (both supplier & customer side)
Build
Test
FAT
Rework
Phase 1
Phase 2
© M+W Process Automation – A Company of the M+W Group
Preparation for a good Migration
Risk Mitigation
 Continuous risk management
 Prepare a Project- and a Quality plan for the project execution
 Plan the work, work the plan
 Use end-user know how supplier specialists in design phase
Prototype
 Carry over people from design to build/test of software
Design
copy
 100% HW and SW FAT
Build
 Use experienced partner for very short shut downs
Test
 Sound hardware migration concept
FAT
 Detailed switch over plan
 Fallback strategy (if any)
Rework
 Experienced installation people
 100% loop check
Phase 1
Phase 2
 Support of end-user specialists during all project phases
© M+W Process Automation – A Company of the M+W Group
Key items to address during a migration
Guarantee
the desired
functionality
Migration
concept
(E&I)
Phases of
the project
FAT of the
solution
Succesful
migration
of a DCS
System
Realisitc
Planning
Guiding
production
on start-up
Loop
testing and
Start-up
Training
© M+W Process Automation – A Company of the M+W Group
Thank you for your attention.
M+W Process Automation
A Company of the M+W Group
Doc. Vers.: 14