atanas anev simplicity of controllers migration june …€¦ · 1996 –fsc integrated in tps /...

Unified Control Environment with EHPM Solutions

SIMPLICITY OF CONTROLLERS MIGRATIONAtanas Anev

June 2016

© 2016 by Honeywell International Inc. All rights reserved.

Delivering continuous

evolution for

40+ years

Honeywell Evolution Vision

Committed to Protecting Your Automation Investments

• Keep your reliable system running longer with different modernization options

• Protect intellectual property and capital investments

• Provide services support forupgrade to the new technology


1983 – TDC 3000 Universal Station

Technology Development in the Past – Summary

1988 – Process Manager

1996 – FSC integrated in TPS / TPN

2004 – Experion Station TPS

2007 – C300 and SM integrated in Experion PKS

1975 – TDC 2000

Classic Technology

21th CenturyTechnology

2010 – Unified HMI using Experion PKS

2013 – Ethernet based EUCN and EHPM


Unified Control Environment Benefits

Support Longevity and Improved Plant Performance

• Expansions with controllers of choice

• Replication of Control functions

• Replication of applications and HMI

Process ExpansionEfficiency

Up to 50% reduction in engineering cost

• Better diagnostics

• Reduced maintenance

• Skilled labor availability

Maintenance Efficiency

Maintenance cost reduction >5% with

modernization

Sustainability

• Keeps your plant running longer

• Protects your Intellectual property (IP)

• Protects your CAPEX investments

• Utilize skills / resources

IP, CAPEX life extension to 2035


Expansions and One-Time UCN Upgrade Solution

LCN

UCN

C300

NIM

HM/AM

ACE

ESV-T

(H)PM

FSC

Triconex

US

PCUS

GUS

Orion EST

SM

EUCNENIM

EHPM

EHPM Solutions Phase 1First Release in 2013

FTE

TPN/EPKS Control Networks as of Today

LM


FTE infrastructure engineering and setup

• FTE cables installation

• Level 2 switches installation

• CF9 firewalls Installation

Preparation for Modernization


What is new: Simplified Migration Approach

The Honeywell solution

• Step-wise UCN controllers upgrade

• TRUE on-process infrastructure setup

• TRUE on-process HPM-EHPM upgrade

• No changes - control, applications, HMI

• Coax <-> FTE devices peer-to-peer communication on the hybrid UCN

• The Best Control Network Modernization We Have Ever MadeThe Best Control Network Modernization We Have Ever Made

Addressed Customer needs

• Investment Linearity

• Investment planning flexibility

• Eliminate process downtime

• Minimized engineering effort

• Minimized upgrade/expansion risks


Step 0 – Initial situation

LCN

UCN

HM/AM

ACE

ESV-T

Two control networks – Common HMI

(H)PM

FSC

Triconex

US

PCUS

GUS

Orion EST

SM

FTE

NIM


Step 1 – Setup of Hybrid UCN (NIM to ENB upgrade)

LCN

UCN

HM/AM

ACE

ESV-T

(H)PM

FSC

Triconex

US

PCUS

GUS

Orion EST

SM

EUCN

FTE

ENB

C300

OPM & step-wise upgrades using ENBPlanned 4Q2016 – ENB (Enhanced Network Bridge)

TPN686.1; EPKS R432.1


• Create a back-up – checkpoint

• Power down – secondary NIM

• Upgrade the hardware

o Select 3 slot position

o Setup FTE index, UCN address

o Connect FTE cables

• Power-up/Load secondary

• Power down – primary NIM


• Power-up/Load primary

• Upgrade - completed

TRUE On-process Upgrade : NIM to ENB


Primary NIM to ENB Upgrade

Front View

Rear View

ENIM node 17 - EUCN 4

ENB node 30 – (E)UCN 10

UCN 10coax

EUCN 10FTE

ENB node 30 (E)UCN 10

ENIM node 17EUCN 4


Step 2 – On-process HPM to EHPM upgrades

Reduced Downtime by TRUE On-Process HPM-EHPM Upgrades

LCN

UCN

HM/AM

ACE

ESV-T

HPM

FSC

Triconex

US

PCUS

GUS

Orion EST

SM

EUCN

FTE

ENB

EHPM

C300

HPM to EHPM upgradePlanned 4Q2016 – TRUE On-Process Upgrade

Retain peer-to-peer communication



• Power down – secondary HPM


o Setup FTE index, UCN address

o Replace hardware


• Power-up/Load secondary

• Power down – primary HPM


• Power-up/Load primary


TRUE On-process Upgrade Steps: HPM to EHPM


Step 3 – Upgrade FSC controllers to SM on EUCN

No Application Changes for FSC - SM on EUCN Upgrades

LCN

UCN

HM/AM

ACE

ESV-T

FSC

Triconex

US

PCUS

GUS

Orion EST

SM

EUCN

FTE

ENB

EHPM

SM

C300

FSC to SM upgradePlanned 3Q2016 - Off-Process Upgrade SM R160.2

TUV approved migration tools



• Upgrade FSC software to R800

• Transition FSC software to SM

• Power down the cabinet

• Execute hardware changes

o Replace card files

o Install SM Central Parts


• Power-up SM

• Install applications

• Reload Checkpoint


Off-process upgrade steps: FSC to SM on EUCN

TÜV Approved

Verification


Step 4 –Triconex-SMM to Triconex-TCMI on EUCN upgrade

No TPS Applications and Displays Changes

LCN

UCN

HM/AM

ACE

ESV-T

Triconex

US

PCUS

GUS

Orion EST

SM

EUCN

FTE

ENB

EHPM

SM

TCMITriconex

C300

Triconex-SMM to Triconex-TCMI upgradePlanned end 2017 - Off-Process Upgrade TPN R687



• Upgrade Triconex to V10.3 or later & include TCM module

• Execute application changes on Triconex system

• Install Honeywell TCMI

• Power down Triconex

• Execute hardware changes

o Install TCM card

o Connect TCM-TCMI cables

• Power-up Triconex system

• Power up TCMI and Checkpoint load


Off-process Upgrade steps to Triconex-TCMI

TCMI

Triconex


Step 5 – ENB to ENIM Changeover

Step-wise control network upgrade completion

LCN

HM/AM

ACE

ESV-T

Triconex

US

PCUS

GUS

Orion EST

SM

EUCN

FTE

EHPM

SM

TCMI

ENIM

ENB to ENIM ChangeoverDisconnect coax cables



• Power down secondary ENB

• Disconnect UCN coax cable

• Remove EPNI and EPNI IO boards

• Power-up/load secondary – ENB becomes ENIM

• Power down primary ENB

• Disconnect UCN coax cable

• Remove EPNI and EPNI IO boards

• Power-up/load Primary – ENB becomes ENIM

• Changeover - completed

On-process ENB to ENIM Changeover


Additional Benefits from Simplified Migration

Reduced Risk and Investments Savings

• Investment linearity

• Step-wise incremental upgrades

• On-process changes

• Changes during shutdown

Automation Planning

Up to 80% automation planning accuracy

improvement

• No changes in control, applications, HMI

• Independence from ageing workforce knowledge

• Minimal engineering / training requirements

Modernization Investment

Total upgrade investment reduction larger than 25%

Production Downtime

• TRUE On-Process initial setup

• TRUE On-Process HPM to EHPM upgrade

• On-Process change to the final setup

Reduce up to 30% of production downtime for

migration activities


Information for Customers

Honeywellprocess.com

https://www.honeywellprocess.com/en-US/explore/products/control-monitoring-and-safety-systems/integrated-control-and-safety-systems/honeywell-upgrades/Pages/tps-tdc-experion-pks-control-unification.aspx

atanas anev simplicity of controllers migration june …€¦ · 1996 –fsc integrated in tps /...

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