Yokogawa System Upgrade

Technical Capability

Our technical capabilities can make all the difference in helping you achieve a smooth migration process. We perform a smooth migration to minimize plant downtime and raise your operation rate, support the continued use of your valued application assets, achieve seamless connections to higher level systems and subsystems, and provide a virtual environment for operator training.

Connectivity

Connections to higher-level systems and subsystems are an important consideration in the distributed control system (DCS) migration process. The CENTUM VP supports a variety of interfaces (e.g. OPC, PROFIBUS-DP, FOUNDATION™ fieldbus, HART) in its standard configuration. With proprietary interfaces and interfaces that are no longer standard (e.g. GP-IB and BSC), junction/conversion equipment is required. Yokogawa works with you to provide an optimal system configuration and integration service, taking your system migration requirements and interface standardization trends into full consideration.

Connections to higher-level systems and subsystems

Operator Training

It is desirable for operators to get used to operating the new system before the system migration. CENTUM VP provides an advanced virtual test function for that purpose. This not only makes it possible to virtually operate the system via an HMI, it also tests the control logic before the new system begins to operate. The quality of user-defined applications/logic can also be improved with this function. For instance, the logic for an abnormal situation can be tested easily using the virtual test function.

Engineering Capability

Yokogawa has experience in more than 340 third party system migration projects. Yokogawa can serve as the main contractor, providing a turnkey legacy system migration solution.

Requirements of migration projects

• Time-critical
• Minimize plant downtime while maintaining safety
• Miniminize reinvestment in plant assets

Yokogawa's approach

Up-front Risk Management

To ensure accuracy, the I/O list generated from the loop drawings is cross-checked with the following:

• P&ID
• Marshalling drawings
• Database downloaded from the existing DCS system
• Junction box drawings 
• Cable schedule

A strong relationship based on mutual trust and respect is essential for dealing with any critical issues that are identified. The identification activities are carried out before/during/after the shutdown period. Critical cutover tasks are prepared, approved, and carried out together with the customer.

Hot Cutover / Cold Cutover

Yokogawa can effectively handle both hot and cold cutovers. For instance, a legacy system migration project including a central control room (CCR) renovation for a customer in the Middle East was accomplished in just 9 days. Originally 14 days had been scheduled for the shutdown. In addition to the 5 days that were saved through well-managed cutover work, 3 days were saved during the plant start-up phase. The completion of this project 8 days sooner than scheduled saved the customer US $6.7 million.

Conversion Tool for Legacy System Engineering Data

Software engineering information (e.g. tag numbers, units, ranges, comments, control schemes, alarm settings, tuning parameters, etc.) can be downloaded from an existing DCS system. The downloaded information can be then fed to the CENTUM VP using a conversion tool, saving considerable time and ensuring a reliable result.

Migration Engineering Workflow

Cost-effective Upgrade

Yokogawa has developed the necessary upgrade solutions so that your legacy Centum controllers and process interface units can be replaced with the newest CENTUM VP I/O and controllers, utilizing upgrade cards and adapter cables that connect to the existing terminal panels of your legacy system. No cabinets need to be rewired in the field, dramatically reducing process downtime. In fact, because of the compact design and the high density of the CENTUM VP I/O cards and controllers, fewer cabinets are required and space is freed up for other uses. We recognize that upgrading the controller and field hardware is only part of the risk management story.  User applications and operator graphics constitutes a major part of work that can be very time-consuming.  With most releases, the translation of control strategies and operator graphics happens automatically with 100% translation. Reports are generated to identify potential problem areas that need manual intervention or review.  This allows for significant risk reduction for your upgrade project.
 
Yokogawa ensures an efficient and secure upgrade of your legacy system to the CENTUM VP, leveraging its field-proven engineering capabilities.
 
Yokogawa has supplied these solutions to customers around the world. They are delighted with their new CENTUM VP systems and are benefiting from increased reliability, lower Total Cost of Ownership, and lower operating risk.

Cumulative cash flow for master plan

Basically, system migration should be regarded separately from ROI because it is a part of equipment maintenance. Our customers are now more focused on ensuring long-term survival by investing to increase productivity and seeking to minimize production losses. Similarly, customers are looking everywhere for ways to improve profits, even in system upgrade projects. Yokogawa believes that a system upgrade can be a very effective step forward in modernizing your plant, and offers a value-added system migration service to make this a reality.

The value-added upgrade process consists of the following phases: 

• Feasibility study that analyzes the gap between targeted and actual results, identifies bottlenecks, proposes practical countermeasures, and estimates the resulting improvement in profits 
• Implementation of system upgrade countermeasures 

Yokogawa's experienced specialists are involved in all phases of this process.

Study area / item		Analysis	Benefit
Innovative production system	MP	Production management center Integrated advanced control system  High efficiency operation	Yield improvement Loss recovery Energy saving Manpower reduction
Refinery modernization	MP	DCS Field instruments APC Consolidation of control rooms  Refinery information system	Yield improvement Loss recovery Energy saving Manpower reduction
Offsite modernization	FS	DCS Oil movement system Optimum blending control Automatic path selection and valve status monitoring system	Demurrage reduction Contamination reduction Reloading loss reduction Manpower reduction
Operation improvement	FS	Alarm/manipulation Operator workload Automation level	Manpower reduction Further safety operation
Advanced process control (APC)	FS	Multi-variable control Quality estimation Benefit/investment analysis	Yield improvement Energy saving Throughput up

Feasibility study (FS)/master plan (MP) for refining industry

Case Study - Yokogawa

Smurfit-Stone Container Corporation, USA

To generate the maximum return with a minimum of investment and ensure that customers remain competitive, Yokogawa is providing solutions for the migration of legacy CENTUM V, CENTUM-XL and μXL DCS systems to new production control systems that employ the latest technologies.

Success Stories

Panama City Mill
Control System Upgrade

• Smooth conversion of existing controls solely by customer
• Lowered cost of ownership 

General specification documents below are available at Yokogawa Plus. Please register to access these documents.

General Specifications:
CENTUM V and CENTUM-XL Migration to CENTUM CS 3000	GS 33Q06W30-31E
Migrating to CENTUM CS 3000 from CENTUM V or CENTUM-XL Operator Station	GS 33Q06Z81-31E
Migrating to CENTUM CS 3000 from mXL Operator Station	GS 33Q06Z82-31E
μXL Operator Station Migration Kit for CENTUM CS 3000 Entry Class	GS 33Q06Z83-31E

Phased Migration for the CENTUM V, CENTUM-XL

Phased migration for the CENTUM V, CENTUM-XL is a three-step upgrade method on a component basis, which reduces the required investment and manpower, and shortens the upgrade period.

Step 1: Upgrading of HMI

Upgrading of HMI brings in the latest HMI environment and network capability, surely one of the most important issues. 

Step 2: Upgrading of CPU of FCS

By utilizing the existing field wiring and I/O cards, the latest control functions are provided, while greatly improving performance and application capacity. 

Step3 : Upgrading of I/Os

Using existing field wiring, the latest I/Os are provided with full compatibility of functions, interface and cabinet layout. 

Phased Migration for the μXL

Phased migration for the μXL is a two-step upgrade method on a component basis, which reduces the required investment and manpower, and shortens the upgrade period.

Step1 : Upgrading of HMI

Upgrading of HMI brings in the latest HMI environment and network capability, surely one of the most important issues. 

Step2 : Upgrading of the control units

Using existing field wiring, the latest I/Os are provided with full compatibility of functions, interface and cabinet layout.