Bailey’s Console Modernization to FactoryTalk View

José Palazuelos – Branch Manager

ECN Automation, Inc.4600 E Washington Boulevard

Phoenix, Arizona 85034

520-342-8227 jpalazuelos@ecnautomation.com

www.ecnautomation.com

• Current situation

• Benefits of migrating to FactoryTalk View

• How the migration is done

• On-site demo

• Success stories

• Next steps

Overview

Current Situation

• Infi 90 Consoles are now Obsolete, and rarely supported

• Bailey’s users are migrating into a new HMI platform to avoid risks of loosing their operator stations.

• Factory Talk View from Rockwell has successfully replaced Bailey’s consoles with important competitive advantages

• Unsupported Operating SystemThe operating system used by PCView Stations is QNX, an obsolete and unsupported platform based on UNIX.

Why Migrate?

• Lack of Spare and Replacement PartsThe Mother Boards, the communication cards and the hardware required by the PCView is now obsolete making it nearly impossible to find replacement parts.

Why Migrate? (continued)

• Limited Data StorageThe hard drives for this console use older hardware technology that highly constrains the functionality and the ability for you to optimize the plant.

Why Migrate? (continued)

• Hard to get Support

System integrators are much less familiar with this system and will stop supporting them since they are using new control platforms. Trained personnel in the Bailey’s system are harder (and harder) to find.

Why Migrate? (continued)

Summary of Benefits

•Station with New Hardware. Support •Latest HMI Technology. Service

• Flexibility . Tailor Made

• Expandable . Opportunities

•Maintenance & Operation. Simplicity

• StationNew hardware, easy to find and replace, low ownership cost. No more floppy disks!

• Latest HMI Technology• FactoryTalk View can use global ojects, this objects can be used trough all the development of the application reducing dramatically the development time.

• FT View is an open system that can communicate with different vendors and control systems and it runs under Windows operative system that is widely supported.

Benefits of Migrating

• Flexibility

FactoryTalk View is customizable so that we can create a tailor made application for our clients.

• Expandable & Upgradable

Using the FT View Platform for the operator stations, allows working in a distributed system

Benefits of Migrating (continued)

• Maintenance

It takes less than 3 hours to install and start running a new station anywhere in the plant without the need of specialized knowledge or further development once the application is completed.

• Transparent to the Operator

We match all the functionality of the Bailey system, so the operator has a control screen that is already familiar with.

Benefits of Migrating (continued)

• Avoid Plant “Blindness”

FT View can operate in a distributed redundant system, or stand alone stations. Remaining with Bailey’s stations represents a risk factor if they get damaged and start loosing control capabilities.

• Communication Network

Communication between stations and servers are trough Ethernet which is a well supported, reliable and easy to use network.

Benefits of Migrating (continued)

Step 1: We extract the application into a TTG File. This file has all the windows, symbols, faceplates and Tag database of the application.

Step 2: Once the application is converted , we will create those windows, symbols and faceplates in a Windows compatible format. (See next slide)

Upgrading

Step 3: We proceed and draw the windows, animate the symbols and import the tag data base and alarms into Factory Talk.

All of these steps are performed Offline – No downtime required

Bailey System

Overview diagram of how OPC90 Server connects ABB Bailey systems

Replacement costs are lower than purchasing new Bailey consoles. Additional savings can be realized when replacing ABB Bailey 5000 tag OIU, MCS or OIS by re-using the CIU already built into these console types.

Ethernet

Original displays through HyperView

Graphic Displays

•Process control screens updated

We recreate the screens almost identically, so that the operator does not needs to be retrained in the usage of the new system. This reduces the learning curve to practically none, saving time and reducing any possible control error.

Upgrading (continued)

•Equipment Drawings

Once that an equipment has been redraw we can use it over and over for the rest of the plant reducing the development cost.

Upgrading (continued)

•Faceplates

By using faceplates, we can replace the bailey functionality 100 %.

MSDD Block Bailey FactoryTalk

Upgrading (continued)

•Faceplates examples.

DCS o STN block Bailey FactoryTalk

Upgrading (continued)

•Faceplates ….

RMCB Block (instruction) Bailey FactoryTalk

Upgrading (continued)

•Functional Templates

• Multiple Popup

Upgrading (continued)

• System Status and Modules

•Functional Templates

Upgrading (continued)

Functional Templates

• Key Board control Access

Upgrading (continued)

• System Security

• Functional Templates

Upgrading (continued)

•Mexicana de Cobre, metallurgic facility “La Caridad” located in Nacozari, Sonora, México

• DCS Infi 90 Migration in 4 different areas with PCView, A total of 10 operator stations and controls

•10,000 I/O point system

Success Story Example

“ECN provided a solution for their system successfully leaving the client with the assurance that they are no longer in risk of losing their operator stations in case of malfunction”.

About ECN

Since 1991, ECN has been developing instrumentation and control systems for process control. Our specialty is the Mining Industry.

We have more than 400 projects developed and 19 Years of experience with clients in the United States & México.

Our Project Team is staffed by dozens of engineers with experience in project management, control engineering, PLC & HMI programming, plant data and instrumentation, control equipment and industrial controls. We are a consolidated, full-service team.

• We have an extensive project data base, which makes our programming approach more efficient and consistently value-adding.

About ECN (continued)

ECN can do the replacement of your stations to both optimize the value and not hinder current operations while the new systems are being installed. We have a long track record of success with over 400 projects in North America.

Contact us to replace the Bailey Station and provide a modern operating station that will allow you to better optimize the mine.

• ECN Automation Inc.

• Contact: José Palazuelos• Mobile 520 – 342 – 8227 • Email jpalazuelos@ecnautomation.com• www.ecnautomation.com

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