migrating your legacy dcs system to plantpax

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Migrating Your DCS to PlantPAx® Mike Vernak – Program Manager Process Marketing

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

Phased Migration or Rip and Replace

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

Success Story

How We Can Help


PlantPAx – It’s a Modern DCS

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It’s a process automation system that gives you everything you want in a world-class, contemporary DCS plus. . . Plant-wide control capabilities Open, flexible architecture Integrated control, power, safety, and information Support by a global network of local experts


Agenda




Success Story

How We Can Help


Global DCS Migration Market Outlook

65B worth of existing Process Automation systems nearing end of life 12B are 25 years or older

• End-User Challenges • Financial Justification (Economics) • Limited Downtime (JIT Inventory strategies) • Loss of Technical resources • Future road mapping (What? When?)

• End-User Persona • Risk Averse • System/Application Centric


End-User Challenges: Financial Justification – TCO vs Benefit Analysis

- HW, SW, networks (multi-systems PLC, drives, DCS) - Engineering - Simulation - Commissioning/decommissioning - Support contracts - Energy - Spare parts (multi- systems)

- Floor space - Training - Operator, Maint, IT - Upgrade, expansion - Off-spec product - EPA Compliance - Un-planned downtime - Obsolescence planning - Consulting

Typical Total Lifecycle Costs Typical Benefits of a DCS Migration - Enhanced optimization capabilities - Reduced life-cycle costs - Increase yield and quality - Decrease product variability - Digital Bus enabled - More data – faster decision making - Easier integration with 3rd party (OEMs, ERP, MES, etc) - PWC scalable (10 to 10K I/O) - Integrated power

End-users require high value upgrades to help justify a DCS migration


Where We are Engaged…Industries

Metals W/Wastewater Mining Specialty Chem Power Oil and Gas


Agenda




Success Story

How We Can Help


DCS Migration and Modernization Solutions

Yes Yes Yes Yes No Yes Yes Yes Yes No Yes No Yes Yes

Partner No No Yes Yes No Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes No Yes

Partner Yes Yes Yes No No Yes Yes Yes Yes Yes No No Yes

Partner No No Yes No No Yes SSB No No Yes TRIO I/O No Yes SSB Yes Yes No No No Yes No Yes Yes No No No Yes N/A N/A N/A N/A N/A N/A Yes

Bailey NET90/INFI90

Honeywell IPC Honeywell TDC/TPS

Moore APACS Fisher PROVOX

Others

Rosemount RS3 Foxboro I/A Westinghouse WDPF Taylor MOD300 Emerson DeltaV Yokogawa mXL


OPC Servers

Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 10

• Commercially available, field proven • For use in architectures using “Whitebox”

PCs, or SAM’s – XP based PC in a ’56 rack • Can be loaded directly on FactoryTalk®

View Server


Integrated Gateway’s

HDL

Ethernet

PROVOX Data Highway

Benefits Peer-to-peer communication Increases performance Same environmental specs as ControlLogix® system ControlLogix controller is data repository Integrated solution Optimized data server


Dedicated Interfaces – RA56-cATM-BLY90 (for Bailey)

CIU/ICI

Serial

Bailey Plant Loop

Benefits Peer-to-peer communication Increases performance Same environmental specs

as ControlLogix system ControlLogix controller is

data repository Data is native to

FactoryTalk® applications Integrated solution Optimized data server


SX010UCN ENet

UCN network

Dedicated Honeywell UCN Gateway – Using UCN Interface – SX101UCN

Benefits Peer-to-peer communication Increases performance ControlLogix controller is data repository Data is native to FactoryTalk applications Integrated solution Optimized data server

Releases in July 2014


Database Conversion Tools

Converts Legacy DCS DB tags to FactoryTalk View OPC tags or CLX tags

Used in conjunction with OPC Servers, (whitebox) PC’s, or the Oldi SAM


PROVOX I/O Scanner – CLX-PVX module from ProSoft

PROVOX Serial I/O network

PROVOX Series10 or Series20 I/O

Benefits Operates in two modes – shadow and scanner Retains legacy I/O – significantly reducing front-end migration costs Fast and row risk legacy controller cutover Can be deployed in redundant configurations Supported by TechConnectSM


APACS I/O Scanner – CLX-APX module from ProSoft

I/O bus

Remote Modulrac

Benefits Operates in two modes – shadow and scanner Retains legacy I/O – significantly reducing front-end migration costs Fast and row risk legacy controller cutover Can be deployed in redundant configurations Supported by TechConnect

Releases in July

2014


Custom Cable Solutions


Foxboro I/A DCS Migration – Custom Cable Solutions for FBM100 I/O

New Release for 2013


Agenda




Success Story

How We Can Help


DCS Migration – Phased Approach

Phase I – HMI Migration Phase II – Interoperate Phase

Phase III – Controller and I/O Migration

Remove the least supported component of the Legacy System first – the HMI consoles

Interoperate new PAx controllers – leveraging the new HMI

Remove the Legacy controllers and, or I/O – leveraging the I/O Scanners or custom cabling solutions

Image courtesy of Evans Consoles


Legacy DCS Migration – What We Need from the Customer

Exported console database – need the .dbf, .txt, .csv, or other files

Hardcopy printouts of the legacy graphics

Actual I/O counts and I/O module types

Legacy controller configuration hardcopy printouts

Existing loop descriptions and loop drawings

Existing P&ID drawings

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Legacy DCS Migration – What We Need from the Customer

We interview: Operators for their opinions and comments on current system operation – and how they control their processes Maintenance Personnel to understand how they troubleshoot and maintain the current system Systems Engineering/Plant Engineering to understand what they expect from their new process automation system Plant Managers to understand their production schedules, challenges, and how PlantPAx can improve production


Plant Loop or Infi Loop

TU TU

PCU 1 PCU 2

CIU CIU

Bailey EWS

CIU

OIS Op Station 2

Bailey Net90 / Infi90 Existing Architecture

OIS Op Station 1



TU TU

PCU 1 PCU 2

CIU CIU

Bailey EWS

CIU

OIS Op Station 2

Redundant Servers

Ethernet

Op Station 1 RA EWS Op Station 2

Bailey Net90 / Infi90 Migration – Phase 1

Bailey Gateway

OIS Op Station 1



TU

PCU 1 PCU 2

CIU CIU

Bailey EWS

Redundant Servers

Ethernet


Bailey Net90 / Infi90 Migration – Phase 2

Bailey Gateway

CLX 1

TU


MTA MTA

MTA MTA

MTA

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APACS Migration – Phase 2 Op Station 1

Ethernet

Redundant Servers RA EWS Op Station 2

MTA

MODULRAC 2

Modulbus

ProcessSuite Client/Server Node

ProcessSuite Development Node

Ethernet

APACS Gateway

IEM

Ethernet

CLX w/APACS I/O Scanner

MODULRAC 1


MTA MTA

MTA MTA

MTA

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APACS Migration – Phase 3 Op Station 1

Ethernet

Redundant Servers RA EWS Op Station 2

MTA

Modulbus

ProcessSuite Client/Server Node

ProcessSuite Development Node

Ethernet

APACS Gateway

IEM

Ethernet

CLX w/APACS I/O Scanner

MODULRAC 2

CLX 2


Rip and Replace of a Foxboro I/A DCS

Nodebus

Fieldbus

CP30/40/60 CP30/40/60

FBM’s FBM’s

WP51 Console 1

WP51 Console 2

AW51 EWS

Redundant Servers

Ethernet


CLX 1 CLX 2


Comparison of the Conversion Strategies

Rip and Replace Does require extended shutdown

for entire project Requires capital expense $

approval (full system) Can be funded with maintenance $

(vertical slice or by area) Is considered high risk to customer Can replace entire system in

weeks (lower TCO) Requires less legacy DCS

expertise for delivery engineering team

Cannot be easily switched back to legacy system

Phased Does not require shutdown for HMI

replacement Can be funded with maintenance $ Is considered low risk to customer Can be easily switched back to the

legacy system as part of a contingency plan

Requires more legacy DCS expertise for delivery engineering team

Can take multiple years to migrate entire system (higher TCO)


Agenda




Success Story

How We Can Help


Global Solutions – Honeywell TDC conversion

Industry/application of the migration project Tissue Manufacturing

Wet and Dry end controls Legacy System(s) converted

Honeywell TDC3000 DCS High Performance Process Manager CL (Honeywell Control Language) code Code originally written 20+ years ago Many obsolete code sections that were not disabled or

removed over time Allen Bradley PLC-5®

1771 I/O was to stay

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Why Migrate?

Obsolescence and high cost of hardware

Difficulty in obtaining spare parts.

High cost of Honeywell system support.

Skills and training of internal support team.

Standardization of controls.

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Migration Project Plan

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General Requirements Control platform standardization Common HMI for tissue manufacturing

process Reverse engineer and recreate

Hardware All TDC I/O upgraded to 1756 I/O 19” Subpanels IFMs replaced the FTAs DHRIO to access 1771 I/O DHRIO to 17 process VFDs ControlLogix L7x series


Migration Project Plan

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Deploy PlantPAx using a Virtual Server system

Used screen captures of HMI to reverse engineer and duplicate in FactoryTalk

View SE

Convert stand alone FactoryTalk View applications and merged into distributed

application

Use PlantPAx architecture with Rockwell Automation GEMS process objects

Convert the CL code to SFCs

Convert PLC-5 logic and merged with recreated Honeywell logic

Develop touchscreen based graphics


Risk Mitigation Plan

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Project Manager and Lead Engineer consistent throughout project.

Regular communications/reviews with key stakeholders

Customer contracted a system expert to consult (retired employee)

Testing

Off-line simulation testing on site at the plant.

Interface testing with OEM equipment suppliers.

Integrated commissioning effort with the customer’s engineering team and plant maintenance and operations groups


Migration Project Execution

6 month project

Parallel project with 5 other projects

10 resources total (4 core members)

Local Rockwell Automation Field Engineering assisted in startup and support

Used tools to assist with converting logic and to mine data values from old code.

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Lessons Learned What would you do the same or different on the next migration project?

Spend more time upfront defining and validating migration standards/approach

Invest in creating a Functional Spec

Direct conversion (recreate what is there) often does not result in the most efficient

code given the advantages of new platforms

For CL code consider structured text vs SFCs where appropriate

Look for behind the scenes scripting

embedded logic in the Honeywell HMI graphics that had to be recreated.

Appropriate training is important for all stakeholders and is often underestimated by

the end user.

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Results

Project started up on time and on budget.

Machine performance has set production records.

Standardization of controls: Replaced both PLC-5 and TDC systems and created a common HMI application for process control on the machine with a PlantPAx system.

The customer is now looking to take advantage of the PlantPAx platform to expand capabilities in recipe control, alarm management, and root cause analysis.

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Agenda




Success Story

How We Can Help


Process Tech Consultants (GPTC’s) Primary task is to work with delivery partners to assist in the technology

adoption of Rockwell Automation process control to the application

Main Customer Types Large End Users – Consult work with corporate engineers to establish

standard for operations. Solution Provider – Train on the best practices of using PlantPAx A&E – Develop specifications for these firms to establish the Rockwell

Automation platform Process OEMs – Work with the OEM to re-write their application on a

Rockwell Platform

DCS Migrations – Help customers understand how we can migrate from legacy DCS to Rockwell

Work across global regions and key customers to assist in project implementation (A&E, contractor, SI, and end user)


Global Solutions Bringing You a World of Experience

Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 41

Combining technology &

application knowledge All major industries Best practices from multiple

industries

Domain Expertise

Manage projects that span multiple geographies

Standard business & project processes

The right team for your project from our worldwide talent

Global Execution

Helping you exceed your business goals.

Information | Process | Discrete Automation Power & Motion | Sustainable Production | Technology Migration | Hardware Integration

80 Countries I 20 Languages I 2500 + employees Single point of contact I Average 13+ Years Experience I

|

Based on PMI ® PMBOK®

Certified project managers Repeatable, measurable,

auditable Risk Management

Project Management


Services & Support Global Support. Local Address. Peace of Mind.

Optimize Plant Assets

Maximize Productivity

Improve Financial

Performance

80 Countries I 20 Languages I 6 Remote Support Centers I 10 Remanufacturing Depots I 9 Exchange Hubs I Average 13+ Years Experience

Meet Your Everyday Technical Needs Online & Phone Support

Training Services OnSite Services Repair Services

Maximize Your Automation Investment MRO Asset Management

Safety Services Energy Services

Network & Security Services Legacy System Migration Plans

Legacy System Migration Turn-Key Projects


Partner Ecosystem

Business Enterprise Partners …Strategic Alliances with companies like Cisco Systems,

Endress+Hauser, and Microsoft

Product and Technology Partners …Over 1000 products from over 100 companies worldwide

help to extend our technology into adjacent areas

Sales and Solutions Partners …Approximately 320 Distributors and over

100 Solution Providers worldwide for local support

A large global ecosystem for solutions and support of your Rockwell Automation installed base


Who should you call for help?

• Your local Distributor Sales representative • Your local Rockwell Automation Sales representative

• Your local NA District or Regional Process Sales Leader • Your local Systems Integrator or Solution Partner

[email protected]


White Papers Published…

DCS Migration White Papers available on Literature Library: * Justification for a Legacy Control System Migration PROCES-WP005A-EN-P * DCS Migration Strategy and Project Implementation PROCES-WP006A-EN-P * Optimization after Migration PROCES-WP008A-EN-P http://Literature.rockwellautomation.com > Support > Product Resources >

http://literature.rockwellautomation.com/


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migrating your legacy dcs system to plantpax

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