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Migrating Your Legacy DCS System to PlantPAx
 

Migrating Your Legacy DCS System to PlantPAx

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Are today's optimization and innovation demands hampered by your old process control system? Is support for your legacy DCS diminishing? This session will explore the advantages of migrating to the ...

Are today's optimization and innovation demands hampered by your old process control system? Is support for your legacy DCS diminishing? This session will explore the advantages of migrating to the PlantPAx system. You'll learn about the multitude of tools--scanners, cables, code conversion, wiring harnesses, etc.--available from Rockwell Automation that can help you migrate your system at a pace that's comfortable for you.

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    Migrating Your Legacy DCS System to PlantPAx Migrating Your Legacy DCS System to PlantPAx Presentation Transcript

    • 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PlantPAx – It’s a Modern DCS 3 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 4 Agenda Phased Migration or Rip and Replace Migration Tools – Reduce Risk and Cost Legacy DCS Market Outlook Success Story How We Can Help
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 5 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Where We are Engaged…Industries Metals W/Wastewater Mining Specialty Chem Power Oil and Gas
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 8 Agenda Phased Migration or Rip and Replace Migration Tools – Reduce Risk and Cost Legacy DCS Market Outlook Success Story How We Can Help
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 9 DCS Migration and Modernization Solutions YesYes YesYes NoYes Yes YesYes NoYes NoYes Yes PartnerNo NoYes YesNo Yes YesYes YesYes YesNo Yes YesYes YesYes YesNo Yes PartnerYes YesYes NoNo Yes YesYes YesYes NoNo Yes PartnerNo NoYes NoNo Yes SSBNo NoYes TRIO I/ONo Yes SSBYes YesNo NoNo Yes NoYes YesNo NoNo Yes N/AN/A N/AN/A N/AN/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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 11 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 12 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 15 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 16 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Custom Cable Solutions
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Foxboro I/A DCS Migration – Custom Cable Solutions for FBM100 I/O New Release for 2013
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 19 Agenda Phased Migration or Rip and Replace Migration Tools – Reduce Risk and Cost Legacy DCS Market Outlook Success Story How We Can Help
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 20 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 23 Plant Loop or Infi Loop TUTU PCU 1 PCU 2 CIU CIU Bailey EWS CIU OIS Op Station 2 Bailey Net90 / Infi90 Existing Architecture OIS Op Station 1
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 24 Plant Loop or Infi Loop TUTU 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 25 Plant Loop or Infi Loop TU PCU 1 PCU 2 CIU CIU Bailey EWS Redundant Servers Ethernet Op Station 1 RA EWS Op Station 2 Bailey Net90 / Infi90 Migration – Phase 2 Bailey Gateway CLX 1 TU
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. MTA MTA MTAMTA MTA 26 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. MTA MTA MTAMTA MTA 27 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 28 Rip and Replace of a Foxboro I/A DCS Nodebus Fieldbus CP30/40/60CP30/40/60 FBM’sFBM’s WP51 Console 1 WP51 Console 2 AW51 EWS Redundant Servers Ethernet Op Station 1 RA EWS Op Station 2 CLX 1 CLX 2
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 29 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)
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 30 Agenda Phased Migration or Rip and Replace Migration Tools – Reduce Risk and Cost Legacy DCS Market Outlook Success Story How We Can Help
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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 31
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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. 32
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Migration Project Plan 33  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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Migration Project Plan 34  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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Risk Mitigation Plan 35  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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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. 36
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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. 37
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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. 38
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 39 Agenda Phased Migration or Rip and Replace Migration Tools – Reduce Risk and Cost Legacy DCS Market Outlook Success Story How We Can Help
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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)
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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 contactIAverage 13+ Years ExperienceI |  Based on PMI ® PMBOK®  Certified project managers  Repeatable, measurable, auditable  Risk Management Project Management
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Services & Support Global Support. Local Address. Peace of Mind. Optimize Plant Assets Maximize Productivity Improve Financial Performance 80 Countries I 20 LanguagesI 6 Remote Support CentersI 10 Remanufacturing DepotsI 9 Exchange HubsI 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 44 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 mpvernak@ra.rockwell.com
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 45 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 >
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank You! Enjoy Your week!
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 47 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!