migrating your dcs system to plantpax-phpapp01

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
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

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
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

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 © 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
TUTU
PCU 1 PCU 2
CIU
CIU
Bailey EWS
CIU
OIS Op Station 2
Bailey Net90 / Infi90 Existing Architecture
OIS Op Station 1

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

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
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

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

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
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
31

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

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

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

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

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

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

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

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 contactIAverage 13+ Years ExperienceI
|
 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 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

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
mpvernak@ra.rockwell.com

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 >

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