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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Rev 5058-CO900E PUBLIC INFORMATION T65 - Migrating Your Legacy DCS System

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Page 1: T65 - Migrating Your Legacy DCS System · PDF fileT65 - Migrating Your Legacy DCS System. ... FactoryTalk View OPC tags or CLX tags Used in conjunction with OPC Servers, (whitebox)

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E

PUBLIC INFORMATION

T65 - Migrating Your Legacy DCS System

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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION

PlantPAx – It’s More Than a DCS

2

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

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Agenda

Phased Migration or Rip and Replace

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

Success Stories

How We Can Help

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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 4

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

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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

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Where We are Engaged…Industries

Metals W/Wastewater Mining Specialty Chem Power Oil and Gas

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Agenda

Phased Migration or Rip and Replace

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

Success Stories

How We Can Help

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Competitor Solution OPC Server S

oftware

Database

Conve

rsio

n Tool

Custom

Cable

s Desig

ns or W

iring

Solu

tions

Control S

trate

gy Li

brary

OLDI S

AM M

odule fo

r OPC Serv

er

Dedica

ted In

terfa

ce to

CLX

Face

plate

Libra

ry

Lega

cy I/

O Scanner o

r Equal

Graphics

and Config

uratio

n

Conversio

n Serv

ices

Bailey Net90/Infi90 yes yes yes partner yes yes yes no yes

Honeywell TDC yes yes yes partner yes yes partner yes yes

Honeywell IPC no partner yes no no no no yes yes

Fisher PROVOX yes yes yes partner yes no partner yes yes

Moore APACS yes yes yes partner yes no partner yes yes

Westinghouse WDPF yes yes yes partner yes no partner no yes

Rosemount RS3 yes partner no partner yes no partner no yes

Rosemount RMV9000 yes partner yes partner no no partner no yes

Foxboro IA yes yes yes partner yes no partner planned yes

Taylor MOD300 yes partner no partner no no partner yes yes

Emerson Delta V yes partner planned partner yes no partner no yes

Yokogawa Micro XL yes no no no yes no no no yes

8

DCS Migration and Modernization Solutions

Legacy DCS Migration/Conversion Tools

Enablers that help mitigate risk and engineering costs

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OPC Servers

Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 9

• 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 FT View Server

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Integrated Gateways

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

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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 FactoryTalkapplications

Integrated solution

Optimized data server

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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 FactoryTalkapplications

Integrated solution

Optimized data server

Releases in

March 2014

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SX009

ENet

LCN network

Dedicated Honeywell LCN Gateway –Using LCN Interface – SX009

Benefits

Peer-to-peer communication

Increases performance

ControlLogix controller is data repository

Data is native to FactoryTalkapplications

Integrated solution

Optimized data server

Releases in

March 2014

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Database Conversion Tools

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

Used in conjunction with OPC Servers, (whitebox) PCs, or the Oldi SAM

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

PROVOXSerial 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 Rockwell Automation’s Tech Connect™

Now Includes SMART I/O

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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 Rockwell Automation’s Tech Connect™

Releases in

March 2014

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Custom Cable Solutions

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

Released in 2013

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Planned Tool Developments

- DB Conversion tool for SATTLine

- Cabling Solution for SATTline

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Agenda

Phased Migration or Rip and Replace

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

Success Stories

How We Can Help

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DCS Migration – Phased Approach

Phase I – HMI MigrationPhase II –

Interoperate PhasePhase 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

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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

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Legacy DCS Migration – What We Need from the Customer

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

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Plant Loop or Infi Loop

TUTU

PCU 1 PCU 2

CIUCIU

Bailey EWS

CIU

OIS Op Station 2

Bailey Net90 / Infi90 Existing Architecture

OIS Op Station 1

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Plant Loop or Infi Loop

TUTU

PCU 1 PCU 2

CIUCIU

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

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Plant Loop or Infi Loop

TU

PCU 1 PCU 2

CIUCIU

Bailey EWS

Redundant Servers

Ethernet

Op Station 1 RA EWS Op Station 2

Bailey Net90 / Infi90 Migration – Phase 2

Bailey Gateway

CLX 1

TU

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MTA MTA

MTAMTA

MTA

27

APACS Migration – Phase 2Op 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

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MTA MTA

MTAMTA

MTA

28

APACS Migration – Phase 3Op 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

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Rip and Replace of a Foxboro I/A DCS

Nodebus

Fieldbus

CP30/40/60CP30/40/60

FBM’sFBM’s

WP51

Console 1WP51

Console 2

AW51

EWS

Redundant Servers

Ethernet

Op Station 1 RA EWS Op Station 2

CLX 1 CLX 2

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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)

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Agenda

Phased Migration or Rip and Replace

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

Success Stories

How We Can Help

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The Rovisys Company – Bailey Migration

Bailey Infi90 was migrated to CLX for soy bean extraction and refining TI PLC migrated at the same time

Eliminate interface and duplicate tags in PLC and DCS

Consolidated tags in Plant Historian

32

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Migration Project Plan and Documentation

System Audit – Assess existing Hardware and Software

System Design

Functional Spec - Architecture, Code & HMI

Electrical – Enclosures, Network, Power, I/O Cables

Cutover Plan

Shutdown schedule

Installation Support/Management

Loop Checks

Final Tuning and Commissioning

33

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Downtime Minimized

Custom Cables to reuse N90 Field Terminations

34

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Risk Mitigation Plan

Dedicated PM

One Lead Engineer for the complete project life cycle

Perform audit of the existing system

Establish client expectations

Total project ownership

Weekly Meetings with client, installer, panel shop, E&I contractor

Electrical Contractor Management included in scope

Operator Training on new system

Cutover Management by RoviSys and Client

35

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Migration Project Execution

Establish standards knowing both the old and new systems

Identification of dead code within the CADEWS

Coding Standards

Conversion of tuning parameters

Graphical Standards/Tag Naming Standards

Collaborative design decisions – get buy in at all levels

Custom cables to expedite cutover and ensure accurate wiring

Cutover Plan

Requirements for staffing and downtime

Assign key responsibilities

Scope of Work for each phase

Testing Requirements

36

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Lessons Learned

Keys to a successful migration

Execute migration plan as separate effort, prior to migration

Ensure that all parties understand project magnitude

Set a reasonable schedule

How did the migration help our customer achieve their goals?

Keep the system up!

Repaired key instruments

Can’t blame system any longer… improve operations

Fully documented system

Local Distributor support, with Rockwell and RoviSys

4,1800 & 10

37

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Agenda

Phased Migration or Rip and Replace

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

Success Stories

How We Can Help

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Global Process Tech Consultants (GPTCs)

Work with delivery partners to assist in the technology adoption of

Rockwell’s 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 best practices of using PlantPAx

A&E – Develop specs for these firms to establish Rockwells platform

Process OEMs – Work to rewrite application on a Rockwell Platform

DCS Migrations - Explain to customers migration paths to Rockwell

Work across global regions and key customers to assist in project

implementation (A&E, contractor, SI and end user)

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Global SolutionsBringing You a World of Experience

Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 40

Combining technology & application knowledge

All major industries

Best practices from multiple industries

DomainExpertise

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.

Based on PMI ® PMBOK®

Certified project managers

Repeatable, measurable, auditable

Risk Management

Project Management

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Partner Ecosystem

Business Enterprise PartnersStrategic Alliances with companies like Cisco Systems, Endress+Hauser, and Microsoft

Product and Technology PartnersOver 1000 products from over 100 companies worldwidehelp to extend our technology into adjacent areas

Sales and Solutions PartnersApproximately 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

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More Information:White Papers Published

• Justification for a Legacy Control System Migration PROCES-WP005

• DCS Migration Strategy and Project Implementation PROCES-WP006

• Optimization after Migration PROCES-WP008

http://Literature.rockwellautomation.com > Support > Product Resources >

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www.rockwellautomation.com

Follow ROKAutomation on Facebook & Twitter.Connect with us on LinkedIn.

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Questions?