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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
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
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. 14
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
TU TU
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
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
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
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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
MTA MTA
MTA MTA
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
CP30/40/60 CP30/40/60
FBM’s FBM’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
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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
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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
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.
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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 contact I Average 13+ Years Experience I
|
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 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
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
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.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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