PR19 - Migrating Your Distributed Control System to the PlantPAx System

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

PUBLIC INFORMATION

PR19 - Migrating Your Legacy DCS to PlantPAx®

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 2

PLANT-WIDEControl and Optimization

SCALABLEand Modular

SECUREOpen and Information-enabled

FLEXIBLEDelivery and Support


Agenda

Phased, Vertical, or Rip and Replace Migration Methods

Migration Tools – Reduce Risk and Cost

Legacy DCS Market Outlook

How We Can Help

Success Stories

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Growth and Spend through 2016 –By Region

Total Shipments of Automation Products and Systems to the Process Industries by World Region(Figures in Millions of US Dollars)

World Region 2011 2012 2013 2014 2015 2016 CAGR

North America 14,086 14,858 15,700 16,594 17,516 18,500 5.6%

EMEA 21,945 22,887 24,083 25,587 27,221 28,971 5.7%

Asia 16,142 17,385 18,943 20,776 22,810 25,045 9.2%

Latin America 2,417 2,629 2,886 3,173 3,491 3,841 9.7%

Total 54,591 57,761 61,614 66,130 71,039 76,358 6.9%


Growth and Spend through 2016 –By Industry

Industry 2011 $MMUSD % 2016 $MMUSD % CAGR

Cement & Glass 872 1.6% 1,243 1.6% 7.4%

Chemical 8,533 15% 11,039 14.5% 5.3%

Electrical Power Generation 9,318 17.1% 13,689 17.9% 8.0%

Electrical Power T&D 2,743 5.0% 4,094 5.4% 8.3%

Food & Beverage 5,339 9.8% 7,392 9.7% 6.7%

Mining and Metals 3,552 6.5% 5,309 7.0% 8.4%

Oil and Gas 8,964 16.4% 13,142 17.2% 8.0%

Pharmaceutical & Biotech 2,564 4.7% 3,545 4.6% 6.7%

Pulp & Paper 3,432 6.3% 3,946 5.2% 2.8%

Refining 4,406 8.1% 5,866 7.7% 5.9%

Textiles 889 1.6% 1,305 1.7% 8.0%

Water & WW 3,976 7.3% 5,782 7.6% 7.8%

Total 54,591 100% 76,358 100% 6.9%


End-User PersonaEnd-User Challenges

Global DCS Migration Market Outlook

• Financial Justification (Economics)

• Limited Downtime (JIT Inventory Strategies)

• Loss Of Technical Resources

• Risk Averse

Process Automation Systems are nearing

End of Life

65BOf remaining systems are 25

Year Or Older

12BOf experts with these systems are

Retired

20%Party contractors are required and

High Risk

3rd


End-User Challenges:Financial Justification

Typical Total lifecycle Costs Benefits of a DCS Migration

• HW, SW, Networks

(multi-systems PLC, Drives, DCS)

• Engineering

• Simulation

• Commissioning/Decommissioning

• Support contracts

• Energy

• Spare Parts (multi- systems)

• Floor Space

• Training - Operator, Maintenance, IT

• Upgrade, Expansion

• Off-spec product

• EPA Compliance

• Un-planned downtime

• Obsolescence Planning

• Consulting

• Enhanced Optimization capabilities

• Reduced lifecycle 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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Industries where we are engaged…

Metals • Water/Wastewater • Mining • Specialty Chemical • Power • Oil & Gas

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Agenda




How We Can Help

Success Stories

9


OPC Server Software

Database Conversion Tool

Custom Cable Solutions

Engineered Interface (SAM)

Dedicated Interface

I/O Scanner Module

Conversion Services

Bailey NET90/INFI90 YES YES YES YES YES NO YES

Honeywell TDC/TPS YES YES YES NO YES NO YES

Honeywell IPC NO PARTNER YES NO NO YES YES

Fisher PROVOX YES YES YES YES NO YES YES

Moore APACS YES YES YES YES NO YES YES

Rosemount RS3 YES PARTNER YES YES NO NO YES

Foxboro I/A YES YES YES YES NO NO YES

Westinghouse WDPF NO PARTNER YES NO NO NO YES

Taylor MOD300 NO SSB YES NO NO TRIO I/O YES

Emerson DeltaV YES SSB NO YES NO NO YES

Yokogawa mXL YES NO NO YES NO NO YES

Others N/A N/A N/A N/A N/A N/A YES

Legacy Process Control SystemMigration and Conversion Solutions

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OPC Servers

• Commercially available –Field proven

• For use in architectures using “Whitebox” PCs, or SAM’s (PC in a ControlLogix® rack)

• Can be loaded directly on FactoryTalk® View Server


Integrated Gateway Solutions

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 Interface for BaileyRA56-cATM-BLY90

CIU/ICI

Serial

Bailey Plant Loop



• Same environmental specs as ControlLogix® system


• Data is native to FactoryTalk® applications



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Dedicated Interface for Honeywell UCN SX101UCN






• No Honeywell equipment required

• Connects directly to UCN network

SX010UCN

UCN network

Ethernet

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SX009

Ethernet

Dedicated Interface for Honeywell LCN SX009 (coming soon)







• No Honeywell equipment required

• Connects directly to LCN network

LCN network

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Database Conversion Tools

• Converts Legacy DCS DB tags

to FactoryTalk® View OPC

tags or ControlLogix® tags

• Used in conjunction with OPC

Servers, (whitebox) PC’s, or

the Oldi SAM

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PROVOX I/O ScannerCLX-PVX module from ProSoft

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™

PROVOXSerial I/O network

IncludesSMART™ I/O

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PROVOX Series10 or Series20 I/O


APACS I/O Scanner CLX-APX module from ProSoft

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™

I/O Bus

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Remote Modulrac



Bailey

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Foxboro IA

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Agenda




How We Can Help

Success Stories

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Legacy DCS Migration

EXPORTED CONSOLE DATABASE

.dbf, .txt, .csv, or other files

FROM THE CUSTOMER

WHAT WE NEED

HARDCOPY PRINTOUTS

of the legacy graphics / controller configuration

ACTUAL I/O COUNTS

and I/O Module types

EXISTING LOOP DESCRIPTIONS

and existing loop / P&ID drawings

22


Legacy DCS Migration

OPERATORS for their opinions and comments on current

system operation – and how they control their processes

FROM THE CUSTOMER – WE INTERVIEW

WHAT WE NEED

SYSTEMS/PLANT ENGINEERING to understand what

they expect from their new process automation system

MAINTENANCE PERSONNEL to understand how

they troubleshoot and maintain the current system

PLANT MANAGERS to understand their

production schedules, challenges and how

PlantPAx® can improve production

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TU

24

Bailey Net90 / Infi90 Existing Architecture

Plant Loop or Infi Loop

PCU 2

CIU

OIS Op Station 1

CIU

Bailey EWS

CIU

OIS Op Station 2

TU

PCU 1


Bailey Net90 / Infi90 Migration – Phase 1

TU


PCU 2

CIU CIU

OIS Op Station2

TU

Op Station 1

PCU 1

Op Station 2

Bailey Gateway

PAx EWS Redundant Servers

Ethernet

CIU

Bailey EWSOIS Op Station1



TU


PCU 2

CIU

TU

Op Station 1 Op Station 2

Bailey Gateway

ControlLogix® 1


Ethernet

CIU

Bailey EWS

PCU 1



TU

PCU 2

TU

Op Station 1 Op Station 2

CIU

Bailey Gateway

ControlLogix® 1


Ethernet


CIU

Bailey EWS

ControlLogix® 2


Bailey Net90 / Infi90 – Vertical Migration

TU


PCU 2

CIU

OIS Op Station2

TU

Op Station 1

PCU 1


Ethernet

CIU

Bailey EWS

CIU

OIS Op Station1

Bailey Gateway

CIU

ControlLogix® 1


Rip and Replace of a Foxboro I/A DCSWP51

Console 1

Nodebus

WP51Console 2

AW51EWS

CP30/40/60 CP30/40/60

Fieldbus

FBM’sFBM’s

Op Station 1 PAx EWS Redundant Servers Op Station 2

Ethernet

ControlLogix® 1

ControlLogix® 2


Comparison of the Conversion Strategies

Financial JustificationPhased Rip and Replace

• Does not require shutdown for HMI

replacement

• Can be funded with maintenance $

• Is considered low risk to customer

• Can take multiple years to migrate entire

system (higher TCO)

• Requires more legacy DCS expertise for

delivery engineering team

• Can be easily switched back to the legacy

system as part of a contingency plan

• 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

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Agenda




How We Can Help

Success Stories

31


Fischer & Porter DCS Migration

Fischer & Porter DCI System Six (ABB) Controllers

Mixing and Bulk Sterilization and Utilities –Two (2) DCU Controllers

Pharmaceutical Manufacturer

• Validated System

Could not afford any lost production time during cutovers

• Needed to formulate a plan to minimize interruptions

32


Driving Factors for DCS Replacement

Lack of replacement parts - F&P System Six (ABB) have become harder to source

• Required plant to keep several costly spare parts on-hand

Technical resources knowledgeable in F&P System Six are extremely limited

System age was becoming a concern – approximately 30 years old

33


DCS Migration Plan

Migration of existing DCS to new Rockwell Automation® PlantPAx® Process Control System (PCS) executed in stages, while not impacting production

• ControlLogix® Processors and Servers installed first

• I/O terminations using Allen-Bradley 1756-IFM termination cards mounted on stand-off DIN rails over the top of existing DCS cards

Shutdown and implementation plan document was generated prior to system design to best outline the execution of the cut-overs

Weekly meetings with Plant and Malisko team to ensure everyone stayed synchronized

34


Migration Execution

Existing system code and functionality was reviewed and documented

• Generation of a Functional Specification and Detailed Design Specification for each DCU (Mixing/Utilities)

• Development of sample Mix Tank using PlantPAx® process objects while mimicking existing screen layouts

Simulation development and initial plant personnel training prior to first cutover

Utilization of IFM termination modules installed on DIN rails mounted on standoffs over existing I/O termination boards reduced cut-over time

System validation split across ‘simulation’ and ‘live system’ to reduce tank downtime

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Results of the Migration

Ability to cut over each system separately without affecting production

New system functionality matches legacy DCS, plus gives new historical data collection and web-based reporting abilities

New system provides more flexible architecture though the use of “off the shelf” servers and client hardware along with readily-available Rockwell Automation® PAC hardware

Ability for Plant Maintenance and Automation Engineers to support system without the need of a specialized (outside) consultant

Additional support options include Malisko, local Rockwell Automation® distributor and Rockwell Automation®

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Agenda




How We Can Help

Success Stories

37


Work with delivery partners to assist in the technology adoption of Rockwell Automation®’s process control to the application

Help customers understand how we can migrate from legacy DCS to Rockwell Automation®

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

Process Tech Consultants (GPTC’s)

LARGE END USERSConsult work with corporate engineers

to establish standard for operations

SOLUTION PROVIDERTrain on the best practices

of using PlantPAx®

PROCESS OEMSWork with the OEM to re-write their

application on a Rockwell Automation® Platform

A&EDevelop specifications for firms

to establish Rockwell Automation®’s platform

Main Customer Types

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Process Tech Consultants (GPTC’s)

36 Process Control System Experts

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Bringing You a World of ExperienceHelping you exceed your business goals

1

2

3

Solutions

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

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

Manage projects that span multiple geographies

Standard business & project processes

The right team for your project from our worldwide talent

1

Combining Technology & Application Knowledge

All Major Industries

Best Practices From Multiple Industries

2

Based on PMI ® PMBOK®

Certified Project Managers

Repeatable, measurable, auditable

Risk Management

3

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

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

MAXIMIZE Productivity OPTIMIZE Plant Assets IMPROVE Financial Performance

MEET YOUR EVERYDAY TECHNICAL NEEDS

Online & Phone Support

Training Services

On-site Services

Repair Services

MAXIMIZE YOUR AUTOMATION INVESTMENT

MRO Asset Management

Safety Services

Energy Services

Network & Security Services

Legacy System Migration Plans

Legacy System Migration Turnkey Projects

Your Investment

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

Partner Ecosystem

ENTERPRISE PARTNERS

SALES AND SOLUTIONS PARTNERS

PRODUCTS AND TECHNOLOGIES PARTNERS

Strategic Alliances with companies

like Cisco Systems, Endress+Hauser,

and Microsoft

Approximately 320 Distributors

and over 100 Solution Providers

worldwide for local support

Over 1000 products from over 100

companies worldwide help to extend our

technology into adjacent areas

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Who should you contact for help?

[email protected]


White Papers Published…

DCS Migration White Papers available on Literature Libraryhttp://Literature.rockwellautomation.com > Support > Product Resources >

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

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http://literature.rockwellautomation.com/


PUBLIC INFORMATION

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