Return on ImaginationHoneywell Users Group 2009

Return on ImaginationHoneywell Users Group 2009

The Migration Process:From PROVOX to Experion

Phil Gibb, Hopewell Chemical Facility

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Agenda• PURPOSE: Discuss migration methodology

from Fisher PROVOX DCS to Experion™Process Knowledge System–Productivity Opportunities–Tools & Methodology–Database Migration–Savings (cost and time)–Migration summary

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Productivity Opportunities• Hopewell, VA:

–Previous Experience: Hopewell Area 6 PROVOX to Experion migration in 2006

–Converted DCS one asset (unit) at a time

• Orange, TX: –Due to July 2008 Hurricane Ike, quickly needed

to replace PROVOX system–Modeled Hopewell migration process

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Productivity Opportunities

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Productivity Opportunities

Follow this process model:

Design Implement Test

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Tools & Methodology1. Export/Edit DCS database configuration from

PROVOX system – MS Access2. Map PROVOX parameters to Experion

parameters – MS Excel3. Convert Excel database into Experion XMLs –

Honeywell Bulk Builder4. Import Experion XMLs – Experion Control

Builder

Re-use PROVOX Design

Test onExperion

Implement on Experion

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“Typical”Points

Tools & Methodology

Define Experion Assoc Displays

Import New IO Addresses

Determine Area Specific Configuration Parameters/Rules

Export

Export/Import Intermediate DB for Alarm Rationalization Review

Import

ImportXML’s

MS Access Database Honeywell

Bulk Builder

Experion Control Builder ERDB

MS Excel “Migration

Map”

PROVOX DB

Define Experion Parent Assets

Revise/Proof

Revise/Proof

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Database Migration – MS Access

• Capture PROVOX configuration–Sort by control strategy type

• Analog: Regulatory control, analog indication• Digital: Device control, digital indication

–Edit tag names, descriptions, states, alarm limits–Associate Experion assets, associated displays

and new IO assignments with PROVOX points

Design Implement Test

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Database Migration – MS AccessQuery to capture PROVOX DB configuration:

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Database Migration – MS AccessEdit PROVOX DB configuration:

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Database Migration – MS AccessUse Append Queries to add asset, associated

display and IO assignments to Experion DB

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Database Migration – MS Excel• Parameter mapping

• Predefined PROVOX to Experion mapping (VB Script) and configuration rules

• Preview and bulk edit of parameter values• Alarm changes• Customize configuration rules

Design Implement Test

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Database Migration – MS Excel• Associate point types with Experion templates or

“Typicals”• IOMs• Analog: RegCtl, Analog Indication• Digital: DevCtl, Digital Indication

Design Implement Test

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GREEN – Input sheet

RED – BB templates

BLUE – Output sheets

Database Migration – MS Excel

Migration Excel HelpSheet

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Database Migration – MS Excel

Migration Excel SetupSheet

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Database Migration – MS Excel

Experion IOPROVOX Tag

Migration Excel Input Sheet

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Migration Excel TemplateSheet

Database Migration – MS Excel

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Migration ExcelOutput 1:IOM Bulk Build Sheet

Database Migration – MS Excel

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Migration Excel Output 2:CM Bulk Build Sheet

Database Migration – MS Excel

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Database Migration – Bulk Builder

• Import Excel Output spreadsheet into Honeywell Bulk Builder

• Build XMLs for import into Control Builder Engineering Repository Database (ERDB)

• Offline and online validation • Extensive validation error reporting• Resolutions made on bulk edits

Design Implement Test

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Database Migration – Bulk Builder

Read Excel Output

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Database Migration – Bulk Builder

Validate Excel Output

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Database Migration – Bulk Builder

Error Check

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Database Migration – Bulk Builder

Export XMLs

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Database Migration – Control Builder• Build “Typical” points for Bulk Builder XML

model• “Typicals” must be built prior to Bulk Builder

step• “Typicals” provide standardization

– Format, history, parameters

Design Implement Test

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Database Migration – Control Builder• Import Bulk Builder XMLs into Control Builder

• Must import IOMs prior to Control Modules• IO assignment is done when CMs imported• Validation and import error report/log• Tested to new site parameters

Design Implement Test

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Database Migration – Control Builder

Import XMLs

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Database Migration – Control Builder

XMLsImporting

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Database Migration – Control Builder

Error Report/Log

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Database Migration – Documentation1. MS Access

• PROVOX database2. MS Excel

• Input sheet (PROVOX / Experion cross-reference)

Design Implement Test

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Database Migration – Test • Test

–Validation–Report–Test to new site parameters

Design Implement Test

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Cost Savings• Savings vary and are based on:

–Desire for Re-use–Complexity–Job Size

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Control Builder Time Savings• Estimated configuration times:

Manual Bulk BuildTypical Analog Input (Daca) 25 min 15 minTypical Control Loop (Pida) 45 min 20 minTypical Device Control 45 min 20 minTypical Digital Input 20 min 10 min

• Assumptions:• ~20% of points will require logic customization following initial

bulk build (skews per-point time statistic)• Remaining un-customized 80% of points will be built in a

fraction of the time• Time estimate applicable to Control Builder only – does not include

HMIweb graphics configuration.

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Time Savings

• Recent studies performed while bulk building points for Hopewell’s Area 7 PROVOX to Experion upgrade suggest an alternate means of estimating time savings:

Logic Customization Skews Total DB Build Time

Manual Build ~0.50 hr/loopBulk Build ~0.20 hr/loop

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Migration Summary

• There are multiple steps in a migration process:– Honeywell project ops developed ways to

automate part of process by producing tools– Tools enable global sharing of migration

knowledge– Tools evolve quickly based on increased

experience and Experion improvements

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Excel Configuration

Migration Summary

PROVOXDatabase(Access)

ExtractEdit PROVOX tag information

Assign / Edit Experion IO

AutomaticConversion(Based on

mapping rules)

Bulk Build Excel sheet Control Builder

Database

HoneywellBulk

BuilderExperion strategies

Alarm RationalizationReview

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Migration Summary

• Strategies can be deployed for global re-use• For identical or similar processes, 90-100% of

PROVOX point configuration is captured

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Migration Summary

• Migration process can be used in conjunction with other Experion features and capabilities:– CAB– Profit loop– SCM– UCF

Savings Dependent on Complexity & Desire for Re-Use

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A Special Thanks

Thanks to Senthil Balasundaram

andWayne Jorde

For their efforts on this project andthis presentation!

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www.honeywell.com