t08 legacy dcs migrations and conversions

Migrating Your Legacy DCS System to PlantPAx 2.0

Mike Vernak – Program Manager

Global DCS Migration Program

Presentation Overview

Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 2

5. Comprehensive Partnerships

2. PlantPAx Process Control Solutions

3. Systems We Migrate / Enabler Update

4. Phased vs Rip and Replace Migration

1. Program Overview and Value Statement

6. DCS Migration Success Story

7. Wrap Up

What are the goals for the DCS Migration / Conversion Program?


• To provide clients innovative, low cost ,and low risk migration solutions to convert their legacy DCS systems to PlantPAx based architectures

• To enable delivery partners to be successful engaging in, and implementing DCS migration opportunities

• To provide high impact Global Centers of Excellence for DCS migrations for clients and engineering partners

• To provide clients the highest value in process control products and solutions across all Industries

Execute real-time control and maintain critical process parameters to respond to diverse customer demands.

• Reynolds • Alcoa• Bethlehem • Mittal• Nucor• USX

Execute real-time control and maintain critical process parameters to respond to diverse customer demands.

• Reynolds • Alcoa• Bethlehem • Mittal• Nucor• USX

Metals

Get to market fastest and build and maintain ultra-pure semiconductor production facilities.

• Intel• Applied Materials• Novellus• TSMC• SMIC• Siltera• ACE• IBM

Get to market fastest and build and maintain ultra-pure semiconductor production facilities.

• Intel• Applied Materials• Novellus• TSMC• SMIC• Siltera• ACE• IBM

Semiconductor

• Pacific Gas & Elec.• Applied Power• AuTau Water Facility• US Navy• British Navy

• Pacific Gas & Elec.• Applied Power• AuTau Water Facility• US Navy• British Navy

Other Markets

Water / WasteWater

Pulp & Paper

Fibers & Textile

Electric Power

Specialty Chemical

Plastics

Airport / Seaport

Marine & Government

Industry Expertise…

Improve quality, reduce costs, increase responsiveness and ultimately improve time-to-customer throughout your supply chain.

• Daimler-Chrysler• BMW• General Motors• Ford • Harley-Davidson• Goodyear• Michelin• Hyundai

Improve quality, reduce costs, increase responsiveness and ultimately improve time-to-customer throughout your supply chain.

• Daimler-Chrysler• BMW• General Motors• Ford • Harley-Davidson• Goodyear• Michelin• Hyundai

Automotive

Optimize your limited human, physical and financial assets, minimize waste, and satisfy demanding consumers and retailers.

• Procter & Gamble• Anheuser-Busch• Coca-Cola• Kellogg• Philip Morris• SAB Miller• M&M Mars• Nestlé


• Procter & Gamble• Anheuser-Busch• Coca-Cola• Kellogg• Philip Morris• SAB Miller• M&M Mars• Nestlé

Food

Reduce costs while meeting the demands of ever-changing complianceregulations.

• Pfizer

• Eli Lilly

•Wyeth-Aherst

• Johnson & Johnson

• Merck

• Abbott Laboratories

• Sanofi

Reduce costs while meeting the demands of ever-changing complianceregulations.

• Pfizer

• Eli Lilly

•Wyeth-Aherst

• Johnson & Johnson

• Merck

• Abbott Laboratories

• Sanofi

Life Sciences & Pharma


• Anheuser-Busch

• Coca-Cola

• SAB Miller

• Carlsberg

• Heineken

• InBev

• Pepsi Co.


• Anheuser-Busch

• Coca-Cola

• SAB Miller

• Carlsberg

• Heineken

• InBev

• Pepsi Co.

Beverage & Brewing

Industry Expertise…continued

React to changing production conditions, while maintaining your plant at peak efficiency.

• ConocoPhillips• Dow Chemical• Exxon/Mobil• Grupo Mexico La Caridad

• Shell• DuPont• Eastman Kodak• PDVSA• Chevron• BP

React to changing production conditions, while maintaining your plant at peak efficiency.

• ConocoPhillips• Dow Chemical• Exxon/Mobil• Grupo Mexico La Caridad

• Shell• DuPont• Eastman Kodak• PDVSA• Chevron• BP

Petroleum & Chemical

Rockwell Automation has deep industry expertise in project delivery…..

The Global Need for DCS Migration Solutions


Many DCS end-users today are demanding the functionality

of multi-disciplined control systems

$6B in next two years!!

Process Consulting Team


•Rockwell Automation recognizes that the key to being successful in process control is having vast process domain expertise•Rockwell Automation has over 30 process control engineers worldwide for pre-sales and technology adoption engagements•Process control engineers come from a variety of industry segments as well DCS companies

•Rockwell Automation recognizes that the key to being successful in process control is having vast process domain expertise•Rockwell Automation has over 30 process control engineers worldwide for pre-sales and technology adoption engagements•Process control engineers come from a variety of industry segments as well DCS companies

Global Process System Expertise in GPTC’s


30+ Process Control System Experts









7. Wrap Up

We can help you get from here……


… to here……


Our Process Automation System










7. Wrap Up


DCS Migration Enablers

OPC Server SW

Database Conversion Tool

Faceplate Library

Graphics and Config Conversion Services

OLDi SAM Module for OPC Servers

Control Strategy Library

Legacy I/O Scanner or Equal

Custom Cable Designs or Wiring Solutions

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Green = Available todayYellow = Future DevelopmentsBlue = Partner Capability

Oldi Dedicated Interface to CLX

OPC Servers


• Commercially available, field proven

• For use in architectures using

“whitebox” PCs, or Oldi “SAMs”

• Can be loaded directly on

FT View Server

SAM (Specialty Application Module)


Benefits

• Windows XP PC in 1756 chassis

• Same specs as ControlLogix system

• ControlLogix controller is data repository

• Integrated solution

• Optimized data server

Dedicated Bailey Interface –RA56-cATM-BLY90


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

Database Conversion Tools


• Converts Bailey Console DB tags to FactoryTalk View OPC tags or ControlLogix tags

• Used in conjunction with Rovisys OPC90 OPC server and (whitebox) PC

Reduce Risk….

Reduce Engineering Hours

Custom Faceplate Libraries


I/O Scanner Products - Honeywell IPC620


IPC620 I/OSerial IO Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

I/O Module

Fisher PROVOX S10/S20 I/O Scanner


PROVOX S10/S20 I/OSerial IO Module

Honeywell TDC 2000 –Communications Adapter


Honeywell MFC Processor Board

QTSQTS-AN-X-HWBP-MON

Custom Cable Solutions – HWL HLPIU


Front View Rear View

Custom Cable Solutions - Bailey



Custom Cable Solutions – Honeywell TDC


Custom Cable Solutions – Fisher PROVOX S10


Custom Cable Solution – Fisher PROVOX S20


Custom Cable Solution – Moore APACS

Custom Swing-arm Solution – HWL IPC620

Swing-arm adapter board

Swing-arm adapter baseplate

Existing Swing-arms

Swing-arm adapter cable









7. Wrap Up

Example of a Phased Migration


CIU

CIUCIU

OIS ConsoleOIS Console

EWS Console

Plant Loop or Infi Net

PCU 1 PCU 2

TU 2TU 1

Bailey Net90 / Infi90 Migration – Phase 1


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 Gateway

OIS Op Station 1




TU

PCU 1 PCU 2

CIUCIU

Bailey EWS

Redundant Servers

Ethernet


Bailey Gateway

TU

CLX 1




PCU 2

CIU

Redundant Servers

Ethernet


Bailey Gateway

CLX 1

TU

CLX 2

TU

CIU

Bailey EWS

Bailey Net90 / Infi90 - Converted to PlantPAx


CLX 1

TU

CLX 2

TU

Redundant Servers

Ethernet

Op Station 1 EWS Op Station 2

Example of a Rip and Replace Migration


CIU

CIUCIU


EWS Console


PCU 1 PCU 2

TU 2TU 1

CLX 1

TU

CLX 2

TU

Redundant Servers

Ethernet

Op Station 1 EWS Op Station 2

Example of a Rip and Replace Conversion (By Area)


CIU

CIUCIU


EWS Console


PCU 1 PCU 2

TU 2TU 1

Comparison of the Conversion Strategies


• Does not require shutdown for HMI replacement

• Can be funded with maintenance $

• Is considered low risk to client

• 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)

Phased 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 client

• 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









7. Wrap Up

Comprehensive Partnerships










7. Wrap Up

Success Story: Bailey Conversion


• Lecithin Plant

• Client Situation

– Customer required replacement of their Infi90 system, parts were becoming increasingly expensive and difficult to find

– Maintenance of legacy system was difficult

• Solution

– PlantPAx solution

– ControlLogix control modules designed to retrofit Infi90 DCS systems

– Allen Bradley 1756/Bailey replacement cables to connect to existing termination units eliminating need to modify field wiring

• Results

– Control system replacement with zero production interruption

– Reduced maintenance

– Improved system diagnostics









7. Wrap Up


Services & SupportGlobal 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 SupportTraining ServicesOnSite ServicesRepair Services

Maximize Your Automation Investment

MRO Asset ManagementSafety ServicesEnergy Services

Network & Security ServicesManaged Services

In Summary ….


� We have experience in many industries migrating DCS and PLC Systems

� We offer innovative solutions for low risk and low cost migrations

� We have comprehensive partnerships for engineering delivery capability

� We offer in-depth Services and Support including StepForward for 3rd

Party for your technical needs and to maximize your investment

We are here to help!

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