Justifying Migration of legacy process control systems

Legacy Migration/ModernizationApplication Series

August 10th, 2016

Presenters

• Dan Burger, P.E., C.E.M. – Business Development Market ManagerHaving over 12 years of direct experience in the migration and modernization of various control system platforms, including the planning, engineering, and cutover. He holds a P.E. in Control Systems Engineering and is a Certified Energy Manager.

• James Riccardi, P.E. – Group Manager, California ProjectsOver 24 years of automation experience including design, implementation, commissioning and validation of various controls platforms across different industries. Jim has previously worked with Air Products and Bailey Controls. He has led projects throughout the US and Asia. He has been with RoviSys since 2000 and is currently based in Ventura, CA.

Given today's slow economic growth, reduced plant engineering and maintenance staffing and tight capital budget constraints, understanding how best to propose, plan, execute and allocate limited resources for successful process control system migrations is imperative for manufacturers seeking to maintain or increase productivity and efficiency.

Business Environment

Project Justification

• Financial• Safety • Production Increases• Maintenance Efficiencies• Integration with Business Systems

. 4

Lobbying for Support

• You are the visionary, determine your approach• Preach the specific benefits • Ask peers for their input• Build a plan and revise as needed• Consult a partner• Generate a FEED Study w/ cost estimate

Why migrate now?

• Legacy Systems are hard to maintain• Limited Spare Parts (and failures increase…)• Old PC hardware and Operating Systems• Communications and diagnostics limitations• People who know them are retiring

• New tools connect to new systems• Legacy Systems are generally closed architecture• Historians, Advanced Control, MES for Plant Pax

Payback $$

• Increasing cost of • Spare Parts• Trained Support (internal + external)• Support Agreements

• Unplanned Downtime• Improved visibility into operations • More efficient operations• New product/process/equipment• Compliance

Migration Approach

1. Rip and Replace2. Phased by system architecture3. Phased by process area4. With same system vendor / select new vendor

Project Definition

• Hands on System Audit • High Level Migration Plan• Savings/Payback• FEL +/- 30% Estimate• Authorization to Proceed?

• Bid Specs• Select Vendors• +/- 10% Estimates• System procurement & Engineering• Cutover• Support

System Audit

• Eyes on Audit• Hardware• Code

• Interview• Operations• Maintenance • Engineering

• Understand Goals and Challenges

Migration Plan

• High level design• Rip & Replace or Phased Migration?• Priorities

• HMI unsupportable• Stock Prep can’t run• New Coater on the way

• Who will drive? • How to justify?

Front End Loading

• Audit drives FEL Estimates• I/O counts• HMI Requirements• E&I Upgrades required?• New network?• Installation challenges

• System Architecture & BOM• Schedule• Resource LoadingChoose Approach Carefully!

Why Consider Phased Migration?Rip & Replace Phased

Manpower Larger team Hit and run

Downtime Longer Outage Many Outages

Risk Higher Lower

Faith All in Focused Effort

Cash Flow One Year Gradual

Cost Most cost effective Higher overall cost

Payback Improvement NOW Time is money

Glass Plant Virtualized Plant PAx

End User - System Architecture

Manufacturing ZoneSite Manufacturing

Operations and ControlLevel 3

Demiliterized Zone (DMZ)

Enterprise ZoneLevels 4 and 5

Cell/Area ZoneLevels 0–2

Internet

FIBER

FIBER

FIBER

FIBER

FIBER

VLAN

VLAN

FIBER

FIBER

Enterprise Zone Provided by End

User IT

HMI Server(Primary) MES/Historian Server

Engineering Workstation #1

HMI Server(Secondary)

VLAN

FIBER

FIBER

Enterprise Zone

Office PC’s

VLAN

FT View SE HMI Clients (QTY 5):

``

`

VLAN

PanelView+ (Qty 5)

FIBE

R

Engineering Workstation #2

VLAN

Terminal Server(Primary)

VLAN

Terminal Server(Secondary)

VLAN Domain Controller(Primary)

VLAN

Domain Controller(Secondary)

VLAN

NOTE: Maximum allowed length of Cat 6 cable is 100

meters (330ft)

VLAN

FT View SE HMI Clients (QTY 2):

``

`

VLAN

HIST01ENG01

ENG02TS01

TS02

DOM01

DOM02

Cisco 3750X Switch Stack

DLR Representation Is Symbolic

Only...See Area Pages For Specifics

VLANCtrl Area 3

Ctrl Area 3 Device Level Ring

RIO – Area 3 2

VLAN

RIO – Area 3 1

VLAN

`

FT View SE HMI Client

HMI STRATIX

CLX – Area 3 0A CLX – Area 3 0BDLR Representation

Is Symbolic Only...See Area

Pages For Specifics

VLAN

Area 4 PLC 4.0with GracePort Interface

Ctrl Area 4


RIO – Area 4 2

VLANCLX – Area 4 0A CLX – Area 4 0B

RIO – Area 4 3

Area 4 PLC 4.1

FIBER

RIO – Area 4 1

Scale Weight (Qty 12)

x12

FIBER

x5

FT View SE HMI Client (Qty2)

VLAN x2

`

RIO – Area 4 4

FIBERArea 4 PLC 4.2

DLR STRATIX

HMI STRATIX

VLAN

AREA 5 PLC CABINET

Ctrl Area 5


RIO – Area 5 2

VLAN

CLX – Area 5 0A CLX – Area 5 0B

MODBUS

RIO – Area 5 1

MODBUS

Ctrl Area 5 Drives (Qty 2)

Spang SCR – Power Control (Qty 7)

MODBUS x7Spang SCR – Power Control (Qty 8)

MODBUS x8

SPANG Network Enclosure

MicroLogix 1100 ATS (Qty 2)

x2

FIBER

Scale Weight (Qty 2)

Power Logic Monitor (Qty 6)MODBUS x6

x2

FIBER VLAN

VLAN

MB STRATIX

DLR STRATIX

HMI STRATIX



VLAN

Ctrl Area 1


Drives (Qty 9)

RIO – Area 1 2

VLAN


RIO – Area 1 3

Area 1 MCC

FIBER

MODBUS

RIO – Area 1 1

MODBUS

Drives (Qty 2)

FIBER

Spang SCR – Power Control (Qty 16)

MODBUS x16Spang SCR – Power Control (Qty 16)

MODBUS x16

SPANG Network Enclosure

HMI STRATIX

MB STRATIX



VLAN

Ctrl Area 2


SLC 5/05 – Gas Safety A

SLC 5/05 – Gas Safety B

Drives (Qty 20)

MicroLogix 1100 ATS (Qty 6)

RIO – Area 2 1 RIO – Area 2 2

FIBER

RIO – Area 2 4

RIO – Area 2 4

Power Logic Monitor (Qty 8)

Generator Control Panel

Area 2 PLC 1.2

Area 2 PLC 1.1with GracePort Interface

VLAN


Gas Safety Panel

MODBUS

MODBUS

MODBUS x8

x6

Drives (Qty 4)

FIBER

VLAN

`


HMI STRATIX

FN_DLRSTRX

MB STRATIX



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1200 I/O, 5 Areas, 8 Consoles, MES/Historian, 30 Drives, Virtualized

Paper Machine Phased Migration2000 I/O, 3 Areas, 10 Consoles, PI Addressing, Virtualized

Glass Plant Paper MillI/O total 1385 2100Remote I/O enclosures 0 21PCU's 4 PCU, 8 MFP 4 PCU, 9 MFCCLX Controllers 5 Redundant Pair 3HMI Consoles 12 10HMI Graphics 25 plus 15 custom popups 99 plus 40 popup faceplates

Interfaces

Resolver Interface Module, 20 30 + ModbusTCP devices, 30+ PowerFlex Drives (new), 50+ HART xmtrs/actuators PI, GE Drives, PLC5, ModBus

Historian x xDrives PowerFlex, in new scope GE Serial InterfaceOptimimzation x interface to VAXPI scope New, FTHistorian yes, to be comverted to FTHistorianScheduleStrategySystem Price$ changes

RoviSys first full Plant Pax Plant Pax look with custom CMs for BaileyCustom faceplates & CMs Work with Bailey configs during phasing

Virtualized Servers Virtualized Servers

Client specify VM Rockwell design for high availabilitysimple, less expensive, 2 servers 3 servers, Vsphere selects Server for reliabilitysupport not as convenient push button' backups

Glass Plant Paper MillI/O total 1385 2100Remote I/O enclosures 0 21PCU's 4 PCU, 8 MFP 4 PCU, 9 MFCCLX Controllers 5 Redundant Pair 3HMI Consoles 12 10HMI Graphics 25 plus 15 custom popups 99 plus 40 popup faceplates

Interfaces

Resolver Interface Module, 20 30 + ModbusTCP devices, 30+ PowerFlex Drives (new), 50+ HART xmtrs/actuators PI, GE Drives, PLC5, ModBus

Historian x xDrives PowerFlex, in new scope GE Serial InterfaceOptimimzation x interface to VAXPI scope New, FTHistorian yes, to be comverted to FTHistorianSchedule install 12 mon after order 2 year plus cutover planStrategy Rip & Replace Phased MigrationSystem Price $1.4MM $1.9MM$ changes $150K $350K

RoviSys first full Plant Pax Plant Pax look with custom CMs for BaileyCustom faceplates & CMs Work with Bailey configs during phasing

Virtualized Servers Virtualized Servers

Client specify VM Rockwell design for high availabilitysimple, less expensive, 2 servers 3 servers, Vsphere selects Server for reliabilitysupport not as convenient push button' backups

Summary

• Plan• Audit• Update Documentation• Migration Plan and FEL Pricing

• Look for Payback• Operations• Maintenance & Support• Long term operational benefits

• Understand what drives your company’s decisions• Partner with someone who has seen it all

Questions?Thank you for Attending!

Who are we?...The RoviSys Company • Founded in 1989

• ~600 Employees

• Rockwell Automation Solution Partner• Certified Member CSIA, Control and Information System Integrators Association• Rockwell’s Bailey Migration Tools, cables, and OLDI cATM-BLY90• Rockwell Cable Solutions to DCS I/O Terminations; Bailey, APACS, RS3, etc.• Automation and Information Systems

Contact Information

• Dan Burger, P.E., C.E.M. – Business Development Market [email protected](330)936-1112

• James Riccardi, P.E. – Group Manager, California [email protected](330)472-3034

mailto:[email protected]

mailto:[email protected]

Justifying Migration of legacy process control systems

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