Americas HUG Workshop QCS MIGRATION BEST PRACTICES Peter Bijsterveld June 11, 2019
© 2019 by Honeywell International Inc. All rights reserved.
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QCS Migration Workshop Overview
• QCS challenges reflect broader industry issues, at a faster pace
• Honeywell Lifecycle Support Policy – QCS Platform
• Microsoft announcement impact
• A brief history of QCS evolution from MXOpen to Experion MX R702.1
• R702.1 Primer – new features
• Virtualization is the foundation for lowest TCO
• DaVinci and Experion MX R6xx to Experion MX R702.1
– Platform Migration Process non-technical overview
– QCS migration expectations
• Questions
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
Common challenges accelerated in Pulp & Paper / Continuous Web industries
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Manufacturing challenges and trends
Pulp and Paper / Continuous Web Solutions
• High system availability required to minimize risk of lost, or off-spec, production
• Maintaining product quality & production while reducing costs
• Conversion of production processes to packaging grades
• Lifecycle cost optimization
• Short downtimes and service breaks favorable for small, incremental, upgrades rather than large rip-and-replace projects
Common Industry Challenges
• Cyber Security threats, protecting against attacks
• Achieving integrated and interoperable systems
• Reducing service and maintenance costs
• Gap in local skills and experience
• Aging workforce
• Rapid IT/Process infrastructure changes
• Multivendor projects
© 2019 by Honeywell International Inc. All rights reserved.
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QCS Lifecycle Challenges
• Limited capital funding available
• Lower Total Cost of Ownership
• Improve system and process reliability
• Reduce product and manufacturing costs
without sacrificing quality and output
• Off-the-shelf
hardware/software rapid
obsolescence
• Constant cyber threat
• Specialized industrial control
applications, measurement,
and control equipment
• Limited spares and repairs for
obsolete equipment
• Limited remote access and
support options for old systems
• Increasing complexity of networks
and infrastructure, IT systems
interwoven with control systems
• Specialized skills required
© 2019 by Honeywell International Inc. All rights reserved.
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QCS Platform Lifecycle Phases
R702.1 R61x* R60x* DaVinciExperion MX
SW version
Windows 10 64 bit
Windows 2016 Server 64b
Application
Enhancements:
• MD/CD MV Controls
• Metals Control R12x
• Security Enhancements
• New HMI Controls
• Alarm Tracking
• Alarm Pager
• Distributed System
Archtecture (DSA)
• Extended History DB
Windows 7 64 bit
• Windows 2008 R2 64 bit
Application
Enhancements:
• MD Control
• Metals Control
• Security Enhancements
• Wyse Z90 Thin Clients
Windows 7 32 bit
• Windows 2008 R2 32 bit
• SQL Server 2008
• Labview 2010
Virtualization Capability
(Experion PKS virt.)
• Experion MX HMI
Experion MX Scanner
and Diagnostics
• Experion MX CD and MD
Controls
Windows
XP SP2 32
bit
• W2003 32
bit
• SQL 2005
(Upd 5)
• Labview 8
Virtual.Cap
(vmware
WS)
• EBR
FTE
Windows
2000 Pro
• Windows
2000 Srv
• RAE HMI
• RAE
Alarms
Upgrade
Steps
New faster, lower cost approach to getting and staying current available!
Low Medium High
* Experion MX and MXProLine R6xx change to Phased-Out in early 2020 due to
announced Microsoft Operating System end of support
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Experion MX R702.1 supports latest Microsoft Operating Systems
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Microsoft Announcement Impact
• Microsoft announced end of support for Windows 7 and Windows Server 2008 in January 2020
– No Microsoft Security patches
– No Microsoft bug fixes - not even for security related defects
– No Antivirus support
• Operating System status change triggers Honeywell Phased-Out lifecycle change for older Experion PKS and Experion MX platforms, and for Experion Mu
– Announced in HINTS Newsletter February 2019
From HINTS February 2019:
All users of traditional MD control applications will receive the Alpha MPC
Multivariable package when they migrate to Experion MX R7XX.X. This migration
path provides robust functionality to traditional controls users. The Alpha MPC
packages fully supports a “Traditional” control strategy while enabling customers to
experience significant additional value when they implement multivariable
optimization strategies provided by the far superior Alpha MPC-based control
application. All users of traditional CD control applications will receive the
Multivariable CD Control package when they migrate to Experion MX R7XX.X. This
migration path provides robust functionality to traditional controls users. Multivariable
CD control application fully supports a “Traditional” control strategy while enabling
customers to receive significant value when they implement additional multivariable
optimization strategies provided by far superior CD Multivariable control technology.
From HINTS February 2019:
Products to be Phased Out / Notice of Change in Product Support
Status The Experion MX and MXProLine Quality Control Systems (QCS)
are impacted by Microsoft’s announced end of support for Windows 7 and
Windows Server 2018. Effective March 31, 2020, Honeywell will phase-out
and declare the end of global support for all R6xx-based versions of the
QCS family. This impacts the following: Experion MX and MXProLine
R610.x, R611.x, R612.x, R614.x & R615.x Experion MX MD Controls
R610 and R611.1 (based on Experion MX R610-615.3 and Experion PKS
R430-R43x system software releases). Experion MX CD Controls R610
(based on Experion MX R610-615.3 and Experion PKS R430- R43x system
software releases)
© 2019 by Honeywell International Inc. All rights reserved.
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QCS: 20 years from MXOpen to Experion MX R702.1Systematic Evolution of the QCS platform towards common Experion PKS architecture
1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 2019
MXOpenDa Vinci Experion MX
Experion PKS Based HMI and Alarms
R60x R61x R702.1RAE 1 RAE 2 RAE 3 RAE 4 RAE 5
• 2010: Experion MX, Q4000, EDAQ
• Current version R702.1 (April 2019)
• 2013: Virtualization
• 2019: DSA Peer to Peer Nodes
• Simplified QCS-DCS integration
• Da Vinci – scanner/sensor/actuator support
• MXOpen –”On Availability” support, Highest Risk
Da Vinci maintenance challenges
• Operating System support ended
• No Anti-Virus or security patches
• Obsolete electronics of early PMP
assemblies
Phased-Out:
• Vision
• 2002 ET
• 2002 HP
1998: Da Vinci with
Real Time Application
Environment (RAE)
Win 7 / Win 2008Win XP / W2k3Win 2k Pro/SrvWin NT /Srv Win 10 / Win 2016
Increasing Experion PKS Infrastructure
© 2019 by Honeywell International Inc. All rights reserved.
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Experion MX R702.1
• Experion MX and MXProLine R702.1 qualify for new QCS support programs:
– Remote platform support and updates, ”One-click” keep current commitment
– Perpetual QCS software license, Enhanced diagnostics and QCS 4.0 features
• New R702.1 features and enhancements:
– HMI, alarm management, diagnostics, improved control systems integration, supports new sensors/scanners
– Extended, enhanced history (EHDB) supports 2 years of data
– Advanced color map displays 400 scans, simplifying quality analysis
– Proven superior Multivariable MD and CD control packages replace Traditional MD and CD control packages
– Distributed System Architecture (DSA) enables QCS-DCS Peer to Peer communication
• R702.1 supports all DaVinci and Experion MX scanners/sensors
– No scanner upgrade required to leverage Experion MX R702.1 features
– Improves performance of existing QCS scanner/sensor hardware
• Reduced-cost virtualization – goal is 100% virtualized QCS sites for enhanced lifecycle management
• Virtual Engineering Platform (VEP) speeds project, enables quick operator orientation
Reduce support costs, enhance performance, leverage new features, keep current
© 2019 by Honeywell International Inc. All rights reserved.
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Cross direction controlMultivariable controller
• Custom designed multivariable controller
MPC (*) controller used
– Optimizes overall quality rather than single
quality parameters
– Honors process constraints and improves
control performance when CD actuators
operate near their limits
Simultaneously Optimize
Dry Weight, Moisture,
and Caliper Profiles
Optimize Moisture Profiles and
Energy Usage by optimizing
steam and moisture application
Optimize Wet Press and Reel
Moisture Profiles to improve CD
draw uniformity and runnability
ProCoat Calcoil
AFT for
Supercalenders
DevronizerAutoSlice
AquaTrolProFlow
* Modular Predictive Controller
Traditional CD
Control users will
receive CDMV
package at
migration
© 2019 by Honeywell International Inc. All rights reserved.
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Machine direction controlMultivariable controller
• Flexible multivariable controller
– Same MPC controller used for CD controls
– Robust controller less sensitive to process changes, requires fewer process model updates
• Simplified configuration
– Integrated tuning tools
• Automatic grade change
– 50% reduction in grade change losses
• Simplified, configurable,operator display
• Full suite of auxiliary controls
– Multi-former control
– Crepe ratio control
– Coater control
– Production optimization
Traditional MD
Control users will
receive the Alpha
MPC MDMV
package at
migration
© 2019 by Honeywell International Inc. All rights reserved.
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R702.1 Distributed System Architecture (DSA)
• Multiple Version compatibility – Requirements met with Experion MX R702.1
– QCS to be compatible with at least 3 previous versions of Experion PKS
– QCS to be compatible with at least 3 future versions of Experion PKS
• Version independent upgrade of QCS and DCS systems – upgrade each on merit
• DSA Peer-to-Peer communication enables:
– Consuming QCS data published through CDA in Experion PKS system
– Accessing Experion PKS displays in QCS OP-Stations
– Accessing hybrid displays in QCS & Experion PKS OP-Stations
DSA enables versatile, flexible QCS – DCS integration
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All Experion MX PC nodes available as Virtual Machines
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Experion MX Virtualization
• Multiple VM platform options, Thin Client HMIs
• Leverages Experion PKS virtualization architecture
• Host based antivirus solution
• Experion Backup and Restore
• Significant lifecycle maintenance benefits
• Flexible installation options
• Improved system availability and recovery from failure
• Experion MX R702.1 is purposely built for virtualization
– Virtual driver and system compatibility is tested to ensure a rugged, stable platform is available for maximum system reliability.
– New/migrated system is built entirely in the virtual environment, ready for deployment to the site virtual platform
© 2019 by Honeywell International Inc. All rights reserved.
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QCS Migration Philosophy – Transformation to low TCO Model
Customized
• System builds:• Vary in approach
• High customization vs. reuse
• Costly to maintain, upgrade, migrate
• Individualistic vs. collaborative
• Remote monitoring services:• Limited, costly to initiate
• Difficult to grow (sites and functionality)
• Value is hidden/poorly documented
• Optimization:• Reactive and limited
• Capacity bound
• Labor-centric vs. value-centric
• Resulting value poorly captured
Optimized
• System builds:• Common starting point with known quality
• Leverage shared application library
• Efficient to maintain, upgrade, migrate
• Signature = Honeywell, not individual
• Connected QCS / Connected Mill/Plant• Fully aligned with remote offerings
• Easy to connect, deliver, and extend
• Value-centric, emphasized in user
experience
• Optimization• Proactive – extension of Connected QCS
• Expandable/globally available
• Value-centric
• Holistic: CD+MD+Grade
Change+Machinery
Transform from customized to optimized
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Standard customization approach: maintain quality / compliance, productize popular ones
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Specials repository for QCS: capture during migrations
• Leverage shared application library
• Candidates for integration
• Detailed documentation via properties sheet
• Known input and output
• Shorter implementation time
• Shared maintenance resources
• Best practice
Displays
I/O links
MIS
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Get to R702.1 quickly and affordably to be cyber secure, reduce TCO, enable services
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2019 and Future Platform Migration Standardization / Pack
Installed
DaVinci,
MXProLine, or
Experion MX
QCS
Run
collection
tools and zip
Send to
COE
System migrated
in Virtual
Platform (VEP)
Site
orientation &
training
System
deployed for Site
Commissioning
Specials
Allocation
© 2019 by Honeywell International Inc. All rights reserved.
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New Standard Platform Migration package time lineSystem migrated and ready for review and remote operator training in ~ 2 weeks
Receive system
info packageSet up in VEP Migration Training on VEP
Document and
deliverRemote FAT
0.5 day 1 day 2 days* 1 day 1 day 1 day
Includes:
• Software build
• Databases integration
• Scanner/Sensor and Actuators integration
• User training
• Virtual platform
• Updated documentation
• Testing minus site equipment integration
• List of previous “legal” specials (no core-code modifications supported)
Excludes Customization and Specials:
• HMI, Reporting, “Convenience Specials”
Local-team ready:
• Install and commission or
• Utilize Specials Allocation bucket
Includes:
• All Honeywell, Microsoft, VMWare licenses
• Choice of Computer specifications for local purchase or
• Computer platform supplied by Honeywell
• All standard QCS system software updated
• MD and CD Traditional Controls migrated to MD and CD
Multivariable Controls (CDMV, MDMV)
Includes allocation bucket for customization:
• Use or apply to QCS 4.0 1st year subscription
Specials Repository:
• Local team registers any specials deployed on R702.1
systems
• Registration process confirms programming best practice and
upgradeability, qualifies for future productization if popular
© 2019 by Honeywell International Inc. All rights reserved.
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Pre-migration stepsGet the details first
• Honeywell tools capture details of the existing system for migration
– Run tools/scripts at site or remotely via Service Node, zip and send to COE
▪ QCS system audit tool (from RAE 5 releases)
▪ QCS diagnostic capture tool (from R6xx releases)
▪ QCS specials finder tool
▪ System architecture
▪ Network topology
© 2019 by Honeywell International Inc. All rights reserved.
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Migration Work Package – site zip package starts process
• The original software version
▪ For recent software releases (RAE 5 and R6xx) will have build-in tools for a smooth migration
▪ Pre RAE 5 releases will need more migrations steps
• The amount of customization
▪ Honeywell will try to limit the amount of customization by using proven solutions in R702.1
▪ If needed, Honeywell will use the already migrated and documented specials in its specials repository, if available.
▪ Honeywell will indicate the (financial) consequences using the remaining customization, on the short and the long term.
▪ Customization comes with a price
– The question remains:
▪ Does Honeywell meet your customized requirements with the R702 software package ?
▪ Are customizations still needed ?
▪ Do we want the same discussion in the future again?
Indication of migration challenges and impact time and costs
© 2019 by Honeywell International Inc. All rights reserved.
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Quick customization check example
No customization Customization
© 2019 by Honeywell International Inc. All rights reserved.
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Continuous Evolution and ServicesIncreased value and reduced total cost of ownership
Unequaled breadth
and depth of service
Over 2000service technicians
18 major support
centers worldwide
200+ local offices
70+ cyber security
experts globally
• System
assessments
and improvement
planning/implementation
• Advanced Solutions portfolio
to improve plant operations
• Industrial cyber security
solutions
• Migration / expansion
planning and support
• Hardware refresh
programs
• Software upgrades
LIFECYCLE
SERVICES
System performance
monitoring for active
monitoring and
patch deployment
Site specialists to
quickly resolve
issues
Parts
management
Global Technical
Assistance Center
Certified recycled parts
Remote connectivity for
faster resolution