Upgrade to a Modern DCS
PUBLIC INFORMATION
Rev 5058-CO900E
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Agenda
1. Why should you consider migration ?
2. Experience & References
3. Migration Tools
4. Conclusion
PUBLIC INFORMATION
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
2
Agenda
1. Why should you consider migration ?
2. Experience & References
3. Migration Tools
4. Conclusion
PUBLIC INFORMATION
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
3
Does this looks familiar to you ?
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Aging DCS System running your production ?
Increase risk to meet your production quota ?
System risks due to lake of spare parts & engineers ?
Inflexibility to quickly change production ?
Are you OPEX maintaining old systems?
• High cost for support , spare parts , System upgrades
• High cost for system expansions & complex licenses ?
• Going through change orders to get what you wanted ?
Does your plant information system looks like this ?
• Using excel for key production reports ?
• Not easy to extract data from your DCS system ?
• Not enough live data to make quick & good decision ?
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
4
Migrate to PlantPAx , a Modern DCS
Reduce current risk of operation and improve productivity
• Where possible, preserve engineering investments in legacy DCS / PLC
• Reduce production downtime during conversion
70’s- 80’s systems are likely to fail from component failure
> Reduce operations risk and unplanned downtime
Move away from systems installed end 80’s early 90’s with
limited capabilities and high maintenance costs
> Leverage modern technology for your production
Convert systems from recent technologies; Provide process
enhancements or expansions following new regulations &
Standards(Traceability, 21 CFR, S88, .)
> Optimized and sustainable production
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6
Different types of Migration
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Rip & Replace
Leverage latest technology
Requires plant shutdown & high capex impact
Requires detailed feed study as typically no documents
Vertical Migration
• Phased migration with reduced risks
• Phased capex with no plant shutdown required
• Allows maintaining parallel systems
Horizontal Migrations
• Reduced risk & operator friendly
• Allows fallback solution & optimized implementation
• Maintained risk for product failure
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7
Phased Migration - Horizontal
EWS
Legacy Console
Legacy Console
Operator Station
Operator Station
CIA
CIA
Legacy EWS
Legacy Console
Operator Station
HDL
CIA
CLX +
HDL
HDL
SAM
Ethernet
Data Highway
LTD
NTD
Data Highway II
Series 10 Control Unit
Series 10 Multiplexer
Series 20 Control Unit
UOC or IFC
Control Unit
UOC or IFC
Series 10 Mux IO
Series 10 Mux IO
HDL
Series 20 Control IO
RTU
RTU
Series 20 Control IO
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8
Phased Migration - Vertical
EWS
ENVOX EWS
Operator Station
Operator Station
Operator Station
HDL
CLX +
HDL
SAM
Ethernet
Data Highway
LTD
Data Highway II
NTD
Series 10 Control Unit
Series 10 Control Unit
Series 20 Control Unit
UOC or IFC
UOC or IFC
UOC or IFC
CLX
CLX w/
PROVOX
I/O Scanner
Series 10 Mux IO
Series 10 Mux IO
CLX
Series 20 Control IO
RTU
PUBLIC INFORMATION
HDL
RTU
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9
Phased Migration - Phase 3
EWS
ENVOX EWS
Operator Station
Operator Station
Operator Station
HDL
CLX +
HDL
SAM
Ethernet
Data Highway
LTD
HDL
Data Highway II
NTD
Series 20 Control Unit
UOC or IFC
CLX
CLX w/
PROVOX
I/O Scanner
Series 10 Mux IO
Series 10 Mux IO
CLX
Series 20 Control IO
CLX
RTU
PUBLIC INFORMATION
RTU
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10
Rip-and-Replace Conversion
(full system)
EWS Console
Op Station 1
OIS Console
OIS Console
EWS
Op Station 2
Redundant Servers
CIU
CIU
CIU
Ethernet
Plant Loop or Net
CLX 1
CLX 2
PCU 1
TU
TU 1
PUBLIC INFORMATION
CLX A
TU
PCU 2
TU 2
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
11
Example of a Rip and Replace Migration
(by area/process)
EWS Console
OIS Console
OIS Console
CIU
CIU
CIU
Plant Loop or Infi Net
PCU 1
PCU 2
TU 1
PUBLIC INFORMATION
TU 2
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12
Agenda
1. Why should you consider migration ?
2. Experience & References
3. Migration Tools
4. Conclusion
PUBLIC INFORMATION
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
13
Customer & Project Profile
• Warwick Chemical: Global market leader in the manufacture and supply of
bleach activators for the detergent and biocides industries.
Supply 60 countries in 5 continents
• What to Migrate? Fisher-Rosemount RS3 DCS installed at the site between 1994
an 2001, by 2013 will attain the status of “Obsolete”
• Business Drivers to change
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Obsolete Technology Platform
Improve support and reduce costs
Future plans for Process improvements at site
Desire for single platform from a supportability Point
of View
•“It has to be said that Rockwell were not initially considered as a potential vendor for the DCS
replacement and it was a discussion that I had with the Account Manager that started the ball rolling,
so in that sense PlantPAx was an outsider. Which underlines the strength of the offering and the open
nature of the assessment process”
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14
The Process
A wide range of chemical
processes employed, including
most of the ‘classic’ chemical
process ‘unit operations’
Continuous reaction
Batch reaction
Distillation
Evaporation
Crystallisation
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Filtration
Vacuum drying
Granulation
Milling
Sieving
Fluid bed drying
Combustion
Incineration
Waste water
treatment
Warehousing
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Project
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Rockwell Automation
EMEA Engineering delivery
• Irish based alcoholic drink producer stated project
was 100% Emerson
• Application focussed on Delta V
• PlantPAx capability overviewed as an alternative
• PlantPAx gave a better solution in Technical,
Size and Life Cycle Costs
• PlantPAx was selected over Delta V
• RA responsiveness and attention to need made the
difference
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17
Rockwell Automation
EMEA Engineering delivery
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UK sugar producer
Dominant Honeywell site with 40,000 I/O on TDC/Experion
High Life Cycle Costs
TDC obsolescence forced review of batching processes
Rockwell Automation LSBM benchmarked against Honeywell
Rockwell Automation solution more advanced than Honeywell
Rockwell Automation Migration Proposal and Life Cycle Options selected
Multi site OEE in progress
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Customer & Project Profile
• CLT – Portugal (Companhia Logistica Terminais Maritimos)
• Deep Water Sea Port for Oil Storage & Logistic Operations
• Supply 100% Crude to Sines Refinery able to refine 220K Barres/day
• Used to export Oil Products (Fuel Oil, Diesel, Gasoline, Naphtha, …)
• What to Migrate? Honeywell TDC-3000, Based on distributed IPC-620 Controllers and I/Os
• Why to Migrate?
• Obsolete system not easier to find spare parts and very
expensive
• High maintenance cost in service contracts
• Provide flexibility to change operations for new
demanding needs and regulations
• New License requirements
• Main Challenges?
• Demonstrate superior value than existing 20+ year partner
• Keep existing communication structure to maintain terminal operation
• Reduce Customer Risk– Shutdown, Downtime, Rockwell Automation Capabilities
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Legacy System Architecture
First system to
be migrated
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DCS migration for water authority
Application:
• Complete upgrade of
a water purification
plant
Solution:
•Controls for filter
beds, fluoride and
pumping
•Design, engineering,
startup and
operator training
Technology:
• PlantPAx DCS
• Smart instruments
Project commissioned without interruption in city water supply
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21
DCS Migration for Paper Mill
Application:
• Stock prep
• Paper machine control
Solution:
•Process and power
control
•Network design
•Design, engineering,
startup and operator
training
Technology:
• PlantPAx DCS
• MV Drives, MCC
US$5 million CapEx reduction for plant reconfiguration
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Customer Testimonial
• Working with Rockwell Automation we found answer and tangible
results for our main concerns:
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“Low risk cutover solutions / short-term operational transition”
“System that utilizes ‘open’ platforms and technologies easier to interface with our
existing management tools” (MES/Asser Management, Reporting)
“Preserve my Intellectual Property (IP)”
“Better Plant Control… notify when a process is ‘going out of spec’ before having
problem”
“Help me to control my processes better to increase production, product quality
and consistency, reduce energy consumption and waste”
“Reduced Life Cycle Costs”
• Capital cost
• Operating costs: Licenses, changes, upgrades, maintenance
“Improve my current support”
“Vendor confidence”
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Agenda
1. Why should you consider migration ?
2. Experience & References
3. Migration Tools
4. Conclusion
PUBLIC INFORMATION
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
24
DCS Migration Tools & Utilities
DCS Platform
Available Tools
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In-chassis (1756) dedicated interface
Custom Cables
OPC Server
Database Convert Tool
• In-chassis (1756) I/O Scanner for S10/S20
• OPC Server
• Custom Cables
• Database Convert Tool
TDC, TPS, IPC, PlScape
Foxboro I/A
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MFC interface
Honeywell DE interface
I/O Scanner for IPC-620
LCN, UCN & HG direct Interface
Custom Cables
Database Convert Tool (TD3000/PlantScape)
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OPC Server
Custom Cables for FBM100 series I/O
Database Convert Tool
Logic Conversion Utility
RA Value
• Enable Phase migration by layer or
area/system
• Provide communication options with current
system and field instrumentation
• No changes for field wiring
• Safe Tag conversion avoid errors,
duplication or omissions
• Rockwell Automation Global Solutions
• Dedicated Process consultants support
provides consultancy services to change
existing standards and adopt new
technology
• Logic Conversion Utility
• I/O Conversion Cables
• I/O Scanner
• Rockwell Automation Global Solutions
• Dedicated Process consultants support
• In house tools to assist during migration
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Communications
OPC Servers & Rack Interface
Benefits
• Enable a fast, easy and integrated way to
communicate to Legacy DCS Systems
• Connects to Bailey, Honeywell, Fisher, Foxboro,
Moore, Yokogawa, etc.
• Rack Interfaces communicates through CLX
backplane using communication bridges to the
DCS’
• Supports Serial, SCSI, and Ethernet
• CLX is Data repository
• Data is native to PlantPAx Visualization, Historian,
etc
• Optimized data server
Interface
Legacy System Network
Net/Infi90™
Connect to Legacy
DCS Systems
TDC/TPS™
PROVOX™
WDPF™
APACS™
Interface
Legacy System Network
Interface
On
show
floor
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Communications
Dedicated Interface to Honeywell
Benefits
Ethernet/IP
Interface
• Direct interface with UCN, LCN & Highway
Networks
• Supports read/write parameter data on
networks, Interface Module (NIM) and
Application Modules (AM)
• Appears as a Node on the UCN, LCN &
Highway
• CLX comms as a Logic Manager
• Can be deployed in redundant configs.
• Connects directly to the UCN, LCN and
Highway
Honeywell UCN/LCN/Highway
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27
Communication
I/O Scanner
I/O Scan
CLX
Honeywell
IPC 620 I/O
PROVOX
Series10/20
ABB MOD 300
TRIO
MOORE
APACS
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Application Conversion
Database
Bailey
Foxboro
PlantScape
Control Strategy
Bailey PID
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Faceplate Library
CLX PIDE
Reduces Risk….
Reduces Engineering Hours
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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29
Custom (TU) cable solution
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PLC Conversion Tools & Utilities
HMI Conversion
(Free Service)
Modicon
Siemens
Telemecanique
TSX
SattCon
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Logic Code
Conversion
(Paid Service)
I/O Swing-Arm /
Field Wiring IF
WW, iFIX
Modicon RIO
(S908)
Proworx32, Proworx
NXT, Proworx Plus,
Modsoft.
WW, iFIX
GeniusLan
Series 6 local I/O
network
Series 6
Series 90
WW, iFIX
Profibus DP
TI RIO
TiSoft
TI 505
WW, iFIX
Profibus DP
(S5 & S7)
Step 5
Step 7
S5
WW, iFIX
Service
TSX
WW, iFIX
Service
GE Fanuc
TI
I/O Scanner to
Logix
800 Series I/O
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31
Remote I/O Scanners
Phase 1
Ethernet (Enterprise)
Factory Talk View
HMI / EOI
Phase 3
Ethernet /IP
Serial
Phase 2
Logix
EtherNet/IP
Remote I/O BUS
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GE Genius
Modicon S908/800
Profibus
TI 500/505
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Wiring Conversion System
Siemens S5 -135
Télémécanique TSX7
TI
Modicon
GE
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33
Agenda
1. Why should you consider migration ?
2. Experience & References
3. Migration Tools
4. Conclusion
PUBLIC INFORMATION
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
34
Upgrade to a better process control system...
Differentiation areas
User Value
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Process control, Safety systems and Motor •
control
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Lower Total Cost of Ownership
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Provide flexible life-cycle asset investment
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& service at a realistic price
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Plant-wide Control with a single, scalable
architecture
Optimized and Sustainable Production
Realize productivity and efficiency goals
Provides a staged upgrade path from
existing legacy system
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Single Multi-Discipline Process Control technology platform
Open information flow from process to enterprise trough control
Scalable across applications, operations and environments
Single Information reporting from multiple sources
EtherNet/IP enabled – IT Friendly
Lower and flexible Hardware requirements & Licensing model
Reduce operator error and training costs
No expensive long term support required
Reduced part needs and improved MTTR
Lower IT integration effort
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Reduce inefficiency and improve product consistency & quality
Enables fast change-over for Batch operation
Better and easier integration of Process Skids
Rationalize Energy and Raw material consumption reducing waste
Better visualization and feedback to improve diagnose
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Increase system availability and reduce downtime risk
Low risk cutover solutions to accommodate short downtimes
Preserve Intellectual Property (IP)
Improve current support, reducing vendor dependence for tech assistance
Standardization and reduction of maintenance costs
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Questions?
For additional information:
 PlantPAx : www.plantpax.eu
 O&G information: http://oilandgas.rockwellautomation.com/en/
 Download Process Safebook: http://www.emea.rockwellautomation.com/
 Request a PlantPax Demo: http://www.emea.rockwellautomation.com/process
 Join us at PSUG & AF: http://www.rockwellautomation.com/rockwellautomation/events/automation-fair/overview.page
PUBLIC INFORMATION
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Rev 5058-CO900E
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.