DCS Modernization Tools, Tips &

Tricks to Mitigate Risks

Chris King • PlantPAx Migration Business Development Mgr | 06.24.19
Lee Swindler • MAVERICK Technologies, Chemical Industry Mgr
Agenda

1 2 3 4
Legacy DCS What is Rockwell How We Can
Market Dilemma Modernization? Automation® Help
& Outlook Solutions

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Global Need to Modernize Continues

Challenges:
$65B >20%
Legacy DCS Specialists have
Installed DCS nearing • Downtime
End of Life; many Retired; 3rd Parties in • Risk
demand; often Retirees called • Financial
>25 YEARS old back = Increased Risk Justification
ARC Link

Traditional Legacy Distributed Control Systems:

• Designed as large, closed & monolithic
• Many end-of-life DCS are “all-or-nothing” to migrate
• Many current DCS still rely on ‘traditional’ approach

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Modernization Barriers

 Legacy System Still Working (Hidden costs?)

 Challenge to Justify Financially
 Perceived RISK of Conversion (Change = Risk… with no Visible
Benefits). New System & Work Flows for:
 Operators Running Plant
 Engineers Learning System
 Technicians Maintaining System
 May Require Downtime  Lost Production
 Technically Complicated; May Require Outside Help

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Modernization Drivers

Resource Loss
System / Retirement Inadequate
Failures/Faults Documentation
Support System New Standards
Costs Limitations / Technology

MODERNIZATION
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Is it Obsolete… or Not?

“Process Plant Legacy DCS Hardware is largely

20-30 years old. It works fine until it doesn’t.”
Larry O’Brien as paraphrased from Failure Models for Process Automation System Components, 7/29/2009)

 Once parts start failing, MANY may fail around the same time
 Most users have no model for equipment failures
 May need to replace lots of hardware at the same time
 Further complicated with loss of competent in-house DCS expertise

There’s no ‘til there’s nothing

Downtime! BUT Downtime…

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End User Challenges:
Typical Total Lifecycle Costs Benefits of a DCS Conversion
• Hardware/Software, Networks • Enhanced Optimization Capabilities

• Spare Parts, Support contracts • Reduced Lifecycle Costs

• Obsolescence Planning • Increase Yield & Quality
• Engineering, Consulting
• Decrease Product Variability
• Commissioning/Decommissioning
• More Data  Unified Analysis  Better,
• Energy Faster Decision Making
• Floor Space
• Easier Integration with Third-parties
• Training - Operator, Maintenance, IT
• Upgrade, Expansion • More Scalable
• Unplanned downtime, Off-spec product • Integrated Power
High Value Upgrades Justify
DCS Conversions
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Poll question
Platform Vendor you’re hoping to
Modernize?
a) Rockwell
b) Honeywell
c) Emerson
d) ABB
e) Siemens
f) Schneider
g) Yokogawa
h) Other

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Agenda

1 2 3 4
Legacy DCS What is Rockwell How We Can
Market Dilemma Modernization? Automation® Help
& Outlook Solutions

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 Modernize

What do we mean by ‘Modernization’? Update Migrate

 Modernization: process of converting an Upgrade Convert

obsolete legacy DCS to a Modern Platform
 Modernization: Unique Opportunity to
IMPROVE plant operation
 Effective Modernization requires a PLAN
 Modernization is an overall lifecycle
 Must DELIVER…
 & motivate to SUSTAIN as well

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Modernization Projects Are Complicated
Various technologies, standards, work processes and considerations
Overall
Risk
SIS
Overall IEC-61511
Cost
Overall Third-party Sys
Schedule Integration
Fired
Batch Equipment
ISA-88 BPCS
TMC
Alarming
ISA-18.2

HMI Design Plant MES / ERP

ISA-101 Historian

HA Bus IT Networks
Requirements Integration

Instrument
Updates
Panel Reuse
Drawing Most users don’t have staff focusing on latest
Updates
trends, technologies & best practices.
Resource
Cutover Plan
Training
They don’t know… what they don’t know…
Installation Optimization MAC

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What Is FEL?
FEL FEL stands for Front-End Loading

PROCESS It’s a process for providing engineering evaluation and assessment prior
to the actual project implementation

THREE FEL is typically broken into three steps: FEL1, FEL2, & FEL3
STEPS

BUDGET Each step has a different technical focus and includes a cost estimate and
SCHEDULE
schedule for implementation

ACCURACY The accuracy of the cost estimate improves through each phase

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Are Early Engagement FELs Important?

ABILITY TO CHANGE OUTCOME COST TO CHANGE OUTCOME

PLANNING DESIGN & CONSTRUCTION &

(FEL1->FEL2->FEL3) DEVELOPMENT COMMISSIONING

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A Good FEL Provides:
I/O List

System architecture

Project execution plan (PEP) with responsibility matrix (RACI)

and risk matrix
Installation and commissioning plan

Project schedule

Total installed cost (TIC) estimate

Total cost of ownership (TCO) estimate

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Conversion Strategies (Pros & Cons)
Rip & Replace Phased
• Requires extended shutdown • No Required Shutdown for HMI
• Requires capital funding approval replacement
• Considered High Risk to customer • Considered Lower Risk
• Replace entire system in weeks • May take years to migrate entire
(lower TCO) system (higher TCO)
• Requires less legacy DCS expertise
• Requires more legacy DCS
• Cannot be easily switched back to expertise
legacy system
• Can be switched back to legacy
DCS as contingency

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Modernization Best Practices: The “E’s”

1. Early Planning
2. Establish Standards Ease
3.Execution Discipline
4.Engage Experts
5. Expect Innovation (Don’t Replicate!)

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Agenda

1 2 3 4
Legacy DCS What is Rockwell How We Can
Market Dilemma Modernization? Automation® Help
& Outlook Solutions

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Poll question
For your Modernization, would you prefer
to:
1. Only replace the HMI layer, Retaining your
Legacy Controllers & I/O?
2. Replace HMI & legacy controllers, Retaining
Legacy I/O cards (e.g., not re-wire field
instrumentation to new controllers)?
3. Replace all control hardware except Field
Terminations, Retaining existing field wiring?
4. Replace everything, including field wiring?

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Talking Tools… you have many choices for Phased Migrations

Phase User Need Tools, Solutions & Services

Early HMI only replacement, keep Dedicated Infi90 interface, Engineered
legacy controllers & I/O Interfaces, OPC servers

Next Replace HMI & controllers Above, plus I/O Scanner Modules

Later Replace HMI, controllers & I/O Above, plus Custom Cable Solutions

ANY Replace database, logic & DB Conversion Tools, re-engineering

graphics services Expect Innovation,
Don’t just Replicate!

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 Legacy Process Control System Migration / Conversion Solutions
Conversion Database OPC Server Custom Cable Engineered I/O Scanner
Vendor / Platform
Services Conversion Tool Software Solutions Interface Module
TDC 3000 / TPS
Green = solution
Ho

IPC-620
ne

available
yw

PlantScape/Experion
el
l

Moore APACS
Si
e

Teleperm M
m
en
s

Fisher PROVOX
Westinghouse WDPF
Blank = no
Rosemount RS3 current solution
Em

Rosemount RMV9000
er
so
n

DeltaV
Ovation
Foxboro I/A
Recent Focus &
Sc

Wonderware
hn
ei

Foxboro Spectrum
d

Improvements
er

Centum CS
Yo

Centum 1000
ko
ga

Micro XL
w

ENABLERS to
a

Bailey NET90/INFI90 Dedicated

Taylor MOD300
Advant help convince &
justify DCS
AB

Freelance
B

System Six
SATTline Modernizations
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 Tool Assisted Migration Services
Exports from Crawlers / ACM
Legacy System
 Reduce Risk
Application Code
Manager
Automated  Reduce Timelines
Conversion
 Leverage SME’s
 Global Consistency
 Enforce PlantPAx®
Manual
Conversion
Guidelines &
Recommendations
Fully migrated system

Review Legacy Logic /

Graphics / Configuration,
Normalize for every Platform
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Review Existing Configuration; Normalize all for every Platform
Configuration Logic Graphics

• Review data extracted from Legacy • Graphical representation of Legacy • Graphical representation of Legacy
system logic displays
• Full report containing: • Supports navigation between pages • Identifies animated graphical
• A complete list of all instructions • Click on instructions to: objects
• 1 sheet / instruction type, including all • Review instruction configuration • Report lists all objects & animation
instances & all configuration details • Launch instruction help file • Click graphical objects to Review:
for each instance • Configuration
• Formatted for ACM import • Animation
• Connections

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OPC Servers

•Commercially Available –
Field Proven

•“Whitebox” PC or SAM (PC

in a ControlLogix® rack)

•FactoryTalk® View can be

host server
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(Honeywell Controller) C200  ControlLogix®
PlantScape or
Experion DCS
C200
Less Risk
Short, Deterministic
Length Downtime
Both use
No Chassis Change Allen-
for Controller & I/O Bradley®
No Field Re-wiring, I/O!
Legacy Terminations stay
All New Warrantied I/O Replace Control
& I/O modules in
Strong RA Expertise / Chassis, Field
Services I/O Wiring
ControlLogix® Untouched
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Cable Solutions
Honeywell

Foxboro IA

Benefits
APACS
• Eliminates
Field Re-wiring
• Reduces
Downtime
• Mitigates Risks
Bailey Provox
• Cost-effective
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 From 2010 ARC
publication:

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I/O Scanners (APACS, PROVOX, IPC620)

Benefits
• 2 modes – Shadow
& Run
Includes
• Cuts costs – retain
SMART
™ I/O legacy I/O
• Fast, low risk
legacy controller
cutover
I/O Bus PROVOX Serial I/O network Serial Remote I/O network

Remote Modulrac PROVOX Series 10 or 20 I/O IPC620 Remote • Redundant or

I/O Rack
Simplex
APACS CLX-APX PROVOX CLX-PVX IPC-620 CLX-IPC

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PMIO Scanner
TDC 3000 I/O Interface: Form Fit for ControlLogix
Reduced-Risk Migration strategy for legacy TDC 3000
28 x IOPs per PMIO Scanner
Redundant I/O Link (Channel A & B)
Redundant PMIO Scanner (Active / Standby)
Dedicated Add-On-Profile (AOP) for Logix Integration
Diagnostics available in Logix
Easy to configure – Slate Configuration Utility

CLASS 1, DIV 2,
GROUPS A, B, C, D

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 Configuration
Scanner Modes:
Run - PMIO Scanner configures IOP, reads inputs & controls outputs
Shadow - Listen only, provides Input & Output Readback values to Logix for
checkout/testing
Learn - Uploads configuration from (Honeywell) pre-configured IOPs
Aparian Slate utility (free downloadable) used for Configuration
Options to Add & Configure IOPs:
EB (Exception Build) File Import (most common)
Online Learn Option
Manual Configuration (not typically done)

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Topology Example
2 x 15 plus 1 x 7-slot racks
35 IOPs (>28)
Two PMIO Scanners
Segmented I/O Link – Run Mode

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Dedicated Interface for Bailey &
Special Application Modules (SAM)
Benefits
• Peer-to-peer Communication
• Increases Performance
• ControlLogix® Environmental Specs
• Data Repository  ControlLogix®
Serial Ethernet Controller
CIU / ICI HDL
• Data Native to FactoryTalk®
Bailey Plant Loop PROVOX Applications
Data Highway
• Integrated Solution
• Optimized Data Server
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Bailey Net90 / Infi90 Phased Migration – Phase 1
Op Station 3 PlantPAx® EWS Redundant Servers Op Station 4

Ethernet

OIS Op Station1 OIS Op Station2

Bailey EWS

Serial to Enet
Converter Serial to Enet
1. Deploy new EWS Servers
Converter & Networks
CIU
CIU CIU
2. Deploy legacy network
interface
CIU Plant Loop or Infi Loop
3. Create/Test new graphics in
parallel with legacy consoles
PCU 1 PCU 2
4. Replace remaining legacy
consoles with new technology
TU TU

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Rip & Replace Example: Foxboro I/A
WP51 WP51 AW51
Console 1 Console 2 EWS

Op Station 1 PlantPAx® EWS Redundant Servers Op Station 2

Ethernet Nodebus
CP30/40/60 CP30/40/60

1. Create/Test graphics &

controller configuration
ControlLogix® 2
ControlLogix® 1
2. Power-off, decommission
Fieldbus

legacy DCS
FBM’s FBM’s
3. Deploy new DCS
Technology

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PLC-5® Migration Tools & Utilities
RSLogix™ Project Migrator:
 Converts legacy RSLogix™ 5
or 500 project export file to
Logix project for MicroLogix™,
SLC™ and PLC-5®
 Free download
 7 step conversion
Integrated Architecture® Builder: Equipment & Wiring Conversion:
 Graphical, user-friendly software tool that  Seamless conversion without
automatically defines and configures a removing any field wires in
contemporary ControlLogix®-based architecture minutes
based on your legacy PLC-5® system
 Builds a detailed bill of materials based on your
current PLC-5® based control system
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Third-party PLC: Swing-arm Solutions from Emphatec

• Modicon 984
• Modicon Quantum
• GE Series Six
• GE 90/70
• Honeywell IPC620
emphatec.com Link PUBLIC | Copyright ©2019 Rockwell Automation, Inc. | 35
Third-party PLC I/O Scanners from ProSoft

Modicon Texas General Square D

Instruments Electric

Enet/IP > S908 Enet/IP > TI RIO Enet/IP > Genius Enet/IP > SQD RIO

AN-X2-MOD AN-X-TI AN-X2-GENI AN-X2-SQD

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Agenda

1 2 3 4
Legacy DCS What is Rockwell How We Can
Market Dilemma Modernization? Automation® Help
& Outlook Solutions

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 Published DCS Migration Collateral
White Papers available on Literature Library MAVERICK White
http://Literature.rockwellautomation.com > Support > Product Resources >
Paper Library

Honeywell Migration Bailey Migration PROVOX Migration Foxboro Migration APACS Migration
MIGDCS-PP005B-EN-E MIGDCS-PP006B-EN-E MIGDCS-PP007B-EN-E MIGDCS-PP008B-EN-E MIGDCS-PP009A-EN-E

Justification for a Legacy DCS Migration Strategy & Optimization after

Control System Migration Project Implementation Migration
PROCES-WP005A-EN-P PROCES-WP006A-EN-P PROCES-WP008A-EN-P

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GPTC’s, Tech Leaders & Industry Specialists
LARGE END USERS
Consult w/ corporate engineers
to establish standards
PROCESS OEMs
Work w/ OEM to rewrite their
applications on PlantPAx®
Help customers understand
how we migrate from legacy
DCS to Rockwell Automation
SOLUTION PROVIDER
Train on best practices Work with delivery partners to
of using PlantPAx® assist in technology adoption
A&E to the Rockwell Automation®
Establish specs for firms process control application
to pre-select PlantPAx®
Work across global regions &
key customers to assist in
project implementation (A&E,
contractor, SI & end user)

Technical Leaders/SME’s
ABB
Emerson
Honeywell
Rockwell Automation®
Siemens

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Rockwell Automation Services
Minimizing Risk. Maximizing Productivity.

Workforce People & Asset Asset & Plant Information

Support & Training Safety Optimization Infrastructure & Security

Product & Application Lifecycle Support

Solving Critical Manufacturing Issues

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Partner Ecosystem

ENTERPRISE SALES & PRODUCTS &

PARTNERS
Strategic alliances with companies
like Cisco Systems, Endress+Hauser,
and Microsoft
SOLUTIONS PARTNERS
Approximately 320 Distributors
and over 100 Solution Providers
worldwide for local support
TECHNOLOGIES
PARTNERS
Over 1000 products from over 100
companies worldwide help to extend
our technology into adjacent areas

A large global ecosystem for solutions and support of your Rockwell Automation® installed base.

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 Thank you
www.rockwellautomation.com

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