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
Ctrl Area 4 Device Level Ring
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
Ctrl Area 5 Device Level Ring
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
DLR Representation Is Symbolic
Only...See Area Pages For Specifics
VLAN
Ctrl Area 1
Ctrl Area 1 Device Level Ring
Drives (Qty 9)
RIO – Area 1 2
VLAN
CLX – Area 1 0A CLX – Area 1 0B
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
DLR Representation Is Symbolic
Only...See Area Pages For Specifics
VLAN
Ctrl Area 2
Ctrl Area 2 Device Level Ring
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
CLX – Area 2 0A CLX – Area 2 0B
Gas Safety Panel
MODBUS
MODBUS
MODBUS x8
x6
Drives (Qty 4)
FIBER
VLAN
`
FT View SE HMI Client
HMI STRATIX
FN_DLRSTRX
MB STRATIX
DLR Representation Is Symbolic
Only...See Area Pages For Specifics
`
FT View SE HMI Client
`
FT View SE HMI Client
`
FT View SE HMI Client
DLR Representation Is Symbolic
Only...See Area Pages For Specifics
1200 I/O, 5 Areas, 8 Consoles, MES/Historian, 30 Drives, 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
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