Migratie oplossingen AUP 20. Nico Stassen CSM Account Manager. Wim van der Heide Solution Architect

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2 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 2 Agenda 1. Waarom zou u moeten migreren? 1. Waarom zou u moeten migreren, welke scenario's zijn er? 2. Migratie Tools 3. Ervaring & Referenties 4. Conclusie

4 Copyright 2015 Rockwell Automation, Inc. All rights reserved.copyri 4 Migratie doelstellingen Onze migratie services en ervaringen zijn er op gericht: Risico s te minimaliseren Gefaseerde aanpak, minimale downtime Kosten te verlagen b.v. bestaande bekabeling te laten bestaan bestaande I/O hergebruiken migratie tools toe te passen, reduceren conversie kosten! Voldoen aan S88 of regelgeving (bv. 21CFR Part 11) Hergebruik opgedane ervaring in projecten Investeringen van onze klanten te beschermen PLC3/PLC5 meer dan 30 jaar op de markt Migratiepad oudere platformen naar nieuwste technologie (Logix platform) Hardware veranderd, applicatie migreren

5 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 5 Komt u dit bekend voor? 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?

6 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 6 Verschillende types/senarios migraties 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

9 TDC 3000 gefaseerde Migratie - Phase 1 Op Station Op Station Op Station EWS/OPC Server Redundant Servers Ethernet US US US EWS App Node LCN NIM AM NIM AM NIM UCN UCN UCN PM HPM APM FTA FTA FTA Copyright 2015 Rockwell Automation, Inc. All rights reserved.

10 TDC 3000 gefaseerde Migratie - Phase 2 Op Station Op Station Op Station EWS/OPC Server Redundant Servers Ethernet CLX EWS App Node LCN NIM AM NIM AM NIM UCN UCN UCN PM CLX HPM CLX APM FTA FTA FTA Copyright 2015 Rockwell Automation, Inc. All rights reserved.

11 TDC 3000 gefaseerde Migratie - Phase 3 Op Station Op Station Op Station EWS/OPC Server Redundant Servers Ethernet CLX EWS App Node LCN AM NIM UCN CLX CLX APM CLX FTA FTA FTA Copyright 2015 Rockwell Automation, Inc. All rights reserved.

12 Copyright 2015 Rockwell Automation, Inc. All rights reserved. TDC3000 Rip & Replace US US US EWS Op Station Op Station Op Station EWS App Node Redundant Servers LCN Ethernet NIM AM NIM AM NIM UCN CLX CLX UCN CLX UCN CLX PM FTA HPM FTA APM FTA FTA FTA FTA

14 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 14 Series 200 I/O Reuse Series 200 I/O (Flex I/O) Series 200 has been used for both SattLine and SattCon 200 As Central I/O using 200-ANN adapter As distributed I/O using 200-ACN adapter on ControlNet ver 1.25

15 Copyright 2015 Rockwell Automation, Inc. All rights reserved I/O Series adapter en netwerken Replace Comm Adapters with AB core network adapter. ControlNet to keep also Network wiring Ethernet for a new network implementation Use the new system controller to control S200 I/Os Change for a new Controller Change this for RA Comm Adapter

16 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 19 I/O Installatie Kit 19 I/Os are obsolete and spare parts are limited Chassis mounting system to install 1756 I/O on the same physical space SattLine 19 AL I/O use standard 19 face mounting style New Chassis assembly to install CLX I/O at rack face Power Supply on the back but with cable no chassis installed Re-use SattLine field I/O wiring

19 Copyright 2015 Rockwell Automation, Inc. All rights reserved. DCS Migratie Tools & Utilities DCS Platform Available Tools RA Value TDC, TPS, IPC, PlScape Foxboro I/A 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 MFC interface Honeywell DE interface I/O Scanner for IPC-620 LCN, UCN & HG direct Interface Custom Cables Database Convert Tool (TD3000/PlantScape) OPC Server Custom Cables for FBM100 series I/O Database Convert Tool Logic Conversion Utility Logic Conversion Utility I/O Conversion Cables I/O Scanner Phase migration enabled 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 RA/SSB Experience GPTC support Provides consultancy services to change existing standards and adopt new technology RA/SSB Experience GPTC support In house tools to assist during migration

20 Copyright 2015 Rockwell Automation, Inc. All rights reserved. Smart DCS Migraties Third Party Crawlers One by Technology ABB Mod 300 Exported File Exported Data GEMS Code Manager Process Objects Honeywell TDC 3000 Foxboro I/A Exported Data Exported Data Data Mapping Utility GEMS Cement SattLine Exported Data Standard Common Format RA Tool Export from Original System Structured Software Ready to reuse

21 Copyright 2015 Rockwell Automation, Inc. All rights reserved. Functionaliteit-equivalent tool Functionality Matching Tool use information from Database conversion tool to: Compare SATTLine function block with RA library blocks Create a equivalence table for reusability Identify exception blocks Possibility to add new block into Lib

22 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 22 Communicatie 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. Net/Infi90 Connect to Legacy DCS Systems PROVOX Rack Interfaces communicates through CLX backplane using communication bridges to the DCS TDC/TPS WDPF Supports Serial, SCSI, and Ethernet CLX is Data repository Data is native to PlantPAx Visualization, Historian, etc APACS Optimized data server Interface Legacy System Network Interface Legacy System Network Interface

23 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 23 Communicatie Dedicated Interface naar Honeywell Ethernet/IP Interface Benefits 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

25 Copyright 2015 Rockwell Automation, Inc. All rights reserved. 25 PLC Conversie Tools & Utilities HMI Conversion (Free Service) I/O Scanner to Logix Logic Code Conversion (Paid Service) I/O Swing-Arm / Field Wiring IF Modicon WW, ifix Modicon RIO (S908) Proworx32, Proworx NXT, Proworx Plus, Modsoft. 800 Series I/O WW, ifix GeniusLan Series 6 GE Fanuc Series 6 local I/O network Series 90 TI WW, ifix Profibus DP TI RIO TiSoft TI 505 Siemens WW, ifix Profibus DP (S5 & S7) Step 5 Step 7 S5 Telemecanique TSX WW, ifix Service TSX SattCon WW, ifix Service

26 Phase I Tools Migratie Modicon Fase I: Monitor Mode Phase II Phase III Phase IV Modbus, Modbus Plus, TCP HMI / EOI* *Making Human Machine the decision Interfaces to keep or replace HMI and before Programming performing Panels controller (IDT) code conversion will save time and money 984,584, or Quantum Controller Peer-to-peer EtherNet/IP Quest Check your converted logic before implementing: Run Logix in monitor mode, reading inputs & outputs disabled S908 Remote I/O Network 800 Series Remote I/O Drop Quantum I/O Drop Quest AN-X module acts as a bridge which allows Logix communications to Modicon I/O 800 Series Remote I/O Copyright 2015 Rockwell Automation, Inc. All rights reserved.

27 Phase I Migratie Modicon Fase II: Controller Vervanging Phase II Phase III Phase IV Tools HMI / EOI Replace the controller w/o replacing the existing I/O Logix Modbus, Modbus Plus, TCP Peer-to-peer 984,584, or Quantum Controller Human Machine Interfaces and Programming Panels (IDT) Quest AN-X module acts as a bridge which allows ControlLogix communications to Modicon I/O EtherNet/IP Quest S908 Remote I/O Network ProSoft communication modules allow for Peer-to-Peer communications 800 Series Remote I/O Drop Quantum I/O Drop 800 Series Remote I/O Copyright 2015 Rockwell Automation, Inc. All rights reserved.

28 Phase I Migratie Modicon Fase III: HMI Conversie Phase II Phase III Phase IV Tools Ethernet /IP Modbus, Modbus Plus, TCP Peer-to-peer HMI / EOI Factory Talk View Human Machine Interfaces and Programming Panels (IDT) Logix EtherNet/IP Quest Replace legacy HMI/EOI w/ Engineering Services graphic utilities to assist conversion of PanelMate, TCP, WonderWare, and Intellution S908 Remote I/O Network 800 Series Remote I/O Drop Quantum I/O Drop 800 Series Remote I/O Copyright 2015 Rockwell Automation, Inc. All rights reserved.

29 Phase I Migratie Modicon Fase IV: Vervanging obsolete I/O Phase II Phase III Phase IV Ethernet /IP Tools Modbus, Modbus Plus, TCP Factory Talk View Human Machine Interfaces and Programming Panels (IDT) Peer-to-peer Logix EtherNet/IP Quest S908 Remote I/O Network With the Swing-Arm Interface legacy Modicon 800 I/O racks can quickly be replaced w/1756 I/O without disturbing the I/O field wiring one rack at a 800 time Series if necessary Remote I/O Drop Quantum I/O Drop 1756 I/O with Swing-Arm Interface 800 Series Remote I/O Copyright 2015 Rockwell Automation, Inc. All rights reserved.

50 Copyright 2015 Rockwell Automation, Inc. All rights reserved. AVEBE VMF Fabriek Application: Migratie Honeywell Plantscape/Experion naar PlantPAx Optimalisatie productie Solution: Standaard Proces library Standard Control AOI, S88 Re-use hardware components VMware Architecture Besparing energie/ruimte Hoge beschikbaarheid Minimale onderhoud Technology: PlantPAx DCS

52 Copyright 2015 Rockwell Automation, Inc. All rights reserved.copyri 52 Hoe kunnen wij u ondersteunen? Onze moderne technologie verschaft u één platform voor de fabriek. Rockwell Automation & Partners hebben ervaring in de Industrie van onze klanten. Onze portfolio aan producten & services geeft de klant een One-stop-shop end-to-end solution. Onze oplossingen en expertise is wereldwijd beschikbaar Vanuit de operators perspectief dezelfde view als het oude systeem Korte shutdowns door gefaseerde migratie aanpak Reduceren van risico's met migratie tools