Migrating Your Legacy DCS to PlantPAx®

PLC-5® & 3rd party PLC Migration Capability

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 PLANT-WIDE SCALABLE SECURE FLEXIBLE
Control and Optimization and Modular Open and Information-enabled Delivery and Support

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 Agenda
Legacy DCS Market Outlook
Migration Tools – Reduce Risk & Cost
Migration Methods: Phased, Vertical, or Rip & Replace
PLC-5® & 3rd Party PLC Migration Capability

How We Can Help

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 Global DCS Migrations Market Outlook

$65B $12B 20% 3rd

Process Automation Systems are Of experts with Party contractors
Systems are nearing >25 Years Old legacy systems are often required &
End of Life Retired High Risk

In NA/EMEA, >75% of
DCS revenues come from
expansion, maintenance, repair
or overhaul (MRO) of
existing process systems

End-User Challenges End-User Persona

• Financial Justification (Economics) • Risk Averse
• Limited Downtime (JIT Inventory Strategies)
• Loss Of Technical Resources
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 End user Challenges:
Financial Justification
Typical Total lifecycle Costs Benefits of a DCS Migration
• HW, SW, Networks • Enhanced Optimization capabilities
(multi-systems PLC, Drives, DCS) • Reduced lifecycle costs
• Engineering, Consulting
• Increase yield and quality
• Simulation
• Commissioning/Decommissioning • Decrease product variability
• Support contracts • Digital Bus Enabled
• Energy
• More data – faster decision making
• Spare Parts (multi-systems)
• Floor Space • Easier integration with third-party
(OEMs, ERP, MES, etc)
• Training - Operator, Maint, IT
• Upgrade, Expansion • PWC Scalable (10 to 10K I/O)
• Off-spec product • Integrated Power
• EPA Compliance
• Unplanned downtime Users Require High Value Upgrades
• Obsolescence Planning to justify DCS migrations
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 Industries where we are engaged…

Metals • Water/Wastewater • Mining • Specialty Chemical • Power • Oil & Gas

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 Agenda
Legacy DCS Market Outlook
Migration Tools – Reduce Risk & Cost
Migration Methods: Phased, Vertical, or Rip & Replace
PLC-5® & 3rd Party PLC Migration Capability

How We Can Help

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Legacy Process Control System
Migration & Conversion Solutions
OPC Server Database Custom Cable Engineered Conversion I/O Scanner Dedicated
Software Conversion Tool Solutions Interface (SAM) Services Module Interface
Bailey NET90/INFI90
Honeywell TDC/TPS
Honeywell IPC
PlantScape/Experion C200 N/A N/A N/A N/A
Fisher PROVOX
Moore APACS
Westinghouse WDPF
Rosemount RS3
Rosemount RMV9000
Foxboro I/A
Taylor MOD300
Emerson DeltaV
SATTline
RTP
Yokogawa Centum CS
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 OPC Servers
• Commercially available –
Field proven

• Use in architectures as
“Whitebox” PCs, or SAMs (PC in
a ControlLogix® rack)

• FactoryTalk® View Server can

Host

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 Database Conversion Tools
• Converts Legacy DCS DB
tags to FactoryTalk® View
OPC tags or ControlLogix®
tags
• Used in conjunction with OPC
Servers, whitebox PCs, or the
Softing “SAM”

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 Cable Solutions Foxboro IA

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 Cable Solutions Bailey

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 Cable Solutions Provox

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 Cable Solutions Honeywell

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 Cable Solutions APACS

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 Integrated Gateway Solutions

Benefits
• Peer-to-peer communication
• Increases performance
• Same environmental specs as
ControlLogix®
• ControlLogix® controller is data
Ethernet
repository
HDL • Integrated solution
• Optimized data server
PROVOX
Data Highway
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 APACS I/O Scanner
CLX-APX module from ProSoft

Benefits
• 2 modes – Shadow & Scanner
• Significantly reduces up-front
costs by retaining legacy I/O
• Fast, low risk legacy controller
cutover
• Redundant or Simplex
I/O Bus

Remote Modulrac
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 PROVOX I/O Scanner
CLX-PVX module from ProSoft

Benefits
• 2 modes – Shadow & Scanner
Includes
SMART™ I/O • Significantly reduces up-front
costs by retaining legacy I/O
• Fast, low risk legacy controller
cutover
PROVOX
Serial I/O network
• Redundant or Simplex
PROVOX Series10 or
Series20 I/O
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 IPC620 I/O Scanner
CLX-IPC module from ProSoft

Benefits
• 2 modes – Shadow & Scanner
• Significantly reduces up-front
costs by retaining legacy I/O
• Fast, low risk legacy controller
cutover
• Redundant or Simplex
Serial Remote I/O Network

IPC620 Remote
I/O Rack
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 Dedicated Interface for Bailey
RA56-cATM-BLY90

Benefits
• Peer-to-peer Communication
• Increases Performance
• ControlLogix® Environmental
Specs
Serial • Data Repository 
ControlLogix® Controller
CIU/ICI
• Data Native to FactoryTalk®
Applications
Bailey Plant Loop • Integrated Solution
• Optimized Data Server
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 Agenda
Legacy DCS Market Outlook
Migration Tools – Reduce Risk & Cost
Migration Methods: Phased, Vertical, or Rip & Replace
PLC-5® & 3rd Party PLC Migration Capability

How We Can Help

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 21
 Conversion Strategy Comparison
 Financial Justification
Phased Rip & Replace
• No required shutdown for HMI • Requires extended shutdown for
entire project
replacement
• Requires capital expense $
• Can be funded with maintenance $ approval (full system)
• Considered low risk to customer • Can be funded with maintenance $
(vertical slice or by area)
• Can take multiple years to migrate • Considered high risk to customer
entire system (higher TCO)
• Can replace entire system in weeks
• Requires more legacy DCS (lower TCO)
expertise for delivery engineering • Requires less legacy DCS expertise
for delivery engineering team
• Can be easily switched back to the
• Cannot be easily switched back to
legacy system as a contingency plan legacy system
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 Bailey Net90 / Infi90 Existing Architecture
OIS Op Station 1 Bailey EWS OIS Op Station 2

CIU CIU CIU

Plant Loop or Infi Loop

PCU 1 PCU 2

TU TU

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 Bailey Net90 / Infi90 Migration – Phase 1
Op Station 1 PAx EWS Redundant Servers Op Station 2

Ethernet
OIS Op Station1 Bailey EWS OIS Op Station2
Bailey Gateway

CIU CIU CIU

Plant Loop or Infi Loop

PCU 1 PCU 2

TU TU

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 Bailey Net90 / Infi90 Migration – Phase 2
Op Station 1 PAx EWS Redundant Servers Op Station 2

Ethernet

Bailey EWS
Bailey Gateway

CIU CIU

Plant Loop or Infi Loop

CLX 1 PCU 1 PCU 2

TU TU

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 Bailey Net90 / Infi90 Migration – Phase 3
Op Station 1 PAx EWS Redundant Servers Op Station 2

Ethernet

Bailey EWS
Bailey Gateway

CIU CIU

Plant Loop or Infi Loop

CLX 1 PCU 2 CLX 2

TU TU

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 Bailey Net90 / Infi90 – Vertical Migration
Op Station 1 PAx EWS Redundant Servers

Ethernet
OIS Op Station1 Bailey EWS OIS Op Station2
Bailey Gateway

CIU CIU CIU

CIU

Plant Loop or Infi Loop

CLX 1 PCU 1 PCU 2

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
2. Power-down &
CLX 1 Fieldbus CLX 2 decommission legacy DCS
3. Deploy new DCS
FBM’s FBM’s
Technology

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 Agenda
Legacy DCS Market Outlook
Migration Tools – Reduce Risk & Cost
Migration Methods: Phased, Vertical, or Rip & Replace
PLC-5® & 3rd Party PLC Migration Capability

How We Can Help

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 29
 PLC-5® Migration Tools & Utilities
RSLogix™ Project Migrator : Integrated Architecture® Builder: Equipment and Wiring Conversion:
 Converts legacy RSLogix™ 5 or 500  Graphical, user-friendly software tool that automatically  Seamless conversion without removing
project export file to Logix project for defines and configures a contemporary ControlLogix® any field wires in minutes
MicroLogix™, SLC and PLC-5® based architecture based on your legacy PLC-5® system
 Free download  Builds a detailed bill of materials based on your current
PLC-5® based control system
 7 step conversion

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 3rd party PLC: Swing-arm Solutions from Emphatec

• Modicon 984
• Modicon Quantum
• GE Series Six
• GE 90/70
• Honeywell IPC620
emphatec.com Link
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 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-X-MOD AN-X-TI AN-X-GENI AN-X-SQD

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 Agenda
Legacy DCS Market Outlook
Migration Tools – Reduce Risk & Cost
Migration Methods: Phased, Vertical, or Rip & Replace
PLC-5® & 3rd Party PLC Migration Capability

How We Can Help

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 33
 Global Process
Tech Consultants (GPTCs)
Main Customer Types
LARGE END USERS SOLUTION PROVIDER
Consult work with corporate engineers Train on the best practices
to establish standard for operations of using PlantPAx®

PROCESS OEMS A&E

Work with the OEM to rewrite their Develop specifications for firms
application on a Rockwell to establish a
Automation® Platform Rockwell Automation platform

Help customers understand how we can migrate

from legacy DCS to Rockwell Automation

Work with delivery partners to assist in the

technology adoption to the Rockwell Automation®
process control application

Work across global regions and key customers

to assist in project implementation
(A&E, contractor, SI, and end user)
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 Global Process Tech Consultants (GPTCs)

Process Control
System Experts

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 Who should you contact?

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DCS Migration Collateral Published…
DCS Migration Collateral available on Literature Library
http://Literature.rockwellautomation.com > Support > Product Resources >

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

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

Justification for a Legacy DCS Migration Strategy and Optimization

Control System Migration Project Implementation after Migration
PROCES-WP005A-EN-P PROCES-WP006A-EN-P PROCES-WP008A-EN-P
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Thank You!

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www.rockwellautomation.com

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