ADVANCED

METHODS
FOR SYSTEM
MODERNIZATION
Rely on Advanced Migration Technologies (AMT) to leverage your
workforce and control assets to keep your business moving forward.
TABLE OF
CONTENTS

3 Introduction
3 How Honeywell Helps You Migrate
4 Meet Challenges
5 Threats to Reliability and Safety
6 Are You “Migration Ready?”
7 Modernize Controls
8 Determine Existing Assets
8 Utilize Expert Assistance
9 Realize Benefits
9 Impact on Your Bottom Line
11 Conclusion
INTRODUCTION
1
Honeywell’s Advanced Migration
SOLUTION FOR
technologies eliminates risk and CONTROLS
makes migration an advantageous MODERNIZATION
experience for customers. Honeywell provides Advanced
Migration Technologies for
Experion® and Experion
As a leading automation technology supplier, Honeywell recognizes
TotalPlant™ Solution (TPS) users
that a successful controls modernization strategy can help customers
who need to modernize their
reduce total cost of ownership, increase production rates, meet regulatory
control system to the Experion
guidelines, and manage risks, extend the life and performance of
R511.5 and R520.2 or later.
systems, and improve response to changing business demands.

HOW HONEYWELL HELPS YOU MIGRATE

Honeywell provides an innovative Advanced Migration Technologies for
Experion® and TotalPlant™ Solution (TPS) users who need to modernize
their control system to the Experion R511.5 and R520.2 or later.

It changes the playing field for customers by eliminating potential risk and
making migration an advantageous experience rather than a burdensome
requirement. The service encompasses migration readiness, software migration,
acceptance testing, and production system upgrading. Honeywell engineers
perform the software migration and then invite the end user to test the new
software release. This includes control configuration and custom graphics.
The Configuration Acceptance Test is the customer’s way of approving
the new release prior to introducing it into their production system.

3
MEET
CHALENGES 2
Taking advantage of the latest
ROADMAP FOR
technology and enabling crucial TECHNOLOGY UPGRADES
assets to operate optimally. Only those organizations with a
solid plan for ongoing technology
Operating companies must find ways to keeping equipment up to date with upgrades can mitigate current
minimum downtime. Only those organizations with a solid plan and a roadmap for risks and ensure efficient plant
ongoing technology upgrades can mitigate current risks and drive plant operations operations without unnecessary
seamlessly without unnecessary disruptions disruptions.

For plant owners/operators, failure to address looming operational or system issues could lead to
crucial assets being rendered inoperable.

4
THREATS TO RELIABILITY of-life operating system poses a – Lack of skilled resource once
AND SAFETY serious threat to the performance, migration is complete
For plant owners/operators, failure availability, and reliability of any – Reliability of SCADA communication
to address operational or system industrial control system. following upgrades
issues could lead to crucial assets
This type of failure leads to higher costs – Compatibility of other Honeywell or
being rendered inoperable. Financial
as plants mitigate the rising risk of non-Honeywell software
loss or possible unsafe operating
operating disruptions, lost production,
conditions from an unplanned Today, an effective migration strategy
data breaches, and compliance failures.
outage could far exceed the upgrade can involve Honeywell Global Migration
At worst, it can jeopardize continued
cost for a legacy investment. Support Centre (GMSC) experts, who
safe operations. Some of the specific
perform the necessary upgrades
Increasingly, plant owners concerns plant owners/operators have
on a 24x7 schedule and are always
are faced with: about release migrations include:
well-versed on the latest lessons
– Managing operations with reduced – Loss of server redundancy for a long learned. This type of migration can
onsite staff duration be accessed by technical support
specialists along with local Honeywell
– System components failures and – Loss of operator stations for an
staff and on-site customers—during
significant downtime extended period of time
a time that suits all parties—to enable
– Limited access to onsite subject – Problems with graphics functionality the fastest migration possible.
matter experts after migration

Industrial sites around the world are – Operating system (OS) changes
challenged by aging infrastructure adding new security parameters
and equipment, which are simply related to break-in functionality (e.g.,
no longer supported, with outdated VB script, Active X, IR version, new
control system proving particularly domain, local user addition due to OS
troublesome. Indeed, an end- change etc.)

Financial loss or possible unsafe operating conditions resulting from an unplanned outage could far exceed the
upgrade cost for a legacy investment.

5
Operator Readiness and enhanced functionality. Users that such that intellectual property
Adoption to the New System migrate to a modern system can also is preserved, and the production
integrate control, safety, and auxiliary system does not have to shut down.
Operators face difficulties when they
systems. And, they can respond to
have received the new version, or the Honeywell Trace documentation
new business opportunities, expand
new environment of the system and it and change management software
capacity, and make use of new
may some time disturb their everyday is intended to minimize errors due to
applications and solutions for advanced
practice. The product version upgrade changes in configurations, improve
process control, asset management
is always a challenge for operators worker productivity, and simplify
and production management.
to adjust to the new interface. automation asset management by
Before controls upgrades can begin, providing a single integrated view of
Advanced Migration Technologies
however, plant owners must ensure complex system interactions. The
offer virtual FAT, a new way to preview
they are truly “migration ready.” Most software can be used to research tags
the Experion system before deploying
legacy systems have grown intellectual that must be cutover during controller
it on online production and also
property organically over the decades migrations and also makes it possible
ensures smooth functionality of
through thousands of manhours of to identify connections within SCADA
the assets and configurations.
engineering work. This process typically points. It provides critical data that
Virtual FAT allows customers and included a variety of workarounds and lets users know why, when, and what
operators to get a holistic preview of stop-gap measures to keep costs low actions were taken and how they
their Experion databases, controller and avoid unnecessary downtime. compare to actions in the past. The
configuration and HMI displays to Unfortunately, documentation precision and comprehensiveness
get familiarized with the new and is often lacking, and many plant of this change analysis can reduce
improved version of the Experion. engineers do not know how the control several days of manual effort.
Virtual FAT before deploying the latest system was actually constructed.
Experion on production system can
Furthermore, control systems are
reduce any unforeseen issues and
more complex than ever before, so
perceived readiness challenges.
there is limited information on how
the different components need to
ARE YOU “MIGRATION
interact. Providing end users with the
READY?”
ability to visualize the entire system in
It’s well proven that control system
one view can increase their awareness,
upgrades offer important advantages
which, in turn, leads to better decision
in terms of operator performance,
making. They can also do migrations
safety, efficiency, cybersecurity, and

Honeywell Trace software can be used to research tags that must be cutover during
controller migrations.

6
MODERNIZE
CONTROLS 3
With greater demands on the plant
STRATEGY TO IMPROVE
workforce, there is a need for expert PERFORMANCE
assistance to ensure performance A modern control system is an

and reliability. opportunity to bring people, the

plant, and data together to drive
better operational and business
A modern control system is an opportunity to bring people, the plant, and data
performance.
together to drive better business performance. But in times of uncertainty and
limited skills/experience, it is not easy to undertake system upgrades.
Plant operators face the risk of downtime and the requirement to take systems
offline and shut down the process while putting new technology in place, or the
potential for longer-term disruption from unforeseen problems when the updated
system is brought online.

Honeywell can help significantly reduce the requirement for project team members to spend time
to handle system upgrades.

7
Honeywell recognizes the importance of a continuous evolution pathway
to system modernization. Our global GMSC experts can efficiently address
the risks and issues of technology upgrades real-time. This service enables
customers to stay up to date more confidently and easily with the latest
cybersecurity and Experion improvements.

DETERMINE EXISTING ASSETS

The first step in preparing for a controls migration is determining where all
existing system assets reside. Project team members need an effective way
to search for system parameters on a site-wide basis. There are a multitude of
interconnections between the Distributed Control System (DCS) and various
safety systems, Programmable Logic Controllers (PLCs) and other subsystems.

Likewise, the first step in Experion migration is to check for readiness of the
cluster for migration and then extract useful information from the Experion
database that needs to be migrated. Experion Migration Data Aggregator
(EMDA) is a part of Advanced Migration Technologies’ tool kit that can
accomplish this process.

In the migration process, this tool helps to determine the migration readiness
of the cluster. EMDA collects data from all the nodes without disruption to the
plant operations and through secure means.
The data collected is compressed and encrypted using industry standard AES
based encryption through a user defined encryption key.

UTILIZE EXPERT ASSISTANCE

Honeywell employs the Experion Migration Assistant (EMA) and data
aggregator tool to collect relevant configuration items for review. The EMA
provides a single location for all interactions between the customer and
Honeywell for Experion migration. It allows 24/7 user updates and easy
migration request generation for Honeywell’s Global Migration Support Centre
(GMSC) review and escalation to its Global Technical Assistance Center (GTAC).
An intuitive dashboard shows the status of the migration project, and a single
tool handles all pre-migration readiness data collection.

8
REALIZE
BENEFITS 4
Experience has shown that Advanced
IMPROVED MIGRATION
Migration Technologies can significantly EXPERIENCE
reduce cycle time, improve workflows, and Honeywell’s Advanced Migration

minimize disruptions. Technologies reduces control

system modernization time and
effort in the field and improves the
Honeywell’s Advanced Migration Technologies reduces control system
overall migration experience.
modernization time and effort in the field and improves the overall migration
experience. The service also helps to mitigate risk while improving equipment
reliability, increasing operational effectiveness, and reducing the total cost of
ownership (TCO) of automation assets.

Customers can leverage Honeywell’s migration support services -anytime, anywhere.

IMPACT ON YOUR BOTTOM LINE

Experience shows that Advanced Migration Technologies and GMSC engagement
have reduced the end-to-end migration cycle for some customers by 50%.
Customer feedback includes appreciation for reduced migration effort and praise
for easier and faster migrations. It also enables customers to take advantage of
Honeywell’s latest enhanced cybersecurity capabilities and control technology
improvements. The specific advantages of Honeywell’s Advanced Migration
Technologies include:

Faster and Less Disruptive Migration

– Automated Data collection
– Less site activities
– Minimum Dual Primary Servers and Operator station unavailability time
– Lower total cost / time

Expert Migration
– GMSC Pole HUBs perform majority of migration work
– Integral Migration CoE and GTAC migration specialists

Easy Workflow, Status Tracking

– Using Experion Migration Assistant Portal

9
Cyber Secured
– Fully cyber secure solution to protect your intellectual property
– State of the art infrastructure
– Comprehensive cyber certifications

Focused Documentation
– System specific migration instructions are set
– Simplified documents for easy reference and use

Continuous Innovation
– Take advantage of the latest technology
– Live migration dashboards available for any site

Reliable and Repeatable

– Every migration performed by GMSC certified experts
– Robust, rigorous, automated process ensures excellent quality

Virtual FAT
– Exercise system before implementation on production system
– Validate functionality
Manufacturers no longer have to delay their technology initiatives due to
unforeseen disruptions to normal operations; beyond traditional on-process
migration, the latest technology advancements allow them to perform
system modernization like a simple update. They can also leverage value-
added support services without putting their personnel or plant at risk.

29d
1d 22d 1d
MIGRATION Migration Provide Create Site Prepare for Execute Execute
AT SITE Registration, site data to Advisory, migration & Validate Controller
Approval Honeywell Work at site L2 Nodes Migration
Typical project Cycle Migration Package Migration at site
COE at site
70 calendar days

3.5X Faster Cycle, 50% Less Customer Effort

GMSC Pole HUBS

5d
1d 4d 5d 1d
GMSC/AMT Migration Automated Migrate, Virtual Deploy Execute
MIGRATION Registration, data validate FAT Migrated Controller
Approval collection, L2 Nodes, L2 Images Migration
submission prep VMs at site at site
Typical project Cycle
for delivery
20 calendar days to site

Advanced Migration Technologies provide Field Service Engineer GMSC Expert Hubs with
the Tools, Processes, and Infrastructure for integral Migration COE/GTAC

highly-automated, robust deliveries. Customer xd Typical Cycle Time

Traditional Migration vs. GMSC Migration using Advanced Migration Technologies.

10
 CONCLUSION
5
Industrial organizations can rely on
IMPROVED MIGRATION
Honeywell’s innovative technologies to EXPERIENCE
keep their businesses moving forward. Honeywell’s Advanced Migration
Technologies reduces control
With severe challenges making it harder run plants efficiently, system modernization time and
profitably, and safely, industrial organizations can rely on innovative effort in the field and improves the
Advanced Migration Technologies to leverage their workforce and overall migration experience.
control assets to keep their businesses moving forward.

Value and Transformation Deliverables

Enablers

Operations Cyber Maintenance AMT &

& Efficiency Security & Reliablility GMSC

• 70% of Process • 200% increase in • Safeguard • Fast delivery cycle,

Upsets caused by disruptive industrial Control Strategies lower customer
Human Performance cyber attacks Q1 Intellectual Property effort
• Depletion of legacy 2021 vs Q4 2020 • 3rd party • Incorporate
systems skills • Average industrial compatibility - Experion best
Capability Gaps

Transforming
• Recruiting & recovery time 17 Windows, Servers/ practices
retaining workforce days, $ millions in Stations, Network • Expert global
impaired by legacy operational impact • No new SW updates migration
systems • Parts, support risks community
• Enabler for greatly increase with • Dedicated, certified>
digitization & obsolescence 10 years migration
productivity experience
• Migration
Command and
Control Center

11
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