In this Issue. The Risk vs. Return of DCS Migrations. Page 1-2 The Risk vs. Return of DCS Migrations Page 3

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1 Update 2010 Issue 6 This edition of Thinking Process focuses on migrating from legacy DCS systems to the PlantPAx Process Automation System. We discuss benefits of migrating from a legacy system using a three-phased migration strategy to eliminate many of the costs, risks and complexities involved with migrations. We also feature success stories that highlight successful migrations, and we invite you to join us to learn more with a full week of process education at our Process Solutions User Group (PSUG) and the Automation Fair event this fall. In this Issue Page 1-2 The Risk vs. Return of DCS Migrations Page 3 Page 4 Three-Phased Migration Process Migration Solutions and Resources Page 5-6 Colorado Springs Utilities Page 7 Page 8 Hwado Water Treatment Facility Events The Risk vs. Return of DCS Migrations Increase productivity and profitability by upgrading your control system in phases The equipment is running for now, but it s taking longer and longer to find replacement parts. You often look for them on ebay because the parts houses you typically use no longer have what you need, and the parts that are in stock are getting more expensive. Finding service is getting tougher too. Your legacy system might be 20 or more years old, and the engineers and technicians who originally installed it are retiring. Even the incumbent vendors are not supporting these old systems anymore. Things can t last like this, but what can you do? It s difficult to justify a system migration based only on what might happen. However, if you re able to demonstrate the improvements that new technology can provide, your argument for migration strengthens. Beyond risk mitigation Migration decisions can be broken down into two categories risk mitigation and performance improvements. Risk mitigation is about what keeps you up at night, and performance improvements are what provide a sustainable and competitive advantage. As companies consider migrating, they want to know and understand their potential gains in both areas. However, it s difficult to get excited about future productivity gains if it means crippling current production. Do I have to update my system all at once? Do we have to stop production? How can I budget a project of this type? These questions are universally voiced across industries when migrations are discussed. Companies today are most frequently migrating away from legacy DCS that only control the process, whether for a chemical plant, steel mill or utility plant. Now, companies can replace these dedicated systems with a single, plantwide control system, connecting the process, conveyor lines, discrete manufacturing, drive, batch and safety applications. Migrating to newer equipment can offer many benefits, such as increased information flow, more production with greater throughput, less training and spares and reduced energy costs. A single, plantwide system allows for an unlimited number of reports, which are easy enough for you to create based on the increased data available. This means better control over quality, tighter process management and greater potential for a satisfied customer, all of which adds competitive advantage. In addition, expert data-sharing helps produce higher quality products, increased operator knowledge and provides corporate entities with improved production capabilities. Justifying funding for a migration Often people seeking to justify equipment migrations are middle managers who are concerned with manufacturing a quality product on time and at a cost point that provides a competitive advantage. Formal financial tools, such as Return on Investment (ROI), Total Cost of Ownership (TCO), and

2 Migration The Risk vs. Return of DCS Migrations (continued) Net Present Value (NPV), are critical to the collection and comparison of numbers. These models consider investments such as hardware and software, support, maintenance, training, spare parts, inventory and carrying costs, etc. These investment costs then need to be offset by performance gains and risk mitigation. Performance gains depend on the manufacturing advantages gained from new technology, such as improved system integration, increased information flow, or energy reduction. This calculation is sometimes difficult with a phased migration because some of the benefits may not be realized in the first phase of the project and must be amortized over time. Risk mitigation comes from reduced breakdown, easier access to parts, and improved service and support. Carrying out migrations in phases, using well-developed tools that build efficiencies, and working with a migration team that has the system, industry, and project management knowledge to help you evaluate, plan and execute your project successfully are keys to reducing risk. Understanding the areas that offer the greatest ROI upfront and working on those areas first can offer greater short-term returns. These short-term benefits may offset having to wait to receive the performance advantages of a completely new system. Plus, parts of the migration can be covered through budgets that have already been in place, without any distribution of capital funds. For more information on migrating your DCS, please visit: solutions/migration/programs.html#dcs To find out more, visit us at 2

3 Three-Phased Migration Process Three-Phased Migration Strategy from Rockwell Automation Helps Transition from Legacy DCS Platforms Program replaces aging DCS systems with the PlantPAx Process Automation System for improved performance, reduced costs and increased plant-wide integration To execute a rip-and-replace migration, users must be willing to shut down the process for a period of time, which can get expensive. Although there is a proper time and place for a rip-and-replace strategy, companies often look for ways to reduce the short-term complexity and expense, even when total system replacement is the goal. Phased migration approaches offer many advantages. By looking at one section of the system at a time, the customer reduces the risk of unseen complications halting the migration midstream. The three-phased migration program from Rockwell Automation helps manufacturers cost-efficiently replace aging DCS systems with the highly scalable, multi-disciplined PlantPAx Process Automation System for improved productivity, lower costs and easier access to parts and service. Responding to a market gap created by many vendors no longer supporting their systems, the program provides customers with a phased approach that eliminates many of the costs, risks and complexities involved with migrating legacy DCS systems while providing a single platform for integrating both process and discrete applications. Phase One The first phase in the migration strategy involves replacing legacy HMI consoles with Rockwell Software FactoryTalk View Site Edition HMI infrastructure. HMI consoles are typically the least supported systems. Twenty years ago, before the influx of standardized protocols and PC technologies, these consoles were proprietary. Today, however, HMI systems are often no longer supported. Customers find it easier to spend money to replace operator consoles and engineering workstations with modern PC-based platforms. An additional benefit of this migration is that console replacements do not require downtime. HMIs are a plug-andreplace item and can interoperate with the existing operator stations. New consoles can also be customized to have the same look and feel as the old system. Phase Two The second phase of a migration involves replacing the controllers. This step can take three months to three years depending on the customer s interest, need and budget. It s important to note that the new controllers can be installed before the HMI swap-out is complete, if the installation timeline is tight. This works with many users, but is not the only approach for a particular migration. To allow communication from the new controllers, many suppliers continue to develop interface solutions to legacy I/O infrastructures. Also, new controllers can be installed in parallel with legacy systems, using the same I/O. It runs in monitor mode until the system is verified as working correctly. Once both systems are up, old systems can be used until everything is double-checked. Then, the transfer from the legacy control to the new control platform can be completed. Phase Three Phase three involves replacing the legacy I/O infrastructure with new I/O. Special cables help retain the existing field terminations that bring instrumentation signals up to an I/O module. Rockwell Automation has developed custom field termination unit cable designs that allow the removal of legacy I/O without the need to remove field wires, significantly reducing installation costs and risks associated with I/O replacement. The custom cables plug directly into the legacy field termination units on one end and into the new I/O module on the other. By incorporating the field wires into this termination unit and cabling the signals from that unit up to the I/O module, Rockwell Automation has essentially eliminated the need to touch the field wiring a huge cost in any migration, as well as a prominent place for errors to be made. This three-phased migration strategy is valuable for lowering risk, providing full connectivity to all automation and production data and offering operator continuity. For more information, please visit: solutions/migration/programs.html#dcs To find out more, visit us at 3

4 Migration Solutions and Resources Rockwell Automation Migration Enablers Tools for converting databases, configuring graphics and making connections to existing field I/O Connecting to a PROVOX Control I/O bus The QTS-CLX-PVX modules from Quest Technical Solutions help migrate PROVOX systems to the Allen-Bradley ControlLogix process automation controller (PAC) from Rockwell Automation. You can retain the PROVOX I/O as the first step in the migration. In monitor mode, the QTS-CLX-PVX module sends PROVOX I/O input and output data to input and status input data in the ControlLogix controller. It cannot transmit on the bus. In master mode, the ControlLogix controller sends output data to the QTS-CLX-PVX, which then transmits it as output data on the PROVOX Control I/O bus. The QTS-CLX-PVX sends PROVOX input data to input data in the ControlLogix controller. The QTS-CLX-PVX supports up to 64 I/O cards. For larger systems, split the bus and use two QTS-CLX-PVX modules. Migrating ABB Bailey Infi 90 or Network 90 Legacy DCS Systems The catm -BLY90 appliance transaction module from Online Development (OLDi) helps migrate legacy ABB Bailey Infi 90 or Network 90 DCS systems to the Allen-Bradley ControlLogix process automation controller from Rockwell Automation. A straightforward graphical interface allows you to map ABB Bailey DCS data blocks into ControlLogix tags. Data can be transferred bi-directionally between the two systems at configured rates. Integrating WinXP or WinCE OLDi offers the 56SAM-800 module to help users integrate WinXP or WinCE 5.0 programs with Allen-Bradley ControlLogix controller applications. It is a highperformance tool available to meet new PC-based applications that influence today s control system designs. In addition to standard PC functionality, the 56SAM-800 module has factory floor specific functions that industrial PCs do not have, such as a high-speed backplane interface and reliable fanless operation. Custom cable solutions Rockwell Automation offers custom cabling solutions for numerous process control platforms, including Bailey NET/INFI90, Fisher Provox, Honeywell TDC 2000 and TDC 3000, Siemens Moore APACS, Beckman RMV9000 and Emerson Westinghouse Distributed Processing Family (WDPF ). These solutions help customers: Preserve valuable production time and reduce risks associated with legacy I/O removal tasks Allow I/O to be removed in minutes and preserves existing field wiring terminations Make commissioning and startup tasks easier, less risky, and much less costly For more information on custom cabling solutions, please visit solutions/migration/programs.html#dcs Migration Brochures Your equipment is your livelihood, enabling you to produce quality products on time, every time. As your equipment ages, it s inevitable that questions about part sourcing, service, potential productivity gains from new technology and increased risks of downtime become stronger. You need to work with a supplier that has the product, service and industry knowledge to partner with you on an upgrade strategy that will help you maximize your competitive advantage. Rockwell Automation and its partners will work with you to outline a plan that fits your application needs and long-term goals. We can help you migrate all at once or in phases, at a pace that is comfortable for you and fits your budget, while leveraging the latest capabilities and technologies of the PlantPAx Process Automation System. Rockwell Automation DCS Migration Solutions Overview Brochure documents/br/proces-br011_-en-p.pdf Bailey NET/INFI90 to PlantPAx Process Automation System documents/pp/migdcs-pp006_-en-e.pdf Fisher Provox to PlantPAx Process Automation System documents/pp/migdcs-pp007_-en-e.pdf Foxboro IA to PlantPAx Process Automation System documents/pp/migdcs-pp008_-en-e.pdf Honeywell to PlantPAx Process Automation System documents/pp/migdcs-pp005_-en-e.pdf To find out more, visit us at 4

5 Success Story Colorado Springs Utilities Standardizes on PlantPAx Process Automation System to Save Estimated $280,000 Annually Process solutions from Rockwell Automation combine project management, industry and technical expertise to provide unified plant control and easy system migration Conversion from aging legacy distributed control to modern control systems is an important strategy to improving plant performance, but is often viewed as a complex challenge. Issues of downtime, reliability, training, maintenance and spare parts are all part of the equation. It takes experienced engineers, industry knowledge and technology expertise to find the right solution. A utility in Colorado used these tools to convert its water treatment plant s control system for annual savings of over $280,000. Colorado Springs Utilities (CSU), a four-service utility that provides electricity, natural gas, water and wastewater services to more than 410,000 customers in the Pikes Peak region near Colorado Springs, Colo. supplies about 24.1 billion gallons of water annually. Challenge CSU s goal was to achieve better control and lower life-cycle costs at its McCullough Complex water treatment plants. It wanted to migrate to a new control system to reliably control and monitor a series of pumps, valves, tanks and filters for the process of turning raw water into potable drinking water. Monitoring water quality is essential to prevent health hazards, and to meet environmental regulations and water demand, says Steve DellaCroce, customer operations superintendent at the McCullough Complex. The existing Foxboro DCS was approaching end-of-life. Spare parts were difficult to find and stock, and in-house aptitude of the legacy system was diminishing as knowledgeable manpower retired. The Unix-based HMI system had limited control and maintenance capabilities, was not user-friendly and required manual control. In addition, a company reorganization left fewer operators and maintenance staff to accomplish the same responsibilities. Solution CSU first hired an independent consultant engineer to do a feasibility study on converting to a Rockwell Automation control system. A life-cycle cost analysis showed Rockwell Automation had lower spare parts prices, and lower service and training costs than CSU s previous supplier, which results in reduced overall operations and maintenance costs. CSU had partnered with Rockwell Automation and authorized Rockwell Automation distributor Rexel, in Colorado Springs, to upgrade control systems at several of its other plants and trusted the company s ability to understand its needs and deliver the best solutions. CSU operations and maintenance staff were confident in Rockwell Automation technology, but more importantly, they saw the benefits and bottom-line value that the automation company provides through its Global Solutions team. The Rockwell Automation delivery team was fantastic to work with, said Steve Moore, a senior instrumentation control specialist at the McCullough Complex. They made the extra effort to get input from all personnel, from executives to operators and maintenance, to make sure we got everything we wanted. They really listened and discussed everything as a team. By using the Global Solutions design-build model, CSU was able to save the cost of a design consultant, eliminate the timeconsuming bid process and maintain continuity between plants. The previous installations at other CSU plants meant that Rockwell Automation could use specifications from pre-tested code stored in knowledge management libraries. Using this pre-existing information reduces development time and cost, and increases support capabilities while reducing the risks of new implementation. Rockwell Automation engaged the PlantPAx Process Automation System for plantwide control. It ties in with CSU s existing SCADA network systems and servers, and historian OSI PI. The system encompasses the Allen-Bradley ControlLogix programmable automation controller, FactoryTalk View SE operator interface and open system networking via ControlNet and EtherNet/IP cabling. It offers real-time visibility into monitoring water quality for chlorine, turbidity and PH, as well as trending of loads, levels and clarity. Wireless transmitting allows remote data visibility and control from CSU control rooms, and also from operator and maintenance laptop computers in other areas of the plants. As part of the solution package, CSU operations employees received comprehensive on-site training on the system operation, including after-hours training for multiple shifts. They also have opportunities to attend free training at one of the Rockwell Automation On The Move regional seminars or at the Rockwell Automation Denver office training facility. Rockwell Automation can also provide group training at the CSU site. Another benefit to the Rockwell Automation solution was cost savings on spare parts storage and management. By standardizing hardware across CSU s water-treatment plants, the McCullough Complex was able to take advantage of an existing agreement, co-managed by Rockwell Automation and Rexel, to store and manage spare parts. The reduction in spare-parts purchase and storage gives CSU operations and maintenance a To find out more, visit us at 5

6 Success Story Colorado Springs Utilities Standardizes on PlantPAx Process Automation System to Save Estimated $280,000 Annually (continued) predictable annual cost and reduces the expense of depreciating assets being stored at each site. Results The new control system was commissioned using Rockwell Automation best practices and CSU standards to provide total cost savings of more than $280,000 annually. CSU was able to reduce annual operating costs by $240,000 due to fewer system operator hours required to perform monitoring and trending tasks. CSU estimates an additional $40,000 annual savings on system support and maintenance thanks to the system s increased control capabilities and ease of use. This new DCS has increased our confidence in the control and monitoring it has a lot more aptitude and is a lot quicker, says DellaCroce. It reduces our concern about poor water quality because we can run more efficiently and fine tune our operations. CSU also says they have received many hours in system and product training from Rockwell Automation. By training employees on one software platform, their skills can be transferred to any CSU facility, which is particularly useful in the event of an emergency. CSU can also leverage its engineering and maintenance services throughout the system life cycle, including consulting/assessments, design, installation/ startup, training, on-site/remote support, asset management and repair services. In addition, the Global Solutions design-build process, compared to a design-bid-build process, resulted in an estimated one-time cost savings of $110,000. The entire DCS installation was completed on budget and ahead of schedule. The original project proposal called for completing the control system projects within two years with the physical installation occurring during the plants off -season, when less water is required by the public. The Rockwell Automation team was able to complete the entire project implementation one year earlier than CSU had projected. CSU expects to achieve full ROI in less than 36 months. For more information please visit idc/groups/literature/documents/ap/waterap011_-en-p.pdf To find out more, visit us at 6

7 Worldwide Adoption of PlantPAx System Korean Purification Plant Cuts Operational Costs by Migrating from an Aging DCS to the PlantPAx Process Automation System. Hwado water treatment facility helps reduce operating costs by 13% The Han River in Korea stretches 514 km, flowing through Seoul, South Korea and merging with the Imjim River before it finally reaches the Yellow Sea. Although it is not a long river, it is an important one because it serves as the source of drinking water for several cities. The Hwado purification plant is responsible for purifying and supplying safe and clean water, pumping more than 55,000 cubic meters per day for local residents and businesses. Challenge The plant employed a DCS to run these operations. However, maintenance costs for the DCS were high, and it was not always easy to get prompt and consistent technical service. The plant faced another challenge with the HMI software used with the DCS system. In the water purification process, controllers turn pumps off and on, open and close valves and send operating conditions temperature, electricity, flow level and other relevant data to a master controller in the main control room. Visibility of this information through the HMI software is critical since it allows operators to monitor and track all of these parameters. The database software that the plant had in place, however, was not able to display more than 20 days of data at once. Due to a high volume of data traffic, retrieving the data over the network also took a long time. Furthermore, when making modifications or adding operations to the HMI, software had to be updated on all of the controllers on which it was installed. Solutions Rather than invest further in its outdated DCS system, Hwado purification plant migrated to the PlantPAx Process Automation System. At the core of the system are fully redundant Allen-Bradley ControlLogix controllers from Rockwell Automation. The fully redundant architecture protects critical processes from unexpected shutdowns, allowing programs to be automatically cross-loaded from the primary to the secondary controllers. If the primary controller fails, control is automatically switched to the secondary system. We definitely needed to change our control platform due to the high maintenance costs of the DCS system, said Ji, Eung-Su, plant manager of Hwado water treatment facility. We wanted another control system with lower operating costs and better flexibility and Rockwell Automation PlantPAx Process Automation System was the answer. The high capacity and advanced EtherNet/IP networking allowed us to run the facility effectively and efficiently. Additionally, Hwado water treatment facility desired an HMI that was interoperable with the PACs. It adopted the FactoryTalk View suite, which allows operators to easily configure applications anywhere on the network and make changes to a running system. Users can directly access tag information in the controller, eliminating the need to create separate HMI tags. In addition, operators can define graphics displays once and reference them throughout a distributed system. Results The migration from a DCS system to the Rockwell Automation PlantPAx system reduced installation costs by over 50 percent resulting in significant Total Cost of Ownership (TCO) savings. Moreover, the facility s management team recorded a 13 percent drop in operation costs, reduced unscheduled downtime across the facility and has spent significantly less time on troubleshooting. Overall, the scalability and flexibility of the Rockwell Automaton PlantPAx system has helped Hwado water treatment facility concentrate on its number one priority delivering safe, clean water to its customers as efficiently as possible. For more information about please visit literature.rockwellautomation.com/idc/ groups/literature/documents/ap/watvpap003_-en-e.pdf To find out more, visit us at 7

8 Events Process Solutions User Group and the 2010 Automation Fair Event First, attend our annual Process Solutions User Group (PSUG) meeting on Monday and Tuesday, November 1 and 2. Share best practices, ideas and experiences with your peers Shape our technical roadmap by voting to prioritize development needs for the PlantPAx system Gather global perspectives on process solutions from the international attendees representing over 200 companies from 30 countries Next, extend your process experience by attending the Automation Fair event on Wednesday and Thursday, November 3 and 4. View the newest technology and meet face-to-face with the experts Attend workshops and technical sessions specifically geared to the process industries Get hands-on experience with live demos For more information and to register, visit: automationfair/psug.html Rockwell Automation on the Move RAOTM events are mobile trade shows that highlight the best from the Rockwell Automation annual Automation Fair event. At these local events, you can attend educational workshops, labs and technical sessions to learn more about the PlantPAx Process Automation System or any other plant-wide solutions that are a part of the Rockwell Automation Integrated Architecture system. In addition, you can mix and mingle with industry and application experts as you examine demos and products in the trade-show portion of the event. Ask your local Rockwell Automation sales person or distributor for more details, and be sure to come see us at the RAOTM event near you! Locations Venue Date Cleveland, OH February 1 4, 2011 Dallas, TX Marriott City Center February 14 17, 2011 Phoenix, AZ Mesa Convention Center February 21 24, 2011 Mexico City, Mexico World Trade Center, Centro Banamex March 7 10, 2011 Guadalajara, Mexico Expo Guadalajara March 14 17, 2011 Raleigh-Durham, NC Raleigh Convention Center March 28 31, 2011 Richmond, VA Marriott Downtown April 4 7, 2011 Philadelphia, PA TBD April 11 14, 2011 Mississauga, Ontario, Canada Pearson Convention Center May 2 5, 2011 Bismarck, ND Bismarck Convention Center May 9 12, 2011 Salt Lake City, UT Davis Convention Center May 16 19, 2011 Kansas, City, KS Overland Park Convention Center May 23 26, 2011 Memphis, TN Memphis Hilton June 20 23, 2011 Chattanooga, TN Chattanooga Convention Center July 25 28, 2011 Columbus, OH Columbus Convention Center August 8 11, 2011 Rockwell Automation Automation University Automation University events offer you a unique way of learning about the capabilities of Rockwell Automation through hands-on lab sessions, demonstrations, presentations, and exhibition that includes Rockwell Automation partners. Please join us at an event near you! Locations Date York, United Kingdom October 5, 2010 Glasgow, United Kingdom October 7, 2010 Graz, Austria October 21 21, 2010 Allen-Bradley, Automation Fair, ControlLogix, Encompass, eprocedure, FactoryTalk, Integrated Architecture and PlantPAx are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. To find out more, visit us at 8 Publication No. PROCES-SP032B-EN-P October 2010