Legacy control system extension, migration and replacement case histories
RoviSys has extensive experience in migrating legacy distributed
control systems, including ABB Bailey Infi 90 and Network 90, Rosemount RS3, Fisher PROVOX, Moore APACS, Foxboro, GE,
MODcell and Modicon.
We've migrated legacy distributed control systems to a number of contemporary solutions including those from Rockwell, Emerson, Siemens and others. In addition to those listed here, previous migrations projects include from a variety of legacy systems to PLC5, L&N Max1 to PLC5, CRISP to PLC5, Bailey Infi90 to Emerson DeltaV, single loop controllers to PLC5 and pneumatic controls to distributed control system and PLC.
We have particularly deep knowledge and experience with Bailey DCS. A number of RoviSys employees were previously employed at Bailey Controls, some directly involved in the design and development of flagship legacy distributed controls, consoles and software tools. Others served as system engineers and have extensive experience in the implementation of Network 90 and Infi 90 systems.
As an independent company, we are technology neutral: We recommend solutions that works best for you, not for us or any vendor. These solutions are open, documented and supportable. Whatever your legacy system extension or migration goal, if you want a conversions partner who has deep experienced in legacy and modern controls, is committed to providing open and supportable
solutions and is independent and resourceful, consider RoviSys.
Legacy control system migration case histories
Bailey Infi90 console migration to modern HMI |
| Application |
Midwestern steel maker
|
| Legacy controls |
Bailey Infi90 distributed control system
|
| New controls |
Redundant Rockwell RSView SE servers
Nine RSViewSE clients on Ethernet plus 10 thin clients for reports
|
| Implementation |
- Phased migration using RoviSys OPC 90 Server interface to existing Infi90 distributed control system with redundant Plant Loop
- Added process calculations in RSView SE
|
| New capability |
Client able to support additional screens and tags (limited legacy ability)
|
Bailey Infi90 system migration to PLC |
| Application |
Blast Furnace Controls
|
| Legacy controls |
Bailey Infi90 redundant distributed control system
|
| New controls |
Rockwell ControlLogix and Modicon Quantum PLCs, one controller per stove.
|
| Implementation |
- Phased migration one stove at a time
- Converted PCU to PLC Control and modified remaining Bailey PCU’s to retain compatibility
- Field wiring untouched using custom cable sets
- One day cutover
|
| New capability |
Scrubber upgrade was integrated into the plan between stoves.
|
Bailey Infi90 with Conductor NT complete replacement
|
| Application |
Powerhouse controls for Midwestern steel maker running four fuels on each of three boilers
|
| Legacy controls |
Bailey Infi90 distributed control system and consoles
|
| New controls |
Complete replacement with Rockwell ControlLogix and RSView SE HMI
|
| Implementation |
- Function block programming replaced Bailey N90 configuration plus ladder
enhancements
- Fast track project
- RoviSys-engineered conversion cables retained field wiring and terminations simplifying installation and loop checks
- Cable and cutover plan allowed reversal back to N90 for client fallback contingency plan
- Installation began three weeks after receipt of order
- One week cutover included demolition, install, startup and operational tuning
- Steam maintained at all times during cutovers, only one boiler offline
|
| New capability |
Fast control reaction, avoiding past trouble during wide load swing
|
PROVOX migration to DeltaV
|
| Application |
$2 million migration for life sciences plant
|
| Legacy controls |
4,000 I/O-point Fisher PROVOX system
|
| New controls |
Emerson DeltaV distributed control system
|
| Implementation |
- Multi-phased approach to minimize production downtime
- P&ID walk-downs and updates
- Complete GAMP life cycle documentation
- Quality and project plans
- Functional and design specifications
- FAT and SAT test plans
- IQ and OQ documentation
- System simulation using MIMIC
- End of run batch reporting
- Commissioning and validation execution and documentation
|
Bailey DCS to DeltaV
|
| Application |
University powerhouse and utilities stoker fired boilers, chillers
|
| Legacy controls |
Bailey Network90 with PC HMI and some PLC sub-systems
|
| New controls |
DeltaV DCS
|
|
Implementation |
Phased Migration coupled with new system designs
|
| New capability |
- Can access any subsystem from DeltaV Operator Stations
- RoviSys developed the Master Plan for campus wide implementation and managed more than 30 projects to upgrade facilities
|
Honeywell TDC logic and HMI extension using Integrated Architecture
|
| Application |
Hazardous waste incineration
|
| Legacy controls |
Honeywell TDC3000 distributed control system
|
| New controls |
Added Rockwell ControlLogix and RSView SE
|
| Implementation |
- BridgeMaster between RoviSys OPC 90 Server and Honeywell OPC Servers
- Existing universal stations display and control CLX loops
- Specification, design and implementation of complete migration done in phase two
|
| New capability |
New RSView screens motivated operations to ask for expansion of RSView
|
Modcell to ControlLogix
|
| Application |
Epoxy reactor control system
|
| Legacy controls |
Modcell controllers and dedicated HMI
|
| New controls |
Rockwell ControlLogix and RSView SE PC HMI
|
| Implementation |
Three-day cutover on holiday weekend
|
Rosemount RS3 to ControlLogix |
| Application |
Multi-tank and -mixer blending operation
|
| Legacy controls |
Rosemount RS3
|
| New controls |
Rockwell ControlLogix
|
| Implementation |
Rip and replace in one week from demolition to full production
|
| New capability |
Now run in full auto mode recipe-based automatic blending in CLX Cycle time and accuracy improved significantly
|
PROVOX to ControlLogix
|
| Application |
Resin reactor and ancillary equipment
|
| Legacy controls |
PROVOX with CHiP interface to subsystems
|
| New controls |
Redundant Rockwell ControlLogix with OPC and serial interfaces
|
| Implementation |
- Cutover in less than one week, including demolition and installation
- PROVOX for two other reactors tied to CLX for common utilities
|
| New capability |
Batch custom recipe builder to meet customer requirements
|
Westinghouse 1500 to DeltaV
|
| Application |
Municipal Utility power generation
|
| Legacy controls |
Westinghouse 1500, FireEye, Analog Devices
|
| New controls |
DeltaV Distributed Control System and Consoles
|
| Implementation |
- Parallel wiring to facilitate fast cutover in phases
- Custom graphics faceplates to mimic Westinghouse screens and reduce operator training issues
- Four combustion systems and two burner management systems have been migrated.
|
Mixed Control Panels to Siemens S7
|
| Application |
University Powerhouse – four boilers
|
| Legacy controls |
Loop Controllers, PLC, manual controls
|
| New controls |
Siemens S7 with WinCC
|
| Implementation |
- RoviSys selected transmitters, drives and control system components
- Feedwater systems, combustion controls, flyash removal and baghouse
controls were all updated and integrated into S7
|
| New capability |
Performance and efficiency data is passed to a campus building automation system. Overall efficiency is at 85% in initial runoff.
|
APACs to ControlLogix
|
| Application |
University Powerhouse
|
| Legacy controls |
Moore Products, APACS
|
| New controls |
Rockwell ControlLogix
|
| Implementation |
Boiler Combustion Controls for 3 units, converted from APACS to ControlLogix with RSViewSE and PanelView HMI.
|
Bailey OIS Consoles to Wonderware ArchestrA
|
| Application |
Power Generating Station
|
| Legacy controls |
Bailey Infi90 and OIS41 Operator Consoles
|
| New controls |
Invensys: Wonderware ArchestrA
|
| Implementation |
- RoviSys developed HMI standards and applied to four boilers in two different control rooms
- Redundant Servers are interfaced to ABB/Bailey Infi90 ICI’s with our OPC90 Server software
- Object oriented capability of ArchestrA was utilized
to improve delivery time and maintainability
|
| New capability |
Wonderware Historian was added to the architecture, giving the plant improved data archiving and reporting.
|
Bailey to ControlLogix
|
| Application |
Tobacco processing and conveying
|
| Legacy controls |
Bailey Network 90 and Infi90
|
| New controls |
Rockwell ControlLogix Safety Controllers
|
| Implementation |
- Phased migration, 8 separate PCU startups
- ArchestrA HMI and historian cutover at same time
- Detailed Cutover Plan provided by RoviSys to ensure downtime was
minimized
|
| New capability |
Documentation up to date, reporting simplified and dead code removed. Maintainability of the ControlLogix system is much better than the highly modified Net90 had become.
|
Rosemount RS3 to DeltaV
|
| Application |
Polyester Resin
|
| Legacy controls |
Rosemount RS3, Moore Products, Allen-Bradley PLC5
|
| New controls |
DeltaV
|
|
Implementation |
- Batch and regulatory control redesign and implemented in DeltaV
- Updated scale interface and HMI
- Mimic Simulation for checkout and training
|
| New capability |
Established a unified process automation infrastructure based on the DeltaV system
|
Rosemount RS3 to DeltaV
|
| Application |
Two acrylic resin reactors, common feed system, with serial interface to external devices
|
| Legacy controls |
Rosemount RS3
|
| New controls |
DeltaV
|
|
Implementation |
- Rip and replace, including control panels, control and HMI.
- Trained operators and engineers during commissioning week
|
| New capability |
Two reactors, migrated from RS3 to DeltaV and implemented a batch control philosophy for the entire system as the existing reactor did not have a batch hierarchy.
|
Rosemont to DeltaV
|
| Application |
Polyester Resin
|
| Legacy controls |
Rosemont RS3, Moore Products, Allen-Bradley PLC5
|
| New controls |
DeltaV
|
|
Implementation |
- Batch and regulatory control redesign and implemented in DeltaV
- Updated scale interface and HMI
- Mimic Simulation for checkout and training
|
| New capability |
Established a unified process automation infrastructure based on the DeltaV system
|
Rosemont to DeltaV
|
| Application |
Two acrylic resin reactors, common feed system, with serial interface to external devices
|
| Legacy controls |
Rosemont RS3
|
| New controls |
DeltaV
|
|
Implementation |
- Rip and replace, including control panels, control and HMI.
- Trained operators and engineers during commissioning week
|
| New capability |
Two reactors, migrated from RS3 to DeltaV and implemented a batch control philosophy for the entire system as the existing reactor did not have a batch hierarchy.
|