Legacy control system extension, migration and replacement experience

RoviSys has extensive experience in ABB Bailey legacy distributed control systems. 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.

RoviSys also has extensive experience in the replacement of the legacy distributed control system with a number of contemporary solutions. In addition to those listed here, previous projects include migrations from 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.

As an independent company, we are technology neutral: We recommend the solution 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 sample case histories

Infi90 console migration to modern HMI
Application	Midwestern steel maker
Legacy controls	Bailey Infi90 redundant 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)

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 enhancement RoviSys-engineered conversion cables retained field wiring and terminations 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
New capability	Project in progress

Honeywell TDC logic and HMI extension
Application	Hazardous waste incineration
Legacy controls	Honeywell TDC3000 distributed control system
New controls	Added Rockwell ControlLogix and RSView SE
Implementation	ProcessLinx between RoviSys OPC 90 Server and Honeywell OPC Servers Existing Universal Stations display and control CLX loops
New capability	New RSView screens motivated operations to ask for expansion of RSView Specification and design for complete migration is underway

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
New capability

Rosemont to ControlLogix
Application	Multi-tank and -mixer blending operation
Legacy controls	Rosemont 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
New capability	Batch custom recipe builder to meet customer requirements PROVOX for two other reactors tied to CLX for common utilities