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Rockwell Automation Introduces New Migration Tools to Help Users Reduce Risk, Cut Costs and Improve Operational Efficiency


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To improve process performance, users with legacy DCS systems migrate to modern, multidiscipline control platforms

MILWAUKEE, Sept. 27, 2012 — Rockwell Automation has expanded its toolbox for companies looking to easily migrate from legacy DCS systems to the PlantPAx process automation system. These new tools are part of a phased migration approach from Rockwell Automation that helps eliminate many of the costs, risks and complexities involved in moving to a modern, scalable, multidisciplined control platform.

“Implementing a single control platform across all plant-floor applications provides our customers with a number of advantages, including reduced spare-parts requirements, more synchronized processes, and lower maintenance and training costs,” said Mike Vernak, DCS Migrations program manager, Rockwell Automation. “It also improves plantwide integration by enabling the seamless transfer of real-time data from disparate control systems for improved decision making and increased manufacturing flexibility.”

The new migration tools from Rockwell Automation include:

  • Database conversion, cabling solution and I/O scanner for migrating a Siemens MOORE APACS system
  • Cabling solution and improved database-conversion tool for migrating the Invensys Foxboro I/A system
  • I/O scanner for Allen-Bradley SMART I/O for migrating an Emerson Fisher PROVOX system
  • Universal Control Network interface for migrating the Honeywell TDC3000 system

Unlike the rip-and-replace migration method, Rockwell Automation uses I/O scanners to shadow the existing system and pull data during runtime into the Allen-Bradley ControlLogix controller, which is at the heart of the PlantPAx system. This data is used to simulate and test the system to mitigate risk during the conversion. In addition, 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. On one end, the custom cables plug directly into the legacy field termination unit, and on the other end, into the ControlLogix I/O module.
Rockwell Automation also leverages database and configuration utilities that convert existing control strategies into information that the PlantPAx system can understand, rather than having to rewrite them from scratch. This helps reduce risk, engineering time and overall project time.

Schweppes Australia previously leveraged two separate control systems in its syrup room – a legacy DCS and a programmable automation controller from Rockwell Automation. Schweppes had growing concerns over the reliability of its DCS, the difficulty in sourcing spare parts, and the potential for component failure resulting in significant production downtime.

“Migrating the process control functionality to the ControlLogix platform was the natural choice, as it can achieve the same level of functionality as a DCS, but allows for greater flexibility for future expansion,” said project engineer, Warren Ung, Schweppes Australia. “We have been extremely pleased with the smoothness with which this system has been implemented. This upgrade will help ensure Schweppes continues to meet rising demand long into the future.”

The new migration enablers from Rockwell Automation expand the company’s portfolio of migration tools, utilities and services designed for migrating legacy DCS systems, including ABB/Bailey NET90, INFI 90; Honeywell TDC2000/3000, Honeywell IPC, Emerson Fisher PROVOX, Siemens Moore APACS,

Emerson Westinghouse WDPF, Emerson Rosemount RS3, Emerson RMV9000, Invensys Foxboro I/A Series, ABB Taylor MOD300, Emerson DeltaV, and Yokogawa Micro-XL.

About Rockwell Automation
Rockwell Automation, Inc. (NYSE: ROK), the world’s largest company dedicated to industrial automation and information, makes its customers more productive and the world more sustainable. Headquartered in Milwaukee, Wis., Rockwell Automation employs over 21,000 people serving customers in more than 80 countries.

For more information:

Media contacts:
Marilyn Muscenti
Rockwell Automation
440.646.4087
memuscenti@ra.rockwell.com

Dani Litt
Padilla Speer Beardsley Inc.
612.455.1726
dlitt@padillaspeer.com


Allen-Bradley, ControlLogix, LISTEN. THINK. SOLVE., PlantPAx and SMART are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.

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