USA Yeast, Hattiesburg, MS

Honeywell Users Group 2008
USA Yeast ProcessLogix Migration
James Cage, Honeywell
Thanks to Stacey Miller, USA Yeast
USA Yeast, Hattiesburg, MS
• Built plant in 2002
• Produces baker’s cream yeast
• Sells to bakery, ethanol, and
nutrition markets
• Focuses on exact control to produce the
highest quality product possible.
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ProcessLogix
• USA Yeast purchased
ProcessLogix control system
• PLX had great control, HMI,
and field network capabilities
• USA Yeast made extensive use of Foundation
Fieldbus and DeviceNet
• Single database, easy-to-use, exact control
• System worked great, and business boomed
High-Quality Control Yields High-Quality Product
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And then …
• System vendor stopped updating the ProcessLogix in 2002
• The ProcessLogix system continued to work fine, but over
time the Fieldbus standard evolved
• PCs and operating system technology also evolved
• USA Yeast liked ProcessLogix and their vendor, so they
contacted them for upgrade options
• PLX vendor proposed replacing control processor with PLC
– Reprogram all control
– Rebuild all graphics
– Replace all history, reports, etc.
• USA Yeast knew the history of ProcessLogix, and also
contacted Honeywell
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ProcessLogix History
• From 1998 until the mid-2000s, Rockwell resold Honeywell’s
PlantScape under the name “ProcessLogix.”
– The ProcessLogix PLX52 controller is the Honeywell C200, made by
Honeywell in the same factories
– The ProcessLogix Server is the Experion (PlantScape) Server
– Almost every component and software option are the same
• In 2002, Honeywell renamed PlantScape “Experion PKS.”
Since then, Honeywell has invested heavily to develop new
features for Experion PKS
• Rockwell can not sell Experion PKS. For that reason, only
one minor upgrade to PLX was released after R500
• Fortunately, it is easy to migrate from ProcessLogix to
Experion PKS
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Ease of Upgrade
• Upgrading from ProcessLogix to Experion
–
–
–
–
–
No need to replace controllers
No need to replace I/O modules – no rewiring
No need to re-write any control code
No need to translate or rebuild any graphics
No loss of existing history or reports
• The upgraded system is Experion PKS, with all the same
features, hardware, and software Honeywell sells today
– Includes six years of enhancements
– Honeywell has 1000s of design engineers, project engineers, and
support personnel who are well trained on Experion PKS
Ongoing Development Æ Long Product Life
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Option
Normal Migration Risk/ Benefit Profile
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Cost
Project
Risk
Benefit
Extend Life
x
Very Low
Low
Incremental
Upgrades
5x
Low
Significant
Rip and
Replace
30x
High
Significant
ProcessLogix Risk and Benefit Profile
Option
Cost
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Project
Risk
Benefit
Extend Life
Low
Very Low
High
Incremental
Upgrades
n/a
n/a
n/a
Rip and
Replace
High
High
Medium?
Differences Between PLX and Experion
• Both products share a common ancestor (PlantScape)
• Experion adds all of the enhancements in Experion
Release 100, 200, 210, 300, and 310
–
–
–
–
–
–
–
ProfitLoop
Console Stations
Sim C200, Sim C300
DeviceNet and HART I/O
Procedural Ops
Data + Event trending, enhanced Chart Visualization, etc.
Many others
• Experion also includes features not available in PLX,
like DSA and integration with PM I/O
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ProcessLogix – Features Not In Experion
There were a few topologies and
interfaces sold with PLX that Honeywell
did not test
Server
• AB 1771 I/O Integration
• PLC-style I/O, used with the PLC/5.
Experion can integrate this I/O through a
PLC or ControlLogix
Stations
• Rack Sharing with PLC
• ControlLogix in the same rack as the
C200. Experion can communicate with AB
devices in separate racks
ControlNet
PLX52
PLX52 + CL5550
ControlNet
AB 100M Ethernet
Fiber
FiberOptic
Optic
Isolation
Isolation
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1771 I/O
• Foundation Fieldbus Linking Device
• In addition to Honeywell’s FIM, Rockwell
resells National Instruments ControlNetTo-FFB Linking Device
• Allen Bradley Non-Redundant 100 M Ethernet
• Rockwell has tested their proprietary
Ethernet Interface with ProcessLogix.
Honeywell uses Fault Tolerant Ethernet
instead (redundant, multi-path)
CNet to FFB
Linking
Device
USA Yeast System
• ProcessLogix did not have a
DeviceNet interface
• USA Yeast decided to bring
DeviceNet to a PLC, and use the
C200’s peer-to-peer capability to
bring across the DeviceNet data.
• The PLC was installed in the same rack as the C200
• Limited space to relocate the PLC to another rack
• Limited time during migration to re-address DeviceNet
to Experion interface
• Honeywell evaluated this at the time of the bid, and
after evaluating the topology, decided to support this
specific system after the upgrade
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ControlNet or FTE
C200 / Allen-Bradley Integration
ControlLogix PLC
ControlNet
PLC/5
Panel View
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The Migration
• USA Yeast contacted
Honeywell in early 2006
• By mid-2006, the
evaluation, bid, purchase
order, and upgrade were all
complete
“With the support of Honeywell, we have successfully migrated our
Rockwell ProcessLogix control system to Experion. We now have greater
access to real-time information and analysis tools to make faster and more
effective decisions.”
Stacey Miller, Applications Engineer, USA Yeast
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Developments After Upgrade
• Honeywell has continued to
invest heavily in both new
hardware (C300) and the
C200-style platform
• Many new software and
hardware enhancements
released and planned for the
future
• Honeywell and Rockwell have
continually reaffirmed
relationship
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Honeywell / Rockwell Joint Statement
“Honeywell and Rockwell Automation have worked together for many years to develop world
class, highly integrated products and solutions based upon shared technologies. Customers of
both companies have benefited from this collaboration, and the relationship remains important
to Honeywell Industry Solutions and Rockwell Automation.
Honeywell is proud to announce Experion PKS™, its next generation control technology that
is based on a unified Process Knowledge System™ architecture. Rockwell Automation I/O and
technology is an integral part of the Experion PKS unified, plant-wide system architecture.
Rockwell Automation has been an integral component supplier to Honeywell Industry
Solutions for almost 10 years, and the company plans to continue supporting and supplying its
products and solutions to Honeywell for decades to come. The continued success of both
company's respective customers remains the highest priority to Rockwell Automation and
Honeywell.
– Steve Eisenbrown
Sr. Vice President, ACIG
Rockwell Automation
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– Jack Bolick
President
Honeywell Industrial Solutions
Questions / Discussion?
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Thank You
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