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.

    Rosemount 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 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.
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