Honeywell Users Group 2008

USA Yeast ProcessLogix MigrationJames Cage, HoneywellThanks to Stacey Miller, USA Yeast

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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 Long Product Life

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Normal Migration Risk/ Benefit Profile

CostProject

Risk Benefit

Extend Life x Very Low Low

IncrementalUpgrades

5x Low Significant

Rip andReplace

30x High Significant

Opt

ion

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ProcessLogix Risk and Benefit Profile

CostProject

Risk Benefit

Extend Life Low Very Low High

IncrementalUpgrades

n/a n/a n/a

Rip andReplace

High High Medium?

Opt

ion

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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

Server

Fiber Optic Isolation

Fiber Optic Isolation

Con

trol

Net

PLX52 PLX52

• 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

There were a few topologies and interfaces sold with PLX that Honeywell

did not test

ControlNet

Stations

• Rack Sharing with PLC• ControlLogix in the same rack as the

C200. Experion can communicate with AB devices in separate racks

+ CL5550

• Foundation Fieldbus Linking Device• In addition to Honeywell’s FIM, Rockwell

resells National Instruments ControlNet-To-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)

1771 I/O

AB 100M Ethernet

CNet to FFB Linking Device

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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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C200 / Allen-Bradley Integration

Con

trol

Net

ControlLogix PLC

Con

trol

Net

or F

TE

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 ourRockwell 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 EisenbrownSr. Vice President, ACIGRockwell Automation

– Jack BolickPresidentHoneywell Industrial Solutions

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Questions / Discussion?

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Thank You