service. The assumption of using this to be online at the same time as the The quality of the migration solution tool is the old graphics and configura- new system for a phased, stepwise determines how much of the existing tion are worth moving. approach to the migration process. The assets can be saved and is the key to suc-

• Enhanced batch management: This older controllers may be viable for cessfully maximizing the return on product is similar to the HMI connec- years after the original HMI that con- existing assets. tivity product, with the exception that it nected to them has moved on. There is an advantage to using a vendor provides connectivity for a new Batch • I/O gateway: The gateway or special- with standard off-the-shelf migration Manager to interface directly to an ized I/O module allows new I/O mod- products rather than using a vendor existing controller’s phase and recipe ules to be connected to legacy (incumbent or not) that uses custom sequence logic. Assuming the existing controllers. In cases where the legacy applications, which tend to raise the total system has ISA-88 structures, this system has the ability to connect to cost ofownership. product transfers the configuration Fieldbus technology, this tool allows for By minimizing TCO, a user can migrate from that system to the newer system, new I/O modules to be installed either to newer technology and at the same time preserving the batch intellectual prop- as local or remote I/O modules. The maximize returns on the existing assets. erty of the plant. The key point of this incumbent vendor usually provides the product is the intellectual investment gateway, and the incumbent controller ABOUT THE AUTHORS

(ISA-88 structures) can endure, while at remains to control the process. Richard Consoli has an electrical en- the same time, a state of the art batch • I/O replacement: This product allows gineering degree and is the president of management system can work to view for the termination and existing I/O Innovative Controls a systems integration and manipulate the older structure. rack to remain. The replacement I/O is company in Tennessee. His e-mail is

• Engineering library: Thelibraryresides part of the new vendor’s offering so rconsoli@innovativecontrols.com. Ken in the engineering tool of the new con- field signals bypass the incumbent’s Keiser and Todd Stauffer work for troller and includes function blocks, controller and move directly to the new Siemens AG in Pennsylvania as migration structured text, and other control lan- vendor’s controller. The incumbent’s specialist and manager. Their e-mails guages that emulate the languages of controller goes away. The new vendor are ken.keiser@siemens.com and the existing controller library. Since the takes responsibility for the old rack in todd.stauffer@siemens.com. new library uses similar function which the new module is mounted.

View the online version at www.isa.org/intech/20060602.

blocks as the old library, an engineer • I/O interface: This product enables the can use these familiar blocks in the new new controller to use an existing I/O controller without the need for new subsystem (field devices, racks, termi- RESOURCES training. The engineer has the option to nations, and I/O modules). The Oil and Gas Supply Chain Peril: recreate the old control scheme or uti- existing I/O stays in place, and the new Integration of process and security lize the newer technology of the new controller interfaces with the old I/O. systems most feasible for oil platforms, controller and create a new control The old controller goes away, but the pipelines, and terminals. scheme using familiar function blocks. intellectual investment in the con- www.isa.org/link/oilperil

• Controller application conversion: troller can potentially stay by using

Treat Your Water Right: Deep tunnel
This tool converts existing process con- other migration solutions. This tool
sewage plant gets supervisory control
figuration (the function blocks as well saves considerable rewiring costs.
with HMI software.
as the links between them, and other • Field termination assemblies (FTAs):
www.isa.org/link/treath20right

IEC 1131 languages), allowing reuse of This hardware solution preserves valuable application code. This one existing wiring by providing a 1:1 Putting the Squeeze on Power Plants: tool will preserve the years of intellec- replacement of existing terminations Empirical modeling techniques improve tual investment made by plant per- and connection to new I/O modules via online efficiency monitoring. sonnel to improve the DCS. While each a new FTA (with same form/fit and func- www.isa.org/link/squeezepower controller is proprietary to each tion). This product is, ideally, the same

PLC and DCS collaborate in an alarming
vendor, the basic organization of the size as the original terminations (so
situation: PLC hardware and firmware is
data in most vendors’ controllers is additional cabinet space is not required)
generally more simple and robust than
very similar. Once a method surfaces to and uses the existing connectors of the
PC-based.
access this data, it can be an easy pro- field wiring so no rewiring is necessary,
www.isa.org/link/plcdcs
cedure to move the data from one savingconsiderablelaborcosts.
controller to another. Therefore, while each component of a Is it time to replace PID?: Applying

• Controller network gateway: This pro- system has different life spans and life model-predictive control at the single- vides peer-to-peer communication cycle profiles, each part can be migrated loop level may yield the next big leap in between legacy controllers and new separately or with another at the same performance gains. controllers. It allows the existing system time or in a phased approach. www.isa.org/link/replacepidtime