将传统自动化迁移到现代平台

Water/Wastewater Operators Rely on Tesco Control’s Proven Automation Migration Experience

在这些例子中, Tesco Controls demonstrates the multi-discipline experience necessary for migrating water/wastewater legacy automation to modern platforms.

拉奈尔, the PLC Applications Engineering manager at Tesco Controls, wrote an article recently published in the December 2020 edition of 控制工程的全球系统集成商报告. CFE媒体,出版 Control Engineering, has ranked Tesco at number 10 among the “2021 System Integrator Giants”这一数字高于2020年的第14位.

Raju的文章标题是 将传统PLC程序迁移到现代PLC硬件 , and it presents Tesco’s expertise in migrating legacy automation systems to modern hardware and 软件 platforms, while avoiding unacceptable downtime and reducing 风险. Following is a summary, or you can click the link above for the full text.

     

老龄化系统带来的挑战

Water/wastewater operators must carefully manage their maintenance budgets, 经常保持系统在过时后运行. Even traditional hardwired controls need to be upgraded eventually, 但这变得更加明显, 在某些方面, more burdensome as automation transitioned to more capable digital systems like programmable logic controllers.

对于许多用户来说, PLCs become mysterious boxes which run well for long periods of time, 所以他们在很大程度上被忽视了. 在过去的几年里, 更新通常没有文档记录, 可能没有备份, 也许团队会失去硬件, 软件, 和/或上传所需的技能, 下载, 或者对代码进行故障排除. When factory support and parts availability come to an end, a migration or upgrade is needed.

迁移计划

在某种程度上, keeping a legacy system as-is and repairing it with eBay-sourced parts is not an option. It is rarely possible to plug-and-play when exchanging hardware platforms. PLC coding means and methods were not standardized among manufacturers or systems integrators (SIs). This variability makes any migration, or upgrade for that matter, more difficult.

而升级可以是一种全新的方法, it also involves an invasive rip-and-replace process with significant downtime, 风险, 和成本. Crucial existing functionality may be overlooked or misunderstood.

It is preferable in many cases to plan a more progressive migration, preserving a system’s control strategies to the greatest extent possible, while incorporating modest improvements where warranted.

迁移工具

Most major PLC manufacturers offer specialized hardware and 软件 migration tools to facilitate the process of transitioning legacy systems to modern systems. Hardware retrofit adapters enable new platforms to interconnect with existing field hardware and connections.

Migrations may take advantage of hardware retrofit adapters so new PLC hardware can be interconnected with existing hardware, 保留现场连接, 加速过渡到新的控制平台.

 

This retrofit is being delivered to the job site for installation into the existing panel. Skilled systems integrators like Tesco carefully design retrofits for easy field installation, 尽可能多地进行车间前期工作.

Software conversion tools are crucial for preserving as much logic as possible, although experienced programmers must still audit the code for unsupported functions, 不匹配的数据类型, and specific concerns such as peer-to-peer communications.

Tesco understands the processes and platforms involved, and it has a strong record of executing migration projects. 乐购团队熟悉现场调查, 在各方之间举办讲习班, and performing the detailed hardware and 软件 design required to deliver a successful project.

例1:罗克韦尔自动化

One wastewater municipality wanted to upgrade their Allen-Bradley PLC-5 platforms to modern ControlLogix Ethernet-based systems, while preserving the existing FactoryTalk View SE supervisory control and data acquisition (SCADA) system. Tesco Controls leveraged Rockwell Automation’s conversion products and tools to efficiently migrate the existing hardware and 软件, performing a seamless hot cutover of the PLCs using good documentation practices, appropriate contingency plans and a thorough understanding of the plant’s operational characteristics and the end user’s goals.

 

These before (top) and after (bottom) photos show how retrofit hardware supports quick and minimally invasive migration cutovers, 让团队更多地关注软件.

 

案例2:施耐德电气

A water treatment plant used equipment and legacy automation platforms which were no longer supported by the OEM, 所以某种形式的升级是必要的. 在备份所有现有代码之后, Tesco Controls performed an initial hardware/软件 migration, with only minimal downtime required for demolition and upgrade work. The work also included documenting the resultant code and combining the function of two PLCs into one.

结论

The saying “nothing lasts forever” certainly applies to industrial automation systems.

When old automation systems finally require an upgrade, a balanced approach of migrating legacy industrial automation programs into new platforms can be the preferred solution. This approach provides the best method for preserving existing functionality while minimizing downtime.

Tesco Controls stands ready as a trusted automation partner to help the water/wastewater industry with any needs for completely new projects, 更换数据库升级, 或有效的迁移.

beplay体育中心公司. 是“? 控制系统集成商协会(CSIA).

作者

拉奈尔的照片
拉奈尔