QCS MIGRATION BEST PRACTICES · – QCS to be compatible with at least 3 previous versions of...

Americas HUG WorkshopQCS MIGRATION BEST PRACTICESPeter Bijsterveld

June 11, 2019

© 2019 by Honeywell International Inc. All rights reserved.

1

QCS Migration Workshop Overview

• QCS challenges reflect broader industry issues, at a faster pace

• Honeywell Lifecycle Support Policy – QCS Platform

• Microsoft announcement impact

• A brief history of QCS evolution from MXOpen to Experion MX R702.1

• R702.1 Primer – new features

• Virtualization is the foundation for lowest TCO

• DaVinci and Experion MX R6xx to Experion MX R702.1

– Platform Migration Process non-technical overview

– QCS migration expectations

• Questions

Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.

Common challenges accelerated in Pulp & Paper / Continuous Web industries

2

Manufacturing challenges and trends

Pulp and Paper / Continuous Web Solutions

• High system availability required to minimize risk of lost, or off-spec, production

• Maintaining product quality & production while reducing costs

• Conversion of production processes to packaging grades

• Lifecycle cost optimization

• Short downtimes and service breaks favorable for small, incremental, upgrades rather than large rip-and-replace projects

Common Industry Challenges

• Cyber Security threats, protecting against attacks

• Achieving integrated and interoperable systems

• Reducing service and maintenance costs

• Gap in local skills and experience

• Aging workforce

• Rapid IT/Process infrastructure changes

• Multivendor projects


3

QCS Lifecycle Challenges

• Limited capital funding available

• Lower Total Cost of Ownership

• Improve system and process reliability

• Reduce product and manufacturing costs

without sacrificing quality and output

• Off-the-shelf

hardware/software rapid

obsolescence

• Constant cyber threat

• Specialized industrial control

applications, measurement,

and control equipment

• Limited spares and repairs for

obsolete equipment

• Limited remote access and

support options for old systems

• Increasing complexity of networks

and infrastructure, IT systems

interwoven with control systems

• Specialized skills required


4

QCS Platform Lifecycle Phases

R702.1 R61x* R60x* DaVinciExperion MX

SW version

Windows 10 64 bit

Windows 2016 Server 64b

Application

Enhancements:

• MD/CD MV Controls

• Metals Control R12x

• Security Enhancements

• New HMI Controls

• Alarm Tracking

• Alarm Pager

• Distributed System

Archtecture (DSA)

• Extended History DB

Windows 7 64 bit

• Windows 2008 R2 64 bit

Application

Enhancements:

• MD Control

• Metals Control

• Security Enhancements

• Wyse Z90 Thin Clients

Windows 7 32 bit

• Windows 2008 R2 32 bit

• SQL Server 2008

• Labview 2010

Virtualization Capability

(Experion PKS virt.)

• Experion MX HMI

Experion MX Scanner

and Diagnostics

• Experion MX CD and MD

Controls

Windows

XP SP2 32

bit

• W2003 32

bit

• SQL 2005

(Upd 5)

• Labview 8

Virtual.Cap

(vmware

WS)

• EBR

FTE

Windows

2000 Pro

• Windows

2000 Srv

• RAE HMI

• RAE

Alarms

Upgrade

Steps

New faster, lower cost approach to getting and staying current available!

Low Medium High

* Experion MX and MXProLine R6xx change to Phased-Out in early 2020 due to

announced Microsoft Operating System end of support


Experion MX R702.1 supports latest Microsoft Operating Systems

5

Microsoft Announcement Impact

• Microsoft announced end of support for Windows 7 and Windows Server 2008 in January 2020

– No Microsoft Security patches

– No Microsoft bug fixes - not even for security related defects

– No Antivirus support

• Operating System status change triggers Honeywell Phased-Out lifecycle change for older Experion PKS and Experion MX platforms, and for Experion Mu

– Announced in HINTS Newsletter February 2019

From HINTS February 2019:

All users of traditional MD control applications will receive the Alpha MPC

Multivariable package when they migrate to Experion MX R7XX.X. This migration

path provides robust functionality to traditional controls users. The Alpha MPC

packages fully supports a “Traditional” control strategy while enabling customers to

experience significant additional value when they implement multivariable

optimization strategies provided by the far superior Alpha MPC-based control

application. All users of traditional CD control applications will receive the

Multivariable CD Control package when they migrate to Experion MX R7XX.X. This

migration path provides robust functionality to traditional controls users. Multivariable

CD control application fully supports a “Traditional” control strategy while enabling

customers to receive significant value when they implement additional multivariable

optimization strategies provided by far superior CD Multivariable control technology.

From HINTS February 2019:

Products to be Phased Out / Notice of Change in Product Support

Status The Experion MX and MXProLine Quality Control Systems (QCS)

are impacted by Microsoft’s announced end of support for Windows 7 and

Windows Server 2018. Effective March 31, 2020, Honeywell will phase-out

and declare the end of global support for all R6xx-based versions of the

QCS family. This impacts the following: Experion MX and MXProLine

R610.x, R611.x, R612.x, R614.x & R615.x Experion MX MD Controls

R610 and R611.1 (based on Experion MX R610-615.3 and Experion PKS

R430-R43x system software releases). Experion MX CD Controls R610

(based on Experion MX R610-615.3 and Experion PKS R430- R43x system

software releases)

A BRIEF QCS HISTORY AND R702.1 FEATURES1998 to Experion MX R702.1


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QCS: 20 years from MXOpen to Experion MX R702.1Systematic Evolution of the QCS platform towards common Experion PKS architecture

1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 2019

MXOpenDa Vinci Experion MX

Experion PKS Based HMI and Alarms

R60x R61x R702.1RAE 1 RAE 2 RAE 3 RAE 4 RAE 5

• 2010: Experion MX, Q4000, EDAQ

• Current version R702.1 (April 2019)

• 2013: Virtualization

• 2019: DSA Peer to Peer Nodes

• Simplified QCS-DCS integration

• Da Vinci – scanner/sensor/actuator support

• MXOpen –”On Availability” support, Highest Risk

Da Vinci maintenance challenges

• Operating System support ended

• No Anti-Virus or security patches

• Obsolete electronics of early PMP

assemblies

Phased-Out:

• Vision

• 2002 ET

• 2002 HP

1998: Da Vinci with

Real Time Application

Environment (RAE)

Win 7 / Win 2008Win XP / W2k3Win 2k Pro/SrvWin NT /Srv Win 10 / Win 2016

Increasing Experion PKS Infrastructure


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Experion MX R702.1

• Experion MX and MXProLine R702.1 qualify for new QCS support programs:

– Remote platform support and updates, ”One-click” keep current commitment

– Perpetual QCS software license, Enhanced diagnostics and QCS 4.0 features

• New R702.1 features and enhancements:

– HMI, alarm management, diagnostics, improved control systems integration, supports new sensors/scanners

– Extended, enhanced history (EHDB) supports 2 years of data

– Advanced color map displays 400 scans, simplifying quality analysis

– Proven superior Multivariable MD and CD control packages replace Traditional MD and CD control packages

– Distributed System Architecture (DSA) enables QCS-DCS Peer to Peer communication

• R702.1 supports all DaVinci and Experion MX scanners/sensors

– No scanner upgrade required to leverage Experion MX R702.1 features

– Improves performance of existing QCS scanner/sensor hardware

• Reduced-cost virtualization – goal is 100% virtualized QCS sites for enhanced lifecycle management

• Virtual Engineering Platform (VEP) speeds project, enables quick operator orientation

Reduce support costs, enhance performance, leverage new features, keep current


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Cross direction controlMultivariable controller

• Custom designed multivariable controller

MPC (*) controller used

– Optimizes overall quality rather than single

quality parameters

– Honors process constraints and improves

control performance when CD actuators

operate near their limits

Simultaneously Optimize

Dry Weight, Moisture,

and Caliper Profiles

Optimize Moisture Profiles and

Energy Usage by optimizing

steam and moisture application

Optimize Wet Press and Reel

Moisture Profiles to improve CD

draw uniformity and runnability

ProCoat Calcoil

AFT for

Supercalenders

DevronizerAutoSlice

AquaTrolProFlow

* Modular Predictive Controller

Traditional CD

Control users will

receive CDMV

package at

migration


10

Machine direction controlMultivariable controller

• Flexible multivariable controller

– Same MPC controller used for CD controls

– Robust controller less sensitive to process changes, requires fewer process model updates

• Simplified configuration

– Integrated tuning tools

• Automatic grade change

– 50% reduction in grade change losses

• Simplified, configurable,operator display

• Full suite of auxiliary controls

– Multi-former control

– Crepe ratio control

– Coater control

– Production optimization

Traditional MD

Control users will

receive the Alpha

MPC MDMV

package at

migration


11

R702.1 Distributed System Architecture (DSA)

• Multiple Version compatibility – Requirements met with Experion MX R702.1

– QCS to be compatible with at least 3 previous versions of Experion PKS

– QCS to be compatible with at least 3 future versions of Experion PKS

• Version independent upgrade of QCS and DCS systems – upgrade each on merit

• DSA Peer-to-Peer communication enables:

– Consuming QCS data published through CDA in Experion PKS system

– Accessing Experion PKS displays in QCS OP-Stations

– Accessing hybrid displays in QCS & Experion PKS OP-Stations

DSA enables versatile, flexible QCS – DCS integration


All Experion MX PC nodes available as Virtual Machines

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Experion MX Virtualization

• Multiple VM platform options, Thin Client HMIs

• Leverages Experion PKS virtualization architecture

• Host based antivirus solution

• Experion Backup and Restore

• Significant lifecycle maintenance benefits

• Flexible installation options

• Improved system availability and recovery from failure

• Experion MX R702.1 is purposely built for virtualization

– Virtual driver and system compatibility is tested to ensure a rugged, stable platform is available for maximum system reliability.

– New/migrated system is built entirely in the virtual environment, ready for deployment to the site virtual platform

PACKAGED MIGRATION TO EXPERION MX R702.1From DaVinci, MXProLine, or Experion MX earlier version


14

QCS Migration Philosophy – Transformation to low TCO Model

Customized

• System builds:• Vary in approach

• High customization vs. reuse

• Costly to maintain, upgrade, migrate

• Individualistic vs. collaborative

• Remote monitoring services:• Limited, costly to initiate

• Difficult to grow (sites and functionality)

• Value is hidden/poorly documented

• Optimization:• Reactive and limited

• Capacity bound

• Labor-centric vs. value-centric

• Resulting value poorly captured

Optimized

• System builds:• Common starting point with known quality

• Leverage shared application library

• Efficient to maintain, upgrade, migrate

• Signature = Honeywell, not individual

• Connected QCS / Connected Mill/Plant• Fully aligned with remote offerings

• Easy to connect, deliver, and extend

• Value-centric, emphasized in user

experience

• Optimization• Proactive – extension of Connected QCS

• Expandable/globally available

• Value-centric

• Holistic: CD+MD+Grade

Change+Machinery

Transform from customized to optimized


Standard customization approach: maintain quality / compliance, productize popular ones

15

Specials repository for QCS: capture during migrations

• Leverage shared application library

• Candidates for integration

• Detailed documentation via properties sheet

• Known input and output

• Shorter implementation time

• Shared maintenance resources

• Best practice

Displays

I/O links

MIS


Get to R702.1 quickly and affordably to be cyber secure, reduce TCO, enable services

16

2019 and Future Platform Migration Standardization / Pack

Installed

DaVinci,

MXProLine, or

Experion MX

QCS

Run

collection

tools and zip

Send to

COE

System migrated

in Virtual

Platform (VEP)

Site

orientation &

training

System

deployed for Site

Commissioning

Specials

Allocation


17

New Standard Platform Migration package time lineSystem migrated and ready for review and remote operator training in ~ 2 weeks

Receive system

info packageSet up in VEP Migration Training on VEP

Document and

deliverRemote FAT

0.5 day 1 day 2 days* 1 day 1 day 1 day

Includes:

• Software build

• Databases integration

• Scanner/Sensor and Actuators integration

• User training

• Virtual platform

• Updated documentation

• Testing minus site equipment integration

• List of previous “legal” specials (no core-code modifications supported)

Excludes Customization and Specials:

• HMI, Reporting, “Convenience Specials”

Local-team ready:

• Install and commission or

• Utilize Specials Allocation bucket

Includes:

• All Honeywell, Microsoft, VMWare licenses

• Choice of Computer specifications for local purchase or

• Computer platform supplied by Honeywell

• All standard QCS system software updated

• MD and CD Traditional Controls migrated to MD and CD

Multivariable Controls (CDMV, MDMV)

Includes allocation bucket for customization:

• Use or apply to QCS 4.0 1st year subscription

Specials Repository:

• Local team registers any specials deployed on R702.1

systems

• Registration process confirms programming best practice and

upgradeability, qualifies for future productization if popular


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Pre-migration stepsGet the details first

• Honeywell tools capture details of the existing system for migration

– Run tools/scripts at site or remotely via Service Node, zip and send to COE

▪ QCS system audit tool (from RAE 5 releases)

▪ QCS diagnostic capture tool (from R6xx releases)

▪ QCS specials finder tool

▪ System architecture

▪ Network topology


19

Migration Work Package – site zip package starts process

• The original software version

▪ For recent software releases (RAE 5 and R6xx) will have build-in tools for a smooth migration

▪ Pre RAE 5 releases will need more migrations steps

• The amount of customization

▪ Honeywell will try to limit the amount of customization by using proven solutions in R702.1

▪ If needed, Honeywell will use the already migrated and documented specials in its specials repository, if available.

▪ Honeywell will indicate the (financial) consequences using the remaining customization, on the short and the long term.

▪ Customization comes with a price

– The question remains:

▪ Does Honeywell meet your customized requirements with the R702 software package ?

▪ Are customizations still needed ?

▪ Do we want the same discussion in the future again?

Indication of migration challenges and impact time and costs


20

Quick customization check example

No customization Customization


21

Continuous Evolution and ServicesIncreased value and reduced total cost of ownership

Unequaled breadth

and depth of service

Over 2000service technicians

18 major support

centers worldwide

200+ local offices

70+ cyber security

experts globally

• System

assessments

and improvement

planning/implementation

• Advanced Solutions portfolio

to improve plant operations

• Industrial cyber security

solutions

• Migration / expansion

planning and support

• Hardware refresh

programs

• Software upgrades

LIFECYCLE

SERVICES

System performance

monitoring for active

monitoring and

patch deployment

Site specialists to

quickly resolve

issues

Parts

management

Global Technical

Assistance Center

Certified recycled parts

Remote connectivity for

faster resolution


MAKE YOUR SYSTEM READY FOR THE FUTURE

With Honeywell as your partner

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QCS MIGRATION BEST PRACTICES · – QCS to be compatible with at least 3 previous versions of...

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