Whitepaper Connectivity Options between Honeywell and DeltaV Systems February 2009 Page 1

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1 February 2009 Page 1 Connectivity Options between Honeywell and DeltaV Systems This paper describes the methods of implementation and the benefits of preparing an existing Honeywell legacy system to connect with a DeltaV system. Page 1 Emerson Process Management All rights reserved. For Emerson Process Management trademarks and service marks, go to The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warrantees or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the design or specification of such products at any time without notice.

2 February 2009 Page 2 Contents Introduction Connecting OPC For Data Exchange Serial Interface DeltaV Connect Solution for Honeywell Systems FlexConnect Solutions Save Device Wiring, Minimize Down Time FOUNDATION Fieldbus for LEPIU Profibus DP for TDC 2000 and TDC 3000 Discretes Transition Services Conclusion

3 February 2009 Page 3 List of Figures Figure 1 DeltaV to TDC 2000 Connectivity Options... 4 Figure 2 DeltaV to TDC 3000 Connectivity Options... 5 Figure 3 OPC Connectivity between DeltaV and Honeywell Systems... 6 Figure 4 DeltaV Connect Solution for Honeywell Systems directly connects to the LCN... 8 Figure 5 DeltaV FlexConnect Solutions for Honeywell TDC 2000 and TDC Figure 6 LEPIU Replacement Solution with Rosemount 848T to DeltaV H1 Card Figure 7 DeltaV Profibus DP to TDC 2000 Discrete I/O Figure 8 DeltaV Profibus DP to TDC 3000 Discrete I/O Figure 9 US-style Faceplate and Detail Displays on DeltaV Graphics Figure 10 GUS-style DeltaV faceplates Figure 11 DeltaV User-configurable Operator Keyboard Figure 12 DeltaV Consoles with Operator Keyboard... 15

4 February 2009 Page 4 Introduction Honeywell TDC 2000 and TDC 3000 systems have provided excellent control for many years. However, the aging components of these systems are mostly obsolete and often unavailable to many users. Maintenance programs (such as SE&SP) are costly without necessarily satisfying your needs and these costs may outweigh benefits of keeping the legacy system. Struggling with basic system maintenance puts you in a weak position when negotiating for system expansions or process optimization using advanced control applications both of which require additional equipment and the advanced controls require interface development, as well. Bringing the legacy system up to current software revision is expensive and usually requires hardware upgrades. Yet, coming current does not necessarily provide compelling new capabilities that help you advance beyond your competitors. Emerson offers excellent migration services and products to facilitate low risk, low maintenance system improvements that help you derive greater benefits from your existing TDC system and plan for a full transition to the DeltaV system and PlantWeb at your own pace. Emerson personnel understand the TDC systems and work with clients to determine the best options for your site, from total system replacements (in phased approaches) to standalone DeltaV systems for new plant areas. These standalone DeltaV systems can integrate with other plant systems more easily than can any other control system. This paper describes how to connect the DeltaV system with TDC systems and the benefits of each connectivity option. Connecting Not shown below is the revolutionary DeltaV Connect Solution for Honeywell Systems. This unique solution makes DeltaV Operator Stations the Human Machine Interface (HMI) for the Honeywell TDC controllers and I/O, and more information about this solution can be found here. For basic interconnectivity, Honeywell and DeltaV systems can share data by several methods. Figure 1 shows TDC 2000 connectivity options: Figure 1 DeltaV to TDC 2000 Connectivity Options

5 February 2009 Page 5 Figure 2 shows connectivity options for DeltaV systems with TDC 3000: Figure 2 DeltaV to TDC 3000 Connectivity Options As shown above, Object Linking and Embedding (OLE) for Process Control (OPC) allows for data exchange between a DeltaV system and a Honeywell system. Various serial interfaces also allow for data exchange between the two systems. FlexConnect solutions provide hardware boards and/or cables that preserve device wiring up through the Honeywell I/O terminations. The next few sections explore benefits of each method. OPC for Data Exchange OPC simplifies the task of sharing data between systems with different operating systems and data types. An OPC server gets data from a source, such as a control system, puts the data into a standard format, and makes it available to be read by an OPC-compliant client. Normally, OPC servers provide data to clients only; however, the DeltaV OPC Mirror enables data sharing between OPC Servers. The DeltaV OPC Mirror then can serve data from various sources up to an OPC client. For instance, one OPC client can see data from TDC 3000 and DeltaV systems in one common format. Benefits OPC Mirror can link to all plant subsystems with OPC servers, in addition to the Honeywell control system. Data historian or information management software can access multiple process control systems through one common interface protocol, OPC. You can select applications by functionality, rather than by conformance to a proprietary communication protocol. Allows operation of a limited number of Honeywell points from a DeltaV workstation and control a limited number of DeltaV points from a Honeywell console. Your Team Emerson Account Manager can show you a video showing this interoperability. You get seamless integration with Microsoft and other OLE compliant applications. You realize reduced integration costs applications already speak the same language; so developers spend no time creating interfaces.

6 February 2009 Page 6 Architecture Figure 3 shows an example of OPC interface architecture and the software required. Figure 3 OPC Connectivity between DeltaV and Honeywell Systems Serial Interface Serial interfaces have been in use for many years. Typically, serial interfaces use a Modbus protocol and drivers must be written for the applications on both ends of the serial link. Special hardware for the serial type I/O is also required. Serial links between Honeywell TPS and DeltaV enable operator actions performed at one system to result in control actions in the other system. Honeywell TPS has three types of serial interfaces, first via the PLC gateway (also EPLCG), secondly, using IOP/FTA serial ports within the APM/HPM and third, connecting via the TDC 2000 DHP (Data Hiway Port). For all of these, the DeltaV requirement is simply a serial I/O card with serial communications terminations and the appropriate (Modbus) protocol. Benefits Serial connectivity is a reliable and well known data exchange method that allows monitoring and operation of Honeywell control data from a DeltaV workstation. Serial interface implementation allows data to be brought directly into a DeltaV controller. Thus, the points become DeltaV tags. Performance Per Honeywell technical specifications, an I/O subsystem, such as IOP/FTA for the APM/HPM has two serial ports per IOP. Each serial port can support <= 10 writes per second and <= 2048 Boolean, 32 integer, 64 real, or weighted combinations of these reads per second. Each Honeywell PLCG has two serial ports with a capacity of 3000 points per gateway. Data acquisition performance depends primarily on the PLC response to requests by the gateway. Point scan rate is 500 points per second, and may be up to 1000 points per second when digital

7 February 2009 Page 7 points dominate the point type mix. Maximum capacity for each PLCG by point type is shown in Table 1 (next page).

8 February 2009 Page 8 Table 1. Maximum Capacity for PLCG Serial Interface Capacity Point Type 3000 digital inputs 1920 digital outputs 1280 digital composites (one in, one out) 1440 analog inputs 960 analog outputs 576 analog composites (one in, one out) 50 critical alarms 600 events 500 point contact cutouts Output requests from other control network nodes go into a stack for first in, first out processing. Rates vary with the frequency of requests from all nodes on the control network that are interrogating the PLCG. While adequate for monitoring, this data exchange rate may be insufficient for control across links between the two systems. DeltaV Connect Solution for Honeywell Systems DeltaV Connect Solution for Honeywell Systems is a low risk, low maintenance option to preserve customer controllers for a period of time, while replacing the HMI immediately with a state-of-the-art DeltaV system, using familiar looking graphics, faceplates and detail displays. This solution enables you to continue using the TDC control and I/O for uninterrupted processing. Adding DeltaV interface stations to the Local Control Network establishes the ability to communicate between the systems. The DeltaV system network is then expanded to include DeltaV Operate HMI stations at a minimum. You can also add a historian and workstations that perform advanced controls such as model predictive and neural applications. Benefits Links to the Honeywell Local Control Network (LCN) and therefore has direct access to all the points & alarms communicating on that network NOT an OPC solution, it is a unique/exclusive interface connecting directly on the LCN Interface does not appear as an LCN node, but communicates as one NO Honeywell system configuration required NO shutdown of LCN nodes required Does NOT require updating older versions (e.g., R5xx) to latest release Reduces # of nodes on LCN, as Universal Stations are removed Connect & manage multiple LCN s data & alarms within the DeltaV system Interface redundancy provides diagnostics for monitoring health status of standby station and minimizes the impact of hardware failure on plant operations Operate Honeywell control points from a DeltaV workstation Seamless integration Honeywell Universal Station (US)-style instrument faceplates provided, easing the learning curve for personnel Standard configuration tools and methods no interface programming required

9 February 2009 Page 9 Architecture The DeltaV Connect Solution for Honeywell Systems architecture is shown in Figure 4: Figure 4 DeltaV Connect Solution for Honeywell Systems directly connects to the LCN Performance Actually reduces traffic on the LCN (compared to an equivalent US/GUS); it does NOT increase it. Alarm annunciation is equivalent to a Honeywell station. Small server supports up to 2,000 tags; large server supports up to 6,000 tags redundant or up to 10,000 tags in simplex mode. Multiple redundant servers may be attached for larger LCNs.

10 February 2009 Page 10 FlexConnect Solutions Save Device Wiring, Minimize Down Time As the Honeywell controllers and I/O are replaced, if the associated field devices are not being replaced, the DeltaV controllers can connect directly to the Honeywell system s I/O terminations. This is done using FlexConnect solutions, a special set of cables, interface panels and pass through cards that transform Honeywell field wiring terminations into DeltaV terminations. Benefits The most compelling of FlexConnect benefits is the dramatic reduction in downtime which can be 75% or more versus rewiring. Another benefit is lower wiring costs; they drop by 50% when using FlexConnect versus rewiring. Table 2a shows wiring costs for a conventional switchover, based on 640 I/O channels. Table 2a. Cost impact of A 640-channel system switchover, conventional method Activities Disconnect old terminations Remove old terminations Install new terminal blocks Re-terminate wires Wire from new terminal blocks to DeltaV system Document Total time required per channel Total installation time for 640 channels Impact 5 minutes/channel 8 minutes/channel 10 minutes/channel 20 minutes/channel 43 minutes/channel 458 hours Labor $22,900 Downtime (not including documentation time) 20 days Table 2b shows wiring costs using FlexConnect solutions. Compare the downtime with that listed in Table 2a: Table 2b. Cost impact of A 640-channel system switchover using the FlexConnect solution Activities Install FlexConnect panels Install inter-connect cables Document Total time required per channel Total installation time for 640 channels Impact 2 minutes/channel 4 minutes/channel 4 minutes/channel 21 minutes/channel 224 hours Labor costs ($50/hour) $11,200 Downtime (not including documentation time) 5 days During planning the installation and startup of the DeltaV system with an existing Honeywell system, the FlexConnect solution makes a phased implementation entirely feasible. Phased startups let you plan and execute switchover of your most critical plant areas first, while keeping other areas running.

11 February 2009 Page 11 Architecture FlexConnect adds cables and/or panels between Honeywell I/O and a DeltaV controller. Some solutions include special terminal strips designed for quick assembly and installation. The exact structure varies with the type of system and the type of I/O. The DeltaV FlexConnect solutions for TDC 2000 and TDC 3000 are shown in Figure 5: Figure 5 DeltaV FlexConnect Solutions for Honeywell TDC 2000 and TDC 3000 Process Interface Unit (PIU) capacities are listed in Table 3. Table 4 lists TDC 2000 I/O types supported with FlexConnect solutions: Table 3. TDC 2000 PIU I/O options with FlexConnect capability Channels HLPIU I/O Type 4 AO, PI 8 AI, DO, Relay DO 16 DI Table 4. TDC 2000 Basic, Extended, Multifunction and Advanced Multifunction controller I/O terminations with FlexConnect capability I/O Type Termination Analog Termination Panels TCB00, 20, 21, 30 Discrete Termination Panel TPM02 Point Card Terminal Panels TCB50, 60 AMC Discrete Input Panel J-RTP00 AMC Discrete Output Panel J-RTP00 AMC Analog Input Panel J-RTP10 AMC Analog Output Panel J-RTP20, 30 AMC Relay Output Panel J-RTP80

12 February 2009 Page 12 One method uses the removable termination strips on the field termination assembly (FTA). Compression terminations can be physically removed from the Honeywell I/O card and inserted onto the FlexConnect panel. Another method uses the IOP cable connection, keeping the FTA in place. The screw terminal type I/O can be seated on the FlexConnect board, in place of the compression terminations. With this type of connection, the raw field signal is brought directly into the DeltaV controller, which allows HART pass through. The AMS Suite Device Manager capability in the DeltaV workstation is then accessible to these devices for monitoring and diagnostics. Table 5 shows the TDC 3000 Field Termination Assemblies for which FlexConnect solutions have been developed: Table 5. TDC 3000 Field Termination Assemblies (FTA) with FlexConnect solutions. FTA Model Termination Type Circuits Size MU-TAIH02 COMPRESSION 16 A MU-TAIH03 COMPRESSION 16 A MU-TAIH12 COMPRESSION 16 B MU-TAIH13 COMPRESSION 16 B MU-TAOX02 COMPRESSION 8 A MU-TAOX03 COMPRESSION 8 A MU-TAOX12 COMPRESSION 8 B MU-TAOY22 COMPRESSION 16 B MU-TAOY23 COMPRESSION 16 B MU-TDID12 COMPRESSION 32 C MU-TDIA12 COMPRESSION 32 C MU-TDIY22 COMPRESSION 32 B MU-TDIY62 NONREMOVABLE SCREW 32 B MU-TPIX12 COMPRESSION 8 B MU-TDOD11 COMPRESSION 16 B MU-TDOD12 COMPRESSION 16 B MU-TDOD13 COMPRESSION 16 B MU-TDOD21 COMPRESSION 16 B MU-TDOD22 COMPRESSION 16 B MU-TDOD23 COMPRESSION 16 B MU-TDOA11 COMPRESSION 16 B MU-TDOA12 COMPRESSION 16 B MU-TDOA13 COMPRESSION 16 B MU-TDOR12 COMPRESSION 16 B MU-TDOR22 COMPRESSION 16 B MU-TDON12 COMPRESSION 16 B MU-TDON52 NONREMOVABLE SCREW 16 B MU-TDOY23 COMPRESSION 16 B

13 February 2009 Page 13 FOUNDATION Fieldbus for LEPIU For the TDC 2000 Low Energy Process Interface Unit (LEPIU) remote multiplexer I/O, a simple and elegant transition solution is to use the FOUNDATION fieldbus device Rosemount 848T. Each MUX has a capacity for up to 16 inputs and up to 16 remote MUX boxes per LEPIU. Benefits This solution allows you to re-use existing shielded twisted pair wire as the FOUNDATION fieldbus home run cable to a DeltaV H1 card. Architecture Figure 6 shows an example of the architecture for the multiplexer replacement with the Rosemount 848T: Figure 6 LEPIU Replacement Solution with Rosemount 848T to DeltaV H1 Card An even newer solution is to replace the MUX box completely, and rewire directly to new wireless 848Ts. Profibus DP for TDC 2000 and TDC 3000 Discretes The TDC 2000 TCB50 and TCB60 and the TDC 3000 FTA discrete I/O can directly connect to Profibus DP modules from either Microsmith or Phoenix Contact. The DeltaV Profibus card connects directly to the Microsmith or Phoenix Contact module, providing a complete path for this I/O to the DeltaV system.

14 February 2009 Page 14 Architecture Figure 7 shows the architecture for TCB50 and TCB60 discretes to connect to a DeltaV Profibus DP card, using a Phoenix Contact module. Figure 8 shows the architecture for FTA discretes to connect to a DeltaV Profibus DP card using Microsmith modules: Figure 7 DeltaV Profibus DP to TDC 2000 Discrete I/O Figure 8 DeltaV Profibus DP to TDC 3000 Discrete I/O Benefits This solution allows you to bring large quantities of discretes through single cable connections into the DeltaV system. You use standard DeltaV engineering tools for the Profibus DP I/O configuration. Transition Services Transferring the required I/O and regulatory configuration from a Honeywell system to a DeltaV system requires careful oversight by engineers who understand both systems. Emerson has migration teams that: Are focused exclusively on conversion services Are experts who understand configuration in both DeltaV and TDC systems Are familiar with common errors in conversions Oversee use of tools Provide new or enhanced design services Control Database Conversion Engineering database transfers are accomplished most efficiently by using a set of conversion tools. Automated tools reduce manual errors and provide expedient entry of required I/O assignments. These are used to the extent possible, based on the system. For instance, you get a TDC 2000 control database via a printer port capture; to get the TDC3000 control database, you export Exception Build files. Either database is then converted to a spreadsheet or Access database and then imported into the DeltaV Bulk Edit Tool. DeltaV Connect Solution Database Conversion Fully automated conversion services are included with the DeltaV Connect solution. This gives you an initial configuration on which you can expand your DeltaV network. Display Conversion TDC displays can be recreated for the original look and feel on the DeltaV Operate workstations. This speeds the learning curve for your operators, but doesn t allow for newer graphic technologies, nor accommodates more

15 February 2009 Page 15 recent customer or industry graphic standards. TDC 2000 EOS displays are converted manually, as are TDC 3000 GUS displays. However, TDC 3000 US display conversion utilities take these displays directly into the format required for the DeltaV system. With any DeltaV project, US style faceplates can be implemented, again to help operators acclimate to the new DeltaV system. Figure 9 shows sample US style faceplate and detail displays on a DeltaV Operate station. These faceplates and detail displays are automatically used for DeltaV Connect Solution for Honeywell Systems. Figure 9 US-style Faceplate and Detail Displays on DeltaV Graphics Figure 10 shows GUS style faceplates on the DeltaV system, with standard DeltaV buttons for fast one-click access to detail, process graphic, trend, engineering, history or alarm summary displays. Figure 10 GUS-style DeltaV faceplates

16 February 2009 Page 16 A user-configurable keyboard allows you to customize display navigation to suit your process needs and operational philosophy. A sample operator keyboard is shown in Figure 11; you can reproduce the familiar USlook keyboard if desired. Figure 12 shows how this keyboard might be installed with your consoles: Figure 11 DeltaV User-configurable Operator Keyboard Figure 12 DeltaV Consoles with Operator Keyboard

17 February 2009 Page 17 With a new DeltaV system, you have several options that can help ease the adjustment and minimize errors in the early learning phases. One of the first considerations is the type of people who will manage and execute the transition. Emerson offers a mature suite of services to help make all control system transitions successful. Emerson engineers and project managers are experienced with Honeywell to DeltaV upgrades. They have implemented successful hot cutovers, as well as performed site checkout and system startups during tight turnaround periods. For details about how customers have benefited from Emerson expertise when upgrading from their Honeywell systems, visit DeltaV Solutions for Honeywell Systems and to learn more about Emerson service capabilities, visit Emerson Process Solutions. Other considerations are training your personnel and providing tools that facilitate quick adoption of the new technologies. As your project progresses, with DeltaV database configuration and graphics complete, you will have the tools needed for training operators on the new system. DeltaV Simulate Pro can provide realistic field responses to operators without connecting to real I/O. In a safe and virtually risk-free environment, operators can practice running the familiar process from the new DeltaV system. For all system sizes Operator Training solutions are available to suit the specific needs of your site and personnel. Emerson also offers custom courses either at your site or in their training centers. For more information about these powerful training systems, please visit DeltaV Operator Training Solutions. Reference sites are available for all of the solutions described in this white paper. Conclusion Successfully implementing Honeywell systems to DeltaV systems connectivity enables you to: Make a low-risk transition to new technologies, at your own pace Significantly lower the costs of maintaining your control systems Save existing wiring and avoid costly re-wiring Reuse existing control strategies and I/O assignments through conversion services using automated conversion tools Train operators and verify configuration in a risk-free, offline environment Replicate familiar operations displays on the new system consoles Easily expand the control system and integrate your process control data with various plant systems Optimize your processes, using embedded advanced controls DeltaV connectivity brings great possibilities to the legacy Honeywell DCS user. Coupled with the expertise of Emerson personnel, the DeltaV system enables you to maximize process potential while minimizing transition costs.