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White Paper Connectivity Options Between Honeywell Deltav Systems Pss en 67786 PDF
White Paper Connectivity Options Between Honeywell Deltav Systems Pss en 67786 PDF
February 2009 – Page 1 Connectivity Options between Honeywell™ and DeltaV™ Systems
www.EmersonProcess.com/DeltaV
Whitepaper
February 2009 – Page 2 Connectivity Options between Honeywell™ and DeltaV™ Systems
Table of Contents
Introduction .............................................................................................................................. 4
Connecting ............................................................................................................................... 4
Conclusion ............................................................................................................................. 17
Whitepaper
February 2009 – Page 3 Connectivity Options between Honeywell™ and DeltaV™ Systems
List of Figures
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 3000 ................ 10
Figure 6—LEPIU Replacement Solution with Rosemount 848T to DeltaV H1 Card ................ 13
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. There might be a few paragraphs in this section.
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 show
TDC 2000 connectivity options:
Figure 2 shows connectivity options for DeltaV systems with TDC 3000:
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.
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.
Whitepaper
February 2009 – Page 6 Connectivity Options between Honeywell™ and DeltaV™ Systems
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.
Architecture
Figure 3 shows an example of OPC interface architecture and the software required.
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.
Whitepaper
February 2009 – Page 7 Connectivity Options between Honeywell™ and DeltaV™ Systems
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
points dominate the point type mix. Maximum capacity for each PLCG by point type is shown in Table 1.
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.
Benefits
Links to the Honeywell Local Control Network (LCN) and therefore has direct access to all the points & alarms
communicating on that network
Does NOT require updating older versions (e.g., R5xx) to latest release
“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
Seamless integration
Honeywell Universal Station (US)-style instrument faceplates provided, easing the learning curve for
personnel
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
Whitepaper
February 2009 – Page 9 Connectivity Options between Honeywell™ and DeltaV™ Systems
Performance
Actually reduces traffic on the LCN (compared to an equivalent US/GUS); it does NOT increase it.
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.
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.
Activities Impact
Disconnect old terminations 5 minutes/channel
Remove old terminations, Install new terminal blocks; 8 minutes/channel
Re-terminate wires
Wire from new terminal blocks to DeltaV system 10 minutes/channel
Document 20 minutes/channel
Total time required per channel 43 minutes/channel
Total installation for 640 channels 458 hours
Labor costs @$50/hour $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:
Whitepaper
February 2009 – Page 10 Connectivity Options between Honeywell™ and DeltaV™ Systems
Table 2b. Cost impact of A 640-channel system switchover using the FlexConnect solution
Activities Impact
Install FlexConnect panels 2 minutes/channel
Install inter-connect cables 4 minutes/channel
Document 4 minutes/channel
Total time required per channel 21 minutes/channel
Total installation for 640 channels 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.
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
Whitepaper
February 2009 – Page 11 Connectivity Options between Honeywell™ and DeltaV™ Systems
Process Interface Unit (PIU) capacities are listed in Table 3. Table 4 lists TDC 2000 I/O types supported with
FlexConnect solutions:
Table 4. TDC 2000 Basic, Extended, Multifunction and Advanced Multifunction controller I/O terminations
with FlexConnect capability
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. (Next page)
Whitepaper
February 2009 – Page 12 Connectivity Options between Honeywell™ and DeltaV™ Systems
Table 5. TDC 3000 Field Termination Assemblies (FTA) with FlexConnect solutions.
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-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-TDOY23 COMPRESSION 16 B
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:
An even newer solution is to replace the MUX box completely, and rewire directly to new wireless 848Ts.
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.
Architecture
Figure 7 shows the architecture for TCB50 and TCB60 discrete to connect to a DeltaV Profibus DP card, using a
Phoenix Contact module. Figure 8 shows the architecture for FTA discrete to connect to a DeltaV Profibus DP
card using Microsmith modules. (Next page)
Whitepaper
February 2009 – Page 14 Connectivity Options between Honeywell™ and DeltaV™ Systems
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 discrete 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 experts who understand configuration in both DeltaV and TDC systems
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
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 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.
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:
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:
Reuse existing control strategies and I/O assignments through conversion services using automated
conversion tools
Easily expand the control system and integrate your process control data with various plant systems
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.
Whitepaper
February 2009 – Page 18 Connectivity Options between Honeywell™ and DeltaV™ Systems
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