Case Study: Migrating a Honeywell TDC 3000 to Experion PKS R530 Virtual Machine Without Downtime
Introduction
The migration of legacy Distributed Control Systems (DCS) is one of the most challenging tasks in the industrial automation sector. Many plants still rely on aging systems such as the Honeywell TDC 3000, which has been a reliable backbone for process control for decades. However, with advancements in IIoT, virtualization, and cybersecurity, industries are moving towards modern solutions like Honeywell Experion PKS R530.
This case study covers the seamless migration of a Honeywell TDC 3000 to Experion PKS R530, ensuring zero downtime, minimizing risks, and enhancing system reliability.
Why Upgrade from TDC 3000 to Experion PKS R530?
Challenges of Aging TDC 3000 Systems
- End-of-Life Components – Obsolete hardware makes it difficult to source spare parts.
- Limited Connectivity – TDC 3000 lacks modern Ethernet/IP, IIoT connectivity.
- Cybersecurity Risks – Vulnerabilities in older DCS are a major concern.
- Limited Scalability – Expanding or integrating with newer systems is cumbersome.
- Higher Maintenance Costs – Increased downtime due to aging hardware.
Benefits of Upgrading to Experion PKS R530
- Virtualization Ready – Reduced hardware footprint and increased system reliability.
- Enhanced Cybersecurity – Meets the latest ISA/IEC 62443 security standards.
- Improved HMI & Alarm Management – Modern graphics, better operator awareness.
- Flexible I/O Migration – Supports existing Honeywell I/O and third-party I/O.
- Seamless OPC-UA, Modbus TCP, EtherNet/IP integration – Future-proof networking.
Migration Strategy
A carefully planned migration was necessary to eliminate production downtime. The strategy focused on gradual transition, avoiding a complete shutdown.
Step 1: Pre-Migration Assessment
- Conducted network topology mapping of the existing TDC 3000 system.
- Analyzed the database, HMI, alarm configurations, and controllers.
- Assessed power, cooling, redundancy, and virtualization readiness.
- Identified critical loops, process interlocks, and failover systems.
Step 2: Virtualization & Experion PKS Installation
- Installed Experion PKS R530 in a virtualized environment (VMware ESXi).
- Created parallel system architecture with virtualized servers running:
- Experion Engineering Workstation (EWS)
- Experion Console Station (ECS)
- Process History Database (PHD)
- Virtualized Experion Controllers
- Configured data replication and I/O mapping between TDC 3000 and Experion PKS.
Step 3: Integration with Legacy TDC 3000 I/O
- Used Experion C300 controllers with a Universal I/O Module.
- Established communication between TDC 3000 and Experion PKS using:
- Modbus RTU/TCP
- OPC DA/UA
- Serial Gateway & Data Highway Plus (DH+)
- Ensured that TDC 3000 legacy I/O and critical loops remained operational.
Step 4: HMI & SCADA Migration
- Converted TDC 3000 HMIs to Experion Graphics using:
- Honeywell GUS Graphics Importer
- Custom-built display conversion
- Integrated alarm and historian data from TDC 3000 PHD to Experion PHD.
- Conducted operator training for the new Experion SCADA environment.
Step 5: Testing & Cutover Plan
- Implemented offline simulation to validate I/O responses.
- Conducted Factory Acceptance Test (FAT) with all stakeholders.
- Used a phased cutover approach:
- Day 1: Switched over low-priority loops.
- Day 2: Migrated critical control loops.
- Day 3: Completed system validation and performance tuning.
Step 6: Post-Migration Optimization
- Fine-tuned PID loops for improved performance.
- Activated advanced analytics and IIoT connectivity.
- Conducted site acceptance testing (SAT) and final commissioning.
Challenges & Solutions
| Challenge | Solution Implemented |
|---|---|
| Risk of production downtime | Parallel migration with virtualized system before full cutover |
| Compatibility with legacy TDC 3000 I/O | Used Experion Universal I/O and OPC-UA gateways |
| Operator resistance to change | Comprehensive training and parallel operation period |
| Ensuring data integrity | Rigorous simulation & validation before full switchover |
| Cybersecurity concerns | Upgraded to latest Honeywell security patches & IEC 62443 compliance |
Key Takeaways
1. Zero Downtime Migration is Possible
By using parallel systems and virtualization, the migration was executed without disrupting production.
2. Virtualization Improves System Reliability
Replacing old physical servers with virtual machines (VMs) reduced hardware failures and increased system uptime.
3. IIoT & Data Analytics Provide Better Insights
With Experion PKS R530, operators now have real-time data analytics, alarm rationalization, and remote monitoring.
4. Future-Proofing Industrial Control Systems
The upgraded system now supports Industrial Ethernet (Modbus TCP, EtherNet/IP), cloud integration, and predictive maintenance.
Conclusion
The migration from Honeywell TDC 3000 to Experion PKS R530 was executed seamlessly, without downtime, ensuring a future-proof, secure, and high-performance control system.
By leveraging virtualization, IIoT connectivity, and cybersecurity best practices, the plant now enjoys higher reliability, lower maintenance costs, and improved operational efficiency.
If you’re considering a similar DCS migration, ensure you plan, test, and implement redundancy to minimize risks and achieve a seamless transition.