System and method for point by point hot cutover of controllers and ios

#This disclosure relates generally to industrial process control and automation systems. More specifically, this disclosure relates to a system and method for point-by-point hot cutover of controllers and inputs/outputs (IOs).

#Industrial process control and automation systems are often used to automate large and complex industrial processes. These types of control and automation systems routinely include sensors, actuators, and controllers. The controllers typically receive measurements from the sensors and generate control signals for the actuators.

#If an existing legacy controller in a control and automation system is approaching its “end of life,” a new type of controller may need to be installed in the system. However, if the new type of controller is considerably different from the legacy controller being replaced, installing the new type of controller may require significant modifications to higher-level controllers, human-machine interfaces, or other components.

#For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:

#FIG. 1 illustrates an example migration from legacy devices to new devices in an industrial process control and automation system in accordance with this disclosure;

#FIGS. 2 through 4 illustrate an example gateway supporting migration from legacy devices to new devices and related details in accordance with this disclosure;

#FIGS. 1 through 6D, discussed below, and the various embodiments used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the invention may be implemented in any type of suitably arranged device or system.

#In the following description, procedures for migration or “cutover” from legacy devices to new devices using a migration gateway are described. A “legacy” device refers to a device being replaced by a more recent, more advanced, or other device. A “legacy” protocol refers to a protocol used by a legacy device, a “legacy” interface refers to an interface that supports the use of a legacy protocol, and a “legacy” network refers to a network that supports the use of a legacy protocol. A “new” or “advanced” device refers to a device that is replacing a legacy device. An “advanced” protocol refers to a protocol used by a new or advanced device, an “advanced” interface refers to an interface that supports the use of an advanced protocol, and an “advanced” network refers to a network that supports the use of an advanced protocol. Note that the terms “migration,” “cutover,” and “replacement” (and their derivatives), when used with reference to a legacy device, include both a physical replacement of the legacy device with a new or advanced device and an upgrade of the legacy device to have one or more features of a new or advanced device.

#A “hot” cutover of a legacy device or system to a new device or system allows users to use custom and other displays, supervisory applications, history applications, and other applications as they are. In many systems, such a hot cutover can be a significant logistical challenge. In accordance with this disclosure, a hot cutover can be achieved by moving control loops from a legacy device, point-by-point, to a new device on-process. More specifically, field device connections are moved from a legacy control system under migration to a new control system point-by-point. The disclosed cutover procedures enable system users to view and control processes from an existing control system during and after cutover. During cutover, control functions of other control loops remain undisturbed. The disclosed procedures also enable the distribution of control loops across legacy and new control environments while providing a unified view to an operator. Any existing custom functions, including graphical functions, can access process and control data from both physical and emulated points.