I want to minimize impact on live production system that has DeltaV SwRev 11.3.0.3865. The migration path in release notes for v12.3.1 says, the system need to be at 11.3.1 to upgrade to v12.3.1. What are the cautions for applying service pack 1 to live system to upgrade to v 11.3.1? Is the upgrade of live system to v11.3.1 a must? If I want to configure an offline ProPlus with v12.3.1, will the migration tool allow database migration from v11.3 to v 12.3.1?.When I deploy the 12.3.1 system, can the controllers (verson 11.3.0.3865) be flashed with this new version?
I will appreciate your replies to implement this upgrade in the safest way with minimal impact to live system. Please include any other related information to this question.
HI,
You propably have the installation disks for 11.3.1?
There you can find the procedure to upgrade the system, read it carefully.
Open the BOLS 11 and look at DV upgrade and migration Guide, read the Before You Start section first.
But first, make sure you have all of the hotfix, upgrade bundles (dv and windows) installed before you start any upgrading procedure.
Backup everything and a little more just to be save...
(upload any desired values)
You can do a "offline" upgrade of the system if you have a new server/PC see in the BOLS:
Creating a New ProfessionalPLUS Workstation with the System Backup Utility
The System Backup Utility backs up/consolidates of all the DeltaV application data into one location (the DVData<date> directory). This allows you to create a new ProfessionalPLUS workstation running the new DeltaV version, without impacting your running system. Once ready (configured and validated), this replacement ProfessionalPLUS workstation can be substituted for your existing ProfessionalPLUS.
When you have done this, you install it on the new computer and start installing the new version 11.3.1 on this computer.
apply all of the hotfixes and so on....
Backup everything.....
Use the e.g. the upgrade wizard (if you can find it in v.12?) and install the latest version + hotfixes and so on.
If you have new computers for OP-stations install them as well (connect to the new Proplus and download and so on)
When your process is NOT in a critical stage swap the proplus, flash the controllers this WILL stop the controller if not redundant also all of the cards needed to be upgraded.
Please FIRST check that your hardware is compatible with the new version....
Depending on your expertice I would suggest that you contact your local Emerson Office for assistance, if you "mess" up the upgrade really bad it can take days and days to get it back up running.
"Some money spent, is much money saved"
Niklas Flykt
Klinkmann Oy
Key Account Manager safety products
nikfly@gmail.com
To answer your direct question, your database must be migrated from 11.3.0 to 11.3.1, and then to 12.3.1. You would need to use the DVMig tool from DeltaV 11.3.1 media, and then the tool from the 12.3.1 media. Migration directly from 11.3.0 to 12.3.1 MAY work, but it is not a supported migration pathway, as per the 12.3.1 release notes. If this is necessary, you should open a call with Emerson and determine the supportability of this method.
A touch-point with your LBP/FSO, or with Emerson Process Management directly, is always advisable before undertaking an upgrade. In this case, going through a major version upgrade, you will need to contact them to procure the version license for the upgraded system.
The DVUpgrade.chm file included with the DeltaV media provides some guidance on the procedure, but, if you're not comfortable with it, I can't recommend reaching out to Emerson strongly enough.
In reply to Niklas Flykt:
Thanks, Niklas. My goal is to do an off-line upgrade from version 11.3 to 12.3.1 and then deploy the entire sytem with servers and workstations. The installation of service pack 1 to upgrade to v11.3.1 may create some intrusion on the live system. Also I am considering upgrade OS to 64-bit for v12.3.1. From your reply, It looks like that I have to back up v11.3 ProPlus (on live sytem) using backup utility.Configure a new temporary ProPLUS (32-bit) 11.3.1 and migrate to the database this version. At the end, configure the 64-bit PRoPLUS for deployment and servers, and workstation and migrate the 11.3.1 database to v12.3.1. This may involve more steps and resources.
Option 2 can be installing service pack 1 on the live system on all servers and work stations and upgrade to v11.3.1 and apply all hot fixes for v11.3.1. and directly upgrade offline system to v12.3.1. This is little intrusive but can be done with Emerson Global Technical Support as you mentioned if required. Controllers flashing to v12.3.1 may be done when the production unit is down.
As you suggested, DeltaV Ugprade and migration guide is a good source. For this particular scenario of v11.3 t0 11.3.1 to v12.3.1 migration, I was looking for best suggestions and possible easier solutions
Thoughts?
In reply to Ray Emerson:
Hi Ray
Thanks for the direct answer to my question. I will check with Emerson if it is possible to migrate the v11.3 database to v12.3.1. I do find guidance in the upgrade and migration guide in disk 2 useful. However when the upgrade is not direct, I consider worthwhile to get some insights and useful tips on practical experience from the experts in this field to help implement upgrade in a methodical way without upheavals.
I have implemented upgrade in past from v10.3.1 to v11.3.1 for other DCS sytems. I agree with you: it a major and critical task and requires planning.
Please share any additional thoughts, ideas, and suggestions.
In reply to Jaimin:
Jaimin, I think there is a difference between upgrading the Pro Plus and upgrading a system. An online upgrade requires meticulous planning and to support this, Emerson does extensive testing on specific versions, therefore you have the supported starting points for migration. This really applies to the Pro Plus as other nodes effectively have their software removed and reinstalled. You do not need to flash controllers to v11.3.1 before flashing to v12.3.1. Similarly, when you upgrade a workstation, it can be taken offline, upgraded by installing v12.3.1 and reconnected to the v12.3.1 Pro Plus.
The most difficult part of the upgrade is the Professional Plus because of the migration of the database. The migration utility for v12.3.1 will migrate a v11.3 FHX file. The Upgrade wizard however, will not run if you don't have a supported version of DeltaV installed. The wizard is extensively tested on the supported starting versions. If you wish to use the wizard, which I'd recommend, you need to upgrade the professional plus to v11.3.1 and then upgrade the system to v12.3.1 with the wizard.
Since you want to move to a new physical computer for the Pro Plus and go to 64 Bit OS, you can manually migrate the pro plus to the new computer, which I will not go into all the steps for this, but recommend you get assistance from Emerson or your local representative. They can best advise you for your situation.
Once the professional plus is upgraded, you can flash controllers and upgrade workstations. The upgrade wizard prompts you to perform these tasks, but they are independent tasks using either the Controller Upgrade utility or installing the new version on the workstations. Careful planning is required to minimize disruption of operations. Again, you do not have to upgrade all the nodes of the live system to v11.3.1 before upgrading to v12.3.1
For online upgrades we strongly recommend a test upgrade to make sure controllers will switch over without disrupting the process. If you've already tested controller switchovers and your configuration works seamlessly, that is definitely good to know, and your upgrade will go smoothly. If you don't know how your controller's behave on a switch over, you need to investigate this prior to the upgrade. That is the major part of the upgrade planning.
If you are doing an offline upgrade, you don't have to worry about online controller switchovers. I would still recommend careful planning and a test upgrade, and with a new Pro Plus server, that will be easy to plan out.
As for IO cards, it is always best to upgrade to the latest firmware. CIOC and WIOC cards are redundant and can be upgraded on line. Since there is no user configured logic in these devices, you don't have to be concerned with configuration specific issues. Local IO cards do not need to be upgraded, but it is best to keep their firmware current. If you are offline during the upgrade you should upgrade the IO cards. We audit the system to identify which cards have new firmware available, what issue or enhancement they provide. We then prioritize the cards to be upgraded and determine if this can fit into the allotted time for the upgrade. If an IO card is deemed mandatory (rarely the case) those are done first. We upgrade as many as is feasible, working down the priority list. Since most IO cards are simplex, these upgrades can disrupt operation, so they are best done during a turn around.
If you've never upgraded a production system, I strongly recommend involving Emerson service personnel with upgrade experience. Although DeltaV upgrade wizard provides a guided process, each system's configuration and physical hardware is different. Combinations of software can result in a unique situation the wizard is not prepared for. If all goes well, the upgrade process is relatively easy. It's the unknown unknowns that are the hardest to prepare for, and having an experienced systems engineer on the team is your best bet for success.
Andre Dicaire
In reply to Andre Dicaire:
This thread has been useful to read through because I will be doing the same thing very soon. We currently run 11.3 and would like to upgrade to 12.3.1. No need to migrate workstations to new computers for us though, so it should be slightly easier.
Dumb question: what does it mean to "flash" the controllers?
In reply to depthcharge623:
'Flash' means to perform a controller upgrade from current version to the new version. The term came from a non volatile but erasable memory called flash memory. Whether it is really flash memory in the controllers nowadays who knows but the term stuck.
Hi Andre
Thanks for providing a very clear and comprehensive post on this subject. I appreciate your valuable advice. As you mentioned and based on my previous experience with offline upgrade from v10.3.1 to v11.3.1 , I am in tune with your statement," It's the unknown unknowns are the hardest to prepare for..."
Usually there is only small windows of less than two days for a maintenance shutdown, we prefer to configure and stage the entire system offline and test it out before deployment except controllers. We want to keep surprises at minimum once the offline tested system is deployed and ready to run the production on schedule. From you post, I glean that we can follow the migration path offline and do not have to disturb the live production system for a version 12.3.1 upgrade. We can flash the simplex controllers when production unit is down and process is not running. An open call to Emerson or support from LBP is definitely helpful to overcome any obstacles and unforeseen circumstances. For the upcoming upgrades, we plan to use 64 bit system only on proPLUS and rest of the system will be 32-bit.
Regarding online upgrade, It appears from Upgrade and Migration guide v12.3 that only one node can be upgraded at a time. We have to factor in the total time constraint for an online upgrade time versus offline upgrade.
While on the subject of upgrade, Would you mind sharing the methods that you follow for:
Besides manually uploading the tuned value in the database, is there a utility/script available for capturing all tuned values that do not match with the database value?
Keeping the VCAT database from the previous version v 11.3 or v 11.3.1 and assimilate it seamlessly into the new upgraded version v12.3.1
Regards,
In reply to IntuitiveNeil:
Thanks for input. The "flashing" term is associated with DeltaV Upgrade and Wizard that involves both controllers and I/0. The DeltaV Upgrade and Migration contains more details about when and how to use this Wiz.
I'd be interested in a script/utility for parameter uploads as well. We recently had a power outage where we lost the UPS eventually. We ended up losing several key parameters which were changed online and not uploaded. Obviously we need to get in the practice of uploading parameters after an online change, but it would also be good to have utility that automatically updates the configuration database for certain parameters.
I think automatic updates to the configuration database can be detrimental if the changes in the tuned values are temporary and Process Engineers are troubleshooting or optimizing or bypassing any interlocks for maintenance purpose.
I am interested in capturing tuned values in a spread sheet and compare with database configuration prior to a major version upgrade. So incase if the tuned values are not uploaded, this document can be used to restore the values considering process safety on start up and then normal operation within control of the operating personnel.
At Intuitive we have just the utility for this online change export to excel task
See the brief of the tool on the last page of the following document that I recently put together on the subject of configuration management for DeltaV. If you want to trial it please give us a shout. We find it a huge time saver.
http://bit.ly/1ehBj5u
See the brief of the tool on the last page of the following document that I recently put together on the subject of configuration management for DeltaV. If you want to trial of it please give us a shout. We find it a huge time saver.
In reply to AdrianOffield:
This is not the complete answer to your request, but there is a tool to get all of the upoad parameters into an Excel spreadsheet (it is shared in the application exchange).
I believe it still works for the latest version (may be worth a try). It once helped us, as it allowed the production staff to determine which parameters they required to be uploaded after a site blackout.
(I would copy the files to an offline machine before testing)
called: "Template for uploads into Excel spreadsheet"
www2.emersonprocess.com/.../Interactive.aspx
Thanks for sharing. The document on the above link contains very useful information for many configuration management tasks. What is the cost of DeltaV online Change Report Tool software that you have mentioned on the last page of this document? How do we download online trial version online? Has this been tested for version up toDeltav12.0 and Excel 2010 or 2013?