Navigating System Upgrades: From Legacy to Leading-Edge

In the realm of industrial software, the upgrade from legacy systems to modern platforms represents more than just a technological shift; it embodies the strategic evolution necessary for businesses to thrive in today's fast-paced environment. My journey through these transformations, particularly focusing on the AVEVA System Platform, has been both enlightening and complex. Here, I aim to share insights and methodologies from this path, reflecting the intricate processes and innovative approaches we employ at ICS of Texas.

The Challenge with Legacy Systems

Legacy systems often symbolize a company's longstanding operational history, yet they pose significant challenges in maintenance, compatibility, and efficiency. Through my work, I've navigated these hurdles, drawing on a wealth of experience to guide strategic system upgrades. This experience is not just about overcoming technical barriers but about leveraging opportunities for growth and efficiency that modern systems offer.

A Methodical Approach to Upgrades

Our upgrade process begins with the meticulous collection of legacy system files, including both Intouch directories and CAB files, alongside essential Kepware configuration and PLC program files. This preparatory stage is crucial for setting a solid foundation for the upgrade.

Following this, a unique blend of pre-built macros—our "secret sauce"—comes into play. These macros facilitate a detailed examination and importation of Tag Database information, ensuring the preservation of vital data such as descriptions, scaling, and alarm point operations.

The subsequent phases involve crafting a CSV Kepware alias file and galaxy load file for each object, laying the groundwork for the new system's architecture. This meticulous process culminates in the creation of a base galaxy, followed by the conversion of graphic screens, guided by legacy Intouch screens to ensure a seamless transition.

Ensuring Success Through Testing

A comprehensive testing phase in a virtual environment is pivotal, allowing us to validate the functionality of the IO system, object popups, navigation graphics, and other critical components. This step ensures that the upgraded system operates flawlessly before its deployment to the client's servers, followed by a thorough Site Acceptance Test (SAT).

A Partner in Innovation

While the essence of this article is to share the knowledge and experiences from these system upgrades, it also subtly reflects the caliber of work we undertake at ICS of Texas. Our commitment to innovation and excellence is a testament to our team's capability to navigate complex upgrades, ensuring success for our clients.

Guide for Upgrade

1. Preparation and Collection

Objective:

Gather all necessary legacy system files, including Intouch directories or CAB files, Kepware configuration files, and PLC program files, to lay the groundwork for a successful system upgrade. This foundational step is crucial for ensuring that all elements of the legacy system are accounted for and can be accurately translated into the new environment.

Action Points:

1. Ensure Comprehensive Collection of Files:Identify all relevant components of the legacy system that will need to be migrated to the new platform.Collaborate with system administrators and operational teams to compile a complete list of necessary files, ensuring nothing is overlooked.
2. Organize and Store Files on a Secure Server:Once collected, categorize the files based on their type (e.g., application files, configuration files) and relevance to different parts of the system upgrade process.Utilize a secure server for storage to protect the integrity of the data during the upgrade process. This includes implementing appropriate access controls and backup procedures to safeguard against data loss or unauthorized access.

Tips for Success:

• Communication is Key: Engage with stakeholders from different departments to understand the scope and nuances of the existing system. This collaborative approach can reveal critical insights into how best to approach the upgrade.
• Document Everything: Maintain detailed records of the files collected, including their original location, purpose, and any specific considerations for their use in the upgrade process. This documentation will be invaluable for troubleshooting and reference throughout the project.
• Prioritize Security: Given the sensitive nature of system files, ensure that the server where files are stored meets the highest standards of security. Regularly review access logs and update security protocols as necessary to prevent breaches.

By meticulously following these action points, you can ensure that the preparation and collection phase of the system upgrade sets a strong foundation for the subsequent steps in the process, ultimately leading to a smoother and more efficient upgrade experience.

2. Analysis and Planning

Objective:

Effectively analyze the Tag Database using specialized macros, aiming to preserve vital information such as descriptions, scaling values, and alarm operations. This step is crucial for maintaining the integrity and functionality of the system data during the upgrade process.

Action Points:

1. Prepare a Detailed Spreadsheet with Pre-Built Macros:Develop or refine a spreadsheet tool equipped with macros specifically designed to analyze and process the Tag Database information. These macros should be tailored to identify and extract key data points efficiently.Ensure the spreadsheet is user-friendly and well-documented, allowing others involved in the upgrade process to understand its functionality and contribute as necessary.
2. Import Integer, Float, and Discrete Parameter Data for Analysis:Utilize the prepared macros to systematically import and analyze data types such as Integer, Float, and Discrete parameters from the legacy system’s Tag Database.Pay special attention to ensuring that all relevant data is accurately captured and categorized, focusing on maintaining the integrity of descriptions, scaling information, and alarm settings.

Tips for Success:

• Test and Validate Macros: Before proceeding with the bulk of the data import, test the macros with a small, controlled set of data to ensure they work as intended. Adjust the macros based on the outcomes of these tests to avoid large-scale errors.
• Maintain Data Integrity: As you import and analyze data, constantly check for anomalies or discrepancies that may indicate issues with the data extraction process. Early detection of these issues can save considerable time and effort.
• Collaborate with Subject Matter Experts (SMEs): Engage with SMEs who are familiar with the operational nuances of the Tag Database. Their insights can help refine the analysis process, ensuring that the macros capture all nuances of the data correctly.
• Document the Analysis Process: Keep detailed records of the analysis methodology, including any challenges encountered and how they were resolved. This documentation can serve as a valuable resource for future upgrades or troubleshooting efforts.

By meticulously preparing and utilizing specialized macros for the analysis of the Tag Database, you ensure the preservation of critical system data, setting the stage for a successful system upgrade that maintains operational fidelity and efficiency.

3. Template Creation and Macro Execution

Objective:

To meticulously examine PLC (Programmable Logic Controller) programs in order to identify data structures and User-Defined Type (UDT) patterns. This analysis is critical for creating a coherent template schema for the new galaxy, ensuring a structured and efficient upgrade process.

Action Points:

1. Identify and Create Master Worksheets for All Templates:Begin by closely examining the PLC programs to identify recurring data structures and UDT patterns. These patterns are essential for understanding the system’s organizational logic and will guide the template creation process.For each identified template type, create a master worksheet that outlines its structure, including all necessary parameters and attributes. These worksheets will serve as the foundation for generating the new system’s architecture and should be meticulously documented and organized.
2. Execute Macros to Generate CSV Kepware Alias Files and Galaxy Load Files:Utilize the previously prepared macros to automate the generation of CSV files for Kepware alias configurations and galaxy load files. These files are crucial for mapping the old system’s data points to the new galaxy, facilitating a smooth transition.Ensure that the macros are designed to accurately reflect the template structures outlined in the master worksheets. This includes correctly mapping data types, scaling information, and any other relevant parameters identified during the analysis phase.

Tips for Success:

• Systematic Validation: After generating the CSV files, conduct a thorough review to ensure that all data has been accurately translated according to the new template schema. This might involve spot checks or using test data sets to validate the macros' output.
• Collaboration and Review: Work closely with a team of engineers and system integrators who can provide additional insights into the PLC programs and template requirements. Peer reviews can catch errors that might have been overlooked initially.
• Iterative Testing: Given the complexity of translating data structures and UDT patterns into a new format, expect to iterate on your template designs. Be prepared to adjust both the master worksheets and macros based on findings during the execution phase.
• Documentation and Version Control: Keep detailed records of all template versions and the rationale behind specific design decisions. Use version control for your master worksheets and macros to track changes over time, facilitating easier updates or reversions if needed.

By thoroughly examining PLC programs and meticulously executing macros for template creation, this phase lays the groundwork for a structured and coherent system architecture in the new galaxy. Accurate template creation and data mapping are fundamental to ensuring that the upgraded system operates seamlessly and meets the original system's functional requirements.

4. Galaxy Construction and Screen Conversion

Objective:

Construct a foundational galaxy using a pre-defined standard template and initiate the conversion of graphic screens from legacy InTouch screens to the new Archestra graphic format. This step is pivotal in ensuring that the visual representation and user interaction with the system are both modernized and optimized for the upgraded platform.

Action Points:

1. Import or Build Templates and Load Files to Construct the New Galaxy:With the templates and load files prepared, begin the process of constructing the new galaxy. This involves either importing the templates into an existing galaxy framework or building a new galaxy from scratch based on the standard template.Pay careful attention to the organization and structure of the new galaxy, ensuring that it reflects the intended design and functionality captured in the master worksheets and load files.
2. Create Archestra Graphic Screens Using Template-Based Embedded Graphics:Transition to screen conversion by taking legacy InTouch screens as references for designing new Archestra graphic screens. This step is crucial for maintaining operational familiarity while leveraging the advanced capabilities of Archestra graphics.Utilize template-based embedded graphics to standardize the appearance and functionality of screen elements. This approach ensures consistency across the system and facilitates easier updates or modifications in the future.

Tips for Success:

• Consistency and Compatibility Check: Ensure that the new galaxy’s structure and the converted screens are consistent with the operational workflows and data visualization needs of the end-users. Compatibility with existing processes and ease of transition should be prioritized.
• Iterative Design and Feedback: Engage with end-users and stakeholders during the screen conversion process to gather feedback on the usability and functionality of the new graphics. Iterative design, based on real user feedback, can significantly enhance the usability of the final product.
• Leverage Archestra’s Advanced Features: Explore the advanced features and capabilities of Archestra graphics to enhance the system’s functionality and user experience. This might include dynamic elements, improved data visualization tools, and customizable user interfaces.
• Documentation and Training Materials: Update system documentation and training materials to reflect the changes and new features of the Archestra graphic screens. Providing users with updated resources will facilitate a smoother transition to the new system.

By meticulously constructing the galaxy and converting legacy screens to Archestra graphics, this phase ensures that the upgraded system not only meets the technical and functional requirements but also offers an enhanced user experience. The success of this phase hinges on careful planning, user-centric design, and thorough testing to ensure seamless integration and operation within the new galaxy framework.

5. Testing and Validation

Objective:

To rigorously test the newly upgraded galaxy within a controlled virtual sandbox environment, ensuring that all components function flawlessly and as expected. This critical phase is designed to identify and rectify any issues before the system goes live, guaranteeing a seamless operational transition.

Action Points:

1. Connect the Upgraded Galaxy to PLC Emulators:Set up a virtual sandbox environment that mimics the operational settings of the live environment as closely as possible. This includes connecting the upgraded galaxy to PLC (Programmable Logic Controller) emulators, which simulate the physical PLCs' behavior.Ensure that the connection between the galaxy and PLC emulators is stable and that the emulators accurately reflect the operational conditions the galaxy will encounter in its live deployment.
2. Test IO Checks, Object Popups, Navigation Graphics, and More:Initiate a series of comprehensive tests covering all aspects of the system’s functionality. This should include input/output (IO) checks to verify the correct reception and transmission of signals, testing of object popups for operational integrity, and evaluation of navigation graphics for user interface efficiency.Implement scenario-based testing to cover various operational conditions, including standard operations, peak load conditions, and system recovery processes following unexpected interruptions.

Tips for Success:

• Detailed Test Planning: Develop a detailed test plan that outlines all test cases, expected outcomes, and criteria for passing. This plan should be comprehensive, covering every functional aspect of the upgraded system.
• Automate Where Possible: Leverage automation tools to run repetitive and extensive test cases, saving time and ensuring consistency in test execution. Automation can be particularly effective for regression testing and performance testing.
• Engage Cross-functional Teams: Involve stakeholders from different functional areas in the testing process. Their insights can help identify use cases that might not have been considered and provide a more thorough validation of the system’s functionality.
• Document Test Results: Keep meticulous records of all test results, including any anomalies or defects discovered. This documentation is invaluable for troubleshooting, future system enhancements, and audit purposes.
• Iterative Testing and Validation: Approach testing as an iterative process. After fixing identified issues, re-test to ensure the corrections are effective and have not introduced new issues. This cycle should continue until the system meets all predefined criteria for functionality and performance.

By thoroughly testing and validating the upgraded galaxy in a virtual sandbox environment, you can ensure that the system is robust, reliable, and ready for live operational deployment. This phase is crucial for identifying and addressing any potential issues, thereby minimizing operational risks and ensuring a smooth transition for users.

6. Deployment and Final Review

Objective:

To successfully deploy the upgraded system onto the client's servers and conduct a comprehensive Site Acceptance Test (SAT) to ensure the system meets all operational requirements and client expectations. This final phase is critical for validating the effectiveness of the upgrade and securing client approval for the system's transition to live production use.

Action Points:

1. Perform a Thorough Review with the Client Prior to Production Release:Arrange a detailed review session with the client to go through the upgraded system. This session should cover all aspects of the system’s functionality, performance, and any customizations or specific requests made by the client.Use this opportunity to address any last-minute concerns or adjustments the client may have. Ensuring that all client queries are answered satisfactorily is crucial for a smooth transition to the production environment.
2. Ensure Client Satisfaction and System Performance:Conduct the Site Acceptance Test (SAT) in the client's operational environment. The SAT should simulate real-world operational scenarios to thoroughly test the system’s performance under live conditions.Collect feedback from the client during the SAT to gauge their satisfaction with the system's performance and to identify any areas that may require further optimization or adjustment.

Tips for Success:

• Preparation is Key: Before the deployment and SAT, ensure that all necessary documentation, including user manuals and operational guides, is updated and readily available for the client. Preparing a detailed SAT plan can also help streamline the testing process.
• Engage Key Stakeholders: Involve key stakeholders from the client’s side in the deployment and review process. Their buy-in and satisfaction are critical for the project's overall success.
• Address Issues Promptly: Should any issues arise during the SAT, address them promptly and efficiently. Quick resolution of problems not only demonstrates your commitment to quality but also helps maintain the client's confidence in the system.
• Follow-Up Post-Deployment: After the SAT and the system goes live, schedule follow-up meetings with the client to ensure the system continues to perform as expected and to discuss any feedback or further needs they might have.

By carefully managing the deployment and conducting a rigorous final review with the client, you ensure that the upgraded system is fully aligned with client expectations and operational requirements. This phase not only marks the culmination of the upgrade process but also sets the stage for ongoing support and future enhancements, fostering a strong and lasting relationship with the client.

About Charles Vance

Charles Vance, is a seasoned IT professional with a rich background in teaching and a deep commitment to technology education. Holding a Bachelor's degree in Computer Science and Information Technology and certified in the latest Archestra technology.

For those on the journey of technological advancement and seeking guidance, Charles Vance represents an invaluable resource, offering insights grounded in real-world experience and a passion for educational excellence.