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How do I plan a PI System upgrade?

How do I plan a PI System upgrade?

Upgrading PI System components requires careful planning to minimize downtime and avoid data loss.

Pre-Upgrade Checklist

  1. Document current versions: PI Data Archive, AF Server, PI Vision, interfaces, clients.
  2. Check compatibility matrix: AVEVA publishes compatibility between PI versions, Windows versions, and SQL Server versions.
  3. Review release notes: understand what's changed, deprecated, or requires migration steps.
  4. Full backup: PI archives, point database, AF SQL database, interface configurations.
  5. Test environment: always upgrade a test system first.

Upgrade Order

Follow this sequence to avoid compatibility issues:

1. PI Data Archive (core server)
2. PI AF Server (depends on PI DA)
3. PI Analysis Service (depends on AF)
4. PI Vision (depends on AF/PI DA)
5. PI Web API (depends on AF/PI DA)
6. PI Interfaces (depends on PI DA)
7. Client tools (PI SMT, PSE, DataLink)

Upgrade Process

PI Data Archive

  1. Stop all interfaces and buffer subsystems.
  2. Run a full backup.
  3. Run the PI Data Archive installer (in-place upgrade).
  4. Verify services start and data is accessible.
  5. Restart interfaces one by one.

PI AF Server

  1. Back up the AF SQL database.
  2. Run the AF Server installer.
  3. Verify AF databases, elements, and analyses are intact.
  4. Restart the Analysis Service.

Rollback Plan

  • Keep the old installers available.
  • Maintain backups for at least 30 days post-upgrade.
  • Document the rollback procedure before starting.

Common Pitfalls

  • Upgrading AF without upgrading the Analysis Service.
  • Forgetting to update PI Buffer Subsystem on interface nodes.
  • Not testing with production-like data volumes.
  • Skipping the compatibility matrix check for Windows/SQL Server versions.

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