Modernization Lessons Learned - Part 1
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Modernization Lessons Learned - Part 1

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Laurie Ben and John Dolenc present Migration and Modernization

Laurie Ben and John Dolenc present Migration and Modernization

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  • Centum XL OPC Server requires a gateway, the ECGW3. This device, if available at all, may be quite expensive. If customer does not already own an ECGW3, then this solution may not be practical, economically. Collection of process values and alarms No Shutdown is requiredCentum-XL OPC Server can communicate with DeltaV OPC server via OPC MirrorThis enables data sharing for bringing controller info onto a common display Supports redundancy on DeltaV side if redundancy is established on CS3000 side Security settings on CS3000 OPC server must be re-configured to allow communication Throughput & robustnessconcerns >5,000 points Recommend &lt; 2500 points/OPC pipeOPC Redundancy is available as an option.An OPC point does not equate a signal Tag, an OPC point can be a parameter within a signal tag; i.e. SP or PV. A tag point can contain several OPC points.In addition to process data, alarms and events can be pushed as well through the OPC pipe.Factors that can drive the cost up include: Adding an OPC server on the PLC side if one is not available alreadyThe amount of software configuration needed is significant (large amount of modules and graphics to be created in DeltaV)Applications involving redundancy across multiple PLC servers. Best Fit:For applications where no more than 3000 points/OPC pipe are configured. This is to avoid bandwidth problems.
  • Why install a new system versus modifying the control strategy in the existing system?

Modernization Lessons Learned - Part 1 Modernization Lessons Learned - Part 1 Presentation Transcript

  • Modernizations & Migrations Lessons LearnedPart I
    Laurie R. Ben
    John Dolenc
  • Introduction
    Part I
    Modernization/Migration Projects Overview
    Choosing the Approach/Strategy
    Justification : Where’s the money coming from? ROI
    Cost Impacts: Where’s the money going? TICC
    Summary: Part I
    Part II
    Risk Mitigation & Best Practices
    Lessons Learned: What to watch for?
    Summary Part II
  • Migration Issues for Management
    What do we need to do?
    What do we gain by modernizing the automation system?
    Who can do this for us? (plan / design / implement / start-up)
    How much will it cost?
    How long will it take?
    How long does the process need to be shutdown?
    What are the other risks of the process not starting back up on time and in spec?
    How are the risks mitigated?
  • Migration Projects Differ from New Projects
    Documentation may not be readily available or up-to-date
    Automation hardware needs to fit into existing equipment or free space
    Small window for installation shutdown or requires hot cutover
    May need to do project in phases
    Intensive testing is absolutely necessary to ensure successful start-up
    Operational improvements derived through better automation are expected
  • Modernization/Migration Planning
    • Approach/Strategy
    • Scope of Work
    • Justification
    • Cost
    • Risk Mitigation
    • Schedule
    Legacy DCS
  • Migration Strategy: Options to Consider
    As-Found – Migrating “EXACTLY” what is in the legacy system to DeltaV
    Functional – Migrating the “FUNCTIONALITY” of the legacy system to the DeltaV system using today’s technology
    Modernization – Applying state of the art applications, including field devices, in addition to functional migration to achieve “BEST IN CLASS” benefits
  • Migration Scope Options to Consider
    Replace the entire automation system at one time
    Cold Cutover
    Completed Replacement (including field terminations)
    Marshalling System (minimizing downtime)
    Hot Cutover
    Phased approach
    Vertical (Process Area)
    Horizontal (Platform Focus)
    HMI interoperability (Controller and I/O remain)
    Controller replacement (I/O remain)
    I/O Card replacement (Field terminations remain)
  • Hot vs Cold Cutover: Key Economic Driver
    Cold Cutover
    Engineering & construction perspective 
    Potential for plant upsets minimized or eliminated
    Safety Hazards greatly reduced
    Environmental releases eliminated
    Manpower/resources deployment flexibility
    Uncertainties of BAD data reduced (instrument or process problem?)
    Hot Cutover
    Economics (no production loss)
    Operations Perspective: process problems typically taken out of equation, smoother transition 
    Operator & Maintenance Training are simplified, one-on-one
    Eliminates time-consuming, expensive, and dangerous start-ups (Continuous Industries)
  • Vertical vs. Horizontal Approach
    Vertical Migration – Based on migrating one complete automation system/area at a time
    Horizontal Migration – Based on migrating “equipment type” at a time across automation systems
    Decision Factors – Operating Philosophy
    Interim Journey: Operate 2 systems for some period of time?
    Plant Area at a Time: Can you divide up by Controller or Control file at a time ?
    Segregated I/O: How is I/O laid out in cabinets? Interchange within areas? How is spare capacity used?
    Best Practice: Detailed/Meticulous site audit of hardware/field wiring terminations
  • Additional Drivers that Direct the Migration/Modernization Approach
    Capital budget restraints
    Production / Shutdown schedule constraints
    Legacy system infrastructure layout
    Free space constraints
    Equipment obsolescence status
    Justification driver
  • Horizontal Migration Phased Approach
    DVOP Server Network
    DeltaV Control Network
    Data
    Server
    HDL
    PROVOX Data Highway I or II
    SRx
    Control
    and/or
    MUX I/O
  • Horizontal Migration Phased Approach
    New in v1.3:
    Support for R4xx, PLCG & EPLCG
    v1.3 Released July 2009
  • Horizontal Migration Phased Approach
    Legacy Platform Support
    Hardware/Software
    Communication Bandwidth
    Communication Style
    Exception Based Reporting
    Token Ring
    Polled / Scan
  • I/O Bus Interface Methods
    Maintain Existing I/O subsystems
    Virtual Interface Module (VIM)
    EthernetIP or Modbus TCP/IP
    Integrates Plant Networks as DeltaV I/O
    PLC I/O Interface
    Migrate control, keeping I/O
    Using standard DeltaV Cards
    Profibus DP examples
    Texas Instruments 500 & 505
    ABB S800
    DeviceNet examples
    Rockwell (Allen Bradley) 1794 Flex IO
  • I/O Bus InterfaceCommunication Protocols Comparison
    Protocol utilization
    (ARC Industrial Ethernet Study 2004)
    Modbus TCP/IP 26%
    Ethernet/IP 25%
    ProfiNet 2%
    Foundation Fieldbus HSE 2%
  • I/O Replacement – Legacy Field Wiring Terminations Remain
    Maintain Legacy Device Wires in Place
    • Get the raw field signal whenever possible
    • Only add conditioning components when necessary
    • No reverse engineering of proprietary I/O protocols
  • Electronic Marshalling- Migrations
    • Use existing cabinets/racks
    • Shutdown or Hot Cut Over
    • Minimize Shutdown durations
    • State of the Art Electronic Marshalling
    • No Hybrid parts or specialty cables
  • Modernization/Migration Planning
    • Approach/Strategy
    • Scope of Work
    • Justification
    • Cost
    • Risk Mitigation
    • Schedule
    Legacy DCS
  • Design for the Justification Driver
    Understand the business objectives
    Review historic plant performance
    Audit existing process for poor performance and variability
    Define opportunities for improvement through automation
  • Items to Consider for Operations: Performance Improvements
    Equipment utilization / efficiency
    Performance variability
    Poor control loop performance
    Too many loops in manual
    Manual actions that are done inconsistently by operator choice
    Scheduling difficulties
    Manual paperwork
  • Modern Control System Features
    Ease of use to apply more complex control strategies and flexibility to easily modify strategies
    Built-in batch sequence control with S88 standards
    Built-in tools to monitor equipment and control loop performance
    Platform for gathering process unit information and easy integration to Plant ERP systems
  • System Migration Justification
    Benefits come from:
    Increased Capacity
    Reduced Manufacturing Costs
    Increased Overall Equipment Effectiveness
    Improved Supply Chain Logistics
    Improved Health, Safety and Environmental Actions
  • Batch Capacity Increase Example
  • Capacity Optimization to Meet Production Demand
    Demand Estimates by Quarter
    Capacity
    Demand
    Actual Demand by Day
  • Improved Control – Run Closer to Limits
    $$$
    Limit or Spec Target
    Set Point
    Before Automation
    After Automation
    • Increased Yield
    • Reduced Energy Consumption
  • Longer duration to scheduled outage
    Asset Management
    Production Control
    Higher sustained production with minimized costs
    +
    $ Profit
    Time
    -
    Shorter scheduled outage
    Fewer unscheduled outages
    Safer operation
    Overall Equipment Effectiveness
  • Example Manufacturing Process - Today
    Process Control
    Data Historian
    Daily inventory update
    Monthly reconciled consumption, production and cost reports
    Business Management
    ERP
    Business Staff
    Develops standard costs
    No daily economic data
    Costs reported on a monthly basis
    Plant Management
    Shift logs and morning report, includes production, quality, safety and environmental data
    Data manipulationData validationData entry
    Operations
  • Integration Capabilities
    • Automatic production reporting
    • Greater visibility of work in progress (for CTP)
    • Actual consumptions for MRP and product costing (for PTP)
    • Operational benchmarking and institutionalization of best practices - Process Excellence Sustainer
    • Performance against benchmark (for KPI’s)
    • Customer technical support (for CRM)
    • Facilitate alignment of plant teams for improvement opportunities
    Plant PerformanceReal-time response to operational variability due to more timely, accurate and contextual information
    Production Management
    ProductionAccounting
    Future Manufacturing Vision
    Business Management
    Accurate decisions based on validated real-time information
    ERP
    Business AgilityImproved decision making with more timely and accurate information
    Business Staff
    • Actual consumption on a daily basis by product batch
    • Automatic classification to the highest margin product
    • Alarming and prompting for assignable cause
    • Batch records that include process variables, lab data, batch number, rail car number, and other relevant business data
    PlantManagement
    KPI
    Operations
    ERP Integration
    Advanced Process Control
    KPI
    Data Historian
    Business Process Integration
  • Health, Safety and Environmental
    Reduce / eliminate releases
    Increased process monitoring
    Conditional interlocking
    Early notification of abnormal situations
    Automate regulatory monitoring and reporting
    On-line alarm response instructions
  • Modernization/Migration Planning
    • Approach/Strategy
    • Scope of Work
    • Justification
    • Cost
    • Risk Mitigation
    • Schedule
    Legacy DCS
  • System Migration Cost Distribution
    Engineering and Installation costs may be greater than equipment/software costs
    Choice of new system components affects the engineering and installation costs
  • What is the impact of electronic marshalling on migration projects?
  • Project Task Analysis – Rack Room Migration with CHARMS I/O
    Existing Marshalling Cabinets
    Existing Cabinet
    Replace termination
    panels
    w/ CHARMS
    I/O
    S-series
    Controller
    Junction Box
    Marshalling Cabinet Activities
    Junction Box Activities
    Controller / I/O Cabinet Activities
    • Cabinet layout
    • Terminations / CIOC Assembly / interposing relay design
    • I/O wiring schematics (reduced)
    • Power & grounding for CHARMS
    • Ethernet network layout
    • I/O lists & controller sizing
    • Cabinet layout (reduced)
    • Power & grounding for controller and I/O cards
    • I/O wiring schematics
    • Loop drawings (reduced)
    • No activities
  • Total Installed and Commissioned CostRack Room Replacement
    TICC WITHIN 2%
  • Project Task Analysis – Modernization with CHARMs FJBs
    S-Series
    Controller
    I/O
    Marshalling
    CHARMs
    Junction Boxes
    Marshalling Cabinet Activities
    Controller / I/O Cabinet Activities
    Junction Box Activities
    • Layout
    • Terminations / CIOC Assemblies / interposing relay design
    • I/O wiring schematics (reduced)
    • Power & grounding for CHARMS
    • Cable tray layout (reduced)
    • Cabinet layout
    • Terminations
    • I/O wiring schematics
    • I/O lists & controller sizing
    • Cabinet layout (reduced)
    • Power & grounding for controller and I/O cards
    • I/O wiring schematics
    • Loop drawings (reduced)
  • Total Installed and Commissioned CostI/O in the Field
    TICC 22% LOWER WITH CHARMS
  • Total Project Cost Distribution
    Traditional I/O
    CHARMS I/O
    10% reduction in Total Cost
  • Summary: Part I
    Modernization/Migration Projects Overview
    Issues for Management
    Differences from New Projects
    Choosing the Approach/Strategy
    Options to Consider
    Horizontal, Vertical, All at Once?
    PLCs: Integration vs Migration
    Electronic Marshalling, Save the Field Wiring
    Justification : Where’s the money coming from? ROI
    Batch or Continuous Automation
    Production or Asset Management
    Obsolescence
    Cost Impacts: Where’s the money going? TICC
    Impact of Electronic Marshalling on Modernization/Migration