Modernization Lessons Learned - Part 1


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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 &amp; robustnessconcerns &gt;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

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