This document discusses key considerations for scoping reinstrumentation projects. It identifies the top three drivers as obsolescence of automation components, safety and industry regulations, and enabling operational excellence. Specific challenges around an aging workforce and process control are also examined. The document provides a six-step approach to successful reinstrumentation projects that includes field surveys, implementation of best practices, and identifying the project scope while reusing existing infrastructure where possible.

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Key Considerations for Scoping
of Reinstrumentation Projects
Hyonsook Kang
Industry Consultant
Retired from Shell – PM/EM
December 13, 2016

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 Host: Josh Perry
Marketing Manager
Josh.perry@us.yokogawa.com
 Presenter:
Hyonsook Kang
Hyonsook.Kang@us.yokogawa.com
Host & Presenters

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Key Considerations for Scoping
of Reinstrumentation Projects
Hyonsook Kang
Industry Consultant
Retired from Shell – PM/EM
December 13, 2016

7. Modernize or Maintain?
• Are the right people involved – business, projects,
plant?
• Is the cost of maintaining the old system worth
spending? What is the total cost of ownership?
• How many more years can the existing system
last? Can the capability and productivity of the old
system be improved?
• Is it safe to operate?
• How much will it cost to migrate the system?
• What are the benefits and value added features of
the new system?
• Downtime for migration and disruptions to operation
and maintenance?
• How will future regulations influence operations in
the future?

8. Top 3 Drivers for Reinstrumentation Projects
• Obsolescence
– DCS
– SIS
– Operator Stations
– Field Instrumentation & Wiring
• Safety, Industry Regulations &
Compliance
– SIS Regulation
– Environmental Compliance Monitoring
• Operational Excellence
– Risk of Aging Workforce
– Advanced Process Control
– Cyber Security

9. Obsolescence – Automation Component Lifecycle
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10. Safety, Industry Regulations/ Compliance
• SIS regulations – IEC 61511 becoming more
stringent. Different parts of the world not
allowing the grandfathering of the existing
systems (separation of BPCS & SIS)
• Environmental Compliance Monitoring
• Modular Process Automation – Operational
safety.
!
Careful consideration of how a possible accident
could affect the Owner’s Company in terms of
workforce safety, equipment damage and loss of
reputation

11. Average Dollar Loss per Major Incident by Cause in $MM
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12. Challenges for Operational Excellence
Risk of Aging Workforce – losing senior operators due to
retirement. How to fill the gap with increase automation and
modular procedure automation
Advanced Process Control – increase throughput in plant
for more effective use of capital. Average increase of 4-10%
depending on the unit
Cyber Security – as moving towards a “connected
enterprise”, moving operations to the shore during
emergencies (for offshore), how to protect the networks from
these hackers and malware infections.

13. People over Age 65
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14. Typical APC Costs & Benefits
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15. Cyber Security
• Industrial plants are moving toward the “connected”
enterprise and enjoying the merits of connection to
information systems
• The control systems installed 10-20 years ago may have
obsolete security measures due to long term operation and
sophisticated new attacking techniques
15

16. 6 Steps to Successful Reinstrumentation

17. Field Survey

18. Implementation of Best Practices and Recommendations
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19. System Architecture

20. Project Scope Identification
• Identify the big
pieces
• Explore all the
opportunities and do
a proper risk analysis
• Maintain a vision of
what constitutes
success

21. Reuse of Existing Infrastructure
years

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Obsolescence Dilemma

23. System & Security Requirements

24. Cyber Security Operations & Maintenance
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25. APC
• Increase overall control stability and throughput

26. Operator Effectiveness

27. Control Room Upgrade
• Well designed control room will create
synergy and flow in the control rooms.
Human centered design philosophy
prioritizes safety, health, and comfort.
• Central Control Room Philosophy – increase
in operator effectiveness and breadth of
operator control and improve
communications.
27

28. Modular Procedural Automation
• Automate Procedures to help mitigate risks
of aging workforce for typical manual
operations.
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29. Benefits of Operator Training System
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30. Human Machine Interface Benefits
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Time shortening of
monitoring cycle
Time shortening of
malfunction detection
Prevention of mistaken
judgment or
maloperation
Reduction of operators’
eyestrain or workload
Inheritance of operation
skills

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Alarm Management

32. DCS/SIS Scope

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Different Upgrade Scenarios
 Step by Step Upgrade: component base upgrade
unlike a full upgrade. For example, HMI is upgraded
without stopping the controllers, or upgrade of
controllers in an area of the unit without stopping other
controllers.
 Competitor System Upgrade: Yokogawa has developed
a comprehensive system migration strategy to address
competitor systems including Honeywell, ABB,
Emerson, Invensys, Siemans, etc, utilizing special
marshalling panels and adapter cables to connect
terminal panels of existing legacy systems and
database conversion tools.

34. Different Upgrade Scenarios
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• Field Instrument
Replacement:
intelligent field
instruments and
process analyzers
accumulate diverse
field information
including process
values and
diagnostics.

35. Questions
??

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Additional Resources
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Re-Instrumentation eBook to
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