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Modernization Lessons Learned - Part 1

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Laurie Ben and John Dolenc present Migration and Modernization

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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 />