Modernization Lessons Learned - Part 1
Download as PPTX, PDF3 likes1,853 views
This document discusses key considerations for modernization and migration projects. It covers choosing a strategy like replacing systems all at once or phased. Options for scope include replacing controllers only or full systems. Electronic marshalling can save costs by retaining field wiring. Managers must consider justification, like increased capacity, and total installed cost impacts. Part I focuses on project overview, management issues, and cost impacts of different modernization approaches.
Modernization Lessons Learned - Part 1
- 1. Modernizations & Migrations Lessons LearnedPart ILaurie R. BenJohn Dolenc
- 2. IntroductionPart IModernization/Migration Projects OverviewChoosing the Approach/StrategyJustification : Where’s the money coming from? ROICost Impacts: Where’s the money going? TICCSummary: Part IPart IIRisk Mitigation & Best Practices Lessons Learned: What to watch for?Summary Part II
- 3. Migration Issues for ManagementWhat 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?
- 4. Migration Projects Differ from New ProjectsDocumentation may not be readily available or up-to-dateAutomation hardware needs to fit into existing equipment or free spaceSmall window for installation shutdown or requires hot cutoverMay need to do project in phasesIntensive testing is absolutely necessary to ensure successful start-up Operational improvements derived through better automation are expected
- 6. Scope of Work
- 8. Cost
- 11. Migration Strategy: Options to ConsiderAs-Found – Migrating “EXACTLY” what is in the legacy system to DeltaVFunctional – Migrating the “FUNCTIONALITY” of the legacy system to the DeltaV system using today’s technologyModernization – Applying state of the art applications, including field devices, in addition to functional migration to achieve “BEST IN CLASS” benefits
- 12. Migration Scope Options to Consider Replace the entire automation system at one timeCold CutoverCompleted Replacement (including field terminations)Marshalling System (minimizing downtime)Hot CutoverPhased approachVertical (Process Area)Horizontal (Platform Focus)HMI interoperability (Controller and I/O remain)Controller replacement (I/O remain)I/O Card replacement (Field terminations remain)
- 13. Hot vs Cold Cutover: Key Economic DriverCold Cutover Engineering & construction perspective Potential for plant upsets minimized or eliminatedSafety Hazards greatly reducedEnvironmental releases eliminatedManpower/resources deployment flexibilityUncertainties of BAD data reduced (instrument or process problem?)Hot CutoverEconomics (no production loss)Operations Perspective: process problems typically taken out of equation, smoother transition Operator & Maintenance Training are simplified, one-on-oneEliminates time-consuming, expensive, and dangerous start-ups (Continuous Industries)
- 14. Vertical vs. Horizontal ApproachVertical Migration – Based on migrating one complete automation system/area at a timeHorizontal 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
- 15. Additional Drivers that Direct the Migration/Modernization ApproachCapital budget restraintsProduction / Shutdown schedule constraintsLegacy system infrastructure layoutFree space constraintsEquipment obsolescence statusJustification driver
- 16. Horizontal Migration Phased ApproachDVOP Server NetworkDeltaV Control NetworkDataServerHDLPROVOX Data Highway I or IISRxControland/orMUX I/O
- 17. Horizontal Migration Phased ApproachNew in v1.3:Support for R4xx, PLCG & EPLCGv1.3 Released July 2009
- 18. Horizontal Migration Phased ApproachLegacy Platform SupportHardware/SoftwareCommunication Bandwidth Communication StyleException Based ReportingToken RingPolled / Scan
- 19. I/O Bus Interface MethodsMaintain Existing I/O subsystemsVirtual Interface Module (VIM)EthernetIP or Modbus TCP/IPIntegrates Plant Networks as DeltaV I/OPLC I/O Interface Migrate control, keeping I/OUsing standard DeltaV CardsProfibus DP examplesTexas Instruments 500 & 505ABB S800DeviceNet examplesRockwell (Allen Bradley) 1794 Flex IO
- 20. I/O Bus InterfaceCommunication Protocols ComparisonProtocol utilization(ARC Industrial Ethernet Study 2004)Modbus TCP/IP 26%Ethernet/IP 25%ProfiNet 2%Foundation Fieldbus HSE 2%
- 21. I/O Replacement – Legacy Field Wiring Terminations RemainMaintain Legacy Device Wires in PlaceGet the raw field signal whenever possible
- 22. Only add conditioning components when necessary
- 23. No reverse engineering of proprietary I/O protocolsElectronic Marshalling- MigrationsUse existing cabinets/racks
- 24. Shutdown or Hot Cut Over
- 26. State of the Art Electronic Marshalling
- 27. No Hybrid parts or specialty cablesModernization/Migration Planning Approach/Strategy
- 28. Scope of Work
- 29. Justification
- 30. Cost
- 31. Risk Mitigation
- 33. Design for the Justification DriverUnderstand the business objectivesReview historic plant performanceAudit existing process for poor performance and variability Define opportunities for improvement through automation
- 34. Items to Consider for Operations: Performance ImprovementsEquipment utilization / efficiencyPerformance variabilityPoor control loop performanceToo many loops in manualManual actions that are done inconsistently by operator choiceScheduling difficultiesManual paperwork
- 35. Modern Control System FeaturesEase of use to apply more complex control strategies and flexibility to easily modify strategiesBuilt-in batch sequence control with S88 standardsBuilt-in tools to monitor equipment and control loop performance Platform for gathering process unit information and easy integration to Plant ERP systems
- 36. System Migration JustificationBenefits come from:Increased CapacityReduced Manufacturing CostsIncreased Overall Equipment EffectivenessImproved Supply Chain LogisticsImproved Health, Safety and Environmental Actions
- 37. Batch Capacity Increase Example
- 38. Capacity Optimization to Meet Production DemandDemand Estimates by QuarterCapacityDemandActual Demand by Day
- 39. Improved Control – Run Closer to Limits$$$Limit or Spec TargetSet PointBefore AutomationAfter AutomationIncreased Yield
- 40. Reduced Energy ConsumptionLonger duration to scheduled outageAsset ManagementProduction ControlHigher sustained production with minimized costs+$ ProfitTime-Shorter scheduled outageFewer unscheduled outagesSafer operationOverall Equipment Effectiveness
- 41. Example Manufacturing Process - TodayProcess ControlData HistorianDaily inventory updateMonthly reconciled consumption, production and cost reportsBusiness ManagementERPBusiness StaffDevelops standard costsNo daily economic dataCosts reported on a monthly basisPlant ManagementShift logs and morning report, includes production, quality, safety and environmental dataData manipulationData validationData entryOperations
- 42. Integration CapabilitiesAutomatic production reporting
- 43. Greater visibility of work in progress (for CTP)
- 44. Actual consumptions for MRP and product costing (for PTP)
- 45. Operational benchmarking and institutionalization of best practices - Process Excellence Sustainer
- 46. Performance against benchmark (for KPI’s)
- 47. Customer technical support (for CRM)
- 48. Facilitate alignment of plant teams for improvement opportunitiesPlant PerformanceReal-time response to operational variability due to more timely, accurate and contextual informationProduction ManagementProductionAccountingFuture Manufacturing Vision Business ManagementAccurate decisions based on validated real-time information ERPBusiness AgilityImproved decision making with more timely and accurate informationBusiness StaffActual consumption on a daily basis by product batch
- 49. Automatic classification to the highest margin product
- 50. Alarming and prompting for assignable cause
- 51. Batch records that include process variables, lab data, batch number, rail car number, and other relevant business dataPlantManagementKPIOperationsERP IntegrationAdvanced Process ControlKPIData HistorianBusiness Process Integration
- 52. Health, Safety and EnvironmentalReduce / eliminate releasesIncreased process monitoring Conditional interlockingEarly notification of abnormal situationsAutomate regulatory monitoring and reporting On-line alarm response instructions
- 54. Scope of Work
- 55. Justification
- 56. Cost
- 57. Risk Mitigation
- 59. System Migration Cost DistributionEngineering and Installation costs may be greater than equipment/software costsChoice of new system components affects the engineering and installation costs
- 60. What is the impact of electronic marshalling on migration projects?
- 61. Project Task Analysis – Rack Room Migration with CHARMS I/OExisting Marshalling CabinetsExisting CabinetReplace termination panelsw/ CHARMSI/OS-seriesControllerJunction BoxMarshalling Cabinet ActivitiesJunction Box ActivitiesController / I/O Cabinet ActivitiesCabinet layout
- 62. Terminations / CIOC Assembly / interposing relay design
- 63. I/O wiring schematics (reduced)
- 64. Power & grounding for CHARMS
- 66. I/O lists & controller sizing
- 68. Power & grounding for controller and I/O cards
- 71. No activitiesTotal Installed and Commissioned CostRack Room ReplacementTICC WITHIN 2%
- 72. Project Task Analysis – Modernization with CHARMs FJBsS-SeriesControllerI/OMarshallingCHARMsJunction BoxesMarshalling Cabinet ActivitiesController / I/O Cabinet ActivitiesJunction Box ActivitiesLayout
- 73. Terminations / CIOC Assemblies / interposing relay design
- 74. I/O wiring schematics (reduced)
- 75. Power & grounding for CHARMS
- 76. Cable tray layout (reduced)
- 77. Cabinet layout
- 78. Terminations
- 80. I/O lists & controller sizing
- 82. Power & grounding for controller and I/O cards
- 84. Loop drawings (reduced)Total Installed and Commissioned CostI/O in the FieldTICC 22% LOWER WITH CHARMS
- 85. Total Project Cost DistributionTraditional I/O CHARMS I/O10% reduction in Total Cost
- 86. Summary: Part IModernization/Migration Projects OverviewIssues for ManagementDifferences from New ProjectsChoosing the Approach/StrategyOptions to ConsiderHorizontal, Vertical, All at Once?PLCs: Integration vs Migration Electronic Marshalling, Save the Field WiringJustification : Where’s the money coming from? ROIBatch or Continuous AutomationProduction or Asset ManagementObsolescence Cost Impacts: Where’s the money going? TICCImpact of Electronic Marshalling on Modernization/Migration
Editor's Notes
- #14: 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 < 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.
- #22: Why install a new system versus modifying the control strategy in the existing system?