Modernization Lessons Learned - Part 1
-
Upload
emerson-exchange -
Category
Education
-
view
2.022 -
download
9
description
Transcript of Modernization Lessons Learned - Part 1
Modernizations & Migrations Lessons Learned
Part ILaurie R. Ben
John Dolenc
IntroductionIntroduction 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 ManagementMigration 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 ProjectsMigration 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 PlanningModernization/Migration Planning
Legacy DCS
• Approach/Strategy
• Scope of Work
• Justification
• Cost
• Risk Mitigation
• Schedule
Migration Strategy: Options to ConsiderMigration 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 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 DriverHot 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 ApproachVertical 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 ApproachAdditional 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 ApproachHorizontal Migration Phased Approach
DeltaV Control Network
Data
Server
Control
and/or
MUX I/O
DVOP Server Network
PROVOX Data Highway I or II
SRx
HDL
Horizontal Migration Phased ApproachHorizontal Migration Phased Approach
v1.3 Released July 2009v1.3 Released July 2009
New in v1.3:
Support for R4xx, PLCG &
EPLCG
Horizontal Migration Phased ApproachHorizontal Migration Phased Approach
Legacy Platform Support– Hardware/Software
Communication Bandwidth Communication Style
– Exception Based Reporting– Token Ring– Polled / Scan
Communication Protocol
OPC Server
Network protocols Varies
Capacity per unit 30,000 parameters
Network speed Varies, 100 Mbaud max
Data throughput 5,000 parameters/s
Stability Medium Low
Redundancy Possible
Ease of use Low
Cost 4X plus
I/O Bus Interface MethodsI/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 ComparisonI/O Bus InterfaceCommunication Protocols Comparison
Serial Industrial Ethernet OPC Server
Network protocols Modbus, DF1 Modbus TCP/IP, Ethernet/IP
Varies
Capacity per unit 3,200 registers (32 datasets)
12,800 registers (128 datasets)
30,000 parameters
Network speed 19.2 Kbaud typical, 115 Kbaud max
10 Mbaud Varies, 100 Mbaud max
Data throughput 1,000 ms / dataset 100 ms / 16 datasets 5,000 parameters/s
Stability High Medium High Medium Low
Redundancy Yes Yes Possible
Ease of use High High Low
Cost 1X 2 – 3X 4X plus
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 RemainI/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- MigrationsElectronic 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
•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 PlanningModernization/Migration Planning
Legacy DCS
• Approach/Strategy
• Scope of Work
• Justification
• Cost
• Risk Mitigation
• Schedule
Design for the Justification DriverDesign 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 ImprovementsItems 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 FeaturesModern 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 JustificationSystem 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 ExampleBatch Capacity Increase Example
REACTOR
BASE BATCH TIME(HRs)
NEW BATCH TIME FROM
AUTOMATION
NEW BATCHES PER YEAR
DELTA CAPACITY
(kg)PERCENT INCREASE
100 12.1 10.3 209
310,000 17%
200 13.7 11.6 364
570,000 18%
300 17.8 14.8 285 490,00 20%
400 26.3 22.9 184
560,000 15%
500 26.3 22.9 184
540,000 15%
Capacity Optimization to Meet Production DemandCapacity Optimization to Meet Production Demand
Demand Estimates by Quarter
Actual Demand by Day
Capacity
Demand
Improved Control – Run Closer to LimitsImproved Control – Run Closer to Limits
Before Automation After Automation
$$$
Limit or Spec Target
Set Point
•Increased Yield
•Reduced Energy Consumption
Safer operation
Fewer unscheduled outages
Time
Shorter scheduled outage
Higher sustained
production with
minimized costs
Longer duration to
scheduled outage
$ P
rofit
+
-
Overall Equipment EffectivenessOverall Equipment Effectiveness
Asset Management
Production Control
Example Manufacturing Process - TodayExample Manufacturing Process - Today
Business
Management
Business
Staff
Plant
Management
OperationsData manipulation
Data validation
Data entry
Shift logs and morning report, includes
production, quality, safety and environmental
data
No daily economic data
Develops
standard costs
Costs reported
on a monthly
basis
Daily inventory update
Monthly reconciled consumption, production and
cost reports
E
R
P
Process Control
Data Historian
Future Manufacturing Vision Future Manufacturing Vision Business Management
Business Staff
Plant
Management
Operations
E
R
P
KPI
KPI
Advanced Process Control
Production
Accounting
Data Historian
Production Management
ERP
Integration
ERP
Integration
Business Process Integration
Business Agility
Improved decision making with more timely
and accurate information
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
Accurate decisions based on
validated real-time information
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
Integration Capabilities
Plant Performance
Real-time response to operational variability
due to more timely, accurate and contextual
information
Health, Safety and EnvironmentalHealth, 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 PlanningModernization/Migration Planning
Legacy DCS
• Approach/Strategy
• Scope of Work
• Justification
• Cost
• Risk Mitigation
• Schedule
System Migration Cost DistributionSystem 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
Installation26%
System Cost21%
Engineering Design21%
DCS Configura-tion20%
Other12%
What is the impact of electronic marshalling on
migration projects?
Project Task Analysis – Rack Room Migration with CHARMS I/OProject Task Analysis – Rack Room Migration with CHARMS I/O
S-series
Controller
Replace termination
panels
w/ CHARMS
Junction Box
Existing Marshalling CabinetsExisting Cabinet
Marshalling Cabinet
ActivitiesCabinet layout
Terminations / CIOC Assembly / interposing
relay design
I/O wiring schematics (reduced)
Power & grounding for CHARMS
Ethernet network layout
Controller / I/O Cabinet
ActivitiesI/O lists & controller sizing
Cabinet layout (reduced)
Power & grounding for controller and I/O
cards
I/O wiring schematics
Loop drawings (reduced)
Junction Box Activities
No activities
I/O
TRADITIONALHIGH DENSITY I/O
CHARMS
Balance ofProject
Install
E&I Design
ControlSystem
Total Installed and Commissioned CostRack Room ReplacementTotal Installed and Commissioned CostRack Room Replacement
TICC WITHIN 2%
Project Task Analysis – Modernization with CHARMs FJBs
Project Task Analysis – Modernization with CHARMs FJBs
S-Series
Controller
CHARMs
Junction Boxes
Marshalling Cabinet
ActivitiesCabinet layout
Terminations
I/O wiring schematics
Controller / I/O Cabinet
ActivitiesI/O lists & controller sizing
Cabinet layout (reduced)
Power & grounding for controller and I/O
cards
I/O wiring schematics
Loop drawings (reduced)
Junction Box Activities
I/O Marshalling
Layout
Terminations / CIOC Assemblies /
interposing relay design
I/O wiring schematics (reduced)
Power & grounding for CHARMS
Cable tray layout (reduced)
TRADITIONALHIGH DENSITY I/O
CHARMS
Balance ofProject
Install
E&I Design
ControlSystem
Total Installed and Commissioned CostI/O in the FieldTotal Installed and Commissioned CostI/O in the Field
TICC 22% LOWER WITH CHARMS
Installation27%
System Cost21%
Engineering Design
20%
DCS Configura-tion20%
Other12%
Total Project Cost DistributionTotal Project Cost Distribution
Traditional I/O CHARMS I/O
Installation18%
System Cost29%
Engineering Design
19%
DCS Configura-tion22%
Other12%
10% reduction in Total Cost
Summary: Part ISummary: 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