modernization lessons learned -part 2

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Modernizations & Migrations Lessons Learned Part II Laurie R. Ben John Dolenc

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Part 2 of Laurie Ben and John Dolenc modernization and migration session.

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Page 1: Modernization Lessons Learned -Part 2

Modernizations & Migrations Lessons Learned

Part II

Laurie R. Ben

John Dolenc

Page 2: Modernization Lessons Learned -Part 2

Introduction

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

Page 3: Modernization Lessons Learned -Part 2

Modernization/Migration Planning

Legacy DCS

• Approach/Strategy

• Scope of Work

• Justification

• Cost

• Risk Mitigation

• Schedule

Page 4: Modernization Lessons Learned -Part 2

Migration Project Risks

Not restarting production on schedule after the cutover

Will new control strategy work

Poor control loop performance

Communication issues

– Interfaces / Migration Products

– Between system and existing 3rd party devices

Missing a key interface or action

Schedule creep

Cost escalation

Page 5: Modernization Lessons Learned -Part 2

Risk Mitigation

Early Engineering and Planning

– Detailed site survey

– Operational functional specification

– Scope of Work

• Definition

• Freeze

• Maximize pre-cutover work

Legacy System Data Mining

Test plan preparation and thorough configuration

testing prior to installation

Experienced project team leadership

Multi-project program management

Page 6: Modernization Lessons Learned -Part 2

Cost Influence

High

Low

Ability to

Influence Cost

Time

100%

50%

0%

Ability to

Influence Cost

Cost

Expenditure

Define Scope

Process Development

Design

Implementation

Start-up

Page 7: Modernization Lessons Learned -Part 2

Phase 1

APPRAISE

Phase 2

SELECT

Phase 3

DEFINE

Phase 4

EXECUTE

Phase 5

OPERATE

FEED PHASECONSULTING

Phase 1

VISION

Phase 2

DEFINE

Phase 3

DESIGN

Phase 4

IMPLEMENT

Phase 5

OPTIMIZE

FEED PHASE(Concept/Study)

Consulting- Idea Generation

- Option Review

- Justification

- Identify Risk

Project Activities- Scope Development

- Engineering & Design

- Project Management

- Risk Mitigation

Optimization Activities- Data Gathering

- Performance Assessment

- Control Strategy Optimization

Independent Project Analysis (IPA) Model: Modernization/Migration Projects

7.5% increased project ROI

30% decrease in project duration

6% additional capacity

Page 8: Modernization Lessons Learned -Part 2

Initial Site Audits

System life cycle audit

Physical infrastructure

Operational objectives

Page 9: Modernization Lessons Learned -Part 2

Example Detailed System Life Cycle Audit

PART NUMBER DESCRIPTION

Total

System

BOM

Site

Stores

Spares

Satelite

SparesDecom.

Hot

Spares

Total

Spares

Rec.

Spares

Spares

GapComments

Site

Failure

Rate

CURRENT

STATUS

CURRENT

DATE

MOVE TO

ACTIVE

MOVE TO

SUPPORTED

MOVE TO

RETIREDCOMMENTS ON NEWER PARTS

Control Files

01984-3048-0001 CONTROLFILE CARD CAGE ONLY ASSEMBLY 10 0 1 2 0 3 2 0 RETIRED Apr-92 Aug-96 Aug-96 Aug-06 Replaced by 10P56500001

01984-0023-0001 CONTROLFILE (CARD CAGE ONLY) 5 0 0 0 0 0 0 0 RETIRED Dec-83 Apr-92 Apr-92 Jul-02 Replaced by 10P56500001

10P56500001 CONTROLFILE CARD CAGE ONLY ASSEMBLY, EMC COMPLIANT 2 0 0 0 0 0 0 1 ACTIVE Aug-96 Oct-03 Dec-10 Oct-13 Replaced by 10P56500001

01984-4164-0004 COORDINATOR PROCESSOR IV+ CARD ASSEMBLY (CPIV) 21 0 1 4 0 5 0 1 RETIRED Jun-91 Jun-95 Jun-95 Jun-05 Replaced by 10P50870004

01984-4064-0004 COORDINATOR PROCESSOR IV CARD ASSEMBLY (CPIV) 7 0 0 0 0 0 0 3 RETIRED Mar-90 Jun-91 Jun-91 Jul-02 If unavailable use 01984-4164-0004

10P50870004 COORDINATOR PROCESSOR IV+ CARD ASSEMBLY (CPIV+), EMC COMPLIANT 4 2 0 0 0 2 4 2 1 ACTIVE Jun-95 Jun-00 Dec-10 Dec-10

01984-4068-0006 MULTIPURPOSE CONTROLLER II (MPC II) CARD ASSEMBLY 98 0 1 14 0 15 8 7 RETIRED Jun-91 Apr-95 Apr-95 Apr-05 Replaced by 10P50400006

10P50400006 MULTIPURPOSE CONTROLLER II CARD ASSEMBLY (MPC II), EMC COMPLIANT 16 3 0 0 0 3 0 1 RETIRED Apr-95 Jun-00 Jun-10 Jun-10

01984-2347-0021 CONTROLFILE NONVOLATILE MEMORY CARD ASSEMBLY (2 MEG) 17 4 1 2 0 7 4 14 ACTIVE Apr-90 Jun-00 Dec-10 Dec-10 Can't use 4MB NVM on a v18 system

01984-1505-0001 CONTROLFILE POWER REGULATOR CARD ASSEMBLY (40 AMP) 3 0 3 0 0 3 0 1 RETIRED Nov-87 Nov-90 Nov-90 Jul-02 Replaced by 01984-3505-0001

01984-3505-0001 CONTROLFILE POWER REGULATOR CARD ASSEMBLY (5 VOLT ONLY) 31 2 0 4 0 6 4 2 ACTIVE Jan-90 Oct-03 Dec-10 Oct-13

01984-1502-0001 CONTROLFILE PEERWAY BUFFER CARD ASSEMBLY 34 0 1 4 0 5 4 6 ACTIVE Aug-84 Oct-03 Dec-10 Oct-13

Consoles

01984-1045-0003 PEERWAY INTERFACE CARD ASSEMBLY 14 1 3 0 0 4 2 1 ACTIVE Nov-84 Oct-03 Oct-11 Oct-13

01984-1540-0009 68020 OPERATOR INTERFACE (OI) PROCESSOR CARD ASSEMBLY 14 0 3 0 0 3 2 BootROMs are v9.26 1 RETIRED Jan-90 May-92 Dec-06 Jan-10

01984-2372-xxxx ELEVATED MAIN KEYBOARD 14 0 0 0 0 0 4 4 Could supply all the spare parts; See Consumable section below4 ACTIVE Nov-95 Jul-01 Oct-10 Jul-11 Actual P/N 01984-2372-1001

01984-1989-0001 MAGNETIC TAPE DRIVE/SCSI ASSEMBLY, 45MB, ARCHIVE P/N 20669-003, MODEL 5945S-1 14 3 1 0 0 4 4 Quote Already Provided 6 RETIRED Aug-86 Sep-92 Sep-92 Sep-02

01984-2780-0001 WINCHESTER HARD DISK DRIVE, 80MB, MODEL 80S 1 0 1 0 0 1 0 2 RETIRED Oct-88 Nov-91 Nov-91 Jul-02

01984-3100-0002 WINCHESTER HARD DISK DRIVE, 105MB, MODEL LPS105S 10 0 0 0 0 0 0 2 RETIRED Nov-91 Nov-96 Nov-96 Jul-02

10P5280000x WINCHESTER HARD DISK DRIVE, 270MB, MODEL LPS270S/MV27S011 2 0 0 0 0 0 0 Quote already Provided for these HDs 4 RETIRED Oct-97 Jul-98 Jul-98 Jul-03

10P58570001 QUANTUM HARD DISK DRIVE, 2.1GB, MODEL QM32, INITIALIZED, WITH BRACKETS 1 0 0 0 0 0 14 14 If upgrading to P1, the supply the 4.5 GB HDD; P/N 12P230400011 RETIRED Jul-98 Mar-00 Mar-00 Mar-05

01984-1137-0001 POWER REGULATOR CARD ASSEMBLY 14 1 3 0 0 4 2 Send in for refurbishment- See KBA 1 ACTIVE Nov-84 Oct-03 Oct-11 Oct-13

01984-2503-0001 COLOR VIDEO GENERATOR CARD ASSEMBLY (PIXEL) 14 2 1 0 0 3 2 BootROM v9.27 is required for newer 10P58900001 card4 RETIRED May-87 Mar-00 Aug-00 Mar-10 Replaced by 10P58900001

01984-1011-0003 PRINTER INTERFACE CARD ASSEMBLY 14 2 1 0 0 3 2 Battery present on this card 6 SUPPORTED Jan-85 Dec-00 Jun-10 Dec-10

01984-1140-0001 SCSI INTERFACE CARD ASSEMBLY 13 1 3 0 0 4 2 1 RETIRED Mar-85 Jun-96 Jun-96 Jun-06 If unavailable use 01984-1140-0004

01984-1140-0004 SCSI INTERFACE CARD ASSEMBLY 1 0 0 0 0 0 0 0 ACTIVE Jun-96 Dec-00 Mar-11 Mar-11

10P50840004 KEYBOARD VIDEO INTERFACE CARD AND BEZEL ASSEMBLY 14 2 2 0 0 4 2 1 ACTIVE Dec-99 Dec-00 Dec-10 Dec-10 I'm sure the customer doesn't have these new versions!

01984-2386-2005 ENHANCED CONFIGURATION KEYBOARD, ENGLISH (MTCC), MODEL G81-1854 12 0 0 0 0 0 12 12 1 ACTIVE Apr-03 Dec-00 Dec-10 Dec-10 Replaces 01984-2386-1005

FlexTerm I/O

01984-1460-0003 FIC: 6 I/O POINTS PER CARD ASSEMBLY 96 4 2 0 0 6 8 2 3 ACTIVE Mar-85 Nov-91 Dec-10 Dec-10

01984-2483-0005 FIC: SMART DAUGHTER CARD ASSEMBLY 26 0 0 0 0 0 4 4 1 RETIRED Nov-87 Nov-95 Nov-95 Nov-05 Replaced by 10P54500005

01984-2491-0001 COMM CONNECT CARD ASSEMBLY 22 0 1 0 0 1 2 1 0 RETIRED Aug-87 Mar-92 Mar-92 Mar-02 Replaced by part number 10P54560001

01984-2494-0001 ANALOG I/O TRANSFER CARD ASSEMBLY 135 4 1 12 0 17 5 0 ACTIVE Nov-87 Oct-03 Mar-11 Oct-13

01984-2518-0002 FIC: 4-20 mA - 2 IN / 1 OUT CARD ASSEMBLY 537 0 0 87 0 87 20 12 RETIRED Jan-88 Nov-95 Nov-95 Nov-05 Replaced by 10P54440002, then 10P59150002

10P54440002 FIC: 4-20 mA - 2 IN / 1 OUT CARD ASSEMBLY 2 0 0 0 0 0 0 0 RETIRED Nov-95 Nov-95 Mar-00 Nov-05 Replaced by 10P59150002

10P59150002 FIC: 4-20 mA - 2 IN / 1 OUT CARD ASSEMBLY 6 2 0 1 0 3 0 0 SUPPORTED Mar-00 Nov-95 Jan-07 Dec-10

01984-2526-0002 ANALOG CARD CAGE 69 0 1 6 0 7 2 0 ACTIVE Mar-87 Oct-03 Dec-10 Oct-13

01984-2543-0001 COMM CONNECT CARD III ASSEMBLY 47 0 0 6 0 6 2 0 RETIRED Mar-92 May-96 May-96 May-06 Replaced by part number 10P54560001

01984-2546-0002 FIC: PULSE INPUT / OUTPUT CARD ASSEMBLY (NPC202) 1 0 0 0 0 0 2 2 1 RETIRED Apr-89 Apr-96 Apr-96 Apr-06 Replaced by 10P54470002, then by 12P25960002

01984-2576-0001 CONTACT FLEXTERM (CARD CAGE ONLY) 12 0 1 0 0 1 2 1 0 ACTIVE Jul-92 Apr-91 Dec-10 Dec-10

Multipoint FIM I/O

01984-4080-0001 FIM: DISCRETE I/O ASSEMBLY (FIM001) 21 1 0 5 0 6 0 Send in for refurbishment- See KBA 2 RETIRED Oct-91 Sep-95 Sep-95 Sep-05 Replaced by 10P53520006

01984-4121-0001 ISOLATED DISCRETE TERMINATION PANEL A 25 1 0 5 0 6 1 1 RETIRED Nov-91 Jun-95 Jun-95 Jun-05 Replaced by 01984-4121-0002

01984-4121-0002 ISOLATED DISCRETE TERMINATION PANEL A, EMC & LVD 7 0 0 0 0 0 0 0 ACTIVE Nov-91 Oct-03 Oct-10 Oct-13

01984-4124-0001 ISOLATED DISCRETE TERMINATION PANEL B 25 1 0 5 0 6 1 0 RETIRED Nov-91 Jun-95 Jun-95 Jun-05 Replaced by 01984-4124-0002

01984-4124-0002 ISOLATED DISCRETE TERMINATION PANEL B, EMC & LVD 7 0 0 0 0 0 0 0 ACTIVE Nov-91 Oct-03 Oct-10 Oct-13

10P53520006 FIM: DIO ASSEMBLY, LOW SIDE SWITCH, 32 POINT 16 0 0 0 0 0 6 6 1 ACTIVE Sep-95 Oct-03 Oct-10 Oct-13

10P54040004 FIM: ANALOG INPUT FIM ASSEMBLY, 16 POINT 14 0 0 0 0 0 0 1 RETIRED Nov-95 Dec-97 Dec-97 Dec-07 Replaced by 10P57700005

10P54080004 FIM: ANALOG OUTPUT FIM ASSEMBLY, 16 POINT 8 0 0 0 0 0 0 1 RETIRED Oct-95 May-99 May-99 May-09 Replaced by 10P58080005

10P54770001 MULTI-POINT AIO TERMINATION PANEL ASSEMBLY, 16 POINT, SCREW TERMINALS ONLY 16 0 0 0 0 0 1 1 1 ACTIVE Nov-95 Oct-03 Oct-10 Oct-13

10P57700005 FIM: ANALOG INPUT FIM ASSEMBLY, 16 POINT 8 0 0 0 0 0 4 4 1 ACTIVE Dec-97 Oct-03 Oct-10 Oct-13

10P58080005 FIM: ANALOG OUTPUT FIM ASSEMBLY, 16 POINT 2 1 0 0 0 1 4 3 0 SUPPORTED May-99 Oct-03 Dec-03 Oct-13

RS3 System Inventory Site Spares Obsolescence Status

Page 10: Modernization Lessons Learned -Part 2

Life Cycle Audit

RS3 „GOTCHA‟

Detailed review consists of analyzing all the I/O types, firmware, and software revision levels to ensure all the I/O is compatible with the transition solution

In most cases, firmware can be upgraded using the RS3 System before the installation of transition solution

Not doing this step could result in I/O not being compatible and/or I/O not at the correct revision level

Startup is a little too late to find this out…

Page 11: Modernization Lessons Learned -Part 2

Modernization/Migration Project Planning

Understand that the original process automation plan may

have been designed to meet minimum requirements with

no regards for future yield and energy optimization

Original Project Criteria & Actions

Energy was cheap

Measurement technology was lacking

I&C scope reduced for project budget reasons

Page 12: Modernization Lessons Learned -Part 2

Modernization/Migration Project Planning

Understand the difference between process / operational

requirements and legacy system methods to perform a task

Process operational functional specification development

based on operational KPI performance

Define a detailed automation system design basis that best

uses the features of the control system to meet the

functional specification

Page 13: Modernization Lessons Learned -Part 2

Modernization/Migration Project Planning

To get improved efficiencies, yield & energy consumption –

NEED TO PUSH THE ENVELOP

Run as close to constraints as possible

– Complex control strategies

– Constraint control

– MPC with Optimizer

Need process measurements

Need to remove variability in control loops

– Control valve performance

– Good tuning of control loops

Early notification of possible abnormal operations

Page 14: Modernization Lessons Learned -Part 2

Modernization/Migration Project Planning

Use control engineers to oversee or review the design of

the control strategy

Thoroughly test system configuration prior to

commissioning

Properly plan and staff the commissioning and start-up

including the use of the system tools such as AMS and

INSIGHT

Page 15: Modernization Lessons Learned -Part 2

Optimize Process Operations after Start-UP

Phase 1

APPRAISE

Phase 2

SELECT

Phase 3

DEFINE

Phase 4

EXECUTE

Phase 5

OPERATE

FEED PHASECONSULTING

Phase 1

VISION

Phase 2

DEFINE

Phase 3

REFINE

Phase 4

IMPLEMENT

Phase 5

OPTIMIZE

MAC SCOPE

FEED PHASE(Concept/Study)

MAC – Main Automation Contractor

Optimize process operations after project start activities

are completed and start-up team leaves. (3-12 months)

Time for data collection of key variable trends, control

reactions and loop interactions

Control Performance Consulting services to evaluate

process trends and recommend strategy modifications and

control tuning

Page 16: Modernization Lessons Learned -Part 2

Optimize Process Operations after Start-UP

Once the process operation is at an optimum performance

level, it is important to keep it there .

Use the system‟s tools

Asset Management

InSight

Page 17: Modernization Lessons Learned -Part 2

Avoid Replacement-in-Kind

Be leery of copying code from

the legacy system

Dead code not removed

Legacy code does not take

advantage of new system

configuration tools

Legacy strategy created to

overcome automation

deficiencies may hinder

performance in new system

Control Logic Conversion –PID Loop Represented in DeltaVControl Logic Conversion Control Logic Conversion ––PID Loop Represented in DeltaVPID Loop Represented in DeltaV

Control Logic Conversion –Loop RepresentationControl Logic Conversion Control Logic Conversion ––Loop RepresentationLoop Representation

A

10902_B7777_FC2

OUT

10902Y1

AIS/FBS

10902_B376_FC132_AI4

AI4

1090202

ASO

10902_B258_FC149_AO1

AO1

1090238

DIGRP

10902_B1105_FC84_DI1

DI1

1090226

T

S9#PRVLEAD:SEL

S1 OUT

S2

S3

10902Y1

F(X)

10902_B7787_FC1

S1 OUT

10902Y1

M/A MFC/P

10902_B7780_FC80

S1 A

S18 O

S3 SP

S4

S5

10902Y1

F(X)

10902_B7778_FC1

S1 OUT

10902Y1

OR

10902_B7776_FC40

S2 OUT

S3

10902Y1

APID

10902_B7773_FC156

S1 CO

S2

S3

S4

10902Y1

TSTQ

10902_B7772_FC31

S2 OUT

10902Y1

TSTQ

10902_B7771_FC31

S2 OUT

10902Y1

NOT

10902_B7770_FC33

S1 OUT

10902Y1

SQRT

10902_B7769_FC7

S1 OUT

10902Y1

ASO

10902_B258_FC149_S4

S4

1090238

Page 18: Modernization Lessons Learned -Part 2

Legacy Platform “Domain” ExpertiseIPA Aligned Deliverables

Phase 1 – Determine the EXACT HW & SW Basics

Phase 2 – Determine the EXACT Class & Custom Content

Phase 3 – Develop controller based Design Work Package

Phase 4 – Extract data in a form useful for project execution

Phase 5 – Generate FAT/SAT documentation for pre and post

start-up operations

Page 19: Modernization Lessons Learned -Part 2

Phase 1 Deliverables– Exact IO cont.

IO from the

Software Perspective

Page 21: Modernization Lessons Learned -Part 2

Phase 3 Deliverables“FEED Work Package”

Controller derived

Design Documents

are marked up and

hyperlinked to

manuals so non-SME

personnel can

interpret data

Page 22: Modernization Lessons Learned -Part 2

Phase 4:Execute

Page 23: Modernization Lessons Learned -Part 2

What to Watch Out

For

Page 24: Modernization Lessons Learned -Part 2

Tuning Conversions“ All PIDs are not Created Equal” Proper Unit Conversion of Existing

Tuning Constants

– minutes/repeat to seconds/repeat, seconds to minutes

– Gain or PB

– Repeats/minutes or minutes/repeat

Implementation of PID

– Form Identification (Parallel, Standard, or Classical)

– Multiple choices per system

– Selectable on each loop

– Tuning constants may produce different response in each PID Form

– All forms may not be capable of duplicating existing response

– Conversion between Forms

PID Options

– Derivative on Error or PV

– Gain on Error or PV

– Variations

Bailey DocumentationBailey Documentation

Bailey Documentation

Function Code 156

Clue: Parallel Blocks

Potential Confusion: Control System Terminology

Clue: S DomainTransfer Functions

Parallel Form PID Users

– MOD300*

– Infi90/Net90*

Standard Form PID Users– ABB Masterpiece, Advant

– RS3, DeltaV*

– VALMET Damatic Classic

– Measurex Open, Vision 2000

– Texas Instrument

– Yokogawa

– Honeywell*

Classical PID Forms Users– Honeywell *

– PROVOX, DPR900, DeltaV*

– FOX I/A, Spec 200

– Bailey INFI90*

– MOD300*

– Fischer-Porter Micro DCI

– Moore - APACS

Page 25: Modernization Lessons Learned -Part 2

Warning – Sometimes Tuning Constant Units are selectable on each PID loop!

Example: Rosemount System 3 (RS3)

– P = %PB or %out/%pv (normalized gain)

– I = Sec/Rep, Min/Rep or Hr/Rep

– D = Sec, Min or Hr

Suppose “AS-FOUND” Constants were:

– P=1.99

– I = 5.98

– D=1.49

And you assumed

– “P” was %out/%pv

– “I” was Sec/Rep

– “D” was Sec

BUT, what if…

Know the Destination! Know the Source!

Page 26: Modernization Lessons Learned -Part 2

Unit Conversions of Tuning Constants (Temperature Loop)

…the units were really P=1.99 %out/%pv, I = 5.98 min/rep

and D= 1.4 min for this loop

Source: Standard PID

P = 1.99 %out/%pv, I = 5.98 min/rep, D= 1.49 min.

Destination: Standard PID

P = 1.99 %out/%pv, I = 5.98 sec./rep, D= 1.49 sec.

Page 27: Modernization Lessons Learned -Part 2

Tuning Conversions“ All PIDs are not Created Equal” Proper Unit Conversion of Existing

Tuning Constants

– minutes/repeat to seconds/repeat, seconds to minutes

– Gain or PB

– Repeats/minutes or minutes/repeat

Implementation of PID

– Form Identification (Parallel, Standard, or Classical)

– Multiple choices per system

– Selectable on each loop

– Tuning constants may produce different response in each PID Form

– All forms may not be capable of duplicating existing response

– Conversion between Forms

PID Options

– Derivative on Error or PV

– Gain on Error or PV

– Variations

Bailey DocumentationBailey Documentation

Bailey Documentation

Function Code 156

Clue: Parallel Blocks

Potential Confusion: Control System Terminology

Clue: S DomainTransfer Functions

Parallel Form PID Users

– MOD300*

– Infi90/Net90*

Standard Form PID Users– ABB Masterpiece, Advant

– RS3, DeltaV*

– VALMET Damatic Classic

– Measurex Open, Vision 2000

– Texas Instrument

– Yokogawa

– Honeywell*

Classical PID Forms Users– Honeywell *

– PROVOX, DPR900, DeltaV*

– FOX I/A, Spec 200

– Bailey INFI90*

– MOD300*

– Fischer-Porter Micro DCI

– Moore - APACS

Page 28: Modernization Lessons Learned -Part 2

What if You Pick the Wrong Form?Parallel vs. Standard (Flow)

Source: Parallel PID P = 0.062 %out/%pv, I = 0.021gain/sec, D= 0

sec.

Normal Response:40 sec to reach setpoint

Destination: DeltaV Standard PID; Convert units but forgot to convert to

Standard tuning: P = 0.062 %out/%pv, I = 47.8 sec/rep, D= 0 sec.

Incorrect Response: 5-6 min to reach setpoint

Page 29: Modernization Lessons Learned -Part 2

What if You Pick the Wrong Form?Series vs. Standard (Temperature)

Source: Series PID: P = 1.04 %out/%pv, I = 0.323 rep/min, D= 2.88 min

Destination: DeltaV Standard PID; Convert units but forgot to convert to

Standard tuning: P = 1.04 %out/%pv, I = 186 sec/rep, D= 173 sec.

(Incorrect!)

Page 30: Modernization Lessons Learned -Part 2

Avoiding the “Gotchas”

Do investigate what new technology is available and

examining ways to use it to improve the process

Base automation system requirements on the system

as a tool for operations to run the plant easier

– Troubleshoot equipment failures

– Optimize the process

– Future system expansion

Specify the control system to meet operational

requirements

– Don‟t specify system component performance criteria, e.g.

process speed & monitor pixel number.

Page 31: Modernization Lessons Learned -Part 2

Avoiding the “Gotchas”

Look at Total Installed and Commissioned Cost versus

lowest cost equipment

– Lower cost of engineering and installation

– Built-in versus custom design

Base configuration on using capabilities in new system vs.

legacy system

Do not be afraid of using multiple field communication types

to match specific application

Make sure “Alarm Design” is a „process‟ engineer design

task/issue vs. control/automation engineer task/issue

– Identify alarm requirements based on process conditions

– Use of conditional alarming

Page 32: Modernization Lessons Learned -Part 2

Avoiding the “Gotchas”

Power & Grounding

– Make sure I/O power requirements are defined

• May need interposing relays for Discrete Outputs

– Grounding efficiency may have changed since legacy system

installation via additions to grounding grid

Control Loop Strategy

– Understand that control loops need to work as a “SYSTEM”

– What loops need to be tuned aggressively and which need to allow

natural process variability

Legacy Configuration Conversion

– Data Mining „ keep the good, get rid of the bad‟

– Legacy Tuning conversions

Page 33: Modernization Lessons Learned -Part 2

Summary: Part II

Risk Mitigation & Best Practices

– IPA Model & Industry Benchmarking

– Best Practices that Mitigate Risk & Improve Performance

– Mining the Legacy System Files

Lessons Learned: What to watch for?

– Plan, Plan, and Plan: Revisit the Plan and adjust as needed

– Use New Technology to Improve Operations

– TICC vs Lowest System Cost

– Mix/Match Communication Protocol to Application

– Alarm Design: Who Benefits from Getting it Right?

– Power & Grounding

– Legacy Tuning Conversions: Impact of getting it wrong

Page 34: Modernization Lessons Learned -Part 2

Associated Workshops and Roadmaps

Type Description

Roadmap RM-583 - Non-Emerson Systems Modernization (Migration)

Roadmap RM-581 - Emerson PROVOX & RS3 Systems Modernization

Roadmap RM-587 - Emerson Systems Services

Session 03-113 - Using FlexConnect to migrate your legacy DS to DeltaV

Session 03-304 - PROVOX and Siemens S5 to DeltaV migration during

operation

Session 03-406 - Total Installed and Commissioned Cost Savings Using

Electronic Marshalling in Brownfield Modernization Projects

Session 07-33 - How to Justify New “Smart” Automation Investments

Page 35: Modernization Lessons Learned -Part 2

Exhibit Hall - Product Showcase

Modernization

Pavilion

Entrance

Page 36: Modernization Lessons Learned -Part 2

Alice Stewart

Yassin Mobarak

Cody Long

John Dolenc

Gordon Lawther

Chris King

Laurie Ben

Mike French

Scott Ross Keith Bellville

Zaidan Kazour