SEPTEM
BER/OC
TOBER 2
012
Modernisation
Pain or opportunity? Replacing the aged process control system The dollars and sense of distributed control system migration They looked, they leaped and they’re grateful Stories of successful modernisation projects from around the world Operations modernisation the Invensys way Why choose Invensys for your DCS migration and enterprise modernisation?
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Contents
Contents
SEPTEM
BER/OC
TOBER 2
012
2 Editor’s notes Replacing the aged process
3 control system
Large Oil and Gas complex migrates multiple 51 legacy systems to the latest Foxboro I/A Series platform for improved operator efficiency
The dollars and sense of
11 distributed control system migration
What a modern DCS can do for
15 you 17
Operations Modernisation the Invensys way Invensys Operations
18 Modernisation programme The clearest path to operations
22 modernisation
Foxboro I/A series Distributed
Pure and simple plug-in
52 migration with Foxboro I/A series I/O modules
Cascades Tissue Group achieves operating efficiencies
55 with Invensys Operations Management solution
Unified control migration at
57 Aracruz Cellulose
Pure and simple plug-in
59 migration with Foxboro I/A series I/O modules
25 Control System – migration by design
Intelligent modernisation with
28 the Foxboro I/A Series System 29 Raising the bar on scalability They looked, they leaped and
32 they’re grateful
Legacy system migration:
33 Improving the opportunities
BC Hydro gets upgrade from
75 (Johannesburg)
ddb@iafrica.com
2012 Training Schedule
Use Protocol Magazine to
43
Invensys powers UK electricity demand at SSE
47
The Salt River project - America’s third-largest public power utility quells nuisance alarms
Marketing Manager: Jaco Markwat Editor: Denis du Buisson, GMT Services
72 Invensys Sentinel Services
Foxboro I/A Series DCS
Invensys Operations Management Southern Africa jaco.markwat@invensys.co.za
69 Modernisation dictionary
74 Customer FIRST
39 ageing Bailey control system to
Owner and Publisher:
Rip and replace or revamp and rejuvenate? Manufacturing 66 2.0 compliant solutions may eliminate the question altogether
Lonmin migrates its vast SCADA
35 resources from iFIX to ArchestrA
Protocol Magazine
Virtual reality can help with
60 technology migration
76 generate business opportunities 78 On the lighter side 80 Protocol crossword #56
Advertising Sales: Heather Simpkins, The Marketing Suite heather@marketingsuite.co.za
Distribution: Nikita Wagner nikita.wagner@invensys.co.za
Contributors Many thanks to the following for their contributions to this issue of the magazine: • Stephen R Blomquist, founder of Blomquist Automation Management for the article on the dollars and sense of distributed control system migration
Facebook: Twitter: YouTube:
Wonderware Southern Africa WonderwareSA WonderwareSA
www.protocolmag.co.za
• Phil Couling, Product Marketing Director, Supervisory HMI, Invensys for the article titled: Raising the bar on scalability • Maurizio Rovaglio, Vice President , Solutions Services, Invensys and Tobias Scheele, Vice President/ General Manager Advanced Applications, Invensys for the article on virtual reality • Gerhard Greeff, Divisional Manager at Bytes Systems Integration for the article on ripping or revamping and rejuvenating systems
September/October 2012 | 1
Editor’s Notes Although replacing legacy hardware is
Modernisation can be extended to the MES
a necessary first step, that’s all it is. But
layer by replacing custom-made software
modernisation is about far more than just
with industry-standard solutions and
replacing the obvious. If you break your
virtualised hardware that will give you and
hip, some guy with (hopefully) clean hands,
your colleagues the connectivity and agility
a scalpel, drill, screwdriver, some screws
you need to be fully informed by connecting
and bits of titanium will put you on your
to the shop floor as well as the top floor. In
feet again in six weeks or so, to the degree
short, modernisation is all about helping you
that your “legacy” bone structure in the
structure a unified and efficient enterprise
affected hip area will have been replaced by
and keeping you and all personnel in control
something you won’t have to worry about
of it – and making sure it stays that way.
in your lifetime, even if you lived several
Modernisation will keep the door open for
millennia. But at the end of it all, you’re
expansion and change while helping you
still back to square one (with the possible
maximise ROI by getting the most from past
exception that you may now be banned from
and current assets.
kick-boxing events).
Modernisation Pain or opportunity?
But what about the cost, because all that will But what if, during your six-week layoff,
surely cost a great deal more than replacing
you had nothing to do but beef yourself up
some control hardware? Yes it will but you
Actually, it’s a bit of the first but a great deal
during physiotherapy and also beef up on
can do it in incremental steps so that you only
of the second. And it would appear that the
your knowledge of everything you always
take the next step once the current initiative
pain is mostly concentrated on making the
wanted to know about without worrying
has proved itself. Let’s talk about money
decision to modernise rather than on the
about your hip? How big is the observable
for a minute. What did your last production
fear of battling technology and crippling
universe (90 billion light years – not bad for
improvement initiative cost? It’s a fair bet
production.
something that came into existence just 14.5
that you’ll remember the number to the last
billion years ago!)? What’s the diameter of
cent if it was a flop but you’ll have to look it
After all, there are printed circuit boards
a neutrino (10-20 m)? What should I have
up if it was a success. Now let’s say you need
available for virtually all the major legacy
for lunch that the medical profession said
to spend R1million on modernisation – a
DCSs that are 100% form factor compatible
would kill me yesterday but have changed
seemingly insurmountable justification job
with their predecessors. This means that any
their minds about today (e.g. eggs)? Why are
in these financial times. Yet, financed over
upgrade is instantly reversible and poses no
Siberian tigers on the endangered species
5-years, this will cost your company about
risk whatsoever. With nothing else having
list and not politicians?
R25 000/month or R150/hour – the cost of
to change, that’s at least a good start to modernisation at the process control level.
the briefest of production stoppages. Even if By the end of your six-week recovery, not
you hire someone to do a lot of the above at
only would you be stronger than ever in the
that salary (come on!) he could still walk away,
But, of course, that’s not the full story. Here’s
leg department and everywhere else, but
negating your investment in him. Modern
a question you may be asking yourself: Why
you would also be INFORMED and generally
technology won’t do that.
should I spend money on new equipment to
feel more in control at the physical and
end up exactly where I was in the first place?
mental levels.
One good answer is that your plant won’t
Modernisation works in a similar way. It’s
error. For larger companies, doubling or
grind to a halt because of irreplaceable
about not looking at things in an isolated
tripling the amount doesn’t give it any
technology. The upgraded boards are fully
way (such as your hip operation) but seeing
more importance when compared to the
warranted, upgradeable and maintainable
you as you should be. Better hardware
consequences of sticking with potentially
which means that your legacy system has
on the shop floor means less risk but it
wealth-sapping technology and approaches
joined the mainstream of modern industrial
also means a greatly improved start to
automation albeit at a somewhat modest
the enterprise information chain with,
Until next time,
level. But maybe you were expecting more
for example, updated and redundant
Denis du Buisson
from your modernisation initiative.
control systems, historians and servers.
ddb@iafrica.com
R1 million for those companies that need to modernise is ’noise’ – almost an accounting
2 | www.protocolmag.co.za
Replacing the aged process control system
Replacing the aged process control system September/October 2012 | 3
Managers in today’s process manufacturing
balance in your bank account is directly
plants must react to factors ranging from
proportional to the amount of time it spends
massive customisation and growing
in the workshop. Hardware wears out – that’s
According to ARC Advisory Group, DCSs valued
demand for change orders in the middle
just the way it is. So control hardware (e.g.
at $65 billion on a global basis are nearing the
of production runs to management
PLCs, disc drives, computers, etc.) eventually
end of their useful life. ARC defines “end of life”
expectations mandating ever-faster
die. But in their death throes (which can last
by two factors. First, the systems can no longer
execution of production orders.
many years), they can adversely affect your
How old is old?
production and your bottom line.
be maintained. Second, the systems cannot meet modern manufacturing requirements
Such constant pressures are driving many
such as optimising asset utilisation or business
manufacturers to re-evaluate the role of their
But more important still, are the software
system integration.
automation strategies while improving the
and information systems running on all this
overall effectiveness of their enterprises.
obsolete hardware. After all, it’s not the
The following questions can help you determine
They’re finding that automation is playing
hardware that influences the decisions you
whether your process control system has
an increasingly important role in the
make but the information it gathers and
reached the end of its useful lifetime, or is
effectiveness and profitability of their entire
presents.
ready for the next generation of enterprise
enterprise, impacting everything from cost
productivity.
of operations to customer satisfaction.
• Does your system enable you to adapt
Fortunately, many are also discovering that
So, what are the main factors that motivate companies to migrate to newer
quickly and easily to a changing business
they can make significant improvements
condition?
throughout their value chain — without
technologies? Inability to obtain replacement parts
being forced to abandon their entire existing • Can you implement advanced process
automation investment.
• Can you easily connect your system to local or wide area networks? • Can you collect real-time production data from system sensors? • Does your system support multiple fieldbus protocols?
Nobody makes old chips anymore unless there’s a premium in it. So, expect to pay an
control without extensive programming? Nearly 30% of respondents to a recent
increasing premium to keep your obsolete
survey said that their systems were more
hardware – well – obsolete (but at least
than 20 years old at the time of migration.
working for the time being). Hardware evolves
Their business IT systems, on the other hand,
and changes. What was an entire circuit
seemed to be upgraded or replaced with
board yesterday is a chip today and, together
the regularity of new fashions. This is odd
with many other chips, the capability per
because, without the control system, there
unit area in the same space as the old circuit
would be no need for business IT – or the
board increases exponentially year-on-year.
rest of the company for that matter.
OEMs continually have to rework new circuit boards to cater for new technology while
• Can you still find a reasonable supply of replacement parts? • Does the manufacturer still offer support for
That’s because production is why mining
retaining the form factor and functionality
and manufacturing companies were started
of the old boards. This is an exercise in
in the first place – and control systems are
diminishing returns and eventually the OEMs
largely responsible for the colour of these
understandably lose interest.
your system? If not, what impact will this have
companies’ bottom lines because they
on your cost of ownership?
control production and almost every aspect
However, that’s not necessarily the end.
of their wealth-creating processes.
Parts recyclers, aftermarket suppliers and companies dismantling old systems, will
If you answer “no” to any of these questions, it may be time to consider upgrading your control
By definition, control systems handle
continue to supply spares long after the
systems. As you will see, this needn’t be as
difficult tasks normally beyond the reach
OEM has stopped but the writing is on the
much of an ordeal as you might imagine.
of human control – that’s why they were
wall. Sooner or later, replacement parts will
bought. How these tasks are managed will
no longer be available and this may force
govern the quantity, quality and cost of
prolonged and costly production stoppages
produced product. So, in reality, control
(among the individuals who participated in
systems are the single, most important links
a survey, the average overall cost per day of
in the supply chain.
a shutdown was $738,000 with 23% saying it was in excess of $1 million).
They deserve more attention than being ignored or neglected for decades.
Then there’s the panic factor. Repeated shutdowns of the magnitude just described
Why change?
will no doubt serve as a powerful motivator to move to a more modern system as quickly
4 | www.protocolmag.co.za
If your car is twenty years old, you will
as possible. Given the complexity of the
probably have noticed that the reducing
task, however, this isn’t going to happen
Replacing the aged process control system
overnight and rash decisions will probably
systems yet they are today’s requirements
while databases are measured in terabytes.
be made in order to re-establish order as
for making businesses more successful.
Then there’s the question of processor speed (54 MIPS at 66MHz on Intel 486DX in
quickly as possible. Increasing maintenance and support costs Not only are replacement parts for old
But when one tries to get this functionality
1992 and 177 730 MIPS at 3.33GHz on Intel
from legacy systems, it’s like trying to retrofit
i7 Extreme Edition 3960X in 2011), intranet
F1 performance into your family saloon, it
and Internet bandwidths, lack of scalability,
simply won’t work - for the following reasons:
inflexible I/O and the list goes on and on. The demanding information needs of today’s
equipment expensive but so are the people that know how to fix it. The older
Proprietary data
manufacturing and mining companies need high technology – and it’s readily available
the equipment, the fewer the number of people familiar with it and the more you
Older systems tend to be purpose-built and
and much cheaper in real terms than your
will have to pay for their services because
“closed” (i.e. access to their information is
old monolithic DCS.
OEMs probably stopped training on the old
limited by the OEM’s software interface). Lack of security
equipment many years ago. Lack of customisation and adaptability Need for increased knowledge
Even if it were possible to upgrade the Older software, because of the nature of
hardware to handle the required traffic
Business needs change all the time and this
the environment for which it was designed,
volume and processing required, older
reflects in different control procedures and
tends to lack configurability which means
systems were not designed to resist the
information requirements. Older systems
that functionality specific to individual
cyber threats roaming today’s networks.
don’t easily lend themselves to this kind
company needs must be developed by
These threats become even more significant
of customisation as they were designed
the OEM and, as everyone knows, custom
when control systems need to move outside
to perform specific tasks in an era when
software is expensive and a nightmare to
their isolated comfort zones in order to share
integrated enterprise-wide information was
maintain.
information in the interest of enterprise-wide intelligence. When business networks need
only a pipe dream in the minds of visionaries and not even a dream in the minds of
Lack of standards
to be linked to plant networks, another magnitude of security is needed to keep the
everyone else. When these older systems were made,
gremlins at bay.
Today, things are very different. People at
information exchange standards such as
all levels of the organisation need to know
ISA-95 were not yet conceived. Furthermore,
the immediate, real-time status of processes
little or no provision was made for the
under their responsibility. Twenty years ago,
development, deployment and maintenance
The vendors of leading DCS/SCADA/
the relationship between the shop floor
of company standards with respect to plant
HMI systems have helped their customers
and Customer Relationship Management,
equipment and structure.
migrate to newer technology for years and know how to make the process of transition
for example, was tenuous at best but now, executives realise that their companies are
Yes but how?
No foundation platform
as painless and cost-effective as possible. Most companies (nearly 75%) said that
integrated entities and that all their activities are interconnect and influence one another.
As control systems grow into information
they made the transition gradually while
The result is that mining and manufacturing
systems, there’s a vital need for a
making use of scheduled downtimes. This
companies cannot survive profitably in
unifying technology that brings together
gradual approach also distributed the cost
today’s economic climate without true
applications, databases, reporting and alarm
over a longer time and allowed for easier
enterprise intelligence.
structures and so on so that these solutions
introduction to operators and their training.
can work in harmony rather than in isolation
What to keep
The modern control system, far from
of one another. This approach safeguards
its isolated “black box” predecessor,
past investments, provides for standards and
is one of the most vital contributors
minimises engineering costs while catering
Nearly 90% of companies that transitioned
to enterprise intelligence because it
for future scalability. This wasn’t available
from older systems left their existing field
provides for rapid, customer-controlled
before 2003 and the advent of Invensys
wiring and devices in place. Although field
and standards-based customisation,
Wonderware’s System Platform based on
devices are getting more intelligent and will
non-proprietary and open access,
ArchestrA technology.
most probably replace their predecessors
virtually infinite scalability, the ability to cope with plant floor changes while
one day in this transition process, the initial Hardware limitations
greatly reducing engineering costs and
priorities lie with the control systems rather than the devices they control.
providing connectivity to any and all
Added functionality demands increased
Manufacturing Execution Systems and
performance. Twenty years ago, a gigabyte
Enterprise Resource Planning Systems –
was almost unheard of and then, only
these specifications were never part of
in terms of large databases. Today, two
Most migration projects start at the HMI
the design requirements of legacy control
gigabytes of RAM in a PC is commonplace
level because that’s where it all happens with
What to replace
September/October 2012 | 5
respect to process control and where operators
high purchase price, the time required
can be best guided and helped to make
to wire and debug a totally new system
the most informed decisions. This is where
and the resulting lost production time,
connections with other applications happen
this approach nearly always represents
(e.g. maintenance) and where operators get
the most expensive route. It’s commonly
their crucial information for action – speaking of
referred to as a “bulldozer upgrade.”
which, this is where the biggest improvement can be made with respect to certain information
• The migration upgrade - It’s almost never
such as alarm prioritisation. Also, the hardware
necessary to bulldoze your entire legacy
at this level gets the most wear and tear which
system. In many cases, for example, you
prompts the use of Thin Clients and their
can “save” parts of your current system
support technology for added reliability and
such as racks and I/O wiring, since
robustness.
leaving these in place won’t hinder the performance of a properly upgraded
Cost comparison: I/A Series plug-in
Available upgrade paths
system.
versus bulldozer upgrade
When you decide you’re ready to upgrade,
Try to avoid solutions that need cutting
By furnishing new I/O modules designed
there are three fundamentally different
and rewiring since this runs the risk
to mount right into an existing legacy
approaches from which to choose. You can
of additional costs for engineering,
chassis, Invensys Operations Management
replace your existing system entirely. You
construction and testing – plus significant
is able to provide users with a brand-new,
can transition or upgrade elements of your
downtime.
modern control system.
existing technology. Or you can simply “plug in” a new system to obtain the advanced functionality that you require. • Total system replacement Unfortunately, because of the risk, the
• Migration via gateway - Another
You don’t cut any wires. You don’t add
migration approach is to keep the old
any racks or cables. You won’t incur the
system and wiring intact while installing
risk of lengthy downtime — because this
a new system in parallel, then integrating
approach makes it possible to convert
the two systems through a gateway. While
a rack back to the original system easily
this can be relatively low-cost and quick
should an unexpected problem arise
to implement, it’s at best a Band-Aid
during installation.
solution. The underlying technology is still obsolete and will continue to age.
Most important, because the new system is set up, staged and fully tested offline,
There are other significant drawbacks.
the time delay before you can resume
As with the cable-connected approach,
production is shortened from weeks or
you need space for two systems. The old
months to hours.
system also generates an additional layer in the communications system, which
The Invensys plug-in solution offers offers
slows operation and creates another area
the most successful path to continuously
of vulnerability.
current performance. It provides the functionality of a state-of-the-art
• The “plug-in” upgrade - Fortunately,
Typical new system replacement costs
6 | www.protocolmag.co.za
control system without the trouble of
one supplier has developed a solution
replacing existing field wiring, at little
that eliminates the negatives associated
more than half the cost of a total system
with traditional migration approaches.
replacement.
Replacing the aged process control system
The business case
equipment manufacturers (OEMs), system integrators and application providers for
Nothing highlights the different realities
primarily the oil and gas, power and utilities,
between business and operations like trying
pharmaceutical, heat treatment, food
to make a business case for the purchase
and beverage industries in the industrial
of new technology – especially if the old
automation market segment.
technology is still delivering the goods. While the CFO is of the “if it works don’t fix it” school of thinking, the plant manager’s philosophy is more on the “if we don’t fix it,
Minimum downtime, risk and cost typically associated with DCS migration
it will stop working” mindset. Invensys offers a complete Obsolescence is high on the agenda for
Migration solution that provides
migrating because eventually, production
minimum cost, risk and process impact
stoppages will send manufacturing costs
to your operations. This unique solution
soaring which will definitely get the
provides fast, easy installation - you will
attention of the CFO. Obsolescence impacts
be operational on day 1, representing
production and profits which means that the
millions in production savings. Standard
plant manager and the CFO both have to
I/A Series I/O modules are manufactured
confront the same problem but for different
to be form-fit replacements for other
reasons.
systems’ legacy I/O modules.
The next and probably more powerful
These standard migration modules are
motivator is functionality. Change is not only
installed in the existing system infrastructure
inevitable but constant. To cope, both the plant
without moving a single process wire
manager and the CFO need detailed, relevant,
and without increasing the footprint
real-time information of their choosing.
of the system; the construction costs associated with rewiring are eliminated
This kind of information cuts across
by Invensys’ Plug-In migration solution.
traditional boundaries and that’s why
Our solution is risk-free - because of our
today, control systems are at one end of an
non-destructive approach, the solution
enterprise information continuum with ERP
is reversible. Testing and database
systems at the other. Legacy control systems
conversion of the new system is carried
can rarely contribute to this scenario.
out offline by Invensys’ Global Migration Centres of Excellence and a full system
The plant manager will want to know about
Factory Acceptance Test is done ahead
equipment performance, availability and
of time to ensure that all conversions are
product quality not to mention the exact
executed properly.
“We went with Invensys, as they had the lowest cost migration option that minimised downtime. This was based on detailed evaluation of three vendors’ migration solutions (including the OEM). We compared and selected a solution with no rewiring. We were able to retain all field wiring, I/O cabinets, terminations and power supplies.”
“Here is what we learned. Do your due diligence on different vendors’ migration strategies and select the one that best meet your business condition and plan. Choose the right people for the project team – process engineer and supervisors, I/E project engineer and designer, I/E maintenance supervisor and technician and DCS engineer and technician. On top of all this – emphasise training, both formal and during loop checkout and commissioning. Do the factory acceptance test – no shortcut, well planned and executed.”
cause of breakdowns. The CFO will want to know the cause of cost variations and how to allocate overheads to individual products, activities, shifts and so on rather than throw
Excellent customer service with a free migration audit for customers
everything into a meaningless lump. In this scenario, the plant manager and the CFO
Invensys is committed for the
have different information needs but which
service, repair and replacement not only
can be met by modernising a control system
of the new system components during
that is common to both.
migration but also of the older competitive systems which undergo migration. The
Control systems provide the reality
older systems and the newly installed
measurements and the integration capability
components together have a new system
with other systems that the plant manager
warranty. The Invensys migration experts
and the CFO need to contribute their
demonstrate to the customers how to
expertise rather than put out fires.
unleash the power of the Plug-In migration
“The project cost met budget within contingency – a significant savings compared to a bulldozed solution.” “Invensys has a ‘Continuously Current’ philosophy maintaining support for products (no ‘Dear John’ letters).”
system free of cost.
Why choose Invensys for your DCS migration?
Additionally, Invensys is the sole manufacturer which enables a free
Invensys is a key supplier to leading original
migration audit for the customers,
Many DCS upgrade questions are answered at: www.real-time-answers.com/migration
September/October 2012 | 7
Legacy system migration – reducing the pain Your legacy system needs to be replaced, but you can’t afford the high cost, high risk and extended downtime of typical replacement solutions. The Invensys Operations Management legacy system migration solution is the only one specifically designed to avoid those penalties. We manufacture our I/O modules as form-fit replacements for your original I/O equipment. We reuse your existing termination assemblies, cabinets, power supplies and I/O racks. Add new controllers and workstations and you have a 100% new, fully warranted I/A Series System. Invensys’ legacy system migration solution minimises the cost, risk and process downtime of a full system replacement. We have helped hundreds of clients successfully migrate their legacy Bailey, Fisher Provox, Honeywell, APACS, Mod 300 and Westinghouse systems to a 100% new, highly reliable, secure and modern I/A Series system.
Key benefits • Minimum cost and downtime: construction costs and lengthy process downtimes caused by rewiring are eliminated. • Fast, easy installation: You will be operational on day 1, representing millions in production savings. • Project expertise: database conversion and testing are performed by our Migration Centre of Excellence. • The no-risk, reversible approach: your original system can easily be put back in place while issues are resolved. • Support for a lifetime: never face obsolescence again by maintaining interoperability and staying continuously current.
Key capabilities • Exceeds original specifications Keeps all process wiring in place and unchanged • Eliminates I/O mapping issues • Improves process reliability • No gateway bottlenecks or constraints • Protects you with a full system warranty on new and remaining legacy equipment • Single vendor responsibility for service and support
further enhancing its service
• Westinghouse WDPF
capability. Invensys has helped hundreds of clients successfully migrate their legacy
liquefied natural gas • Moore APACS
Bailey, Fisher Provox, Honeywell, APACS, Mod 300 and Westinghouse systems
• Helps produce 62% of the world’s
• Helps refine 17% of the world’s refined • Taylor Mod 300
products
to a 100% new, highly reliable, secure and modern I/A Series system.
• Foxboro Spectrum & Spec2000
Invensys offers migration solutions for:
About Invensys
• Helps Run 36% of the world’s nuclear power plants using Foxboro control systems • Serves 23 of the top 25 petroleum
On a global scale, Invensys Operations • Honeywell TDC2000 & 3000
Management:
• Fisher Provox Series 10 & 20
• Helps generate 20% of the world’s
companies • Serves 47 of the top 50 chemical companies
electricity • Bailey Net90 & Infi90
• Serves 19 of the top 20 pharmaceutical • Helps produce 23% of the world’s chemicals
8 | www.protocolmag.co.za
companies
Replacing the aged process control system
Hardware and software are commodities – your business isn’t.
be able to cope with your company’s increasingly sophisticated production and information needs. Hardware and software are commodities – your business isn’t. The technology to keep you on top of your
• Serves 30 of the top 50 nuclear power plants
game exists right now. Migration can be far cheaper and less risky than you might think and a far better proposition than the
• Serves 650 fossil power units with a total capacity of 200 G
inevitable alternative. It opens the way to enterprise integration and the benefits of decision support at all levels. Operational
Conclusion
personnel and management deserve no less if their job is to contribute to a profitable
Migrating from your old control system to
organisation 24/7.
newer technology is not only inevitable but highly beneficial for the many reasons listed
One last thought; it’s probably safer to
above. It’s you who should be calling the
replace your aged process control system
shots, not some dated piece of hardware
while you can still do so proactively and in
or software that, although having served
a controlled manner. Waiting till the last
you well for many years, might no longer
minute has never been a good idea.
September/October 2012 | 9
imagine a better future Cost Reduction
Security
Resources Optimization
Building intelligence
Better Services
Public Utilities management
integrated management of the City
Traffic that flows. Intelligent buildings that save energy. A public infrastructure that delivers whole new levels of service at lower cost. Systems, assets, people and the environment living in harmony. You have imagined ArchestrA, the Wonderware technology that lets you manage your infrastructure as you like in an integrated way. Open, scalable, affordable. Turn imagination into reality with Wonderware. Visit wonderware.com/Infrastructure for more info.
Facility Management • Environment • Power • Smart Cities • Transportation • Waste • Water & Wastewater Avantis
Eurotherm
Foxboro
IMServ
InFusion
SimSci-Esscor
Skelta
Triconex
Wonderware
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The dollars and sense of distributed control system migration
The dollars and sense of distributed control system migration Introduction
can be extensive. This is also the highest risk approach as there is no going back to
Distributed Control System (DCS) users
the old system if you have problems with
are increasingly being faced with the dual
the new system.
dilemma of aging systems and increasing calls for productivity and quality. Industry
• Phased migration - Other companies
experts estimate that there are nearly
take a partial migration path where plants
$65 Billion in automation systems in need
utilise their existing I/O systems and
of migration to current more available
simply purchase gateways to interface
technology. The challenge for users is
with the new processors, HMI and
developing the economic justification for
software. This has the advantage of
making these expensive investments. While
minimising the cost and time of replacing
many plants recognise the general growing
the I/O but has the clear downside of not
need to migrate their systems, engineering
addressing a common point of failure
teams struggle to capture the economic
that will inevitably have to be replaced at
benefits of the needed investments. Let’s
some point.
take a look at the issues, costs and benefits
Steven R Blomquist is the founder of Blomquist Automation Management, a full service consulting firm specialising in assisting plants, equipment suppliers and systems integrators solve complex automation business problems
of control system migration.
• Cable solutions - Some vendors attempt to minimise the expense of demolition
What is DCS migration?
and installation by utilising either wiring harnesses or I/O bus interfaces to tie
Before going further, I’d like to review what
new I/O systems to the existing field
I mean by control system migration. A
wiring. While this approach preserves
DCS migration replaces old often obsolete
the installed I/O wiring, it adds a layer
hardware and software systems with
of complexity in I/O mapping and often
technically current more readily available,
requires additional panel space.
higher performance control systems while preserving as much intellectual property
• I/O substitution - A few vendors offer an
as possible from the legacy system and
innovative approach of offering new I/O
minimising the impact on operations.
cards in the form factor of the existing I/O
Different vendors approach migration quite
such that they simply plug into the plants
differently.
existing I/O racks, eliminating significant time and expense. This allows a very quick
Generally, there are four approaches to DCS
change-over with virtually no impact to
migration:
existing wiring and cabinets. This is also a very low risk approach as it possible to
• Full system replacement (the Bulldoze
test the entire system off-line and then tie
Approach) - Many vendors require a
in to the existing system through simply
complete system replacement from the
swapping the I/O cards. Further lowering
I/O racks and cards to the processors
the risk of this approach is the ease
and displays. Obviously, this can be
with which a retrofit can be temporarily
quite costly as well as time-consuming
reversed if problems are encountered
and difficult to schedule as the time to
during commissioning. This is the
remove, install and wire the new systems
only approach that is easily reversible
September/October 2012 | 11
should operational pressures require
plants migrate one or more systems to
complete new system approach favoured by
a quick return to full production while
achieve the benefits associated with having
many vendors is the most costly approach
problems are addressed off-line.
a single common platform. Finally, the aging
as it includes the cost of the DCS itself
workforce at many plants is raising the costly
plus the required new I/O cabinets and
A control system migration is much more
possibility of needing to train new hires on
auxiliary electrical equipment. Other less
than merely replacing the old stuff with
20+ year old technology.
comprehensive upgrades can save the cost of new cabinets and auxiliary equipment.
new stuff. This is one of the few times plants can seriously consider a change in control system providers. I recommend
DCS upgrade financial benefits
The I/O substitution approach is the least costly approach as it utilises all the existing I/O cabinets, racks and auxiliary electrical
plants use this event to evaluate the current
control equipment.
and future offerings of the major DCS
What can plants expect in the way of
providers and make sure they are choosing
financial benefits from a DCS migration?
the platform which meets the quality,
The first savings is in the reduction of
Demolition and installation costs are
productivity and profitability needs of the
unplanned downtime due to equipment
generally the most costly aspect of a system
plant both now and in the future. Plant
failure. With downtime costing up to
upgrade other than the actual cost of
engineers must think beyond traditional
$100,000 per hour for some users, small
the downtime. Once again this expense
control paradigms and consider how new
reductions have very big paybacks.
can range from complete demolition of the
technologies and open platforms might
The second and related expense is the
old system and installation and wiring of
positively impact their businesses in the
reduction of hardware costs replacing
the new system at a substantial expense to
coming years.
failed system components. This can also
the simple replacement of I/O cards with
be a significant expense as parts for
virtually no demolition or installation costs
systems nearing end of life can be quite
dependent upon approach. In between are
expensive. Some plants are forced to utilise
several variations of scope such as using pre-
Migration pressure comes from several
expensive third party resources to make
assembled wiring harnesses to reduce the
sources. The most recognisable pressure
modifications to their older equipment due
cost of rewiring to the I/Os. In short, this is an
is the declining system reliability and
to lack of in-house expertise. Productivity
area of great cost and tremendous variation
resulting loss of production which can
improvements are also seen in the area of
in the offers of the DCS vendors. I suggest
result from aged systems. Often a plant
reduced changeover times. Once again
all plants carefully analyse the different
reaches the point where their system must
with the high cost of downtime, even
approaches and fully understand their impact
be updated to newer technology due to
small reductions in changeover time can
on demolition and installation expense.
the high maintenance costs and excessive
generate big savings over the course of a
downtime that older systems can create.
year. Less easy to measure but still quite
The third area of major cost is in the
Parts availability and available expertise on
valuable are the overall improvements in the
engineering. There are three aspects to
the vintage systems are also major catalysts
plant operation due to tighter integration
the engineering. First are the physical
for a system upgrade.
to plant business systems. Finally there is
designs of new cabinets and new wiring
the equally important factor of reduced
diagrams. Second is the engineering and
However, there are other reasons plants
“lost opportunity” costs due to ease in
programming of the actual application.
upgrade which are not so readily apparent.
changeover, increased system flexibility and
This is a chance to work with your vendor
First among these is lost opportunity cost
ease of expansion. All of these items should
to not just duplicate the existing software
due to the existing system’s inability to
be carefully considered when developing
with all its idiosyncrasies and shortcomings
respond to rapid changes in customer
the economic justification for a migration.
but to optimise the performance of the new
Why migrate?
needs. Today’s global economy demands smaller batch sizes and quicker changeovers
system capitalising on new technologies
Migration costs
which some older systems simply cannot
and experience. When doing this it is important your upgrade provider have a
handle efficiently. Another common issue
Balancing the cost savings above is the
deep application expertise in your industry
that can drive a system upgrade is the
cost of implementing a new control system.
and with your applications. The third area of
inability to cost-effectively expand the
The costs of a migration break down into
engineering is the creation of new operator
system for increased production. Other
five categories: equipment costs, demolition
interface screens. Again this is a chance to
problems that plants can often only
and installation costs, engineering costs,
clean up any deficient areas and capitalise
address through a system upgrade are
commissioning costs and finally the cost of
on the latest technologies available.
lack of transparency, i.e. the inability to see
the downtime required to perform the work.
enough process data in a timely fashion
Following is a more detailed look at each of
System Acceptance Tests and
and interfacing of the existing system
these costs.
Commissioning are costs that are often overlooked when evaluating upgrade costs.
to more modern plant business systems in a real-time manner. This is becoming
Equipment costs are the most easily
Like virtually all the upgrade costs, these can
increasingly important as plants deal with
captured expense of a system upgrade, but
range from the high commissioning expense
variable costs such as energy which can
can vary widely dependent upon the vendor
of a complete new system to the relatively
vary greatly over the course of a day. Some
and their associated upgrade approach. The
low cost of commissioning a system with
12 | www.protocolmag.co.za
The dollars and sense of distributed control system migration
• Application knowledge - The third
I/O substitution cards. The latter is always
There are four things that I recommend
much quicker to get back on line as it uses
plants look at when considering a DCS
critical evaluation point is application
the same wiring, so the commissioning is
migration project:
knowledge. In order to maximise your
really limited to the new application software
investment you need to work with people
and HMIs, both of which can be effectively
• Migration approach - The first thing
who understand both your business and
tested and demonstrated during the earlier
one must carefully evaluate before
your applications. Make sure your chosen
Factory Acceptance Testing phase. When
choosing a migration system provider
vendor has a depth in resources that know
evaluating Test and Commissioning expense
is their approach. As I have mentioned
and understand both.
I recommend that you work very closely with
previously, the approaches from the
your potential suppliers to understand their
main DCS providers range from the
• Commitment - Finally, a DCS system is a
true expectations of the Loop Checking
most common “out with old, in with
long term investment. Accordingly make
and System Commissioning durations. Also
the new” approach to relatively simple
sure you are dealing with a company who
insist on a full Factory Acceptance Test
I/O card substitution in the form factor
will be there with you for the long haul.
before you begin your shutdown for the
of the existing I/O racks. This decision
system upgrade.
will greatly impact the total cost of
Let’s do the math
ownership and potential justification of The costs and risk associated with the
your new system. Make sure you choose
For our example, let’s use a typical DCS
commissioning phase varies greatly
a vendor whose approach fits with the
system with 900 discrete I/O points, 600
dependent upon the migration approach.
needs of your plant in terms of available
analogue I/O points and 150 control
Plants need to carefully evaluate the
downtime and the urgency to implement
loops. The equipment cost ranges from
expense and risk of extended downtime
the upgrade as soon as possible.
approximately $275,000 to $325,000 dependent upon your choice of vendor
and lost production should problems arise during this phase of the project. Make sure
• Enterprise-wide Integration capability
and approach. System Engineering may
your chosen supplier has a contingency plan
- The second thing to evaluate with the
run from $230,000 for an I/O substitution
to minimise your added expense should
DCS offering is the openness and ease
upgrade to $520,000 for a full system
commissioning problems arise.
of interfacing with existing and future
replacement. As a reference, ARC Advisory
plant business and auxiliary systems.
Group suggests a Rule of Thumb of
Closed, proprietary systems are a thing
$1,500 engineering cost per page of
of the past so make sure your new
graphics and three lines of code per hour.
Throughout our discussion I have referred
system has the flexibility of standard
Note that the engineering is not only
to picking the right vendor as being critical
communications and an open architecture
affected by the upgrade approach, but is
to the success of any DCS migration. Please
in order to meet your plant’s enterprise-
also dependent upon the quality of the
allow me to expand on this important topic
wide integration needs for the life of the
conversion tools used by your chosen
for a few minutes.
system.
supplier such as back documentation
Choosing a vendor
September/October 2012 | 13
“With the lower cost I/O substitution method, the return on investment could be 344% with a payback period of only 3.5 months.”
• Reduced downtime is the often the
healthy return to be sure. The payback
measure. Downtime can cost anywhere
period is the time, generally in months,
from $10,000 to $100,000 per hour
it would take to pay back the initial
dependent on the plant production
investment. For this example that would
rates and the value of the product being
be $1,000,000/$3,435,000 X 12 months per
produced.
year = 3.5 months which is an exceptional
tools and advanced process graphics. It is also important to note that reusing the
or 344% over a one year period, a very
biggest benefit and also the easiest to
payback period. • Reduced maintenance expense driven
existing field devices and I/O wiring has a
by fewer failures with the new equipment
We can make the same calculations for the
significant effect on the engineering effort.
and the ability to generally service
more expensive approach of a complete
The final major component of upgrade cost
and maintain the system with in-house
new system, the benefits would be the
is the demolition and installation. These
resources
same at $3,435,000 per year but the cost
costs range from virtually no demolition or installation costs for I/O substitution
would be substantially higher at $4,500,000. • Incremental productivity gains due to the
The return on investment would be
migrations to as much as $230,000 for full
power of the more current technologies
$3,435,000/ $4,500,000 or 76%. The payback
system replacement. Following is a pictorial
allowing more transparent data, faster
period would be $4,500,000/$3,435,000 X 12
view of these numbers.
change -over times and tighter interfacing
months per year = 15.7 months.
to other plant systems. These gains
What does it all mean?
To summarise, the cost of our 1500 I/O point
need to be evaluated on a plant by plant
DCS upgrade can vary greatly dependent
basis taking into account the operating
upon the approach the plant chooses ranging
practices of the plant and the capabilities
DCS migrations are becoming increasingly
from a low of approximately $510,000 for
of the new system.
necessary as large amounts of installed equipment reach obsolescence. This
an I/O substitution upgrade to as much as $1,075,000 for a full system replacement.
• Ease of expandability can be another cost
presents an interesting opportunity
savings as it allows plants to move into
for plants to re-evaluate vendors and
On top of the equipment, engineering
new production activities with less cost
technology and make the best choice for
and installation costs are the very
than would be otherwise expended.
their specific plant based on factors such as transparency, open architectures, ease
substantial costs of taking the plant down to perform the upgrade. In the case of a
For our example, let’s assume downtime
of system expansion and cost and ease of
card substitution upgrade, the required
cost of $50,000 per hour and a reduction
implementation. Complicating the process is
downtime is short enough that it can
in downtime from 1% down to 0.5%. The
the broad spectrum of migration approaches
usually be completed during a regularly
savings from that improvement in downtime
supported by the major DCS providers with
scheduled shutdown. Some plants have
alone would equate to $2,190,000 per year.
an accordingly broad range of associated
implemented this type of upgrade during
Add to that reduced maintenance expenses
costs.
a shutdown as short as 48 hours. At the
of $150,000. Small productivity gains can
other end of the spectrum, a full system
result in huge savings. For our example we
Plants need to carefully evaluate the
replacement requires a substantial
will assume a productivity improvement
offerings of the major DCS providers and
shutdown of many days and even weeks.
of .25% which equates to an additional
make sure they choose a supplier which
For that reason these upgrades often must
$1,095,000 in annual savings. As the numbers
meets their short and long term technology,
be implemented in phases. This make the
spell out, even nominal reductions in
business and profitability needs. At the same
investment justification even more difficult
downtime and improvement in productivity
time they need to also choose a migration
as the full system benefits are often not
can mean big financial gains for a plant.
approach which meets the needs of the plant in terms of financial justifications and
realised until the complete system has been upgraded which is some cases requires
With financial gains after migration equating
impact on operations. DCS migrations can
scheduled shutdowns over a number of
to $3,435,000 we can calculate our return
generate very strong returns on investment
years. For purposes of our calculations, we
on investment and our payback period.
and very short payback periods when the
will use the downtime numbers of $500,000
Return on Investment or ROI is calculated
newer low cost migration approaches
for I/O substitutions and $3,500,000 for full
by dividing the total financial gain, or return,
are combined with highly functional and
system replacements.
over a given period of time by the total cost,
flexible control platforms. With a thorough
or investment, over the same period of time.
evaluation and careful selection, plants have the ability to position themselves for
Total cost for our little 1500 I/O system would range from right around $1,000,000 to over
With the lower cost I/O substitution
long-term profitable operation with the next
$4,500,000 for a full system replacement.
approach, the cost of the migration is
generation of DCS controls.
On the benefits side, following are the cost
$1,000,000 which means our return on our
benefits customers often recognise.
investment would be $3,435,000/1,000,000
14 | www.protocolmag.co.za
What a modern DCS can do for you
What a modern DCS can do for you Automation technology has probably
standardisation and preservation of business
from any vendor, or any fieldbus protocol
changed significantly since your existing
logic.
into our system.
and so has the business climate. Today’s
Foxboro Control Software provides a
successful industrial operations require
unified HMI and Engineering environment
4. An integrated system — enterprise-wide
much more from their DCS than just
that enables standardisation of operating
safely controlling the process. To remain
practices and techniques across the
Utilising and sharing data from your
competitive, driving control excellence
organisation and the flexibility to easily
manufacturing and business processes adds
across the plant or entire enterprise is
change plant-wide applications, control
better visibility, collaboration, productivity
critical to a company’s success. Business
programmes and workflow to quickly
and overall increased profitability. You get
operations and production processes need
respond to any business issue. Foxboro
the right information, at the right time to
to be synchronised and optimised for overall
control software configuration tools not only
better optimise your processes.
efficiency and sustained profitability. Only a
reduce mundane programming tasks, they
modern DCS can provide the data to do that.
make it easier and far less risky to implement
The I/A Series system is more than a DCS.
application changes—ensuring global
Embedding our ArchestrA System Platform
We’ve assembled a quick checklist of some
consistency and best practices. The cost of
into the Foxboro I/A Series system extends
of the capabilities we believe you will need
project implementation is greatly reduced
a common object technology throughout
in your next control system platform:
making your life easier and more productive.
the entire enterprise, from process control
1. An architecture that evolves with your needs
In fact, indirect costs associated with control
third-party system. This means that you can
systems add as much as 20 percent to the
engineer all plant systems, databases and
purchase price. Field wire marshalling makes
software applications from the same core
Dear John letters should be a thing of
up a large part of this added cost, but
software components. The result is superior
the past. Today a system should offer an
Invensys eliminates this with a new I/A Series
collaboration, execution and visibility
evolutionary architecture that will expand
Intelligent Marshalling solution that provides
across the entire enterprise. You’ll be able
with your needs and provide a sustainable
a universal I/O module, significantly reducing
to synchronise production and industrial
lifecycle. Indefinitely!
your total cost of system ownership.
operations with business objectives,
Invensys’ Continuously Current philosophy
3. A truly open technology platform
system was installed 10 or 20 years ago
to the business system level and out to any
obtaining the speed and flexibility to attain ensures that customers have a cost-effective path forward. Since its inception in 1987,
sustained profitability.
5. High reliability and performance
the I/A Series system has been infused with
Industrial operations often require
innovative technologies while providing
integration of data from disparate
interoperability and co-existence with
sources. Plants may use different systems
Unscheduled downtime can mean a loss of
previous generations. And no one offers
from multiple vendors with different
hundreds of thousands of dollars per hour
faster, more cost-effective migration of other
communication protocols and this data
– something no one can afford in today’s
vendor’s offerings. As your needs continue
must be integrated easily, cleanly and
competitive market. Ensure that your next
to evolve, so does the I/A Series system.
inexpensively. Today’s control systems can
control system has an outstanding reliability
offer a secure, open platform that provides
rate with no single point of failure.
2. A lower total cost of ownership
interoperability with either a previous
The typical lifecycle cost of a control
I/A Series users aren’t locked down with
architecture including the Mesh Network,
system — from design to implementation
proprietary technology and aren’t required
control processors, conventional, remote
to maintenance — can be high. Modern
to rip out what they already have to do one
and intrinsically safe I/O and fieldbus
DCSs can keep lifecycle costs down by
stop shopping. The I/A Series “any bus”
interface modules, that ensure highest
integrating control operations, maintenance
fieldbus strategy accommodates customers’
reliability and maximum uptime of our
and engineering functions, which promotes
needs supporting integration of any device
customers’ process.
generation or a third-party system.
The Foxboro I/A Series system, for example, boasts a top to bottom fault-tolerant
September/October 2012 | 15
6. A verifiably cyber-secure system
procedures, people, products, networks and
and Remote Desktop technology fully and
applications. Our solution is unique because
uses Smart Card technology, which makes it
of the quality of our consulting teams, the
the most secure manufacturing HMI in the
Process control technology for the
complete cyber security compliance for
market.
automation industries has evolved
your critical infrastructure and its ability
rapidly in just a few years, migrating from
to be seamlessly integrated between
proprietary technologies to more open and
manufacturing operations and corporate IT
interoperable control systems. The greater
networks.
vulnerability of these systems increases the potential risk of cyber attacks via the Internet
8. Improved asset management Modern control systems offer predictive
7. An easy-to-use system
and from other external and internal network
maintenance and asset management tools to drive productivity and availability of your
intrusions. Fortunately, cyber protection
Modern control systems provide intuitive
plant assets. They are designed to help you
has advanced as well and today’s control
tools to empower engineers, operators,
take maximum advantage of the intelligence
systems are increasingly engineered for
maintenance and all mobile workers to be at
that is increasingly built into field devices.
better protection and compliance with
their best. But don’t be deceived by a pretty
With new systems your team can be
industry standards.
interface. Modern HMIs should also bring
proactive instead of reactive when it comes
new intelligence and security as well as ease
to managing device failures and potential
Invensys addresses your compliance
of use. The right interface can help your
downtime.
and cyber security challenges from
people achieve their fullest potential, which
analysis through to implementation and
can add more bottom-line value than almost
The Foxboro Field Device Manager enables
management. Our technology meets
any other investment you can make.
you to configure commission, maintain
the highest global standards for cyber
and diagnose your fieldbus devices
protection and we complement that with
The I/A Series now uses the enhanced
throughout their entire lifecycle with our
expert consulting and a track record of
Wonderware InTouch 12 HMI, which
comprehensive, fully integrated engineering
global success. A world class team of cyber
provides a common interface to ArchestrA
and maintenance environment. Our user
security experts can help assess your current
engineering and I/A Series configuration and
interface and diagnostic capabilities
compliance situation then help you craft a
run-time operations. The ArchestrA graphic
provide the means to increase uptime and
cyber security plan and remediation strategy
tools load at start up. The interface also
performance while significantly lowering
that encompasses all of your processes,
supports Microsoft Hyper-V virtualisation
your maintenance costs.
16 | www.protocolmag.co.za
Operations Modernisation the Invensys way The best way to modernise your operational facilities is with the help of a trusted partner who’s been there before and who can steer you clear of pitfalls and costly experimentation – because this is certainly not the time for a trial-and-error approach to sustained wealth creation.
September/October 2012 | 17
In a nutshell ... The Invensys Operations Modernisation programme is an exciting new global initiative aimed at developing a deeper relationship with our Brownfield clients by becoming a trusted advisor for their modernisation needs. The foundation of the programme is a consultative engagement that helps clients
Invensys Operations Modernisation programme
identify and prioritise modernisation requirements through an ROI-based exercise. The results can then be used by clients to justify a modernisation project to management, which is often the primary barrier they face. The initial focus of the engagement can include DCS upgrade / migration, Turbomachinery Control, Cyber Security hardening of the control network and Process Lifecycle Safety. The consultative engagement may uncover more areas that need to be addressed that go beyond modernisation. At the end of the exercise, clients have a recommended roadmap to not only modernise their facilities but also to improve their operations. Figure 1: What are the priorities for business leaders?
Across all industries and in every corner of
Market transitions
set of primary challenges, driven by the
These questions need to be considered in
increasingly dynamic market requirements
the context of a number of broad market
that we’re all striving to address.
trends. To meet these set of primary
• How do we address changing demand, where change can mean growth one day
global market.
from a holistic, versus island, view that recognises the contribution of
doing business:
all systems and processes to overall profitability
• Move from headcount reductions and restructuring of the past to a renewed
be addressed in the context of three main requirements:
more comprehensive view that recognises
bottom line performance and operating in
all the production considerations and
a safe and sustainable manner?
interdependencies
18 | www.protocolmag.co.za
addressing changing market requirements While these changes are critical, they must
• There is a progression from independent optimisation of production processes to a
• How do we do all of this while improving
• We need to find ways to be more agile in
resource – our people
flexible so that we can be more responsive to address the changing dynamics.
• We need to look at the corporation
changes in the way industry is collectively
focus on empowering our most critical • How do we become more agile and
on past and historical information
challenges we are seeing 5 fundamental
and declines the next. Or both at the same time in companies dealing in the
• There is a drive to manage our businesses in real-time, rather than basing decisions
the world, organisations are facing a similar
• Safety and reliability – getting the most from your assets, safely
Invensys Operations Modernisation programme
Figure 2: Striving for operational excellence in four key areas
• Sustainability – minimising environmental
How do I get there?
practice • Geographic Balance – thinking globally,
Modernisation provides a great opportunity
aware of present shortcomings as listed in
for thinking “out of the box” while following
figure 2 and so it would be wise to draw
some sound guidelines:
up a list of requirements that you believe would address these problems. This
but delivering/executing locally • Take a holistic, long-term perspective
Modernisation
• Develop a plan to address current and future needs – You should be keenly
impact and adhering to good business
should be done without any consideration
– If you’ve lived with a 20 or 30-year-old
for technologies or approaches – take it
legacy control system, for example, be
for granted that today, virtually anything
One of the challenges an industry faces is
aware that your new system will easily
is possible.
the legacy systems and processes currently
outlive that and that its role should be
in place which were not designed for this
viewed in that context. So it should offer
• Prioritise operational technology
new paradigm of business. Subsequently,
no boundaries as to what you’re likely to
opportunities - Today, you can do
modernisation is rapidly becoming a higher
need. But control systems are only one
things that weren’t thought of when you
priority with a focus on achieving operational
aspect of modernisation (see figure 2). In
bought your current solutions all that time
excellence in 4 key areas of operation
our approach, we believe that you have
ago. For example, centralised software
– control, assets, people and safety/
to look beyond just the technology. You
maintenance and deployment coupled
environment:
need to consider all your production
with the ability to define, deploy and
processes (production, operations,
maintain standards will save you a great
maintenance, hr, control, safety, training,
deal of engineering money and effort in
it, etc.)
the long run but may not occur to you as
• Environment and Safety – ensuring that our employees work in a safe environment and that regulatory and environmental requirements are fully addressed • People – empowering our increasingly leaner and specialised workforce
a priority if you live within the constrained There is value in not re-inventing the
mindset of legacy technology. A unifying
wheel, learning fro m others and taking
technology platform will also give you the
the best of what applies to you. As we
opportunity to change quickly in order to
saw earlier, there are many different
meet new business challenges
places to start and many initiatives and • Asset – obtaining the maximum value
programmes that can add value. By
Typical technology issues addressed in a
from existing assets and shortening the
taking a broader perspective and by
modernisation initiative include:
time to value for new capabilities
measuring the benefits you can realise, it becomes possible for you to prioritise
• Control – taking control of the business from top to bottom
these efforts and justify projects that will
Control and safety system migration / upgrade
provide the biggest return. Turbo machinery control improvements
September/October 2012 | 19
consider these interactions as well as the
•
•
FREE assessment of feasibility and potential Executives get a value proposition based on the “bigger picture”
3 – 5 year modernisation plan
operational requirements of personnel at all levels. • Leverage experience and get started
Budgetary costs Rough estimate of benefits based
– You know what you need and you have
on industry standards and evaluation
plenty of expertise in your company who
results
can help you get there because it’s a
•
•
Simpler way to match needs to potential solutions Roadmap to unlock future value
fair bet that that’s also what they want.
Invensys consultants have a lot of experience
Harness that intellectual property and get
in your industry and with a range of
some trusted outside help if you need it.
situations. We have seen solutions that work and some that don’t. We understand how to
The Invensys approach
apply various work approaches in a way that is effective and we can draw upon a large
•
All initiatives supported by our highly-experienced multifunctional teams
Invensys has developed a standard approach
range of skills and experience to work with
that addresses the “bigger picture” to
you to identify solutions that will really work.
identify specific areas that will return value to your organisation.
•
•
Start with initiatives with the fastest ROI and highest impact Take a holistic rather than piecemeal perspective
And that’s key – we realise that we can’t come in as the “lofty experts” and fix
There are hundreds of products you could
your problems. While we wouldn’t be
buy and many available solutions, but which
talking to you if we didn’t feel that we
one is right for you and which should you
had some understanding of your situation
consider first?
and potential opportunities, we know that the “real” solution is only going to come
Our structured assessment will provide a
from working together to leverage your
roadmap for future change – an outline of
knowledge, skills and experience with our
potential projects with measurable benefits.
own.
The approach can be applied to a particular
The assessment delivers:
Why should you consider Invensys as your modernisation partner?
• Operational KPI review
The main reason is that, at Invensys,
plant, or across the entire enterprise.
modernisation is a way of life, to the • Plant technology review
degree that, insofar as control systems are concerned, it’s a term foreign to our
• Best practices review (control, maintenance, safety, process)
customers. For more than two decades, “modernisation” has simply involved installing the latest software release or
• Skills assessment and knowledge management assessment Process safety engineering Cyber security hardening
for example, have been kept continuously current for nearly a quarter of a century.
• Benefits analysis including ROI • Consider people, processes and
To their owners, “modernisation” simply means installing the latest release – no
• Lifecycle support strategy
of “islands of information”. A unified enterprise is a profitable enterprise and
way. The Foxboro I/A Series DCS and Wonderware InTouch HMI/SCADA solutions,
• Operational process review
enterprise needs – Gone are the days
hardware upgrade in an evolutionary
fuss, no mess and total protection of their past investments with never a need for full
• Opportunity prioritisation and sequencing
replacement.
• Presentation of results
With our goal of providing greater long-term
one way of unifying an enterprise is to interconnect its people and the processes they control with the information they need at all levels. So, control systems,
value with lower risks and costs, there • Systems Gap Analysis
for example, are no longer “black boxes” buried somewhere in the depths of the shop floor but a vital source of
modernisation partner: Recommended system architecture and solution map
information for the rest of the company. Modernisation initiatives need to
20 | www.protocolmag.co.za
are more reasons for selecting us as your
• We really understand control and safety better than most
Recommended project roadmap
Invensys Operations Modernisation programme
• We have more than a century of innovation and experience • We have a broad technology portfolio • We are committed to preserving your technology investment • We adopt a true top-to-bottom, operations-to-business perspective • We have enterprise scale capabilities and vision
Driven by services Modernisation services protect your investment through every stage of the automation lifecycle: • Global migration excellence centres • Proven project execution excellence • Intelligent engineering approach • Customer FIRST Programme • Cyber security and regulatory compliance • Eco-system partners and programmes
What can we achieve together?
Figure 3: The scope of Invensys offerings is reflected in the map of the InFusion Enterprise Control System
We have some specific goals from our
and value of any proposed initiative.
different product but that’s not good for
assessment approach:
This measurement and identification
you, or us. If we work with you to step
translates into business cases for actual
back from the day-to-day problems, we
projects. With measurable value, you can
can develop a bigger picture perspective
with your perspective. We need to verify
compare costs and identify real payback
of your situation, take advantage of our
our understanding of your needs so that
for future investments. Let Invensys work
experience and knowledge and produce
we can identify potential solutions that
with you to determine opportunities and
a roadmap of identified and measureable
really do fit.
identify benefits while you leverage our
milestones. This will all give you a simple
experience, skills and tools.
and single way to measure value and you
• We want to make sure that we are in sync
• We want to work together to identify real opportunities that make sense to you so that we can measure the impact
won’t have endless and confusing product • And, we don’t want to pester you. We
lists to browse through.
could show up every week trying to sell a
September/October 2012 | 21
The clearest path to operations modernisation While your process automation and safety
• Lower the total cost of ownership
assets may be getting the job done today,
− If you currently have technology
how do you know whether your plant is
that is becoming increasingly more
producing at its full potential and that it can
challenging to support, whether
do so in the future?
it is acquiring spare parts or finding qualified technical personnel
How exposed is your business to unplanned
to assist, now is the time to
downtime, unnecessary costs, or other
modernise.
issues? Systems running at your plant and considered cutting edge 20-30
• Increase your production efficiency
years ago, may not be today. In order to
and manage risk − Avoid the impact
stay competitive in today’s market you not
of having inefficient, unreliable
only have to maintain your automation and
systems in place. Minimise
safety assets, but improve their performance
unplanned shutdowns and the related
and contribution.
production losses. Maximise plant utilisation by eliminating unreliable
Consider taking the journey toward
and failure-prone systems.
improved performance today with the help of Invensys Operations Management.
• Extend the life, performance and
Invensys will provide a clear, manageable
reliability of systems − Avoid a major
and cost-justified modernisation
capital investment and make use of
path encompassing updates of older
what you already have.
Figure 1: What are the priorities for business leaders?
systems to leading edge standards as well as the related processes and best
• Avoid obsolescence − Define a clear and
practices. This comprehensive approach
cost justified strategy and plan to address
allows companies in the continuous process
mature and obsolete technology.
performance.
• Meet regulatory requirements and
Efforts to avoid or postpone modernisation
and environmental requirements. • Improve cyber security − Define and
will make it harder to compete and,
implement the necessary steps to ensure
ultimately, to survive. The risks of not
that your plant systems are safe and
modernising are significant. Aging legacy
secure against threats.
technologies are expensive to operate and maintain and can adversely affect your
investment in place?
improve corporate image − Ensure that your systems meet current safety, health
Why modernise?
operations? • How do you maximise the use of the
industries to minimise the risks inherent in obsolete technologies and maximise asset
• How do you minimise the impact to the
• How do you maintain and improve intellectual property and knowledge? • How do you justify changes to management? Invensys understands that companies considering modernisation will have these
Where do you start?
ability to support new business priorities,
questions and many more. Organisations may already have reviewed some options,
or apply new technologies and solutions
Modernising a facility can be a daunting task
or have a specific problem area in mind for
to increase performance. Furthermore,
as process automation and safety systems
modernisation. While Invensys has one of
the complex design of legacy systems is
encompass a range of vendor solutions
the broadest portfolio of product solutions
frequently based on outdated technologies,
of varying vintages, where knowledge
available, we have something else even
making them difficult to change and slower
about the systems, site operations and
more valuable – experience. Whether you’re
to respond to market shifts. Can you afford
known issues are dispersed throughout the
ready for the next step in your modernisation
to wait? Invensys combines advanced
organisation. Questions that must be tackled
journey, or not sure where to start, Invensys
technologies and services to help:
in this environment include:
has established a proven approach that applies a unique perspective to address
22 | www.protocolmag.co.za
The clearest path to operations modernisation
your questions, identify priorities and
innovation is based on finding the best way
develop the cost justification. You’ll not
to apply the right technology to the right
only know where to start, you’ll know how
problem.
to get where you want to go and be able to justify the modernisation effort to your
Modernisation For customers facing obsolescence issues, we
What can you expect?
management.
offer a comprehensive set of products, services and solutions that extend the life of systems
The first step along the journey towards While our Operations Modernisation
Operations Modernisation begins with
approach can assist you in planning for the
your people. Through a structured
modernisation of any system or asset, our
Modernisation Workshop, we will work with
areas of specialty include:
you to review your company’s business
and enhance their capabilities including: • Legacy migration • Safety and critical control
goals, objectives and needs. From there, • Leading edge Control systems built on
we help translate your business goals into
more than a century of innovation and
reality by transitioning technology from
engineered to evolve with business needs
systems and processes that limit current or
over the life of the installation
future business performance, into solutions that meet, or exceed your current and future
• Full safety lifecycle programme including
• Turbomachinery performance • Cyber security • Operations optimisation
business requirements.
PHA, LOPA / LOPA Review, Quantitative
• Rich portfolio of services and consulting
Risk Analysis, Conceptual Design, Safety
Our approach is proven and it works.
Requirement Specification and full SIS
With the input provided by you and other
implementation
business/plant/operations resources, we will
What happens next?
create a high-level strategy and roadmap along with execution plans that balance
As a result of the Workshop, a multi-year
entire process control network – readiness
risk, change and cost, to deliver maximum
Operations Modernisation roadmap
assessment, procedures development,
business value at the pace that best suits
is created by Invensys consultants and
equipment specification and installation,
your business. The resulting solutions are
subject matter experts. Once the roadmap
compliance monitoring
based on open systems, open standards
is agreed upon, the schedule is set,
and an open architecture, thus providing a
resources identified and we begin executing
solid foundation for the future.
against the plan.
Together we will develop a long-range plan
During the Operations Modernisation
and strategy, which will include a thorough
project, you can expect the following:
• Full Cyber Security hardening for the
• Complete DCS migration solution with no downtime, scheduled or unscheduled, on all major competitive systems • Best in class safety systems for all SIL 0 through SIL 3 applications
understanding of the impact on your people, skills and sustainability. During the planning process, we will: • Develop an automation and technology
design and implementation for Generator
strategy that links projects to business
AVR, Turbine Generator Sequencing,
strategy and long-range business plans
Motor and Turbine Drive
• Create awareness at all levels of the change management programme
• Concise articulation of your existing critical business processes
• Demonstrate clear return on investment • List of opportunities for potential
and operator skills such as OTS, workflow tools, learning services, simulation and
You will leverage Invensys’ lengthy
other products.
experience, depth of talent and understanding of technology applications to
• A range of performance improvement
consultants work with your team to deliver:
organisation by implementing an effective
• Multiple options to strengthen and modernise your operational processes
The Operations Modernisation Workshop is at the heart of our approach, where our
Surge Control, Turbine Generator Control and Performance Control for both
will ensure reduced project risk, on-time delivery and quality.
• Full Turbomachinery control modernisation including consulting,
• A PMP-certified project manager that
develop an approach that you can be
solutions that cover a number of specific
confident will deliver results. Our experience
operational areas
extends across a wide range of industry and vendor technologies. We will deliver a
The scope is customised to your identified
practical, long-term plan that makes the best
priorities and the nature of your operation.
use of the right technologies, processes and
And, we are not restricted to a single
skills to modernise your operation.
performance improvements • Roadmap for enabling the process through technology • Insight into how current technology investments can be maximized • A full analysis around the investments required and the value returned
vendor’s technology. Our history of
September/October 2012 | 23
• A proven, global team of Invensys
improvements (real-time measurements)
consultants and subject matter experts that work with you to clearly establish
proven history of delivering improved and sustainable asset performance through
• An approach that ensures that you get
innovative services and solutions. We really
priorities, issues, cost and benefits and a
the best resources when you need them
DO get it – we’ve combined more than a
path forward.
through our delivery team and extensive
century of experience with the broadest
partner ecosystem
portfolio of expertise and capabilities for a
• A holistic approach that includes the
unique approach that extends the life and
Ensuring your success
performance of your production assets.
modernisation, supported with automated
Unlike point solution vendors, our approach
Don’t get left behind. Give Invensys the
solutions, processes (workflow),
is based on innovation and the broadest
opportunity to take this journey towards
knowledge management (training)
portfolio of technology and expertise.
Operations Modernisation with you; let’s
and tracking and reporting around the
Invensys is the only company with a
work together to secure your future.
“people” aspect; integrating the human element into a holistic perspective of
24 | www.protocolmag.co.za
Foxboro I/A series Distributed Control System – migration by design
Foxboro I/A series Distributed Control System – migration by design In a nutshell ...
The I/A Series® distributed control system from Foxboro, measurably improves plant-wide operations,
performance and asset utilization in today’s modern manufacturing
enterprise. A key component of the
Continuously current
Ensures high availability of your process.
InFusion™ Enterprise Control System, the I/A Series system offers the greatest
Introducing the latest I/A Series®
Self-healing Mesh control network
system from Invensys Process Systems.
breadth of capabilities for providing optimal performance for operators,
Powered by innovative technologies,
Delivers blazing, one-gigabit speed
backed by world-class Foxboro® service
and intelligent data routing to deliver
Not only will you maximise plant
and supported by superior Foxboro
the right data to the right people in real
performance, you will maximise your
industry and application know-How.
time. The Mesh control network can act
business operation in real time, allowing
The I/A Series system meets all your
as an additional layer of security to your
you to focus on optimal profit control.
process automation needs with
system to protect it against internal and
the most comprehensive, reliable
external threats and vulnerabilities.
infrastructure available for the industry—
engineers and maintenance personnel.
Protecting your investment as your needs evolve.
today and tomorrow.
Fast, easy migration solution
Since its inception, the I/A Series
I/A Series I/O modules provide
current philosophy, the I/A Series
system has been driven by a unique
plug-in replacements for end-of-life
system is continuously infused with the
continuously CurrentSM philosophy
systems, minimising cost, risk and process
latest technologies while maintaining
conceived to protect our customers’ systems
downtime.
interoperability with earlier generations.
Driven by our unique continuously
investment. Consequently you can be sure your I/A Series system is continuously
This assures easy upgrades, significantly One tool belt, any device
infused with the latest technology while maintaining interoperability
Field Device Tool-based (FDT)
with earlier generations. This assures
maintenance environment provides truly
an easy transition path for upgrades,
open tools, allowing you to leverage any
significantly reducing your cost of ownership.
field device and drive down costs.
The I/A Series system is the industry’s most
Easy device tool integration
advanced process automation system and the proven Foxboro Continuously Current
Robust modules offer more choices with easy
philosophy ensures it stays that way.
connection to virtually any device using various communications protocols.
Continuously advanced The I/A Series system is packed
Empowering plant performance
with innovative advanced technologies designed to maximise your plant
The I/A Series system measurably improves
performance.
plant-wide operations and performance by delivering the right information. It empowers
Top-to-bottom fault tolerance
reduces your total cost of ownership and guarantees to keep you competitive in
users to do their jobs better, faster, more
today’s evolving industries.
“Based on our review of the market, Invensys offers one of the broadest portfolios of products and services in the process automation industry. Their commitment to customers is exemplified in the recent enhancements to the I/A Series system—where they manage to provide an evolutionary migration path to the latest technologies without requiring customers to abandon their inv estment in earlier I/A Series systems.” Larry O’Brien, ARC Advisory
efficiently and cost effectively.
September/October 2012 | 25
Plant managers
• Live updating loop drawings
The I/A Series system meets all your
• One-spot engineering environment
to invoke additional tools to bring you more information. • Enhance the operator
process automation requirements and ensures that your plant continues to operate
• A common database integrating
experience - Comprehensive
at full capacity. The I/A Series system allows
system, control, display and field device
HMI software complemented with
you to:
configuration in one tool
ergonomically designed consoles provide a complete operator experience.
• Maximise plant uptime - Depend
Reuse intellectual property
Maintenance technicians
on maximum plant uptime with multilayer, fault-tolerant architecture.
Bulk generation and maintenance tools let
From top to bottom, the I/A Series system
you capture and reuse intellectual property.
offers superior designs for fault tolerance in the Mesh network, control processors,
I/A Series system’s powerful diagnostic, Reduce errors and rework
conventional I/O and fieldbus interface modules.
Ensure the health of your plant with the predictive maintenance and system management tools. The I/A Series system
The I/A Series system provides an
allows you to:
engineering environment that dramatically • Rugged, secure operation - And, because the I/A Series system was
reduces errors and associated rework, with a library of preconfigured strategies.
engineered for digital busses, our tight integration of FoxCom, HART,
• Stay connected - The Foxboro approach to fieldbus, complemented by FDT technology, provides connection to all
Leverage any field device
communication and fieldbus standards.
FOUNDATION Fieldbus, Modbus, Profibus and OPC at the I/O level delivers
Innovative FDT technology provides a
• Advance your diagnostics - Smart device
rugged, robust and secure field operation
single, open engineering environment
technology enables advanced diagnostics
while allowing for seamless integration of
to configure, commission and
and maintenance of valves and
new technologies.
manage field devices. Access the best
transmitters.
diagnostic capabilities regardless of • Access industry-leading know-how -
device type or manufacturer.
system is applied and supported by
Redefining plant intelligence Plant operators
Project Engineering team ensures that
The I/A Series system provides
your system is implemented on time, on
an environment that far exceeds
spec and on budget. To ensure continued
traditional workstations, by allowing you
system performance, LifeTimeSM services
to:
Plant engineers
optimise performance of field devices.
ArchestrA integration Designed to simplify engineering efforts
offer 24/7 global support, including around the world.
capabilities to commission, maintain, diagnose, replace and
superior industry expertise, the Foxboro
service centres strategically located
descriptor and FDT technology, the I/A Series system delivers advanced
the industry’s most knowledgeable experts. With proven capabilities and
• Advance your asset management capabilities - Using both device
Rest assured that your process automation
• Access real-time data - The I/A
and improve the user experience,
Series system allows quick and easy
Foxboro Control Software 3.0 embeds the
access to real-time data and historical
company’s ArchestrA® System Platform
records. The Foxboro Windows-
and Wonderware® InTouch HMI within
based workstation encourages the
the Foxboro I/A Series system, applying
The I/A Series system supports an
use of third-party applications for
common object technology from process
open engineering environment that
performance optimisation, advanced
control up to the business system level
saves time and costs, preserves existing
control, historical data collection, business
and out to any third-party system. This
engineering investments and intellectual
integration and more.
allows users to integrate all of their plant
property and minimises errors. The I/A Series system allows you to: Reduce time and costs I/A Series system configuration tools reduce
devices, systems, databases and software • Respond faster - The I/A Series system
integration with the latest advanced software
delivered securely and reliably via the
applications from Invensys, including
Mesh network, enabling fast, accurate
its mobile workforce management and
responses to potential problems.
workflow offerings, provide more systems
engineering time and costs with:
flexibility, adaptability and responsiveness, • See more data - The intuitive graphical
• A highly intuitive design environment • Graphical configuration
26 | www.protocolmag.co.za
applications. Additionally, enhanced
handles alarms in a smarter way,
helping to reduce total cost of ownership.
interface combines tight coupling
By enabling real-time access to critical plant
between process alarms and process
and business data, users are better able
graphics and extends the environment
to balance competing strategic objectives
Foxboro I/A series Distributed Control System – migration by design
related to controls, assets, environment
the world. It is a simple, elegant solution that
brands, including Avantis®, Foxboro,
and safety and people to optimise their
eliminates traditional marshalling panels as
SimSci-Esscor®, Triconex® and Wonderware®.
overall business and maximise operational
we know it.
Invensys Process Systems offers the
effectiveness.
industry’s only single, unified automation
Intelligent Marshalling
Continuously current then, today and tomorrow
Intelligent Marshalling is designed to greatly
For nearly a century, Foxboro automation
hardware and software, our solutions
reduce installation costs. With traditional
products have been innovating our industry
include powerful simulation software,
control systems, field wiring must be sorted
with technology firsts. Our groundbreaking
leading plant intelligence software, asset
out in a marshalling cabinet before it is
I/A Series system offers an ideal illustration
management, precision instrumentation and
connected to the main I/O module terminal
of this commitment to innovation and the
high-availability critical control. Combined,
strips of the DCS panel. It’s an inflexible
technology. Introduced in 1987, the I/A
they represent the most comprehensive suite
approach that often leads to expensive
Series system defied standard practices with
of automation solutions and performance-
indirect costs. But because the I/A Series
a system that continually redefines DCS
improvement services available from a single
Intelligent Marshalling solution features the
architectures.
vendor.
Get more from one with Invensys
We don’t just improve the performance of
and information platform covering all facets of plant operations. Along with high-performance process control
Universal Fieldbus Module, a per-channel, configurable I/O module that supports a variety of analogue and digital signal types, it eliminates the need for marshalling entirely.
isolated areas of your plant—we deliver measurable performance improvements
Today’s I/A Series system uses a
across your entire operation, including
Additional marshalling equipment, field
one gigabit, self-healing Mesh data
all of its processes, assets, people and
and control side wiring, engineering,
network that handles multiple faults,
sites. We do so by providing a unified,
documentation and inventory can account
provides more powerful control processors,
interoperable platform that’s easier and
for as much as 20 percent of the total project
delivers more integrated functionality and
more cost effective to implement, modify
cost. Unlike other control offerings on the
offers FDT technology. What’s more, it
and maintain. A platform that squeezes
market today, with Intelligent Marshalling,
seamlessly integrates with previous I/A Series
the most availability from your plant and
each channel is software-configurable on
systems, while preparing the way for the
helps you predict, prepare and most
a per-point basis, with no extra hardware
innovations of tomorrow’s I/A Series system.
importantly, prevent disruptions of your
required. All configurations can be done at
plant and profits. You’re armed with the
the workstation which means that a point
Invensys Process Systems is comprised of the
intelligence you need to make informed
can be securely configured from anywhere in
leading process automation and optimisation
business decisions, quickly and accurately.
September/October 2012 | 27
PR ES SR EL EA SE
Intelligent modernisation with the Foxboro I/A Series System Innovative Intelligent Marshalling and
supports a variety of analogue and digital
The new Foxboro Control Software
revamped Foxboro Control, HMI and
signal types, it eliminates the need for
Simulation 3.0 offering simulates Foxboro
engineering software make modernisation
marshalling entirely.
Control Software 3.0 applications for rapid, high-quality systems checkout without
faster, easier and more economically feasible
“Additional marshalling equipment, field
the need for control hardware. Simulation
As the core DCS component of the
and control-side wiring, engineering,
capabilities include dynamic control of
company’s InFusion® Enterprise Control
documentation and inventory can account
time, alarms and trends using the same
System, the latest I/A Series system includes
for as much as 20 percent of the total
configuration files that are used in a live
an innovative Intelligent Marshalling solution
project cost,” said Deon van Aardt,
I/A Series DCS. The software also provides
and high-performance Foxboro Control
Divisional Director, Invensys Operations
an instant interface to the company’s
Software and Simulation software, which
Management Southern Africa. “Unlike
SimSci-Esscor® DYNSIM®, Foxboro FSIM®
reduce total cost of ownership and expand
other control offerings on the market today,
and Triconex® TRISIM® dynamic simulation
traditional DCS functionality for superior
with Intelligent Marshalling, each channel
engines, which are used to simulate plant
collaboration, execution and visibility across
is software-configurable on a per-point
operations, behaviour and responses in
the enterprise.
basis, with no extra hardware required.
conjunction with the DCS or simulated DCS.
All configurations can be done at the
“The new I/A Series system allows users
workstation, meaning you can securely
“Process manufacturing is facing what
to begin their journey towards real-time
configure a point from anywhere in the
could be characterised as a perfect storm.
business optimisation by taking full
world. It is a simple, elegant solution that
The loss of experience as a result of the
advantage of their existing automation
eliminates traditional marshalling panels as
shifting demographics, the need to operate
systems, while preserving their existing
we know it.”
proactively rather than reactively, the
ability to empower knowledge workers
investments and lowering their total cost
of ownership,” said Mike le Plastrier, MD of
Designed to simplify engineering efforts
with actionable context and more are
Invensys Operations Management Southern
and improve the user experience,
all new challenges that require changes
Africa. “These latest offerings - Intelligent
Foxboro Control Software 3.0 embeds
in our processes and tools,” said Dave
Marshalling, which significantly improves
the company’s ArchestrA® System
Woll, vice president, consulting services,
the approach to system implementation
Platform and Wonderware® InTouch HMI
ARC Advisory Group. “With the Foxboro
and design and Foxboro Control Software
within the Foxboro I/A Series system,
Control Software 3.0 release, Invensys
3.0, which allows users to integrate their
applying common object technology
provides component-object technology
plant systems, databases and software
from process control up to the business
throughout the Foxboro I/A Series system
applications - address major phases of
system level and out to any third-party
up to the operations management level.
system modernisation and allow our
system. This allows users to integrate
Its open-technology platform transcends
customers to upgrade at their own pace
all of their plant devices, systems,
disparate systems, providing the unique
with minimal disruption. Together they
databases and software applications.
ability to collaboratively apply best-of-
link business processes with production
Additionally, enhanced integration with
breed solutions, from Invensys or third
processes, enabling real-time business
the latest advanced software applications
parties. This level of enterprise-wide
optimisation and creating a fully-
from Invensys, including its mobile
integration makes it significantly easier
empowered workforce.”
workforce management and workflow
to access, manage and contextualise
offerings, provide more systems flexibility,
information for a wide variety of operations
With traditional control systems, field wiring
adaptability and responsiveness, helping
users, allowing them to drive and deliver
must be sorted out in a marshalling cabinet
to drive lower total cost of ownership. By
greater production value in real time. We
before it is connected to the main I/O
enabling real-time access to critical plant
are also observing a strong resurgence
module terminal strips of the DCS panel. It’s
and business data, users are better able
with customers refocusing on cost of
an inflexible approach that often leads to
to balance competing strategic objectives
ownership and the preservation of their
expensive indirect costs. But because the
related to people, controls, assets,
investments over the lifecycle of their plants
I/A Series Intelligent Marshalling solution
environment and safety to optimise their
and systems. Maintaining focus on product
features the Universal Field bus Module, a
overall business and achieve operational
lifecycle management pays dividends for
per-channel, configurable I/O module that
excellence.
them in the long term.”
28 | www.protocolmag.co.za
Raising the bar on scalability
Raising the bar on scalability Modernisation includes taking every precaution to prevent the current situation from reoccurring at a future date and that means understanding the true nature of scalability. Phil Couling, Product Marketing Director, Supervisory HMI, Invensys Operations Management explains.
1. Introduction The term “scalability” has been so overused in regard to industrial software systems that most users, integrators and decision makers are completely desensitised to its use. Those same individuals, however, care deeply about true scalability. Scalability is not merely starting small and growing big. There
Figure 1: The challenge of scalable functionality
are many dimensions to consider and most are critical to true investment protection for
future, simple to complex, single piece of
implementation and grow to the size needed,
the end user. This white paper will explore
equipment to entire enterprise. Meeting
when needed, with modest incremental effort
these dimensions of scalability and hopefully
those requirements demands a level of
and without increased risk?
set a new expectation for scalability for
architectural design of automation and
industrial software system purchasing
information systems that is purposefully
Traditionally, the underlying software
decisions in the future by “raising the bar”
constructed to support scalability in all
platform has been an enormous constraint;
on scalability.
dimensions. Those kinds of demands cannot
small systems simply have not been
be met by “bolting on” interfaces, repeating
designed to grow into large systems
expensive design work or rip-and-replace
without completely replacing the underlying
tactics. The result would be inadequate and
architecture (see Figure 1). Wonderware
Automation and information systems
unbearably costly. To meet that challenge,
breaks this tradition with a truly scalable
represent a major investment for all
Invensys, through its Wonderware®
software platform called ArchestrA, which
industrial businesses, large or small.
business, embarked on the development
effectively removes these constraints
Long-term protection of that investment is
of ArchestrA® technology, a software
and enables a smooth evolution of the
a significant consideration when selecting a
architecture designed to be inherently
software solution from small to as large as
partner and a system. Though technology
scalable in all meaningful dimensions.
the business requires, without replacing
lifecycles may precipitate change, it is
Wonderware software solutions leverage
the underlying technology. At the heart of
extremely important to be able to evolve
the powerful capabilities of ArchestrA
ArchestrA is a plant model, which supports
solutions over time, expand them into
technology, ensuring remarkable ease-of-use
the gradual evolution of an application
previously unforeseen areas, and integrate
and scalability.
by permitting additional attributes and
2. The challenge
them with other systems which may or may not already be in place. In many cases, it is
functionality to be added to the solution and
3. Functional scalability
also important to consider the ramifications
deployed throughout the operation from any given development station.
of potential merger or acquisition activity
Traditional small projects involve low initial
and how systems may be affected by that
cost, low risk and short implementation time,
eventuality.
all important characteristics. However, many
4. Solution scalability
small projects are difficult to functionally
Growing a system from small to large
All the while, businesses must stay focused
extend and very difficult to scale. In
requires another dimension of scalability
on protecting intellectual property,
contrast, traditional large projects are more
in addition to functionality. True scalability
minimising disruption to operations
functionally complete and enjoy full-scale
demands that a solution can be easily
and doing so cost-effectively. These
implementation, but they have much
extended from a single, simple application
requirements match system characteristics
higher initial costs, require much longer
— perhaps a single machine — to a
along dimensions of scalability, from
implementation time, and carry much higher
comprehensive networked solution serving
small to large, one to many, current to
risk. Wouldn’t it be nice to start with a small
the needs of an entire multi-plant industrial
September/October 2012 | 29
of abstraction from the specific devices is required. The ArchestrA architecture offers outstanding integration with a vast array of devices while providing true abstraction from the details. What does this mean in practice? Well, it means for example, that a device-independent application could be developed for a project using one specific family of PLCs, making use of all of the connectivity capabilities provided by that device. The challenge comes when it is necessary to automate a similar area at a facility — one that was built at a different time and uses a completely different family of PLCs and automation equipment. With Wonderware’s DA Server (Data Access Server) and DI Object (Device Integration Object) capabilities, the software application can be easily re-purposed for a different family of hardware devices without changing the application. Multiply that efficiency over many pieces of equipment and many different hardware systems, and the result is a truly Figure 2: Overview of a Scalable Connectivity and Software Integration architecture.
scalable software solution. Of course, implementing the application is just part
enterprise. What if it is necessary to have
one. In the same way that each department
of the effort. For effective scalability,
multiple supervisory applications that are
in an organisation needs to integrate and
it is necessary to be able to configure,
different but have similar components, and
collaborate smoothly, supervisory systems
monitor and run diagnostics on multiple
must be kept separate but benefit from
need to integrate and enable collaboration
I/O interfaces from a convenient central
each other’s design? What if the applications
with other systems in an industrial enterprise.
location. Wonderware’s device connectivity
must be able to operate, change and grow
Effective industrial software solutions must
architecture provides comprehensive
independently?
be capable of efficient, scalable integration
remote management capabilities, built-in
with enterprise-level systems such as ERP,
diagnostics and flexibility to deploy in
This is a real-world scenario for which
Supply Chain Automation, Enterprise Asset
a variety of architectural topologies to
the ArchestrA architecture and the
Management and other corporate systems
suit the needs of the industrial enterprise
ArchestrA System Platform were designed.
for planning and reconciliation. Invensys’
— the hallmarks of a truly scalable
Wonderware has combined the most
strong commitment to standards — and
infrastructure.
powerful capabilities of object-oriented
continued active involvement in defining
plant modelling, InTouch®, the world’s
industry standards — means that integration
ArchestrA technology enhances scalability
favourite graphical HMI (Human Machine
and scalability are built into all Wonderware
through the separation of application code
Interface) and unparalleled device
solutions. Standards such as XML, OPC® and
from device communications management,
integration capabilities. This combination
SQL are complemented with Web Services
so that both can be easily managed and
provides maximum re-use of engineering
and ISA-95/XML B2MML support
updated:
effort where appropriate, with flexibility
(see Figure 2).
where required; common application logic
• Takes a flat communications model and
with device-independence; consistent
Vertical scalability also means scaling to
application visualisation with security and
the plethora of field device connectivity
application-specific detail; all of which
requirements that exist today. While
can be deployed and managed from a
supervisory systems may provide interfaces
available globally for any application to
centralised, standards-based environment.
to physical devices such as RTUs and PLCs,
use
adds structure and better manageability • Makes individual communication paths
these interfaces are typically simplistic and
5. Vertical scalability
foster integration solutions which are closely
• Enables communications and device
tied to the physical hardware. To achieve
naming to be different for the same
A supervisory system is just one part of an
true scalability for device connectivity, a
application, facilitating re-use on any
industrial operation, albeit a significant
software architecture that provides a level
machine
30 | www.protocolmag.co.za
Raising the bar on scalability
6. Horizontal scalability Supervisory systems do not operate in isolation. They need to integrate smoothly and reliably with a wide range of peer-level systems including MES, DCS, Historians, LIMS, Workflow, Field Mobility Solutions and Quality Management systems. Historically, the solution to these kinds of integration tasks has frequently consisted of crude interfacing attempts using proprietary interfaces, middleware and limited data-level integration. These approaches, while barely satisfactory for standalone solutions, are the antithesis of scalability, requiring custom engineering approaches and significant expenditure for system integration work. A truly scalable solution for horizontal integration of this kind requires a purpose-built integration architecture. Wonderware InTouch and ArchestrA System Platform supervisory solutions are designed with scalability and integration capabilities built-in (see Figure 2). Embracing standards such as OPC, SQL, OLE DB/ADO and XML with an object-oriented architecture has enabled
Figure 3: Model View and Deployment View
Wonderware to deliver the most easily scalable industrial software solution set
Training, skills and familiarity with
powerful MES, workflow and mobile
available.
automation systems in one area of
solutions, Wonderware has set a new
operation are immediately transferable
benchmark for combining ease-of-use with
to different areas. This kind of scalability
unparalleled scalability.
7. “Baked-in” scalability
delivers tremendous economies of scale as Traditionally, scalability cannot be added
automation solutions are rolled out to new
To learn more about Wonderware’s
into operational systems after the fact. True
areas of the operation. A unique, logical
Supervisory HMI Software Solutions, visit
scalability comes from purposeful design.
abstraction through a model view versus a
http://global.wonderware.com/EN/Pages/
Legacy systems can be integrated into a
deployment view (see Figure 3) provides
WonderwareHMISCADA.aspx
scalable infrastructure, but the real benefits
unsurpassed capabilities to retain and re-use
come from starting with the right software
engineering efforts put into a system, while
platform. The ArchestrA System Platform was
increasing application functionality, one step
developed from the ground up to provide
at a time.
ease-of-use from day one and scalability for the lifetime of the operation. This “baked-in”
8. Summary
scalability comes from a powerful, pragmatic, object-based engineering environment
Ease-of-use and scalability are two of
that enables valuable engineering and
the most important characteristics of a
best practices to be re-used and securely
supervisory software solution. Combined
deployed across multiple facilities — without
with outstanding functionality and
physically visiting each facility. This scalability
connectivity, it is these characteristics which
also comes in the form of centralised
provide real investment protection for the
management which permits oversight,
future. Wonderware software’s scalable
configuration, diagnostic analysis and security
design and easy-to-use tools uniquely
management of entire automation systems
embody these characteristics — specifically,
deployed across numerous computers that
the powerful ArchestrA System Platform
are geographically distributed across a multi-
and InTouch visualisation tools. With the
site industrial enterprise.
broadest range of integration options,
September/October 2012 | 31
They looked, they leaped and they’re grateful It’s always a good idea to look before you leap and these companies did just that – and you can bet they looked quite hard at the options they had for modernising. The end result in all cases is success and a sense of excitement at the new opportunities that present themselves.
32 | www.protocolmag.co.za
Legacy system migration: Improving the opportunities
Legacy system migration: Improving the opportunities Before reading some of the success stories, see what a few of our
“We chose to implement Foxboro intelligent remote I/O because of
customers have to say about some of the projects we helped them
the increased architectural flexibility and lower cost it provides”.
bring to a successful conclusion:
Luiz Renato Chagas Figueiredo, Automation Manager, Aracruz Celulose
Power generation “By choosing to go with Invensys, we made the decision to utilise
Control system upgraded: Honeywell TDC3000 “Our BMS migration from Bailey Symphony to the Foxboro I/A
their products for future modifications or upgrades... We expect
Series Distributed Control System went very smoothly. Checkout of
that it will also ensure a high degree of reliability in the future.”
the new BMS was substantially complete within three days.”
Mike Considine, Project Leader, Ontario Power Generation.
Huitt Manering, Principal Engineer and Task Manager, BC Hydro.
Control system upgraded: Leeds & Northrup
Control system upgraded: ABB Bailey
“The percentage of time the operators had to devote to regulating and manually intervening with the old control system had been relatively large, leaving them less time to focus on enhancing unit
Sterling Chemical Q&A session with Automation World
performance. Now, with the new Foxboro I/A Series Distributed Control System, the operators can spend more time focusing
“We went with Invensys, as they had lowest cost migration option
on other issues for enhancing the performance of the unit.
that minimised downtime. This was based on detailed evaluation
Performance on the parameters is much better than before our
of three vendors’ migration solutions (including the OEM). We
retrofit. Our control range is well within — or very near — our
compared and selected a solution with no rewiring. We were able
target and deviations are much less than with the old system.”
to retain all field wiring, I/O cabinets, terminations and power
Joe Chow, Plant Manager, Castle Peak Power Station.
supplies.”
Control system upgraded: Alstom & Babcock “Invensys has a “Continuously Current” philosophy maintaining “The migration approach offered by Invensys Operations
support for products (no “Dear John” letters).”
Management showed that an alternative to the existing vendor’s upgrade solution was a viable option.” Hugh Ferguson, C&I Engineer & DCS Upgrade Project Manager,
“The project cost met budget within contingency – a significant savings compared to a bulldoze solution.”
Keadby Power Station SSE. Control system upgraded: Westinghouse WDPF
“Here is what we learned. Do your due diligence on different vendors’ migration strategies and select the one that best meet
“It’s all about keeping our automation system continuously current.
your business condition and plan. Choose the right people for
The days of being locked into a multimillion dollar control system
the project team – process engineer and supervisors, I/E project
that must be replaced every 10 or 15 years are over. The I/A Series
engineer and designer, I/E maintenance supervisor and technician
system provides us an open, flexible digital control platform which
and DCS engineer and technician”
can add the automation that is right for our business, as we need it.” Brian Sumner, Maintenance Manager, Kentucky Utilities E.W. Brown Station. Control system upgraded: Westinghouse WDPF
“On top of all this – emphasise training, both formal and during loop checkout and commissioning. Do the factory acceptance test – no short cut, well planned and executed.”
Pulp and paper Dennis Yieh, Sterling Chemical “The level of engineering start-up, system commissioning and site support from the Invensys Operations Management application engineers, service engineers and technical team was outstanding.” Mike Armstrong, Electrical and Instrumentation Manager, Cascades Tissue Group. Control system upgraded: ABB Accuracy Model 1180 QCS and Honeywell SLC
September/October 2012 | 33
And now for what one of the world’s leading consultants has to say: Frost and Sullivan 2010 Global DCS Client Value Enhancement Award Catering to the DCS migration challenge
Troubleshooting without affecting the production schedules
“One of the key reasons for Invensys’ stable performance is its I/A Series system offering. The Foxboro Plug-In migration solution
“Due to the reversible and non-destructive nature of the Foxboro
is one such solution which caters exactly to the DCS migration
migration solution, any troubleshooting services, if required, are
challenge, providing users with a competitive legacy system
carried offline by the Invensys’ service engineers without affecting
installed a path to the latest Foxboro I/A Series system”.
the production schedule of the customer. Additionally, Invensys is
ROI with Foxboro plug in migration
customers, further enhancing its service capability.”
the sole manufacturer which enables a free migration audit for the
“A bulldozer upgrade which involves replacing an old system completely with a new system costs the customer a huge amount. The savings associated with the Foxboro Plug-In migration as compared to a bulldozer upgrade is $ 550 per I/O point. So, typically a system with 1000 I/O points amounts to a savings of $ 550,000.”
34 | www.protocolmag.co.za
Lonmin migrates its vast SCADA resources from iFIX to ArchestrA
Lonmin migrates its vast SCADA resources from iFIX to ArchestrA “In my view, the most outstanding features of this new system include the management of standards, its scalability and the ability to do development work on multiple fronts with multiple SIs simultaneously.” Percy French, Automation Manager, Lonmin Smelter
Goals
Solutions and Products
• Replace existing iFIX SCADA system with a modern, supported
• Wonderware System Platform
solution that would provide world-class technical and operational functionality
• Wonderware Historian
• Develop plant and company standards
• Wonderware InTouch HMI/SCADA
Challenges
Results
• Reconfiguring 300 000 I/O and redeveloping 530 SCADA screens
• Enhanced performance
without loss of production • Single set of standards • Prove the effectiveness of the chosen solution against all others and the ability of Lonmin to own the solution
• Easier maintainability
• Tight time and budget constraints
• Superior reporting and delivery
• Concurrent running of old and new systems
• Fully-supported and constantly-current software
• Simultaneous development by multiple SIs
• Ensured continued operation of production processes
September/October 2012 | 35
Figure 1: System topology
Lonmin’s huge plant in Marikana near
legacy to modern technology but that would
different system. This wasn’t an upgrade
Rustenburg is in the business of mining and
also provide the future-proof scalability and
but a replacement of extensive facilities
processing some of the most costly minerals
flexibility they were looking for.
(300 000 I/O would have to be reconfigured and 530SCADA screens would need
available today – platinum and the family of platinum group metals. This is a non-stop
Project goals
redevelopment using the new automation standards library that would have to be
operation that relies on the effectiveness of a vast control system which, in this case,
The goal of this project was to replace
developed). And it all had to be achieved in
was approaching the end of its useful life.
the existing iFIX SCADA system at the
a short period of time with the ever-present
Lonmin looked for a solution that would
Lonmin platinum smelter in Marikana,
threat of production losses.
not only provide a risk-free migration from
with a modern, supported solution that
“As far as I know, the approach to this project was and still is unique in the market where Wonderware’s technical knowledge was used to develop best practices which multiple system integrators then used to develop the solution working from different locations.” Percy French, Automation Manager, Lonmin Smelter
36 | www.protocolmag.co.za
would provide world-class technical and
Yet another challenge was the necessity to
operational functionality and allow Lonmin
prove the capabilities of the chosen solution
to define, deploy and maintain automation
vis-a-vis all competitors regarding the
standards while improving system up-time
technology used (standards management
and on-line development time. In other
and performance), the supplier’s support
words, the project needed to deliver an
capabilities and Lonmin’s ability to own and
award-winning SCADA migration using the
control the solution.
best functionality the chosen product could offer, on time and within budget constraints.
The existing PLCs were to remain and the plant should not be stopped at any time
Risk management and other challenges
during commissioning therefore the old and new system would need to be run concurrently until the operational personnel
Lonmin considered that this was a very risky
was satisfied that the new system had at least
project mainly because of the move to a
the same functionality as the old system.
Lonmin migrates its vast SCADA resources from iFIX to ArchestrA
Lonmin at a glance Lonmin is one of the world’s largest primary producers of Platinum Group Metals (PGMs) which are essential for many industrial applications, especially catalytic converters for the control of internal combustion engine emissions. PGMs also have a widespread use in jewellery. • Lonmin’s operations are based in the
Figure 2: The standards development process
North West and Limpopo provinces
Solution selection Although Wonderware was already a
Historian, it was important that all system
of South Africa and comprise 14
integrators were certified professionals in all
extraction shafts, 9 concentration
these products.”
de-facto standard with Lonmin, persisting with this brand would only be considered
plants as well as extensive smelting and refining facilities.
Implementation
if their solutions met the system design
• Resources include 175 million troy
and performance criteria as well as all
The project was implemented over 8 plant
ounces of PGMs and 43 million
project requirements. Another factor in
areas (each with dedicated redundant servers),
ounces of reserves
Wonderware’s favour was the additional
11 operator / control room view stations, 10
software the company could offer to
remote panel view stations and 25 manager
add benefit to the installation. Once the
view-only stations linked to Terminal Server.
Wonderware offering had proved that it
• The number of full time employees is around 27,800 (year ending 30 September 2011)
would address the required issues, the
The scope of the project was split into two
company was appointed to manage the
major components, where Wonderware
project as a whole.
managed the project end-to-end, developed
• Lonmin has a primary listing on LSE and the JSE
the User Requirement Specification, the “It was important that the delivery of the
detailed design specification, developed
project was still done through our channel
the necessary templates and was also
partners while minimising risk,” says Percy
responsible for the quality control of the
PGMs) produced and 721,000 ounces
French, Lonmin automation manager at
delivery of the project. Wonderware
of Platinum sold (year ending 30
the Marikana smelter. “So Lonmin followed
appointed Jaco Laubscher of Realization
September 2011)
stringent selection criteria and, because
Africa as the full-time project manager
of the large scale of the project, Control
and allocated consultants to develop
Systems Integration, Hatch Africa, Iritron
the required documents as well as all the
past and their experience and participation
and Quad Automation were the system
required standards. Wonderware Southern
would contribute to the delivery of a
integrators selected for the implementation
Africa also teamed up with the Global
successful project.
while Wonderware Southern Africa managed
Delivery Team from Wonderware in the USA
the project. Since the new system would be
in order to leverage their capabilities in
The second major component was
based on the Wonderware System Platform
developing an ArchestrA Standards Object
regarding the templates that were be used
using ArchestrA technology as well as
Toolbox for Lonmin. This US team had
to develop and instantiate the necessary
InTouch SCADA / HMI and the Wonderware
completed a number of these projects in the
SCADA screens, modifications to the PLC
• 719,000 ounces of platinum in concentrate (1.436m ounces of total
September/October 2012 | 37
while the third SI tackled the converters, the
integrating QI Analyst for Statistical Process
SO2 plant as well as the Wonderkop and MV
Control and using the Information Server
substations.
portal to publish graphics and reports.
A unique navigation and menu system was
Benefits
developed that would be intuitive for the operators and that would need the minimum
• Enhanced performance
of keystrokes to access the required functionality. The system is connected to the
• Single set of standards
plant’s intranet which has control room and remote office viewing nodes. Drivers from
• Easier maintainability
Software Toolbox were used throughout and the old and new systems ran concurrently
• Superior reporting and delivery
until the team was comfortable to switch over. There was no change to the PLC code.
• Fully-supported and constantly-current software
“In my view, the most outstanding features of this new system include the management of standards, its scalability and the ability to
• Ensured continued operation of production processes
do development work on multiple fronts with multiple SIs simultaneously,” says French.
Conclusion
“This allowed accelerated development with the project starting in October 2010
The modernisation of any company’s core
and the migration being completed by
wealth-creation processes is justifiably
July 2011 and we’ve been busy with a
looked upon with trepidation by production
programme of ongoing enhancements
and financial management alike. Production
$202 905 or R1 677 925 / ingot as on
ever since. In hindsight, it would have been
management is worried because of the
21 July 2012
even more expedient to bring the various
magnitude of the task and the ever-present
SI development teams to a single location
threat of production stoppages. Financial
code in consideration of the new ArchestrA
rather than have them work remotely since
management is concerned about the
objects and finally, the ArchestrA objects
this would have helped resolve issues
expense of such a move and is also worried
themselves, all of which was completed by
quicker.”
about the loss of income and goodwill production stoppages could cause.
selected SIs. These ArchestrA objects would form the Lonmin toolkit which would be
Regarding the development, deployment
used by the SIs later in the project.
and maintenance of standards, French said
This large SCADA modernisation project at
that they could always be improved but
Lonmin’s Marikana plant categorically proves
Three SIs were appointed to instantiate the
there came a time when a design freeze
that migrating from a legacy system to
templates on the estimated 530 SCADA
needed to be imposed to prevent delaying
modern technology can be done without any
screens using System Platform graphics and
the project. “It’s best to regard standards as
interruption to production, no matter how
300,000 I/O items on the plant. The plant
evolving entities that will be refined on an
complex or critical, and that any financial
was divided into 3 equal parts in terms of I/O
on-going basis after system commissioning.”
concerns are dwarfed by the confidence that the company’s wealth-creating machinery
with the first SI responsible for the slag plant, the receiving and blending section and the
Future plans include enhancing the graphics,
will continue to operate uninterruptedly for
filter plant. The second SI was responsible
review the alarm strategy, incorporating
the foreseeable future.
for furnace No. 1, utilities and Pyromets
various capital projects into the system,
38 | www.protocolmag.co.za
BC Hydro gets upgrade from ageing Bailey control system to Foxboro I/A Series DCS
BC Hydro gets upgrade from ageing Bailey control system to Foxboro I/A Series DCS
“Our BMS migration from Bailey Symphony to the Foxboro I/A Series Distributed Control System went very smoothly. Checkout of the new BMS was substantially complete within three days.” Huitt Manering, Principal Engineer and Task Manager
Goals
Solutions and Products
• Replace obsolete Bailey control system to increase efficiency and
• Foxboro Distributed Control System - I/A Series
reliability of power generation • Foxboro Measurement & Instruments • Improve and optimise unit heat rates
Results • Centralise plant controls in one room • Provides clean energy to more than 1.6 million customers • Provide a real-time focus for plant operation and improve process control
• Decreased maintenance time/effort, BMS checkout was reduced from three weeks to three days
Challenges • Reduced upgrade costs by half and shortened downtime from weeks • Continue delivering reliable power with the least possible
to days
environmental impact to its growing base of commercial and residential customers
September/October 2012 | 39
The route to a simple solution is usually extraordinary Get an end to end solution tailor-made for your business with Business Connexion’s Professional Services When it comes to making extraordinary connections, nothing comes close to the human brain. That’s why it’s the inspiration behind our Professional Services. With our unique understanding of your business model, value chains and strategy, we can supply you with an end to end solution that helps you make the most of your Business Processes, Applications Portfolio, Application Management and third party solutions. With our unique integrated solutions, we can help you build systems that enable you to enhance and grow your business. We call it the amplifying power of Connective Intelligence™.
www.bcx.co.za 40 | www.protocolmag.co.za
September/October 2012 | 41
British Columbia, Canada BC Hydro provides high-value, reliable power
the selective cathodic reduction technology
upgrade costs by almost half and shortened
installed in 2000 to reduce nitrogen oxide
downtime from weeks to days.
emissions by 90%.
to fuel economic growth and development
Invensys also provided the BMS design and
throughout Canada’s British Columbia
Besides repairing these deficiencies, other
the boiler/generator coordinated controls,
province. The utility provides energy
upgrade objectives included improving
as well as balance-of-plant (BOP) controls
solutions to more than 1.6 million customers
and optimising unit heat rates, sustaining
and seamless integration with data from new
in a socially responsible way, balancing its
required availability, centralising plant
safety systems and other on-site third-party
users’ energy needs with environmental
controls in one room, providing a real-time
systems. In addition, Invensys handled
concerns. BC Hydro has constructed a world-
focus for plant operation and improving
the upgrading of Foxboro intelligent field
class integrated hydroelectric system of close
process control. Requirements also included
transmitters and intelligent valve positioners.
to 11,500 megawatts of generating capacity
a burner management system (BMS) and
— over 87% of which is hydroelectric. Due
upgraded boilers.
to this efficient, reliable system, British Columbians enjoy some of the lowest electricity rates in the world.
BC Hydro’s challenge
Upgrade and easy migration to a Foxboro I/A Series Distributed Control System
Delivering higher levels of control and efficiency The migration enabled Burrard’s system engineers to retain existing field wiring terminations, system enclosures and power
After comparing proposals from
supplies. Their new system delivers a major
To continue delivering reliable power with
Bailey, Fisher and Invensys Operations
leap in functionality and ease of use in startup,
the least possible environmental impact to its
Management™, BC Hydro determined
runup, rundown and runback sequences.
growing base of commercial and residential
that a Foxboro plug-in migration solution
customers, BC Hydro implemented an
would provide the greatest reliability and
Huitt Manering, Principal Engineer and
ambitious environmental improvement
performance at the lowest cost with the least
Task Manager, said, “Invensys developed
and plant modernisation initiative. A vital
interruption of service.
a new discrete I/O module to meet our
element: migration to a modern digital
requirements and the result was a well-
control system at the utility’s Burrard
Rather than “bulldoze” the existing
designed card that was delivered on time
Generating Station in Port Moody, on
infrastructure — a costly and highly
for our first installation. Our BMS migration
Vancouver Harbour.
disruptive alternative — BC Hydro was
from Bailey Symphony to the Foxboro I/A
able to implement the Foxboro I/A Series
Series Distributed Control System went very
Supplementing the utility’s 32 hydroelectric
Distributed Control System on its legacy
smoothly. Checkout of the new BMS was
facilities, Burrard is one of two thermal plants
racks, without rewiring. The Foxboro
substantially complete within three days —
that supply critical base load support to the
migration solution simply replaced
as compared to approximately three weeks
electrical grid in years of low water run-off
the Bailey I/O modules with I/A Series
for the initial Bailey BMS commissioning.”
or during maintenance outages. Each of the
electronics packaged in the exact same
station’s six gas-fired CE boilers generates
form factor. Most of the actual migration
Burrard operations personnel report the
155 MW. However, its obsolete Bailey control
then involved simply substituting the
new I/A Series System is delivering levels of
system was becoming increasingly difficult
repackaged I/A Series I/O modules for those
control and efficiency higher than they have
to maintain. It also jeopardised operation of
from Bailey. This unique approach reduced
ever experienced before.
42 | www.protocolmag.co.za
Invensys powers UK electricity demand at SSE
Invensys powers UK electricity demand at SSE
“The migration approach offered by Invensys Operations Management showed that an alternative to the existing vendor’s upgrade solution was a viable option.” Hugh Ferguson, C&I Engineer & DCS Upgrade Project Manager, Keadby Power Station
Jonathan Thacker - http://www.geograph.org.uk/photo/2006958
Goals
Challenges
Control System
• The company needed to address
• Incomplete loop drawings, faded
• SimSci-Esscor® ROMeo Online
the obsolescence of its existing DCS
conductor identity and the risk of human
and to provide an expandable solution
error during I/O change-out were
to extend the working service life of its
considered significant upgrade obstacles
Keadby Power Station
Performance Suite • SimSci-Esscor Dynamic Simulation Suite Results
• Limited documentation available on • The vendor needed to deliver the
existing software applications presented
• The Invensys solution was delivered on
total upgrade solution in time for a
software migration and testing dilemmas
time for the planned outage and within
planned major shutdown and in parallel
for the project team.
the SSE budget for the project.
with other plant projects, with minimal commissioning time
Solutions and Products
• The upgrade addressed both the obsolescence and expandability issues.
• InFusion™ Enterprise Control System (the first major InFusion solution in the UK)
• Plant personnel realised major benefits of simulation, including improved
• Foxboro® I/A Series® Distributed
operator training and familiarisation and the facility now has a rigorous test-bed for process testing.
September/October 2012 | 43
Scunthorpe, North Lincolnshire, United Kingdom
contractor, SSE also maintains over
As planning progressed, it became
one million lights.
clear that the DCS upgrade had to be
The River Trent has a history of changing
The company has a total of more than
maintenance activities as well as other
course over the ages, with mention of
11,300 megawatts of capacity, 2,000
expansion projects. Furthermore, site
its meanderings even in the works of
megawatts of which is installed renewable
works needed to take place with minimal
William Shakespeare. Once a major
capacity. As such, SSE is the UK’s second
disruption to the outage programme. A
commercial waterway marking the
largest generation business overall and
risk assessment of the project requirement
traditional boundary between Northern
the largest generator of electricity from
identified two key areas of concern: the I/O
and Southern England, the river is
renewable sources. SSE, formed with the
upgrade and application software migration.
relatively stable today and is the source
merger of Scottish Hydro Electric and
For the I/O upgrade, plant engineers at
of recreation and drinking water, as well
Southern Electric, also has an ownership
Keadby cited challenges such as faded
as cooling water for a large number
interest in more than 100 thermal and
conductor identification labels, incomplete
of coal- and gas-fired electrical power
renewable power stations.
loop drawings, human error risks and the
conducted in parallel with essential major
plants along its route. One of those plants,
potential impact on the outage programme
Shining the light on a new infrastructure approach
associated with on-site rewiring and testing
United Kingdom. The Keadby plant, which
Before the upgrade, the majority of
“Although the existing system had
began commercial operation in 1996, is a
the plant was operated by a site-wide
been reliable in the past, problems
720-megawatt combined-cycle gas turbine
Emerson WDPF (Westinghouse Distributed
were emerging,” said Hugh Ferguson,
generating facility.
Process Family) DCS system. A moderate-
C&I engineer at Keadby Power Station
sized control system, this included 26 fault-
and project manager for the DCS
The Keadby power-generating plant
tolerant controllers; 12 HMI workstations,
upgrade project. “An increasing number
includes two General Electric frame
including one historian and comprising
of components were either no longer
9FA gas turbines, one Alstom steam
6,046 hardwired I/O, eight control
available or no longer repairable. Plus,
turbine, two Babcock three-pressure
level data links (Modbus, Allen-Bradley
controller memory was near capacity
waste heat recovery boilers and a
DH+, GE-GSM); three supervisory level data
and most of the data highway bandwidth
Siemens GT10B auxiliary gas turbine. It
links (Modbus-TCP, ODBC, OSI-PI); and 190
was already utilised.”
is maintained and operated by a staff of
process screens, including approximately
53 including managers, engineers and
130 overlays and 48 sequences.
Keadby Power Station at Scunthorpe in North Lincolnshire, is operated by SSE, one
of approximately 6,000 loops.
of the largest energy companies in the
technicians. When SSE management
Migration of the application software was also considered a potential problem
realised the facility’s Distributed Control
SSE engineers initially identified 7 key
area. Documentation was limited and
System was approaching plant-
criteria for the DCS upgrade project at
there were no control narratives available.
wide obsolescence, the company chose
Keadby Power Station. Top of list was
This meant that the application software
Invensys Operations Management
that the upgrade had to be completed in
itself had to be used as the source for the
to upgrade the plant to a more
time for a scheduled major plant outage
migration process raising concerns over
flexible, scalable and supportable
and the system migrated with minimal
the potential for human error, the skill-sets
solution.
site commissioning time. In addition,
required and the functional acceptance test
the new DCS system had to address
criteria.
SSE is a vertically integrated energy
the pressing obsolescence issues and
utility and is involved in the generation,
remain current for the remainder of the
Based on the potential obstacles, it was not
transmission, distribution and supply
plant’s expected service life. Sufficient
clear whether there was an alternative to
of electricity as well as the storage,
expandability in terms of controller
upgrading to Ovation, the next generation
distribution and supply of natural
memory, I/O capacity and network
of the WDPF platform. However, because
gas, telecommunications, contracting
bandwidth together with simplified
of concerns over software acceptance
and energy services. SSE has more than
online configuration was also considered
testing and continued support for the
10 million customer accounts in the UK,
a key requirement. Because of the
existing I/O hardware, SSE decided to
supplying natural gas and electricity
potential impact on operating procedures
go out to Tender for the project.
to more than 3.5 million homes and
and other human factors, engineers also
businesses. It owns the UK’s largest
specified that the new plant solution should
Six DCS vendors pre-qualified for
onshore gas storage facility at Hornsea
maintain the existing control strategies and
the proposed migration project, with
in East Yorkshire and is currently building
HMI interface standards.
four vendors asked to present formal
a new, larger facility at Aldbrough. In addition, the company has one of the largest electrical contracting businesses in the UK, operating from 60 regional offices. As the UK’s largest street lighting
44 | www.protocolmag.co.za
technical evaluations of their proposed
Upgrading systems in harmony with existing operations and upgrades
solutions. Invensys Operations Management was ultimately selected by SSE because of their
Invensys powers UK electricity demand at SSE
proven plug-in I/O card migration solution
further enhancement the system including
demonstrate the validity of the resulting
for WDPF, WDPF migration expertise,
Sequential Function Charts for DCS
process simulation.
in-house simulation capabilities and the
sequences and the ROMeo Online
incorporation of a model-based plant
Performance Suite for plant performance
Te DCS and OTS teams joined together for
simulator for application software testing
metrics.
the integration and testing phase. The DCS
and operator training.
Invensys mastery of the migration process
controls and third-party gas turbine controls ROMeo is an advanced, unified modelling
(GE-Mark-Vie) were loaded and I/O cross-
environment delivering online optimisation
references between these and the process
applications to help users obtain peak
model were built and verified.
performance from their operating units. Invensys WDPF migration-style FBMs
ROMeo offers process optimisation
“Plant simulation greatly assisted the
are a plug-in replacement for WDPF
across an entire enterprise with
software migration process and allowed us
Q-Line I/O cards which allow the existing
online modelling and equation-based
to catch a number of software integration
WDPF I/O racks, power-supplies and
optimisation capabilities providing more
issues before the system was accepted
field wiring to be retained and re-used
accurate, current operating information
for installation on site. I am therefore
by the new Foxboro IA system. From an
to better manage changing market
convinced that without it, the plant would
IA system perspective, these modules
pressures, product values, energy costs and
not have returned to service as smoothly
appear identical to standard Foxboro
equipment performance.
as it did and would certainly have required
200-series FBMs.
much more commissioning time,” said “The migration approach offered by
Hugh Ferguson. “But if you are using a
Semi-automated tools were offered to
Invensys Operations Management showed
simulator for software acceptance testing,
migrate the Westinghouse application to
that an alternative to the existing system
avoid integrating DCS code too early since
the Invensys InFusion environment. InFusion
was a viable option,” said Hugh
(just like on the real plant), control updates
is the Invensys delivery mechanism for
Ferguson. “Simulation is also proving
often take time, particularly if they require
enterprise control and consists of the
particularly useful at resolving hard-to-
additional (virtual) plant run-ups to install
hardware and software components
replicate problems and was invaluable
or test.”
necessary to provide a true aggregated
in leveraging the experience of plant
view of information across an
operators during migration of the
Virtual plant commissioning was
organisation, enabling a robust foundation
application software.”
implemented on a plant area-by-area
for collaboration between people, processes and systems.
basis; Balance of Plant 1, Balance of Plant Initially, migration of the DCS application
2, Gas Turbines, Waste Heat Recovery
software and development of the OTS
Boilers and the Steam Turbine. Virtual plant
The SimSci-Esscor Dynamic Simulation
plant model were undertaken as separate,
commissioning on the Simulator mimicked
Suite provides both model-based plant
parallel activities by separate Invensys
that which would have occurred on the real
simulation and a platform for enabling a
project teams. Once completed, these two
plant and included plant pre-start, start-up,
complete Operator Training Simulator
elements were then combined to allow
steady-state operation and shutdown by
(OTS) solution comprising virtualised
functional testing in the Factory, prior to
an experienced Keadby operator. Once it
DCS control processors, interfaces to
installation at site.
had been demonstrated that it was possible
third-party virtual controllers and a
to operate the plant in accordance with
feature-rich training environment. The
Once the system architecture and hardware
existing operating procedures, SSE gave
SimSci-Esscor solution provides the
and been specified, the Invensys DCS team
the “green light” to proceed with the site
full power of rigorous dynamic simulation
began by developing migration tools and
installation phase of the DCS upgrade.
and control system emulation for process
carrying out code analyses; breaking the
engineers, plant engineers, operators and
application down into HMI components,
managers to improve plant design, check
interlock/ protection logic, sequences,
out controls, train operators and improve
unique strategies and typicals. Migrated
plant performance. It also offers a modern
DCS components were then tested on a
The project was delivered in time for
alternative to dated, fragmented, empirical
modular basis via a combination of code
Keadby’s planned shutdown and within
and hard-to-use products with which many
reviews and basic I/A Series functional
SSE budget parameters. The equipment
engineering firms and plants currently
testing.
upgrade was completed in less than 13
A plan well-devised is a plan well-executed
days, compared with the 18 days that were
struggle. The OTS team’s first task was to mark up
scheduled. There was only one minor
Invensys also demonstrated an extensive
plant piping and Instrumentation diagrams
two-hour delay to the Return-To-Service
track record for supporting the Foxboro
(P&IDs) in order to clarify the required
programme attributable to the migration
I/A Series Distributed Control System,
scope and topology of the SimSci-Esscor
to the new DCS. The unique Invensys
a key component of the Invensys
DYNSIM processing model. Once the
migration solution with plug-in I/O modules
InFusion Enterprise Control System and
model had been constructed, this was
allowed for unparalleled minimal plant
were able to offer a number of products to
followed by model acceptance testing to
downtime for the project.
September/October 2012 | 45
In addition, the expandability issue has
analysis via the third-party PAS PlantState
operability and system configurability.
been resolved as the new DCS now
Suite.
Furthermore, we now have a number of new
supports up to 2,000 nodes and the central
tools in our toolbox. For example{ not only
processor loading is less than 25 percent
“The project has satisfied all of our
did the simulator play an important role
of capacity. Keadby also enjoys simplified
technical objectives and we now have a
in the migration project, is it now proving
on-line configuration.
supportable system with the capacity we
particularly beneficial both for staff training
need to proceed with a number of control
and as a rigorous test-bed for control and
Invensys also successfully delivered a
improvements which were being held-up
process changes.”
model-based OTS system, DCS sequence
by the limitations of the previous system”
enhancements, process interlock
said Hugh Ferguson. “Not only was the
The extensive migration upgrade at the
diagnostics/overrides, an on-line heat
migration completed with minimal impact
Keadby Power Station resulted in several
balance reconciled performance package
on routine plant operations, it has been
gains for the plant and SSE acknowledged
via the Automated Rigorous Performance
possible to retain much of the look and
Invensys for providing a standardised and
Monitoring product that is part of the
feel of the previous system but at the same
successful migration solution.
ROMeo suite and alarm performance
time making improvements to consistency,
Legacy Moore APACS Migration Plug-in I/A Series migration cards enable upgrade of legacy Moore APACS ACM and ACM+ control systems to I/A Series DCS and InFusion ECS technologies. I/O modules are designed to plug directly into existing system racks and swapping can be accomplished without replacing existing field wiring, termination assemblies, system enclosures, or power supplies. APACS per-channel configurable I/O approach is retained and APACS ProcessSuite graphics can be re-used within InFusion View HMI.
Pure and simple plug-in migration with Foxboro I/A series I/O modules: • Manufactured to be form-fit replacements for your legacy Moore APACS I/O modules I/A Series I/O modules in a Moore APACS form factor
• Meets or exceeds original specifications • Requires no new cabinets, racks,
• Eliminates I/O mapping issues
termination assemblies, or power supplies
all new and remaining legacy equipment • Improves reliability by providing
• Keeps all process wiring in place — unchanged
46 | www.protocolmag.co.za
• Protects you with full system warranty on
redundant communication to every I/O module — no single point of failure
The Salt River project - America’s third-largest public power utility quells nuisance alarms
The Salt River project America’s third-largest public power utility quells nuisance alarms
“Now we have valid alarms that mean something to operators so they can respond appropriately. This increases efficiency and reliability. Operators now see the alarm system as a tool they appreciate, instead of a necessary annoyance.” Ron Bewsey, I&E supervisor and I/A administrator
Goals • Improve the performance of the Santan and Navajo plants by reducing the
Solutions and Products • Foxboro® Distributed Control System - I/A Series®
number of alarm floods
Results
• Reduce the increasing number and frequency of occurring process alarms
up to four hours to complete can now be performed by one operator in less than
• SimSci-Esscor® Dynamic Simulation
Challenges
start-up previously took two operators
two hours • New system resulted in a 44% reduction of configured alarms
• Implementing the alarm system design
while keeping the power plant safe and
at the nine Santan units dramatically
profitable
reduced the frequency of alarms. Plant
September/October 2012 | 47
Phoenix, Arizona
Commenting on the start-up progress at
(EEMUA) best practices and described the
the Navajo plant, Salt River Project (SRP)
system improvement methodology.
The Salt River Project (SRP) was established
Dispatchers said, “Dispatchers could not
in 1903 as the nation’s first multipurpose
believe what they saw when the unit took a
The second phase focused on system
reclamation project authorised under the
400 MW runback at an average of 200 MW/
performance improvement. SRP
National Reclamation Act. It is the nation’s
Min. The boiler and turbine parameters were
implemented an advanced alarm notification
third-largest public power utility, providing
not only in line, they were ‘flat line.’ Anyone
that will “focus on reducing alarm floods,”
up to 6,500 megawatts (MW) of power to
with any experience operating a once-
said the SRP alarm management team. This
more than 900,000 customers throughout a
through unit knows that this is remarkable.”
phase included development of an alarm system philosophy, alarm rationalisation,
2,900 square mile service territory in central Arizona. Its Navajo generating station on
One benefit of a powerful control system
execution of alarm system changes and a
the Navajo Indian reservation near Page,
is the ability to generate alarms that
human machine interface (HMI) that enabled
Arizona, operates three 800 MW coal-fired
notify operations of changing conditions.
plant personnel to visualise alarm system
generating units. Its Santan station in Gilbert
Unfortunately, the number and frequency
performance and history.
runs nine combined cycle units, providing
of those alarms began to threaten and
a combined total of about 1100 MW. Its
overwhelm operators.
SRP’s alarm management team prioritised the alarms (1 – 5) based on economics,
Kyrene station, located 15 miles away in Tempe, generates an additional 430 MW
Commenting on the extent to which the lack
safety, environment severities and the time
from one combined cycle and three simple
of alarm management was jeopardising the
required to respond to each alarm. Priorities
cycle units.
efficiency of the entire plant, Ron Bewsey,
one, two and three were sent to the
I&E supervisor and I/A administrator, said,
operator. Alarms coded as priority four were
“We were getting alarm horns all the time —
sent directly to maintenance for diagnoses
at start-up, shutdown and during day-to-day
and repair. Priority five alarms were sent only
Process alarms are critical to the safe and
operation. In one 18-hour period, operators
to the historian for recording purposes. This
profitable operation of a power plant, too
were confronted with 5,000 alarms, every
was all in accordance with SRP’s new alarm
many and too frequent alarms can have
one of which required intervention of some
philosophy.
a major impact on plant operations. To
sort and 98% were designated top priority.
reduce the number of alarm floods that
The plant had to designate an operator just
Prior to the documentation and
were occurring with increased frequency,
for alarm management.”
rationalisation process, 98% of all
Client challenge
SRP implemented an effective alarm
alarms were assigned a priority 1, with
management solution from Invensys at its
Using Invensys’ alarm management solution
the remaining 2% of the alarms spread
Navajo and Santan generating stations.
and proven execution strategy, SRP met this
across the rest of the priorities. Once the
challenge and implemented the solution
documentation and rationalisation process
SRP began consolidating aging analogue
at all of Santan’s nine units and one more
was complete, only 11% of all alarms were
plant controls at these stations into a
Navajo unit.
set at priority 1, 14% set at a priority 2 and
single, modern digital control system in
the remaining 75% were set at a priority 3.
1990, based on the Foxboro I/A Series
“Now,” Bewsey said, “we have valid alarms
The new alarm priorities were programmed
Distributed Control System from Invensys.
that mean something to operators so they
into the Foxboro I/A Series Distributed
It now encompasses more than 40,000
can respond appropriately. This increases
Control System, which managed the routing
SRP I/O points, including coordinated
efficiency and reliability. Operators now see
of all alarms to the appropriate location.
control of turbines, burners, plant logic,
the alarm system as a tool they appreciate,
scrubbers, data acquisition and performance
instead of a necessary annoyance.”
monitoring. The benefits of switching to Invensys’ digital control system have been dramatic for SRP from the initial start-up.
A three-phase alarm management solution
Dramatic reduction of alarm frequency Implementing Invensys’ alarm system design at the nine Santan units dramatically reduced
Starting with the two units at the Santan
the frequency of alarms. Plant start-up
station, SRP assigned an I&C specialist
previously took two operators up to four
and an experienced control room
hours to complete can now be performed by
operator to work with Invensys engineers
one operator in less than two hours.
full time to implement a three-phase
48 | www.protocolmag.co.za
alarm management solution. In the initial
Rees Scott, Control Room Operator,
phase, the Santan/Invensys team studied
commented that, “We can now attend
alarm system performance in depth and
to each alarm instead of just hitting the
produced a report, (which defined baseline
‘acknowledge’ button and we also have
alarm system performance) established
more time to concentrate on improving the
performance targets based on Engineering
performance of the units rather than just
Equipment and Materials Users Association
trying to stop the noise.”
The clearest path to modernisation. Bypass the risk and cost of obsolescence through our unique and comprehensive approach. To start mapping out your path, visit us at iom.invensys.com/Modernise.
Secure your future with Foxboro and Triconex
0800 INVENSYS | contact@invensys.co.za | iom.invensys.co.za
Avantis
Eurotherm
Foxboro
IMServ
InFusion
SimSci-Esscor
Skelta
Triconex
Wonderware
Real Collaboration. Real-Time Results.
TM
September/October 2012 | 49 Š Copyright 2012. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.
Reducing the noise level and eliminating
the Plant alarm philosophy. This resulted in
new alarm system design before the changes
the number of alarms at the plants freed
a 44% reduction of configured alarms. The
are implemented. Once the Unit 1 project is
operators to address plant efficiency in
rationalised alarms were implemented at
complete, the process will be repeated on
positive ways (such as decreasing heat rate).
SRP Navajo’s SimSci-EsscorŽ plant simulator.
the remaining two units and scrubbers.
The Navajo plant is now using the simulator At the Navajo station, results were even
to train operators on the new alarm system
The third phase of the project will continue
more dramatic. The alarm management
and plant alarm philosophy. The simulator
to optimise the alarm system and further
team rationalised and reprioritised Unit 1
models operation of the plant in real-time
reduce the frequency of alarms within SRP
alarms according to EEMUA standards and
and enables a prediction of the impact of the
plants.
50 | www.protocolmag.co.za
Large Oil and Gas complex migrates multiple legacy systems to the latest Foxboro I/A Series platform for improved operator efficiency Introduction The client is an oil and gas manufacturing complex. Since its origins in the early 1900s, the refinery has grown in size and sophistication with the addition of a number of units designed to extract the maximum value from crude oil. These additions have included a fluid catalytic cracker, alkylation unit, platformer and hydro-desulphurisation plant. The complex now has a refining capacity of more than 10 million tpa.
September/October 2012 | 51
Project scope
provide plug-in replacements for end-of-life
cutover successfully, preventing the process
systems. Second, migration where feasible,
unit from having to be shut down.
Health, safety and the environment are
would be conducted on-line, without
at the top of this client’s agenda and is
having to shut down the relevant process
Aside from the enhanced safety aspects,
exemplified by a significant investment
units, hence leading to significant financial
a modern and unified control room offers
to construct a new control room at the
savings due to reduced downtime. This was
major benefits in the area of operator
manufacturing complex. This was a major
a particular issue for the Crude Distillation
communication. Previously, the operators of
commitment to the continuous improvement
Unit, which if shut down would take virtually
the five control rooms rarely communicated
in safety performance. A project was defined
a week to get up and running. Aside from
with each other face to face. As the site is
to build a state-of-the-art central control
these financial benefits, on-line migration
a large, integrated complex with numerous
room in the non-hazardous area of the
would also improve safety, by avoiding
inter-dependencies between products and
industrial site. This involved the sequential
unnecessary risks during plant shutdowns
feedstocks, process operators can now
relocation of five smaller, autonomous
and start-ups.
easily communicate with each other and
control rooms and all the associated workstations to this new facility, as well as
when problems arise within the complex,
Results
the upgrading of the control systems of five production units.
operators can immediately notify their colleagues so that the appropriate actions
The new blast-resilient central control room
are immediately taken.
is located opposite the site’s fire station.
Further developments
Invensys, a key supplier to the client for
With a total floor area of approximately
a number of years, has been involved in
3,000 m2, the building houses a main
upgrading the chemical plant’s control
panel room of around 950 m2. Office
The successful implementation of this
systems to Foxboro® equipment. The
accommodation is provided by a single
project led directly to Invensys being
previous area of the complex was a
upper floor area, which provides a full
awarded a further migration project. This
traditional Honeywell® user. Consequently,
view of the main control area. The design
was for the migration of off-site dual
for the new control room project both
incorporates three staircases, which provide
blending applications, including tanker
Invensys and Honeywell were asked to
occupants with access to the nearest fire exit
movement and storage. Invensys is also
submit bids.
during an emergency. Invensys consulted the
involved at the site with dynamic simulation
operators during the design phase and their
on a higher olefins plant, which for many
Based on a sound technical solution, the
comments were incorporated into the final
years experienced serious start-up problems
presence of strong engineering resources
plan. They now enjoy ultra-modern working
after shutdown. Dynamic simulation
(including a dedicated client project team)
conditions under the single roof of a control
modelling of the plant was a great success
and the excellent results obtained in
centre.
and led to significant improvements in
improving operations at the chemicals site,
terms of faster, smoother start-up and the
Invensys was awarded the contract for the
The migration project proceeded smoothly
associated financial benefits. The next stage
upgrade project.
as planned. On-line migration was
is to expand that model to build an operator
performed on one Honeywell and two
training simulator that is based on Invensys’
Foxboro systems. The other two systems
FSIM Plus™ simulation tool powered by
were migrated during scheduled plant
Invensys’ SIM4ME® common modelling
The initial project scope involved upgrading
shutdowns at the customer’s request. The
environment. The comprehensive control
two Foxboro Spectrum and three
migration project involved a team of 8-10
system checkout and simulation tool will
Honeywell TDC 3000 control systems at the
engineers, plus an Invensys project manager
further improve safety, enhance the skills of
manufacturing complex to new Foxboro
and migration experts.
operators and enable changes to be verified
Client challenge
I/A Series® process control systems. The
and validated prior to implementing on the
planned migration would need to be
A minor setback was experienced when
completed quickly and be conducted
switching over one of the old Foxboro
without requiring the systems to be shut
Spectrum controllers to a new Foxboro I/A
To further ensure safe production at the site,
down. This would minimise cost, risk and
Series controller. A software problem was
Invensys is helping the client with their asset
process downtime.
identified that could have seriously delayed
management initiative. The Invensys team
the process. Invensys’ migration philosophy
helped install, test and implement a variety
is to be able to revert back to the existing
of solutions such as alarm management
control system if a problem arises. Invensys
and advanced process control and interface
Two elements in Invensys’ strategy that were
engineers were quickly able to switch
them with the client’s management
key in the successful implementation of this
back to the original Foxboro Spectrum
information systems. Invensys has also been
solution. First, the planned migration would
system. This enabled Invensys to analyse
invited to update obsolescent safety systems
be fast and easy, as I/A Series I/O modules
the software fault, correct it and repeat the
for a biofuels plant at the facility.
Invensys solution
52 | www.protocolmag.co.za
live plant.
Large Oil and Gas complex migrates multiple legacy systems to the latest Foxboro I/A Series platform for improved operator efficiency
Legacy Honeywell DCS migration Replace your legacy Honeywell TDC2000 or TDC3000 System by plugging in a brandnew, low-cost, no-risk I/A Series System
Pure and simple plug-in migration with Foxboro I/A series I/O modules • Manufactured to be form-fit replacements for your legacy TDC2000 or TDC3000 I/O modules • Our HART capable replacement modules provide information from intelligent devices and give you the ability to better manage your assets • Meets or exceeds original specifications • Supports basic, extended and multifunction controllers • Supports all IOPs for PM, APM and HPM • Supports high-level & low-level process interface • Requires no new cabinets, racks,
• Eliminates I/O mapping issues
• Protects you with full system warranty on all new and remaining legacy equipment
termination assemblies, or power supplies • Improves reliability by providing • Keeps all process wiring in place – unchanged
redundant communications to every I/O module – no single point of failure
September/October 2012 | 53
54 | www.protocolmag.co.za
Cascades Tissue Group achieves operating efficiencies with Invensys Operations Management solution
Cascades Tissue Group achieves operating efficiencies with Invensys Operations Management solution
“The level of engineering start-up, system commissioning and site support from the Invensys Operations Management application engineers, service engineers and technical team was outstanding.” Mike Armstrong, Electrical and Instrumentation Manager
Goals
Challenges
Results
• Reduce standard deviation of basis weight
• Update outdated controls at the Eau
• Improved product quality reduced
and moisture • Automate controls and save time, maintain
Claire mill and continue to strength its
breakage, resulting in improved uptime,
position in the increasingly competitive
greater overall capacity utilisation and
global paper industry
lower maintenance costs
spec and ensure product consistency
Solutions and Products • Increase uptime, greater overall capacity utilisation and lower maintenance costs
• The multivariable expert adaptive control brings greater efficiency in energy
• Foxboro® Distributed Control System - I/A Series® • Wonderware® InTouch® HMI Software
utilisation, improves waste and discharge handling. • New system prevents to the corrosive environment at the mill floor
September/October 2012 | 55
a grade change manually can take the better
With the new controls from Invensys, it met
part of an hour — and there is still chance of
both objectives. In addition to contributing
human error. By automating, we cannot only
to product quality, the new system has
save time; we also maintain spec and ensure
reduced breakage in parent webs, resulting
product consistency.”
in more uptime, greater overall capacity utilisation and lower maintenance costs.
To meet this challenge, Cascades automated
Eau Claire, Wisconsin Founded in 1964, Cascades, Inc. is a
control of moisture and gauging on two
Another important benefit of the upgrade
tissue machines — migrating from an ABB
was laying the foundation for implementing
Accuracy Model 1180 QCS system running
more advanced process controls. For
a conglomeration of single-loop controllers
example, the new Foxboro I/A Series
to a modern Foxboro I/A Series Distributed
Distributed Control System currently uses
Control System.
multivariable expert adaptive control, which reduces consistency swings while
North American leader in the production, conversion and marketing of packaging products, fine papers and tissue papers.
Implementing new technology
enabling performance trending and simplified troubleshooting. This brings greater efficiency in energy utilisation, plus
Internationally, the Cascades Group employs more than 14,000 people and operates some
The new Invensys control architecture
waste and discharge handling. Because
160 modern and versatile operating units in
built on Foxboro technology includes a
components are now housed in a central
Canada, the United States, Mexico, France,
fault-tolerant I/A Series system controller,
control room, equipment is not exposed to
England, Germany and Sweden. In addition
a server, two human machine interface
the corrosive environment of the mill floor.
to its brands, Cascades Tissue Group is a
(HMI) workstation terminals, with 200-series
major supplier of private label products for
Fieldbus I/O modules, all communicating
System maintainability and reliability also
major chains and drugstores. Its bathroom
across a high-speed Ethernet network. This
improve dramatically. Consolidated controls
tissue, paper towels, paper hand towels,
network configuration enabled the I/O to
reduced the overall number of system
facial tissue, paper napkins and related
be located near the tissue machine wet
components, with many of the components
products are offered under brand names
end operation, reducing both control room
deployed equipped with self-diagnostics.
such as Cascades, Doucelle and Capri for
space and field wiring. Cascades Tissue Group’s capital investment
the retail market and New Horizon, North River, Decor and Perkins for the commercial
Using this Invensys solution, the operations
is well protected. The open architecture of
and industrial markets.
engineers have implemented regulatory and
the Foxboro I/A Series Distributed Control
supervisory control functions in a unified,
System is designed to accommodate
open system architecture. Operators receive
advances in process control, information
better trending analysis that enables them
technology, application development
to correlate variability for each production
tools, instruments, networking and
Cascades Tissue Group, a leading supplier
run. Stock preparation controls help
communications as benefits become
of tissue paper products for more than
reduce disturbances that can significantly
available. This includes technology resulting
100 years, recently experienced growing
impact paper quality and paper machine
from Invensys engineering or third-party
concern that outdated controls at its Eau
performance.
commercial off the shelf (COTS) solutions.
the increasingly competitive global paper
The pulp and paper industry experts
Commitment to backward compatibility
industry.
of Invensys supported the Cascades
of new technology ensures that Cascades
production management teams throughout
Tissue Group will continue to receive
their engineering efforts.
substantial return on its automation
A hundred years of continuous service
Claire mill would jeopardise its position in
Paul Olson, Paper Mill Superintendent, said, “Making tissue that is soft, yet strong and consistently high in quality requires superior
investment for years to come.
Results and future growth
control over the moisture and gauging, especially during paper grade changes.
Cascades set out to reduce standard
Adjusting for basis weight and moisture after
deviation of both basis weight and moisture.
56 | www.protocolmag.co.za
Unified control migration at Aracruz Cellulose
Unified control migration at Aracruz Cellulose
“We chose to implement Foxboro intelligent remote I/O because of the increased architectural flexibility and lower cost it provides.” Luiz Renato Chagas Figueiredo Automation Manager
Aracruz Cellulose modernises and upgrades production at world’s largest pulp producer using multiple Invensys solutions
Solutions and Products
Results
• Foxboro® Distributed Control System I/A
• Plant was expanded to become the
Series®
largest single pulp production facility in the world, capable of producing more
• Foxboro Measurements and Instruments
Goals
than two million tons of market pulp per year
• Triconex® Critical and Safety Systems • Allow each Fiberline to operate independently and provide a unified view
• Boiler using Fisher Provox DCS with 1000 • SimSci-Esscor® Dynamic Simulation
into all operations for better management of overall plant productivity
I/O was migrated to Foxboro I/A in 3 hours and 7 minutes
• Wonderware® InTouch® HMI Software • Provides a strong avenue for future
Challenges • Plant has multiple systems from different vendors, most of which are outdated
growth in production capacity • Expanded overall production capacity and eliminated production bottlenecks
• Current plant capacity is limited and needs to be expanded to meet demand
September/October 2012 | 57
Following a year of planning, consultation and project definition, Aracruz management decided to continue their strong relationship with Invensys Operations Management and use the Foxboro I/A Series DCS to operate Fibreline C and upgrade the majority of lines A and B – including interfacing to all the production equipment for major process steps. Fibreline A was upgrade from its original pneumatic control systems to the I/A Series system. The Fibreline A controls architecture was so effective that it was used as the basis for the Fibreline C plant expansion. Significant savings in reusable engineering were realised. Figure 1: Details of processes linked to a DCS on the three lines prior to Line B migration.
Fibreline B’s boiler and evaporation units were controlled by a Provox system.
Espírito Santo, Brazil
building of Fibreline A, which was capable of
Retrofitting controls on Fibreline B
producing 400,000 tons a year of bleached
was simplified using Foxboro’s plug-in
Lush green forests sweep grandly from the
pulp. This first line was controlled by
migration strategy. I/A Series I/O modules,
mountains to the ocean in the coastal states
Foxboro PCI-100 pneumatic instrumentation.
manufactured to be one-for-one, form fit
of Espírito Santo and Bahia, Brazil, about
The plant’s production capacity was
replacements for the original Provox I/O
450 kilometres north of Rio de Janeiro. What
expanded in 1986 when Fibreline B was
modules, plug-in to the legacy I/O racks.
is unusual about these forests, however, is
brought online to produce an additional
The physical switchover was accomplished
that they are part of nearly 420,000 acres of
600,000 tons of pulp a year.
without moving any field wiring. Total
eucalyptus plantations owned and managed
process downtime to migrate this 1,000
by Aracruz Cellulose, one of the world’s
In 1995, Aracruz management overhauled
leading producers of market pulp.
both lines to modernise and eliminate production bottlenecks – while expanding
Project scope
point system was 3 hours and 7 minutes.
Production on a massive scale
their overall production capacity to 1.2 million tons per year. At this time, they
Despite its enormous size, the Aracruz plant
Aracruz Celulose is unusual in that the mill
replaced the original pneumatic control
is a typical modern pulp mill. Logs arrive
here uses eucalyptus trees for making pulp,
systems with Foxboro I/A Series Distributed
daily by truck from the plantations. Much
which is shipped around the world to paper
Control System. These were configured in
of the wood is stored in the wood yard, for
producers who make tissue, fine printing,
a five-node local area network, combining
use as a buffer supply, while the remainder
writing and specialty paper products. The
multiple application processors, user
is unloaded directly into debarkers and
advantage of eucalyptus trees is that they
workstations interfaced to programmable
chippers that feed each line. The chips are
grow so quickly, reaching mature heights
logic controllers (PLCs). As many as 125 field
conveyed into the pulp digesters, where they
of about 35 meters within just seven years
enclosures provided the I/O interfacing to
are cooked with caustic liquors to form the
of growth. This means that they can be
more than 1,500 field instruments, using
pulp. The modern stainless steel digesters,
harvested much more frequently than the
FoxCom communications. In addition,
rising high above the plant floor, look more
slow growing pine forests of North America.
InTouch Human Machine Interface software
like rocket ships than production equipment.
In addition, while their fibre was originally
from Wonderware was installed to create
considered to be secondary quality, because
new process visualisation screens for
The brown pulp stock is washed and
of their shorter length, it now is sought after
operator control of wood yard operations.
screened before being bleached white and
because of its characteristics that provide
fed into drying machines. These dryers
high opacity, softness and good absorption
This approach to production control
look much like standard papermaking
of inks.
worked so well that in the year 2000 Aracruz
machines, but instead they simply dry
management undertook their largest project
the pulp to form continuous blankets. At
For all of these reasons, the Aracruz pulp
of all – the construction of Fibreline C and
the end of each drying machine, the pulp
mill has now grown to be the largest single
the upgrading of Line A and B controls.
blankets are cut into rectangular sheets
pulp production facility in the world, capable
The goal was to allow each line to operate
and baled for shipping. The wrapped bales
of producing more than two million tons of
independently but to provide a unified view
are transported by truck to the nearby
market pulp per year. Operations just east
into all operations for better management of
port at Aracruz where they are shipped to
of the city of Aracruz began in 1976 with the
overall plant productivity.
customers around the world.
58 | www.protocolmag.co.za
Unified control migration at Aracruz Cellulose
In addition to the production equipment
pressure and temperature devices to
Foxboro Command Centres with thin profile
deployed to make the pulp itself, Aracruz
magnetic, mass, pH and conductivity devices
LCD displays have now been installed in
operations include several production
– are all interfaced with the system by means
all three control rooms. The processors
support systems. These include the chemical
of the FoxCom protocol, using remote I/O
and I/O cards from the competitive system
plants that produce the caustic liquors used
racks that are physically close to the process.
have been swapped out for Foxboro I/A
in the digesters; the recovery boiler that
Motor controls are connected via intelligent
replacements that have the same form
reclaims used liquors for recycling in the
MCCs to as many as 25 Micro I/A nodes via
factor, but which incorporate today’s latest
production process; the evaporative systems
Profibus networks, without having to use
electronics circuitry technology. This helped
used to reclaim water from the washing
PLCs.
bring the new line on-stream faster – and
and screening process; a chemical plant for
under budget – and it provides a strong
producing bleaching agents; and a power
Foxboro I/A Advanced Controls packages
avenue for future growth in production
plant for supplying electricity for the entire
were also installed in each production
capacity. In fact, with this facility upgrade
facility. All are managed using the Foxboro
area to gather baseline measurements for
Aracruz was the first pulp mill in the world to
I/A control system.
evaluating performance improvements
start up with all advanced controls in place
obtained from the advanced process
and running.
Sophisticated remote I/O
controls.
The complete Foxboro I/A Series DCS on
All engineering work for regulatory control
the so-called “paper-less revolution” that
Fibreline C consist of five network nodes
is being managed by Invensys as well,
people have talked about for years has
with Windows NT workstation processors.
through subcontracts with the nine primary
never really occurred – and that means the
A Trident triple modular redundant safety
equipment suppliers. Simulation packages
world will always need fine papers for use
shutdown system from Triconex is used
for this effort, to emulate actual use of all
in computer printout, copiers and old-
for protection of the oxygen reactor. All
control processors and Micro I/A units, were
fashioned hand-written letters.
Foxboro field instruments – ranging from
supplied by SimSci-Esscor.
That is a good situation to be in because
Legacy Fisher PROVOX DCS Migration Replace your legacy Fisher PROVOX System by plugging in a brand-new, low-cost, no-risk
• Requires no new cabinets, racks, termination assemblies, or power supplies
I/A Series System. • Keeps all process wiring in place –
Pure and simple plug-in migration with Foxboro I/A series I/O modules
• * Eliminates I/O mapping issues
• Manufactured to be form-fit replacements
• * Improves reliability by providing
for your legacy PROVOX I/O modules
unchanged
redundant communications to every I/O module – no single point of failure
• Our HART capable replacement modules provide information from intelligent devices and give you the ability to better
• * Protects you with full system warranty on all new and remaining legacy equipment
manage your assets • Supports UOC, UOC+, MUX and IFC for Series 10 and Series 20
September/October 2012 | 59
Virtual reality can help with technology migration In the previous issue of Protocol, we saw how virtual reality helped introduce personnel to aspects of operations, maintenance and safety and you have just seen how many of the migration successes we included in this issue also depended on virtual reality for their migration to a new, legacy-free environment. So, here’s information on SimSci-EsscorŽ as presented by Maurizio Rovaglio, Vice President , Solutions Services, Invensys and Tobias Scheele, Vice President/ General Manager Advanced Applications, Invensys.
60 | www.protocolmag.co.za
Virtual reality can help with technology migration
Introduction
Unfortunately, there is a tendency to think in terms of head-mounted displays when considering VR systems and this narrow perspective
Until recently, the use of virtual reality (VR) had been limited by systems
leads to confusion when talking about other types of VR. The solution is
constraints. Real-time rendering of equipment views places extreme
to use “VR” as an all-embracing term to cover all forms of VR systems,
demands on processor time and the invariable need for expensive
including stereoscopic auditorium, 3D localisation in conventional
hardware. As a result, VR solutions were largely ineffective, being
projection or a mix of both. Some individuals use the term virtual
unrealistically slow or oversimplified.
environments instead of VR adding further confusion.
However, as VR technology continues to develop, ongoing advances in
However, it is better to think of a virtual environment as a computer
hardware processing power and software development will allow VR to
representation of a synthetic world. This means a virtual environment
be used as the interface with computer-based multimedia activities that
can be defined irrespective of the delivery technology. But it is
include training, process design, maintenance and safety.
not simply sufficient to produce a lone virtual environment. Their component parts require controlling in such a way that the user
This paper discusses the range of multimedia VR aids that can be used
believes they are actually immersed in a real environment. This requires
economically and effectively to support computer-based multimedia
a process/machinery simulation tool that interacts with the virtual
activities.
environment in a tangible action/reaction mode.
Overview
Different forms of delivering VR systems are defined by their peripheral technologies. For example, the term “desktop VR” does not relate
For the purposes of this article, VR is defined as: “A three-dimensional
to the virtual environment, but the delivery technology used. Today, a
(3D) environment generated by a computer, with a run-time that closely
desktop VR system is generally based on a PC platform, which employs
resembles reality to the person interacting with the environment.”
the latest graphic systems to provide optimum performance at a reasonable cost.
This environment is further defined as:
The virtual plant • Immersive — where extra computer peripherals (such as goggles and gloves) are used to produce the effect of being inside the
The 3D content section of the VR environment requires a CAD file
computer-generated environment;
as the basic source of the material. This either can be in standard 2D, or advanced formats (such as those created by COMOSFEED™,
• Non-immersive — the environment is displayed in a conventional
SMARTPLANT® and AUTOCAD®). These programmes generate a 3D
manner on a display screen and interacts through standard computer
CAD® file used to speed up the conversion process required for photo-
inputs (such as a mouse or a joystick).
realistic, real-time graphics. Initially, a basic 3D geometry is created to reflect plant specifications and then software such as 3dStudioMax®
The key feature that VR brings to computer-aided process engineering
or Maya® is used to process graphics details. This software adds the
is the real-time rendering capability. This has been used to great effect
details and small adjustments needed to turn a flat CAD into a photo-
in other areas (such as the gaming, aircraft and medical industries) and
realistic product. Various other tools and applications optimise textures
is now poised for use within the process industry.
and illumination to further improve the effect.
The key to an effective virtual environment system is the close
Unlike conventional, non real-time rendering, a real-time programme
integration of the enabling hardware with software support tools. This
allows users to move and interact freely within the environment. Special
process, known as systems integration, demands that operation and
graphic technology permits the environment to be rendered at 60
implementation — hardware and software — be dealt with together.
frames a second, compared to one frame per second in the traditional approach. Specific optimisation techniques are required to achieve 60
However, before considering the type of technology used to implement
frames a second that include the following:
a VR system for process purposes, it is useful to consider the various forms of the virtual environment.
• Level of detail (LOD) geometries, used where the detail is not needed
It is assumed that a VR-based system can only be provided by a headmounted display. However, a head-mounted display may be the wrong device to use for some applications as it only creates a single-user
• UV maps compression for the illumination data that is baked on textures
experience. Therefore, a broader definition of VR must be assumed, one that retains the key attributes of a VR system, for example, the
• Texture tiling to prevent pixel wastage
greater sense of presence and interaction the user receives when immersed in a virtual environment.
• BSP/portals generation for large-scale environments
The technology used to deliver the virtual environment is very
Once the graphics have been created, the next step is to detach the
important, whereas the technology used to create the virtual
geometries that represent the interactive actors. This is important
environment is critical.
because it separates dynamic geometries (those that can move and
September/October 2012 | 61
Figure 1: Basic 3D visualisation
Figure 2: A detailed, photo-realistic environment
be interacted with) from static geometries
providing additional functionality to
(those that cannot).
users. Meanwhile, the main client station
Impact of VR on training
reproduces the plant environment and
The main advantage that VR brings to both
The final step is to create a collision
allows users to perform actions on plant
theoretical and conceptual training is that
geometry that resembles the graphics
elements (for example opening a valve),
it allows trainees to become much more
geometry. This allows users to collide with
playing the role of Field- Operator. All
familiar with the layout and operation of
the virtual environment rather than simply
actions performed by the virtual Field
the subject matter. For example, training
passing through it.
Operator are tracked and synchronised with
on a specific piece of equipment not only
the other platform elements, including the
involves 3D models that can be viewed from
process simulator. Outputs can be displayed
any angle, but also allows that equipment
on various systems, from standard desktop
to be set in motion. For integrated systems,
The VR interactive system is a server-centric
monitors and head-mounted displays to
such as complex processes, VR allows
distributed application that centralises
immersive projection systems. Both mono
trainees to walk around the 3D model and
scene updates. Therefore, it enables
and stereoscopic vision can be used.
improve their spatial awareness of the
VR platform and architecture
scene rendering to be carried out on many
plant.
concurrent stations. The server synchronises
The VR system requires a monitoring station
directly with SimSci-Esscor’s SIM4ME®
that centralises all information on a running
In addition, when integrated with the
simulation engine, so the properties of each
simulation. This includes the number and
detailed DYNSIM simulation environment,
plant element in the VR scene is constantly
type of connected stations to the 3D model
VR techniques can be used to enhance the
updated in time with the process simulation.
used and specific training exercises being
representation of process unit behaviour.
Other stations have various roles within the
carried out within the simulation. The
There are three main ways for this
simulation and are able to communicate
monitoring station can be integrated with
integration to be represented:
with each other through a network using the
the Instructor Station on traditional OTS
standard TCP/IP protocol.
systems, giving a single point for managing
• A navigational front-end representation
a full training session. Events and training
of continuous rather than discrete state
The server application handles
exercises are triggered by the Instructor
for multi-degree of freedom objects. This
communication among the various modules
Station and transmitted to both the SIM4ME
supplies visual feedback only, with no
and is responsible for the updated version of
engine and the VR platform.
equipment interaction
all scene parameters. It retains a copy of the scene graph — a hierarchical representation
IPS’ DYNSIM® and FSIM Plus® interface directly
of the 3D scene — that is synchronous with
with the VR system main simulation modules.
the one present in each satellite application.
They give a fully synchronised integration
The server application constantly updates
between the 3D world and the process/
synthetic world) by a link between process
scene graph data, notifying changes via the
control simulation. So any action that the Field
simulation models and physical-spatial
network protocol to satellite applications.
Operator carries out in the 3D environment is
models for all training objectives
• As above but with equipment interaction • Complete environment emulation (a
immediately reflected in DYNSIM. Conversely, These satellite applications are in command
any value that is updated by DYNSIM is also
Note that giving users a fully interactive
of rendering the visualised data and
updated in the VR platform.
view can, in some cases, detract from the
62 | www.protocolmag.co.za
Virtual reality can help with technology migration
•
Technical training focussed on
transferring technical knowledge
them. Therefore, some trainers might introduce tasks slowly in a progressive learning curve, while others might prefer
•
Operational training focussed on
skills and procedures
that trainees meet the full task in all its complexity (step-by-step guidance/task guided mode).
•
Safety training focussed on
possible hazards
4. VR training allows skills transfer rather than simply knowledge transfer.
•
Emergency response; how to
react to a critical situation
Importantly, it also allows these skills to be tested. So assessing trainee performance becomes a simpler task.
Figure 3: A schematic system architecture
•
Interpersonal skills training (crew
Note that the platform also includes
training): communication, collaborative
alternative modes to score results from
decision-making and teamwork
training sessions.
objectives being taught, as it can be a much more complex system to understand.
These are all supported by the VR platform.
VR Models in Process Design
Some training modules may be solely The main elements of a training session are:
devoted to process knowledge, for example
Fig. 4 shows an example of iterative and
a session that provides greater process
concurrent process design based on
understanding for operators. However, most
the use of VR models. The client/EPC is
training sessions should deal with all the
responsible for the overall design process
2. Outlining contents;
elements listed above.
while the design teams within construction,
3. Choice of methodology;
2. The majority of the training sessions
responsible for the design of the plant
will be structured around the learning
subsystems, (such as process equipment,
of specific tasks. The content is normally
building structure and installations). All
structured in the form of a detailed
design teams are also responsible for
account of tasks.
providing correct and updated input data to
1. Setting objectives;
mechanical, control system, etc., are
4. Assessment. The VR platform should guide the user through the development of all the following
the “VR database”. The VR provider, working 3. The VR platform facilitates good
for the client, manages all the VR data and
teaching practice by allowing trainers
makes updated and corrected VR models
1. Setting ‘training objectives’ highlights
to individually match up trainees with
accessible for everyone involved in the
the different options available:
the training mode most suitable for
design process.
elements:
Figure 4: An iterative design process with specified VR models in a concurrent and multi-disciplinary design situation.
September/October 2012 | 63
• Replication - being able to reproduce the reported fault. • Identification - being able to accurately diagnose the source of the fault. • Rectification - correcting the fault by taking action appropriate to the policies of the maintenance establishment. • Confirmation - checking to see that the identified fault has been cleared. Each of the four stages described above requires a mixture of generic and specific physical and mental skills. When using VR facilities, the usual Figure 5: A screenshot extracted from a VR model showing a design solution that would have
approach is to train users to have a deep
blocked the access.
understanding of both the maintenance task itself and the science behind the involved
The VR models from 1 to n in Fig. 4 provide
rather than searching through piles of
equipment. This means that the structure
the design teams with structured and
drawings.”
of a typical training course includes training
easy-to-understand design information. This
objectives that can be taken from a broader
is done in such a way that is not possible
Increasing time-pressure on projects,
using a traditional design approach based
partnerships and/or MAC roles is likely to
on 2D CAD drawings. By navigating in the
be the stimulus that enhances collaboration
models, stakeholders can analyse the design
between stakeholders. This could lead to
from both a general and a more detailed
a concurrent design approach in which
perspective. Moreover, with VR models, it is
VR models are used to coordinate and
easier to explain and discuss different design
communicate the design to the client. In
solutions with a larger group of stakeholders,
addition, as well as making it easier for them
particularly where they have different ways of
to make crucial decisions, VR models can
interpreting 2D design drawings. This ability
also involve the client in everyday design
to collect views from different perspectives
work. Being able to quickly sort the relevant
gives a better and more productive overall
information and present it in an easy and
design approach. It also makes it much
comprehensible way enables the client to
simpler to discover and correct collisions
collect opinions from a wider audience, such
and design errors earlier in the design
as the operations and maintenance staff
phase.
and to improve the organisation’s decision-
number of training categories: • Initial Theoretical Training • Instructor Led Training • Systems Appreciation • Fault Diagnostics Training • Recognition Training • Equipment Familiarisation • Scenarios Simulation
making procedures. Fig. 5 shows how a VR model identified a bad design solution, in this case process
VR in maintenance tasks
water outlets hindering access. Finding a solution to this type of error after the event
To understand the training aids required
is often highly costly. Such an error also
for maintenance training, the first
affects production by generating delays in
sensible, logical step is to look at the task
the re-scheduling and re-planning of some
that the trainee is expected to perform
activities.
after completing the course. In process operations, for example, the organisation
During a trial on the use of VR models,
of that task is heavily dependent on the
users commented that a major benefit of
industry sector, the range of equipment
the technology is that it gives a far greater
to be maintained and specific company
appreciation of other skilled areas involved
culture.
in the overall project. It also saves time. Said one design manager, “I was sceptical
Irrespective of the subject matter,
at first. Then I realised that by studying
however, in general a maintenance task
Figure 6: A screen shot showing the use of avatars
one VR model I could save a lot of time
can be broken down into the following
for investigating the maintainability of the process
and be more focused on important issues
subtasks:
machinery in the plant.
64 | www.protocolmag.co.za
Virtual reality can help with technology migration
• Visual Appreciation
held devices. Once immersed in a virtual environment where everything resembles
• Hand/Eye Coordination
reality, all normal and abnormal situations can be experimented on and tested by
• Spatial Appreciation
operators. Any action either in the field or in the control room is simulated rigorously
For example, in the analysis of an overall
in terms of process behaviour with a clear
plant working environment, a specially
action/reaction perception. In practice, VR
designed avatar of large size could
allows operators to test every abnormal
mimic the behaviour of operational and
situation that can be thought of, alongside
maintenance staff. This is primarily a system
little-understood atypical plant behaviours.
analysis (3, 8 and 10) where working spaces,
Both expected and predictable malfunctions
escape routes, risky areas and transportation
can be tested in their entirety, up to and
need to take real equipment off-line and
routes within the plant are investigated from
including the disaster that might result. After
risk production. This allows users to learn
a logistics viewpoint. The result of such
all, learning from a virtual disaster can help
within computer-generated environments
analysis allows maintenance procedures
avoid the real thing.
and gives them the opportunity to make
to be optimised and highlights if there is a
Figure 7: A virtual fire
mistakes and suffer the consequences
need to ask a design team for improvements
The strength of this approach is two-fold:
or modifications.
safety can be tested and experimented
without putting themselves at risk.
upon as a training tool; and risk-assessors
Overall, VR improves design procedures
A second example (see fig. 6) also refers to
are better able to identify hazardous
and is a far superior training tool to more
spatial appreciation (10), but this time to
scenarios. Together, they improve the ability
traditional approaches. As a result, it saves
improve equipment familiarisation (6) and
of operators to make the right decisions
both staff time and money.
hand/eye coordination (9). The operation
at the right times. In other words, VR
of a highly automated industrial process
makes training, risk assessment and safety
depends largely on the maintainability
management more effective and realistic
of its process equipment. Because of the
than ever before.
To meet your virtual reality operator training needs, Invensys offers EYESIM. EYESIM is
huge economic impact that a failure could have, preventing such events has a very
EYESIM for VR
Conclusions
a comprehensive solution linking Control Room Operators to Field Operators and
high priority. Therefore, to make sure that maintenance can be properly conducted and
VR provides a 3D computer-generated
Maintenance Operators by means of a
performed on time, maintenance personnel
representation of a real or imaginary world
High-Fidelity Process Simulation and Virtual
can participate in training using avatars or
in which the user experiences real-time
Walkthrough Plant Environment. EYESIM
in “first person” through VR models of the
interactions and the feeling of actually being
provides complete Plant Crew Training
process machinery and layout. Therefore,
present.
to improve skills that are safety-critical by enabling operators to perform tasks in
maintenance issues involving diagnostics, timing and procedures can be highlighted
VR technology is well developed and
a simulated environment, allowing them
and consequently optimised.
cost-effective, even for smaller organisations
to react quickly and correctly, facilitating
or companies who might be considering
reactions in high stress conditions and
its use. The flexibility of VR-based training
instilling standards for team training and
systems means that they are simple to
communications.
VR in Safety Using VR, field operators feel completely
configure, use and will form an increasingly
immersed and perceive the virtual
important element of new training systems.
environment as if it was the real plant. By
The EYESIM solution is comprised of a modelling engine, powered by SimSci-
simply putting on their goggles, they are
The ability to simulate complex processes
Esscor’s DYNSIM; services through the
able to see stereoscopically the spatial
by virtual actions means that trainees
SIM4ME bridge and is coupled with a high-
depth of the surroundings, walk-through the
experience an environment that changes
performing Virtual Reality Engine and a high
virtual plant and “feel” it. 3D spatial sound
over time. At the same time, using computer
quality 3D Modelling/Scanning toolset.
contributes to this natural feel, as does the
models of real equipment is risk free and
ability to perform tasks using different hand-
allows endless experimentation without the
September/October 2012 | 65
Gerhard Greeff – Divisional Manager at Bytes Systems Integration
Rip and replace or revamp and rejuvenate? Manufacturing 2.0 compliant solutions may eliminate the question altogether
Companies replace systems or technologies
last 5 or 10 years). But should it be replaced
in the plant have already moved on to new
when: They feel the technology does not do
with a different technology, or should it be
technology as a result of the benefits to be
the job anymore; The technology does not
upgraded or rejuvenated? This is a question
gained (such as speed, processing power
provide critical functionality inherent in other
that is often asked by companies, especially
and stability), a SCADA system still running
more modern technologies; or The support
when they see the cost of the upgrade.
on Windows NT will not be maintainable.
cost for the current technology becomes too
Not only from a software perspective,
expensive.
Unsupported technology
When a specific technology cannot do the
There is a definite benefit in keeping
operating systems such as Windows NT. The
job anymore, it should be replaced. This is
all systems current in terms of software
risk of staying with the outdated technology
true whether the technology is at the ERP
releases and upgrades. Unfortunately this
in this case is high and may result in the
level (when the company has out-grown the
is a fact often overlooked by companies
plant becoming unstable, unsafe or stopping
small bookkeeping system for instance),
for short-term gain. Defaulting on yearly
altogether. A business case can thus be
at the MOM level (when the bespoke-
software maintenance may result in a
made for replacement.
developed system is just too cumbersome
yearly financial gain and reduce operating
to maintain or all the skills to maintain it
cost, but the end result is most often that
The cost of getting the software back on
have been lost) or at the control level (when
the software becomes inadequate for the
support to enable upgrade to the latest
the SCADA/PLC or DCS is at the end of
changing information needs and technology
version (in order to access the newer
its life as it has not been upgraded for the
advances in other areas. If all other systems
functionality or just to be able to buy a
but also from a hardware perspective as current hardware is incompatible with older
66 | www.protocolmag.co.za
Rip and replace or revamp and rejuvenate?
replacement server) then seems prohibitive
functionality that can be provided by the
direction the company is adopting. The
and companies often go to market to
current technology.
management level of the plant may also resist the change, as the new technology
replace the installed technology with another. This is obviously not the fault
In the above cases, the business-case will
may highlight inefficiencies in the process
of the technology provider, but rather a
not be made as result of a risk to production
and the manipulation of data that was
result of the short-sightedness of previous
or human life, but will require a return on
possible with the old technology. This may
management and executives of the plant.
investment motivation. The questions asked
not be possible with the new technology,
for this type of replacement would therefore
resulting in reduced financial benefits (such
be around the quantifiable benefit that can
as production bonuses). Without the correct
be derived by the increased functionality.
behavioural change management, providing
Extravagant cost
all levels with the vision of the integrated
In some cases, software is at the latest version, but the continued support cost of the solution seems extravagant and without
Change in management personalities
landscape, providing a skills-development plan and adjusting the performance metrics used to calculate rewards, this initiative will
any apparent additional benefit. In this
be bound for failure.
case, companies often compare the licence
When management is restructured or a
support cost of the current solution with
specific architectural influencer leaves the
the cost of a complete solution re-build
company, the architectural vision of the
using a different vendor technology. If the
company often changes. For instance,
current system can be replaced in totality
the head of (or a powerful minority group
In some cases rip-and-replace projects
with a different technology, with additional
within) architecture may have been staunch
are implemented to “standardise”
value-adding functionality not provided by
supporters of Oracle. They pushed for all
manufacturing applications. This
the current solution, then obviously the rip-
databases to be based on Oracle. Due
standardisation strategy is often the
and-replace initiative would have a strong
to the influence of these architects within
brain-child of a small group, with executive
business case. When making this decision,
the management structures and their
support but often lacking general business
the disruption to production, the retraining
persistence regardless of resistance, the
support. As a strategy, this is not necessarily
of technical resources and the change-
strategy gets implemented at most levels of
a bad one as standardisation bring benefits
management of personnel adopting the new
the organisation under their direct influence.
such as the easy transfer of skills between
solution will be critical to consider as these
Should these architects leave the company,
sites, reduced spares stocks and less licence
would be the major barriers to success.
the strategy may change to Microsoft almost
contracts to manage. According to MESA
overnight. Similar technology strategy
International and Gartner however, these
Perception of inadequate functionality
changes can happen at SCADA, DCS and
groups have misunderstood the concept
MOM levels as well.
of “standardisation” at the manufacturing
If the technology is at the latest version,
Often, the change in strategy is embraced
focussed on standardising integration
but still does not provide the required
quickly and painlessly, especially if the
concepts such as Master Data Management,
functionality required by business, then
previous strategy was forced through by
Message Structures and Message Services
obviously it will be a good reason to replace
powerful individuals within the architectural
to transport data between systems.
it. In the current technology landscape
structure. The reasoning for the change in
however, most technologies provide very
strategy may not always make sense to all
From a business perspective, the strategy
similar functionality, but it may be that
levels of the company and some resistance
may be even less valid, as individual
the current implementation doesn’t have
may result. However, the new architectural
businesses have specific needs and
licences for the value-adding functions.
strategy, if sponsored at the highest level
technology skills suited to their specific
To rip-and-replace in this case may not be
will be pushed through and it will eventually
environments. A rip-and-replace initiative
the right thing to do and revamping or
be implemented throughout the company,
will mostly be resisted by business as it
rejuvenating may be more worthwhile.
regardless of general acceptance.
will involve huge change throughout the
To decide between replacement or
Architectural change
Solution standardisation
technology level. They should rather have
manufacturing facility. Business in this rejuvenation most often companies opt
case would rather go for a technology rejuvenation initiative as they would see it as
for replacement. This decision, more often
In the cases where solutions are considered
than not, has nothing to do with the actual
for rip-and-replace due to changes in the
vendor technology itself. The decision is
architectural landscape of a company, the
taken as result of architectural changes
initiative often gets resistance from all levels.
within the company solutions landscape,
The operators want to continue using the
In some cases, solutions are inadequate for
the vision of solutions standardisation or a
current system as they are familiar with it and
business needs in their current form. They
change in personalities within the IT, C&I
don’t know how the new system will work.
may be some upgrades behind or they may
or information management executives.
The C&I personnel will resist the change as
be at the latest version but without some
The decision is therefore often a biased
they may not want to learn new skills and
functionality that may only be available in
decision without any relevance to the actual
they may not agree with the architectural
other modules not owned by the company.
less disruptive.
Solution rejuvenation
September/October 2012 | 67
In these cases the company may decide to
(around message and data management),
upgrade the solution to the latest version
M 2.0 architecture will eliminate the need
or to acquire the modules containing the
for ripping out systems to replace them
additional functionality. These initiatives may
with others providing mostly the same
even involve the rejuvenation of the solution
functionality. An M 2.0 Architecture initiative
PMC delivers an integrated solution strategy
visualisation to give it a different “look
may not be as flashy as a rip-and-replace
and implementation practice designed to
and feel”. Depending on specific business
initiative and may take longer to implement,
help organisations leverage their installed IT
needs, a rejuvenation project may add a lot
but from a business perspective, it can add a
environment and enable them to increase the
more value and be a lot less disruptive than
lot more value.
ROI from their overall solution investment.
a rip-and-replace project.
PMC is a division of BYTES Systems Integration
Manufacturing 2.0 architecture
About Bytes Process Management and Control (PMC)
and operates primarily in the Manufacturing IT sector. PMC is highly regarded for its
Conclusion Most companies, at one time or another evaluate whether they need to replace
achievements in implementing integrated MES,
In most cases of change due to “inadequate
or rejuvenate a system. Decisions should
MIS, EMI, SCADA and other plant automation
functionality”, a change in manufacturing
be based on sound strategic reasoning,
solutions.
systems vision may eliminate the need
combined with a valid business case and
for any rip-and-replace projects. A
underpinned with a thought-through change
PMC boasts an impressive 15-year track
Manufacturing 2.0 (M 2.0) architecture will
management plan to ensure success. Make
record of successful consulting and solution
enable functionality to be added at most
the decision for any other reason at your
implementations. PMC specialises in assisting
architectural levels within a standardised
peril.
its customers to achieve operational excellence
integration framework, without the need
by combining their experience in industrial
to replace source systems. Where systems
For more information, contact :
processes and information technology to
lack certain functions, these functions can
Gerhard Greeff,
deliver value-adding solutions. These solutions
be provided by other systems, all within the
Divisional Manager: Bytes PMC
include all levels of industrial IT such as:
same M 2.0 framework. Combined with a
Cell : (+27) 82-654-0290
real technology “standardisation” initiative
Mailto: gerhard.greeff@bytes.co.za
• Manufacturing application needs analysis and strategy formulation, • Enterprise Manufacturing Intelligence (EMI) solutions, • Manufacturing Execution Systems (MES), • Process monitoring and control systems (SCADA/PLC), • Equipment anomaly detection and failure prediction/online condition monitoring (OCM), as well as • Integrating these multi-level industrial information systems into the ERP
68 | www.protocolmag.co.za
Modernisation dictionary
Modernisation dictionary Acronyms APACS
Application Access and Control System
DCS
Distributed Control System
FDT
Field Device Tool
embedding ActiveX controls onto web
available means of connecting industrial
pages.
electronic devices. The main reasons for the extensive use of Modbus in the industrial
Fieldbus
environment are:
Fieldbus is the name of a family of industrial
• It has been developed with industrial
computer network protocols used for realHART
Highway Addressable Remote Transducer Protocol
HMI
Human-Machine Interface
I/O
Input/Output
OEM
Original Equipment Manufacturer
OLE
Object Linking and Embedding
OPC
OLE for Process Control
OTS
Operator Training Simulator
PMP
Project Management Professional
SCADA
Supervisory Control And Data Acquisition
VR
Virtual Reality
WDPF
Westinghouse Distributed Processing Facility
applications in mind
time distributed control, now standardised as IEC 61158.
• It is openly published and royalty-free
A complex automated industrial system
• It is easy to deploy and maintain
— such as manufacturing assembly line — usually needs an organised hierarchy of controller systems to function. In this
• It moves raw bits or words without placing many restrictions on vendors
hierarchy there is usually a Human Machine Interface (HMI) at the top, where an operator
Modbus allows for communication between
can monitor or operate the system. This
many (approximately 240) devices connected
is typically linked to a middle layer of
to the same network, for example a system
programmable logic controllers (PLC) via a
that measures temperature and humidity
non-time-critical communications system
and communicates the results to a computer.
(e.g. Ethernet). At the bottom of the control
Modbus is often used to connect a
chain is the fieldbus that links the PLCs
supervisory computer with a remote terminal
to the components that actually do the
unit (RTU) in supervisory control and data
work, such as sensors, actuators, electric
acquisition (SCADA) systems. Many of the
motors, console lights, switches, valves and
data types are named from its use in driving
contactors.
relays: a single-bit physical output is called a
ActiveX
coil and a single-bit physical input is called a
Marshalling
discrete input or a contact.
software components in a programming
In computer science, marshalling is the
.NET
language-independent way. Software
process of transforming the memory
applications can then be composed from
representation of an object to a data format
The .NET Framework (pronounced dot
one or more of these components in order
suitable for storage or transmission and it
net) is a software framework developed by
to provide their functionality.
is typically used when data must be moved
Microsoft that runs primarily on Microsoft
between different parts of a computer
Windows. It includes a large library and
It was introduced in 1996 by Microsoft as
programme or from one programme
provides language interoperability (each
a development of its Component Object
to another. Marshalling is similar to
language can use code written in other
Model (COM) and Object Linking and
serialisation and is used to communicate
languages) across several programming
Embedding (OLE) technologies and is
to remote objects with an object, in this
languages. Programmes written for the
commonly used in its Windows operating
case a serialised object. It simplifies
.NET Framework execute in a software
system, although the technology itself is not
complex communication, using custom/
environment (as contrasted to hardware
tied to it.
complex objects to communicate instead of
environment), known as the Common
primitives.
Language Runtime (CLR), an application
ActiveX is a framework for defining reusable
virtual machine that provides important
Many Microsoft Windows applications — including many of those from Microsoft
MODBUS
services such as security, memory management and exception handling. The
itself, such as Internet Explorer, Microsoft Office, Microsoft Visual Studio and Windows
Modbus is a serial communications protocol
class library and the CLR together constitute
Media Player — use ActiveX controls to
published by Modicon in 1979 for use with
the .NET Framework.
build their feature-set and also encapsulate
its programmable logic controllers (PLCs).
their own functionality as ActiveX controls
Simple and robust, it has since become a
The .NET Framework’s Base Class Library
which can then be embedded into other
de facto standard communication protocol
provides user interface, data access,
applications. Internet Explorer also allows
and it is now among the most commonly
database connectivity, cryptography,
September/October 2012 | 69
web application development, numeric
Turbomachinery
algorithms and network communications. Programmers produce software by
In mechanical engineering, turbomachinery
combining their own source code with
describes machines that transfer energy
the .NET Framework and other libraries.
between a rotor and a fluid, including
The .NET Framework is intended to be
both turbines and compressors. While a
used by most new applications created
turbine transfers energy from a fluid to
for the Windows platform. Microsoft also
a rotor, a compressor transfers energy
produces a popular integrated development
from a rotor to a fluid. The two types of
environment largely for .NET software called
machines are governed by the same basic
Visual Studio.
relationships including Newton’s second Law of Motion and Euler’s energy equation
PROFIBUS
for compressible fluids. Centrifugal pumps are also turbomachines that transfer energy
Process Field Bus is a standard for field bus
from a rotor to a fluid, usually a liquid, while
communication in automation technology
turbines and compressors usually work with
and was first promoted in 1989 by BMBF
a gas.
(German department of education and research) and then used by Siemens. It should not be confused with the PROFINET standard for Industrial Ethernet. PROFIBUS is not an openly published and royalty-free protocol as older ones like MODBUS.
70 | www.protocolmag.co.za
Acknowledgement: Wikipedia
Events - MESA SA “Adapt or Die” 2012 Conference
s e c i v r t e r S o p p u S d an
September/October 2012 | 71
Invensys Sentinel Services In a Nutshell ... Invensys offers advanced remote services technology that enhances our ability to deliver higher availability and reliability of plant assets to your company.
Key benefits • Increased uptime • Frees you to focus on looking after production rather than control systems
Key features • 24/7/365 remote monitoring and notification of issues
Who’s supervising the supervisors?
We achieve this by installing special “agent software” on each Wonderware server located at your sites. These agents monitor
You trust your Invensys Wonderware
the system on a 24x7 basis to ensure that
Industrial IT solutions to supervise your
critical resources are performing within best
wealth-creating processes but who’s
practice norms.
• Detect and rectify issues or problems before they become mission-affecting • Provide better management of system resources to improve asset performance
supervising them? Let Invensys Sentinel • Streamline diagnosis process
Services (ISS) be your SCADA’s SCADA
If an unacceptable threshold is reached, an
by remotely and constantly monitoring
alarm is raised and Invensys engineers are
and reporting 24/7 on the KPIs of your
alerted before an issue develops. Remote
Wonderware-based systems so that
connectivity is also designed to ensure
potential problems can be nipped in the
that, if there is a problem, Invensys experts
bud. This will give you the peace of mind
can work with you to make appropriate
you need to focus on improving your
adjustments to correct the issue and return
company’s bottom line rather than looking
your system to normal operation quickly and
after systems.
easily.
Using technology to provide world-class support
The process
Reporting
• Fast and systematic event resolution eliminates trial and error and cuts costs • Clear and regular reports provide insight into possible improvements
Our event management system monitors
A key aspect of Invensys Sentinel Services is
Peak performance in our operating plants is a
anomalies or events that occur in the
feedback to you. As a result, we ensure that
continuous process that is being threatened
Wonderware customer environment and
we provide monthly system health status
on a daily basis. As skills scarcity increases,
focuses on detecting issues and generating
reports which include:
most production technicians are stretched
meaningful notifications. These notifications
to the limit with their daily tasks. Little time is
are reported to the Invensys Command
left to maintain the running software systems
Centre which offers a single point of contact
and very few can find the time to develop and
for customer incidents and requests.
maintain specialist knowledge to diagnose
• Overall health status for the month • Critical, major, medium and minor system issues and errors for that month
faults on these systems. • Changes or corrections made to fix As a result, Invensys offers ISS whose job is
errors that occurred in the Wonderware
to monitor the performance of your Invensys
environment
Wonderware assets — continuously.
72 | www.protocolmag.co.za
Invensys Sentinel Services
• Proposals for Wonderware system modifications to ensure that the system
Optional value-added services
conforms to best practice standards
Contact us For more information please contact:
• Anti-virus reporting
Monitored events
Zaine Domingo, ISS Product Manager — Invensys Operations Management
• Wonderware and Microsoft patch Monitoring includes examining the KPIs
management
of the Wonderware System Platform and Historian, hardware performance, event logs,
T +27 (0)11 607 8191 | 0800 INVENSYS | zaine.domingo@invensys.co.za
• Operating system platform support
Wonderware machines (where applicable) among others. There is also a monthly audit of OS, Windows and Wonderware version control, Wonderware licence status, IP configuration and more.
September/October 2012 | 73
Support – Customer FIRST Maximise asset performance
to meet contractual obligations to your customers and the loss of business that
Downtime costs businesses millions of Rand
Comprehensive Services
- Customer FIRST support gives you options to maximise productivity by keeping your operations running smoothly.
In a nutshell ...
may ensue. • Customer FIRST also gives you access to Invensys technical resources to
Customer FIRST is not just technical
help you ensure that your system is
support, it’s a comprehensive
Outages, both planned and unplanned,
back to capacity in as short a time as
programme to help you manage your
are costly; businesses increasingly need to
possible. Our world-class global service
systems and protect your investments.
employ effective pre-emptive strategies
organisation is available locally, so the
to reduce risks and employ efficient and
help you need is never far away.
Real Value
effective resourcing strategies to ensure that non-productive time is kept to a minimum.
Asset performance is not just about
Customer FIRST members enjoy the
maximising availability though; you need
many benefits of a closer collaborative
Customer FIRST is not just technical support,
to ensure that your assets are working to
relationship with Invensys.
it’s a comprehensive programme to help
their maximum potential. You also need
you manage your systems and maximise the
to minimise the risk to your business of
performance of your assets.
missed schedules, poor quality or regulatory violations, with the business consequences
Downtime hurts - Customer FIRST can help
• Responsive services • Depth of expertise
that may follow. • Proactive planning Customer FIRST gives you proactive remote
Even the most reliable equipment requires
health monitoring services to spot warning
downtime, perhaps for routine maintenance,
signs before problems occur and advanced
preventative maintenance, upgrades or
consulting services to tune your systems to
replacement. You need to ensure that
maximum performance.
downtime is kept to a minimum and to
• Continuous performance monitoring • Emergency contingency provisioning • Deep discounts on hardware
as a result.
Customer first – our mission: your success
• Software and services
• Customer FIRST provides you with
ensure that there is minimal production loss
Customer FIRST membership gives you
These important elements make the
access to great hardware maintenance,
access to award-winning technical support,
Customer FIRST membership an
software maintenance and comprehensive
hardware and software maintenance
essential part of your business success.
lifecycle management services to help
services, lifecycle management and remote
you optimise your planned downtime and
Services, training and consulting services
minimise unplanned downtime events.
and much more. The programme provides you with comprehensive services and flexible
Recovery time is critical and any delays
options to choose exactly the right kind of
in acquiring either replacement parts, or
programme to suit your business needs and
the expertise required to quickly resolve
help you to maximise asset performance.
problems, can have a significant financial impact on your business.
Contact information
• Customer FIRST provides you with timely
Support Telephone Number:
access to critical spare parts with the
0861-WONDER (0861-966337) or
ability to manage spares more easily and
0800-INVENSYS (Toll Free)
ensure the reliability of your systems. E-mail: What’s more, extended downtime presents other risks to your business such as failing
74 | www.protocolmag.co.za
support@wonderware.co.za or
support@invensys.co.za
2012 Training Schedule
2012 Training Schedule (Johannesburg)
i
Did you know that your bottom line is directly proportional to the effectiveness of your workforce?
InTouch Part 1 Fundamentals (includes New Graphics) • 3 – 7 September
Historian (includes ActiveFactory and Wonderware Information Server)
• 8 – 12 October
• 17 – 21 September
• 29 October – 2 November
• 15 – 19 October
• 26 – 30 November
• 12 – 16 November
InTouch Part 2 Advanced (includes New Graphics)
• 3 – 7 December
NOTE: The dates shown apply to training at our offices in Bedfordview, Johannesburg. Regional training is presented on demand. A minimum of six delegates is required to arrange a course.
Regional training venues: Durban: Khaya Lembali, As the owner of some of the world’s
• 10 – 14 September • 5 – 9 November
Morningside.
most popular, advanced and versatile industrial automation, information and
Cape Town: Durbanville Conference
MES software solutions, you’ll want to
Centre.
get the most from your investment and
System Platform – Application Server (includes new graphics)
that includes getting the best training
Port Elizabeth: Pickering Park
in the business. We routinely train about
Conference Centre, Newton Park.
600 professionals like you every year not only on how to use our solutions but how
• 1 – 5 October
to turn our product features into real business benefits.
• 19 – 23 November
So, let us suggest a training curriculum best suited to your needs. For all your training requirements, contact Emmi du Preez at emmi.dupreez@wonderware.co.za or call her on 011 607 8286
September/October 2012 | 75
Use Protocol Magazine to generate business opportunities Protocol magazine continues to be well
you’re a solution supplier) or recognition
The Guideline is in the form of prompts to
received on a bi-monthly basis by 6500
(if you’re an end-user)
which you supply the answers to the best of your ability. This, together with the graphical
industry professionals like you, at every level of the country’s leading mining and manufacturing companies. You can
• It must generate market awareness of your capabilities
information required, will be used to write the article which will be sent back to you for editing, approval, etc.
leverage this highly-qualified readership to be heard.
• It must do all that at a reasonable cost
How do you promote yourself right now?
Protocol magazine meets all these criteria.
The Permission to Publish form must be signed by the end-user of the installation and system integrator / solution vendor
Some of the things you might be doing could include inserting opinion pieces,
If you’re an end-user, your stakeholders are
(if applicable) before work on the article is
adverts, editorials and other material
most interested to know how well you’re
started. This ensures that all the work that
into South Africa’s leading manufacturing
looking after their interests by lowering costs
goes into compiling the story will not be
and mining magazines. A good choice
and improving efficiency. Your colleagues
wasted.
since these are excellent and professional
in the industry are keen to see how you’ve
publications that land on decision-makers’
implemented Wonderware solutions so that
You are free to use the completed success
desks every month.
they can evaluate if these will have the same
story in any marketing sense you wish and
benefits in their environments.
you have hundreds of examples on our web site and in past issues of A2ware and
What Protocol offers is all the advantages of a professional magazine with a large
If you’re a system integrator, end-users
circulation but the cherry on the cake is
want to know what you’ve done so that they
that all the readers of Protocol have one
can consider you as a solution supplier for
thing in common – Wonderware solutions
their next project.
FutureLinx.
Opinion Pieces: Once again, there’s no cost involved and
in the areas of SCADA, MES, EMI, BPM and enterprise integration – in fact, anything to
If you’re a hardware or software vendor,
you don’t have to worry about probably
do with industrial and corporate production
end-users and system integrators want to
not having majored in English. Decide on a
IT. Everything in Protocol is aimed at helping
know about how well your offerings work
central theme and the idea(s) you want to
end users get more from their Wonderware
in the Wonderware environment and how
put across, then jot down all the reinforcing
investment and trigger them to look at new
they can help them do a better and more
arguments you can think of (as well as
possibilities. Nobody wants to reinvent a
cost-effective job.
references if applicable). Also include any supporting graphics you feel will better
costly development or investigation wheel to stopping that happening.
What medium will work best for you?
Let’s think for a minute about your perfect
Success stories:
and what you have to offer will go a long way
illustrate the point. Send your draft article to your account manager
you:
They won’t cost you a cent and you don’t have to write them. Simply send an e-mail
• It must convey your message in a
to your account manager stating that you
professional manner to a large, targeted
have the makings of a good story and why
and qualified audience
you think it is so. You will then be sent a
• It must generate incremental business (if
76 | www.protocolmag.co.za
and, if necessary, we’ll make the necessary edits before returning it to you for approval.
promotion vehicle and what it should do for
Comments to the editor, Q&As, Product and/or service information:
Guideline and a Permission to Publish form
Send your submissions to Denis your
to complete and return.
account manager and they (as well as the
Use Protocol Magazine to generate business opportunities
answers) will be published in the next issue
So what are we really saying?
(if interesting and relevant).
and we have made it as easy as possible for As an end-user or supplier of Invensys
Material formats
In other words, what you have to say matters you to say it!
Wonderware and associated solutions, you form part of the world’s largest ecosystem
You will be talking to people with the same
Text – In Microsoft Word format
of professionals in the fields of industrial
reality as you and who have the same
Graphics – In PowerPoint, Bitmap or JPEG
automation and the delivery of actionable
problems and concerns.
format (the last two in the highest possible
intelligence from the shop floor to the top
resolution you have)
floor.
Advertising:
That makes you pretty special.
For all your advertising requirements –
That makes what you have to say significant
including the drafting of effective adverts
and important.
So, what we’re really saying is, use Protocol magazine to say what you believe needs to be said.
from scratch – contact Heather Simpkins at The Marketing Suite.
i
Did you know that if you don’t talk to anyone, they’re not likely to talk to you or send orders? September/October 2012 | 77
On the lighter side
can we explain the success of those we don’t like?” • Who is General Failure and why is he reading my hard drive? • 12 years ago I married a lovely young
• We are born naked, wet and hungry. Then things get worse. • Make it idiot proof and someone will make a better idiot. • He who laughs last thinks slowest
virgin and if that doesn’t change soon, I’m gonna divorce her.
• Always remember you’re unique, just like everyone else.
• Out of my mind. Back in five minutes. • Lottery: A tax on people who are bad at • Cover me. I’m changing lanes. • Sometimes I wake up grumpy; Other times I let her sleep • I want to die in my sleep like my grandfather - not screaming and yelling
math. • Very funny, Scotty. Now beam down my clothes. • The sex was so good that even the neighbours had a cigarette.
like the passengers in his car.... • Be nice to your kids. They’ll choose your • The gene pool could use a little chlorine.
nursing home.
In this issue, we check if you’ve got a head for heights and present you with another bunch of those philosophical one-liners
• When you do a good deed, get a receipt, in case heaven is like the IRS.
• There are 3 kinds of people: those who can count and those who can’t.
that will give you some insight into why headshrinkers can charge what they do:
• I took an IQ test and the results were negative.
• I like you, but I wouldn’t want to see you working with subatomic particles.
• Any woman can have the body of a 21-year-old, as long as she buys him a few drinks first.
• If we aren’t supposed to eat animals, why
• I killed a 6-pack just to watch it die.
are they made of meat? • Sex on television can’t hurt you unless you
• “The world is governed more by appearances than realities, so that it
• Time is the best teacher; Unfortunately, it
is fully as necessary to seem to know something as to know it.”
fall off.
kills all its students! • Knowledge is power, if you know it about • Warning: Dates in Calendar are closer
the right person.
than they appear. • “When I was born I was so surprised I didn’t talk for a year and a half.”
• At every party there are two kinds of • Give me ambiguity or give me something else.
• “We must believe in luck. For how else
78 | www.protocolmag.co.za
people: those who want to go home and those who don’t. The trouble is, they are usually married to each other.
On the lighter side
• Get the facts, or the facts will get you. And when you get them, get them right,
• Sometimes I think I understand everything and then I regain consciousness.
or they will get you wrong.
• “Just because something doesn’t do what you planned it to do doesn’t mean it’s useless.”
• I have never understood why women love • What is the most important thing to learn in chemistry? Never lick the spoon. • I was at this restaurant. The sign said
cats. Cats are independent, they don’t
• “My family told me to stop having
listen, they don’t come in when you call,
intimate dinners for four, unless there are
they like to stay out all night and when
three other people.”
they’re home they like to be left alone and
“Breakfast Anytime.” So I ordered French
sleep. In other words, every quality that
Toast in the Renaissance.
women hate in a man, they love in a cat.
• When a man says he approves of something in principle, it means he hasn’t the slightest intention of putting it into
• Genius may have its limitations, but stupidity is not thus handicapped.
• Personality can open doors, but only
practice.
character can keep them open. • Cleavage is something you can look down
• Life is pleasant. Death is peaceful. It’s the transition that’s troublesome.
• It is a sad fact that 50 percent of marriages other half end in death. You could be one
• “Today’s public figures can no longer write
of the lucky ones!
their own speeches or books and there is some evidence that they can’t read them either.”
decides; sometimes he decides correctly, but he always decides.
between them is that some admit it. I
• If a man is talking in the forest and there wrong?
• An executive is a person who always
• All men are frauds. The only difference myself deny it.
is no woman there to hear him, is he still
on and approve of at the same time.
in this country end in divorce. But hey, the
• Most human beings have an almost infinite capacity for taking things for granted.
• To do is to be [Descartes]. To be is to do [Voltaire]. Do be do be do [Frank Sinatra].
• Mediocrity knows nothing higher than itself, but talent instantly recognises
• I like pigs. Dogs look up to us. Cats look down on us. Pigs treat us as equals.
• Kinky sex involves the use of duck duck.
• An adventure is only an inconvenience rightly considered. An inconvenience is an adventure wrongly considered.
• Elections are won by men and women chiefly because most people vote against
• An intellectual is a person who has
somebody rather than for somebody.
discovered something more interesting than sex.
• My wife thinks “freedom of the press” means no-iron clothes.
genius.
feathers. Perverted sex involves the whole
• I’m a psychic amnesiac. I know in advance what I’ll forget.
• In real life, unlike in Shakespeare, the sweetness of the rose depends upon
• You do not need a parachute to skydive.
the name it bears. Things are not only
You only need a parachute to skydive
what they are. They are, in very important
twice.
respects, what they seem to be.
September/October 2012 | 79
Protocol Crossword #56 When you’ve completed the crossword, the letters in the coloured boxes spell out what the reversible nature of Foxboro’s I/A Series DCS means to your migration plans (2,4) Note: This magazine contains the answers to a number of the clues. E-mail your answer to: editor@wonderware.co.za. The sender of the first correct answer received will get a hamper of Invensys Wonderware goodies..
Clues across: 1. The adoption of new technologies and approaches (13) 12. Not DC (2) 14. Can be as big as a berg (3) 15. Sea between Greece and Turkey (6) 16. Australian wild dog (5) 18. Made frantic arm and hand movements (12) 21. Artificial Intelligence Network (3) 22. Swept leaves (5) 23. Audio Frequency (2) 24. Push off the vertical (4) 25. Indefinite article (2) 26. Of or like a donkey (7) 30. Not as dark (5) 31. The thing (2) 32. He works with stone (5) 33. Two-toed sloth (2) 34. He “manages” ladies of the night (4) 36. Manufacturer of TDC2000/TDC3000 that can be upgraded by Foxboro’s I/A Series DCS components (9) 40. Preposition (2) 42. It surrounds a castle (4) 43. Girl’s name (3) 44. Champions (4) 45. Neon symbol (2) 46. End Of Line (3) 47. Every room has one (7) 49. Argon symbol (2) 51. Precipitation (4) 53. Exists (2) 54. Another name for production automation (7,7) 60. Communist (3) 61. Theoretical space phenomenon which could allow faster-than-light and time travel (8) 62. Bone (2) 63. Is attractive or interesting (7) 65. Vertical Take Off (3) 67. Automated Ordering System (3) 68. Albatross, for example (7) 73. _____ to the future (4) 75. Lines (2) 76. Merriment (3)
80 | www.protocolmag.co.za
78. Something inserted within the border of a larger
57. Transmission (abbr.) (2)
one (5)
58. Expression of surprise (2)
79. Name of Invensys Operations Management ‘s
59. __ and behold! (2)
enterprise control system (8)
64. To jab with a finger or stick (4) 66. ___ -Wan Kanobi or sash (3)
Clues down:
69. Alien’s name (3)
1. Moving from one place or circumstance to another (9)
70. ___ Ray DVD technology (3)
2. Sea (5)
71. Radio Frequency Interference (3)
3. You’re probably sitting at one right now, especially if
72. Singing pair (3)
you’re doing this during office hours! (4)
74. Indefinite article (2)
4. Surprise attack by police (4)
77. Nearest Neighbour (algorithm) (2)
5. Nuclear Energy Commission (3) 6. Large tropical lizard (6) 7. Inconsiderate of others (7) 8. American Automobile Association (3) 9. Trinitrotoluene (3) 10. Weird (3) 11. Nickel symbol (2) 12. Modern DCSs make companies more _______ in their ability to respond to changes (5) 13. It’s often distributed (7,6) 17. If you’re a hammer, everything looks like one (4) 19. Scones are traditional for this occasion (7) 20. For example (2) 24. Far Eastern island (6) 27. South African bucks (7) 28. Hangman’s choice (5) 29. Boredom (French) (5) 30. What SARS expects you to do (3) 31. Intellectual Property (2) 35. Legacy DCS which can be easily upgraded with Foxboro’s I/A Series DCS components (5,5) 37. Slippery fish (3) 38. Electrocardiogram (3) 39. The (French) (2) 41. Closest (7) 47. Computerised Numerical Control (3) 48. Integrated Natural Resource Management (4) 50. Spare it and spoil the child (3) 52. They are completely surrounded by water (5) 54. DCS model made by Fisher (6) 55. Hooters (4) 56. It smells (4)
Answer to Protocol crossword #55: Question: What is the Invensys foundation for all applications that now supports virtualisation? Answer: SYSTEM PLATFORM
Measurement Under Control
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