Invensys Protocol Magazine – "Modernisation – Pain or opportunity?"

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SEPTEM

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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

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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

10 | www.protocolmag.co.za © 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.


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

Achieving competitive and efficient process plant operation is an increasingly tough challenge in today’s fast moving business environment. Selecting the most reliable and longest life measurement instrumentation is more important than ever. Invensys Foxboro offers time proven innovative measurement solutions that make this possible, leading the way with longer life pH, redox and conductivity measurement sensors and instrumentation.

View our full range of measurement tools and instrumentation at: www.invensys.co.za or call 0800 INVENSYS for more information


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When market tastes change. You’ll be ready. Flexibly manage change, while maintaining product quality, consistency and safety with Wonderware and WonderwareMES MESsoftware. software.For Formore moreinformation, information,visit visitwonderware.com/FlexibleMES wonderware.com/FlexibleMES and get a free whitepaper called “Be ready for changing tastes, a new approach to plant software”.

0800 INVENSYS | contact@invensys.co.za | iom.invensys.co.za

© 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.


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