RETROFIT LARGE CONTROL SYSTEM IN MULTIPLE PHASES
In a control system modernization project, amount of risk for returning to last production in preschedule time, necessity for plant downtime and budget of migration plan against advantage can be gained by new control system conduct customers to choose between these modernizations scenarios:
2-Controller and HMI
Unlike HMI or HMI and controller upgrading solutions that customer has to stay with vendor technology, Switch over to another technology when intended to change the control system completely is a good idea to gain more advantage, although it cannot be always an advantage in all projects. In case of large automation projects like as control system of refineries where there are multiple DCS in the different process areas the best solution for complete changes is to keep vendor technology and implement project in multiple phases.
Phase 1- HMI Migration
By implementing this phase in process online condition, operation efficiency will be increased and operators can gain all advantages of modern operation system. Main automation vendors have developed automatic conversion tools for migrating to new HMI, this is a bump-less change, by utilizing gateway both old and new monitoring system can be operated at the same time, there are many advantages in this solution, the operators can get on job training and all issues may they can find or any adjustment may they need in the new monitoring system will be done before turning the old monitoring system off.
Phase 2- Upgrade Controllers
Replacing controller with newest ones, significantly increase system performance and asset efficiency. For a quick installation and commissioning the production stop only for few hours, IO cabinets and field wiring remained untouched. Succeeding in this phase needs collaboration of the customer. The new logic must be rewrite manually by contribution of the customer.
Phase 3- Complete changes
Outstanding old control system parts replace in phase three. Having experienced and trained technician team at site aside good planning is main factor for 100% succeeding in this phase. Utilizing invented devices and solutions for migration projects like as interface board for adopting old field terminal by new IO modules can make installation and commissioning quicker and significantly will reduce plant downtime. Hot cutover method is one of those effective solutions for fast and safe migration, in a hot cutover plan loops move to new control system during plant running time.
But regardless of solutions and techniques, the most important factor that guarantee 100% success in renovation projects is a good detailed planning for implementing modernization operations during expected plant downtime.
Cost of revenue loss during plant downtime in some plants is higher than budget of new control system There are many tools and solutions in the market for renovation of a control system and the best decision may a customer can get is to choose a reputable independent system integrator among competent candidates in the market to provide them a tailor-made cutover solutions. We have experience in upgrade, revamp and retrofit of multiple projects in different industries like as project 7508.