mon 14.50 automation hot cut over abb apc9

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© ABB GroupSeptember 18, 2011 | Slide 1

Keeping the Plant on-line during anAutomation Hot Cutover

John Jones, 19th September 2011, APC9 IChemE, York Conference




Requirement For Change !

Existing Control System

Pneumati

c Control

ObsoleteComputer

Control Systems

Poor Control

Room

Environment

Poor

Reliability

Poor

Information

Flow

High

Maintenance

Costs

Obsolete

Panel

Control




Upgraded Automation System

Integrated Control & Information System

Field bus

MIS

Labs

Optimisation

Maintenance

Systems

APCSafety

Systems

Enabling

Infrastructure




Evolution of Control Systems Upgrade

1788 1922 1959 1968 1975 2000 2011

Time

Watt Governor

The PID Controller

The first industrial

control computer

system

The DCS

The PLC

Panel Pneumatic / Electronic

Early DCS

1996

New Generation

Modern DCS

A B

A = Panel to DCS -> lower complexity

B = DCS to DCS -> Higher complexity




Why do you want to upgrade ?

Drivers:

Obsolescence

Maintenance / Reliability issues

Productivity / Quality

Functionality

Profitability - Business demands

System capacity limits




Requirement

for

changeFeasibility /

Migrationstudy

FEED

Decommissioning

Cut OverProcedures

Detail Design &

Enabling work

Detail Design

Pre Shutdown

workShutdown

Installation

Test &

Commission

Upgraded

Automation

System

Cut Over

Automation Upgrade Road Map

On-line

Shutdown




Shutdown Window,

Advantages

Potential reduction in time for the control system upgrade

Perceived Easy option

Reduced risk & cost

Plant “buy-in”

Disadvantages

Shutdowns are for maintenance/overhaul activities

DCS will always become the critical path – another reason why shutdownsget extended!

Process Cold/black start up on a new DCS system

Control system brought on-line immediately!

No fallback

Plant modifications/projects happening – impact on new DCS




Requirement

for

change

Feasibility /

Migration

study

FEED

Decommissioning

Cut OverProcedures

Detail Design &

Enabling work

Detail Design

Pre Shutdown

workShutdown

Installation

Test &

Commission

Upgraded

Automation

System

Cut Over

Automation Upgrade Road Map: Hot Cut Over




Feasibility / Migration study

Purpose :

Understand the plant (As – is)

Determine where the plant wants to be (2B)

Gap Analysis of “As-is” Vs “2 B”

How will they get there - options

How & When ?




Migration study activities…

Existing Automation system ( & Plant if necessary) is surveyed

Options are investigated

URS (User Requirements Specification) produced

Issued to Automation vendors

Tender analysis performed

Commercial

Technical

Recommendation of options

Budget estimate of project cost

Project programme produced




FEED stage

Chosen migration path validated Site surveyed to validate proposed solution path

Documentation gathered/quality

Cutover points - confirmed

Identification of “How it will be done” with regards the location of the new

DCS equipment

System rationalisation addressed - graphics, redundant areas

Safety - voltages, process

Technical issues resolved with Automation vendor

Estimate refined Critical loops identification - criteria

Identify enabling work if required

Implementation strategy/plan on-line cutover plan




FEED - On-Line Upgrade

Criticality Review (1st Risk Assessment)

Loop by loop assessment of importance / availability

Allocate each loop a criticality grading based upon grading scale developed

for project

Systems implementation review – what can not be done on-line?

Identify enabling work if required

Enabling work

Work required to allow cutover on-line – System Hardware / Process

Implementation plan for enabling work

Some design now or later (shutdown driven)?




End of FEED review - Is everything still OK ?

Implementation strategy still valid in-line with migration study.

Plant operations – no changes

Business buy-in




On-Line Upgrade – Detail Design

Documentation gathered

Enabling I/E Design I/E design

Cabinet design

Cutover points

Ancillary systems design e.g. UPS, lighting,

H&V Cable routing

Control room design - including non-

automation hardware e.g. F&G, Telecoms,

CCTV

Interconnection wiring

DCS vendor liaison

Detailed plan

Pre and Hot Cutover procedures

Reviews




Reviews / Risk Assessment Loop Critically Review

Risk Analysis Study

Implementation Strategy Review

Cut-Over Methods Review

Hazcon Reviews

Training and Validation Requirement Review

Detail design reviews Failure Mode Effect Analysis (FMEA) Review

Ensure that each step in the procedure was thecorrect step to be made and in the correct order

Ensure that there is a fallback position available forevery step

To guarantee that if all the steps are followed in thecorrect order then the result would be a successfulcutover of the loop

Highlight any design or construction/commissioningproblems that may occur

Highlight any tools or specialist equipment that may be

required during the cutover




Measurement Function & Control Complexity

Legacy code issues

Eccentricities of system

Poor documentation ofcontrol schemes

Potential requirement to

reverse engineer system.




On-Line Cutover procedures

What are they ?

Pre-Cutover procedure

Hot Cutover procedure




Hot Cut Over Methodology




Pre Cutover Procedure

Does the new system mimic the old system? – no surprises!!

Cutover point confirmation

Format is a detailed line by line checklist

Ensures loops are operational prior to cutover

Ensures graphics details and alarm pages are correct

Ensures Loop configuration details are correct, including

ranges, alarm settings, titles, controller actions etc.

Check existing plant equipment associated with the Cutover

operates correctly Example: Test manual bypass valves, Do manual hand

jacks work?, etc.

Key stage, risk assessment - Go / No-Go for Hot Cutover




Typical Analogue Input “Pre Cutover Procedure”Method statements that detail loop testing requirements prior to Hot Cutover

Prerequisites

Work control permit in place.

Ferrule & termination details

are in accordance with loop

diagrams.

New transmitter, impulse

lines & secondary isolation

valves are installed in

accordance with hook-up.

New cables are installed,

ferruled & terminated, tight &

secure

New transmitter, impulse

lines & secondary isolation

valves are installed in

accordance with hook-up

Procedure

Check DCS configuration, using

data from the project database

Confirm knife edge terminals

within DCS cabinet are open.

Connect relevant signal source at thetransmitter cutover point as shown on

the loop diagram & hook-up.

Remove DCS alarm suppression.

Close knife edge terminals in

DCS cabinet.

Simulate transmitter input signal to the DCS confirm

the following:

•Correct representation of DCS graphic

•Process alarms active on DCS, if applicable

•Bad PV alarm activates on high & low signal

•Correct representation on graphic

Disconnect signal source &

open knife edge terminals inDCS cabinet.

Confirm primary control button

on the DCS faceplate links to the

correct graphic.

Suppress DCS alarm.

Completion

Complete & sign relevant

section of “loop control

documentation”.




Hot Cutover Procedure

Standard procedure

Complex / bespoke procedure

Format is a detailed line by line checklist

Hot Cutover procedures need to be reviewed using FMEA

process

Written procedure to allow the safe transfer of the existingsystem to the new whilst on-line

T i l A l I t “H t C t P d ”




Typical Analogue Input “Hot Cutover Procedure”Method statements that detail loop testing requirements to complete the Hot Cutover, inclusive of any prerequisites

and post cutover testing.

Prerequisites

Pre-cutover loop tests are complete.

Work control permit is current and

applicable to the loop detailed.

A copy of the loop diagram is

available for reference.

DCS loop isolations are complete, i.e.

knife edge terminals are open.

All relevant test certificates are in

place.

Procedure

Ensure DCS input point is displayed on

the DCS.

Confirm the existing loop is stable,

record the PV.

Identify the field instrument, withprocess, isolate & blow down lines.

Confirm no leaks from isolations.

Carry out any work identified on the field

hook-up.

Confirm DCS input tag is reading zero.

Connect the DCS signal by closing the

appropriate knife edge terminals

Record the DCS PV.

Confirm the DCS and

existing PV’s are similar, if

not find out why before

moving onto next procedure.

Completion

Complete & sign relevant

section of “loop control

documentation”.

DCS alarm suppression is removed

Correct PPE available

With process & using the works

procedure, open isolation valves putting

process onto the transmitter, confirm no

leaks.

Complete & sign changeover

notification label(s) and fix to

appropriate locations.




Develop detailed Pre & Hot Cutover packs

Work Packages for Pre cutover and Hot cutover

Good clear and simple check sheets

Typical sections:

Purpose

Prerequisites

Procedure

Completion

For each type of generic loop develop a detailed method

Involve those who are to perform actual cut-over

Identify the equipment required - special tools, chocks etc.

Test the methods on none critical loops

Perform trial run and follow up with review




On-line Cutover stage

Cutover team

Cut-over team, managed by Commissioning Managercomprising:

DCS / System Engineer

Process Operator / FLM

Technicians / Electrician

Project Designer

Pre Cutover activities:

Follow pre cutover procedures

loops to be cutover as soon as possible

Hot Cutover activities:

Follow plan and Cutover procedures !!!




Decommissioning

Leave old system operator station running for a period oftime - to be used for reference purposes

Can you pull the plug ????




On-line Upgrade - Success factors!

Ensure business understands inherent risks

Operations buy-in to deliver

The project process used

The review process undertaken

The documentation quality

The implementation strategy for cut-over

The cutover team resource

The cutover methods developed

Cutover methods followed

Enabling work

Training




It is very important to remember...

“Plants are process driven NOTEngineering driven!” & “Operations is

always King!”

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