• About US
  • Terms of use
  • Cookie Policy
  • Privacy Policy
  • Advertising guide
No Result
View All Result
BBG Architecture Life
  • Architecture
  • Design
  • Interiors
  • Technology
  • Trends
  • Projects
  • Collections
  • Education
  • House
  • Restaurant
  • Greenhouse
  • Hotel
BBG Architecture Life
  • Interiors

    Miami Beach residence by SAOTA takes indoor-outdoor living to the extreme

    Vision unveiled for London school powered by Thames tide

    Erasmus exchange programme could remain open to UK students after Brexit

    Sou Fujimoto creates ornate bookshelves for Basel installation

    Frank Lloyd Wright merged eastern and western architecture at Tokyo’s Imperial Hotel

    Drone footage captures brutalist Robin Hood Gardens ahead of imminent demolition

    Dan Brunn renovates Frank Gehry-designed LA house for an illustrator

  • Design
    Screen Shot 2019-10-14 at 8.49.03 AM

    The Design Spark 2019 Product Showcase Set to Show Innovations Around Independent Living | Best Brothers Group of Companies

    Ho (left) and Chang sharing EcoWorld’s future plans at the Eco Sanctuary Gallery. (Photos by Low Yen Yeing/EdgeProp.my)

    Malaysia: Universal Design for EcoWorld’s Future Projects | Best Brothers Group of Companies

    A computer model of one of the accessible homes.

    How Gaming Technology is Helping Design More Accessible Homes | Best Brothers Group of Companies

    New Universal Design Guide Aims to make Public Spaces Pleasant for All | Best Brothers Group of Companies

    New Universal Design Guide Aims to make Public Spaces Pleasant for All | Best Brothers Group of Companies

    University Students Design Wheelchair Hand Warmer for Persons with Muscular Dystrophy | Best Brothers Group of Companies

    University Students Design Wheelchair Hand Warmer for Persons with Muscular Dystrophy | Best Brothers Group of Companies

    The Home Innovation Challenge

    UK-based Design Council Focuses on Accessible Home Innovation   | Best Brothers Group of Companies

    Private Transport Provider to Offer an Inclusive Experience in Malta   | Best Brothers Group of Companies

    Autonomous Vehicle Design Should Benefit Broader Group of Potential Drivers   | Best Brothers Group of Companies

    Ikea to Use 3-D Printing to Make Furniture More Accessible for Persons with Disabilities   | Best Brothers Group of Companies

    Ikea to Use 3-D Printing to Make Furniture More Accessible for Persons with Disabilities   | Best Brothers Group of Companies

    Toyota Improves Universal Design Taxicab for Quicker Wheelchair Access   | Best Brothers Group of Companies

    Toyota Improves Universal Design Taxicab for Quicker Wheelchair Access   | Best Brothers Group of Companies

  • Technology
    Dahua USA Releases New LincX2PRO Line Linking Homes with Professional Systems – Dahua Technology USA Inc | Best Brothers Group of Companies

    Dahua USA Releases New LincX2PRO Line Linking Homes with Professional Systems – Dahua Technology USA Inc | Best Brothers Group of Companies

    Dahua Helps Retail Operations Run Smoothly – Dahua Technology USA Inc | Best Brothers Group of Companies

    two people seated on a table and signing agreements Two people standing behind them on a stage.

    Mada Assistive Technology Centre Signs MoU with Korea Trade Promotion Agency | Best Brothers Group of Companies

    A computer model of one of the accessible homes.

    How Gaming Technology is Helping Design More Accessible Homes | Best Brothers Group of Companies

    Government of Canada Announces New Accessible Technology Program Funding Recipients | Best Brothers Group of Companies

    Dahua Technology USA Announces Product Lineup for GSX 2019 – Dahua North America | Best Brothers Group of Companies

    Dahua Technology Partners with Pepper to Bring Heightened Security to Its Video IoT Devices – Dahua North America | Best Brothers Group of Companies

    Dahua Technology Partners with Pepper to Bring Heightened Security to Its Video IoT Devices – Dahua North America | Best Brothers Group of Companies

    India: Assistive Technology for All 2030 Conference Focuses in Infrastructure, Assistive Devices | Best Brothers Group of Companies

    India: Assistive Technology for All 2030 Conference Focuses in Infrastructure, Assistive Devices | Best Brothers Group of Companies

    Private Transport Provider to Offer an Inclusive Experience in Malta   | Best Brothers Group of Companies

    National Federation of the Blind Applauds Introduction of Greater Access and Independence through Nonvisual Access Technology (GAIN) Act | Best Brothers Group of Companies

  • Projects
    Ho (left) and Chang sharing EcoWorld’s future plans at the Eco Sanctuary Gallery. (Photos by Low Yen Yeing/EdgeProp.my)

    Malaysia: Universal Design for EcoWorld’s Future Projects | Best Brothers Group of Companies

    European Commission Provides 20 Cities with Funding for Innovative Projects on Inclusion  | Best Brothers Group of Companies

    European Commission Provides 20 Cities with Funding for Innovative Projects on Inclusion  | Best Brothers Group of Companies

    The Portland Art & Learning Studio Encourages Diverse Projects by Artists with Disabilities | Best Brothers Group of Companies

    The Portland Art & Learning Studio Encourages Diverse Projects by Artists with Disabilities | Best Brothers Group of Companies

    Yoocan Seeks Collaborative Partners, Highlights Projects at Naidex 2019   | Best Brothers Group of Companies

    Yoocan Seeks Collaborative Partners, Highlights Projects at Naidex 2019   | Best Brothers Group of Companies

    Vision unveiled for London school powered by Thames tide

    Climate change forces emergency repairs to “failsafe” Arctic seed vault

    Grenfell Tower fire deaths raise questions about safety of post-war renovations

    Santiago Calatrava’s World Trade Center Oculus continues to leak

    Note Design and Afteroom hack IKEA kitchens to make living room furnishings for Reform

No Result
View All Result
BBG Architecture Life
No Result
View All Result
Home BBG

Taking an Incremental, Multi-Stage Approach When Upgrading Aging DCS Systems

Admin by Admin
January 14, 2020
in BBG
0 0
0
Taking an Incremental, Multi-Stage Approach When Upgrading Aging DCS Systems
335
SHARES
2k
VIEWS
Share on FacebookShare on TwitterShare on Google Share on Linkedin
Taking an Incremental, Multi-Stage Approach When Upgrading Aging DCS Systems


By Stephen Armstrong, Freelance Industrial Writer


As Distributed Control Systems (DCS) age, there can be increasing risks to the process manufacturer.  An old or obsolete DCS system may no longer be supported by the original supplier, spare parts may no longer be readily available, and system performance issues may begin to appear.  With some DCS systems now decades old, system users often know they need to upgrade but find the task daunting given the cost and potential for disruption of operations while the new system is brought online.


Even if process manufactures have installed newer equipment alongside legacy components, there can be considerable challenges maintaining disparate legacy systems, associated spare parts and the different skill sets required to support multiple control system platforms.  This can lead to “islands of automation” that diminish the effectiveness of a user to integrate, control and optimize the entire process from beginning to end.  It may be that the system user has simply outgrown the existing control system due to increased production demands and/or newly added processes.


“Most process manufacturers are looking to maximize their automation investments and run them as long as they can before upgrading or replacing,” explains Dwight Wood, Vice President of Global Sales for Owings Mills, Maryland based NovaTech LLC Process Division whose D/3 DCS system solution was introduced 38 years agoas the first hybrid batch and continuous control architecture.  “A number of process manufacturers have come to us with I/O, controllers and even servers that are 30 to 40 years old.”


When process manufacturers ultimately decide to move forward on an upgrade, however, they often find that their DCS supplier has implemented a new generation of technology that lacks a cost and mission effective migration path to update the existing system often requiring a rewrite of applications programming or a complete “rip and replace.”


Fortunately, ripping and replacing a dead-ended DCS system is not required. 


“Addressing the vulnerabilities that are present with a legacy DCS does not always require a disruptive all-at-once approach,” says Wood.  “For a plant of any scale running at or near capacity, taking down processing lines for any amount of time can be extremely expensive in terms of lost production and business impact.”


Instead, many engineering, operations and procurement teams are opting for a multi-stage implementation over a total system overhaul by phasing in newer DCS servers, controllers and applications.  This approach can be more affordable and less disruptive, while still allowing gaps, points of pain and cybersecurity risks to be addressed immediately.


 


A Multi-Stage Approach


The process typically begins with a consultation and “deep dive” into the current system and application, said Wood. “We begin the process diagnostically to identify the pain points, gaps, operating challenges, and any other potential risks in the current process and control system implementation.  This supports a more targeted approach that focuses on areas of improvement that can bring the greatest impact in terms of operations and addressing risk exposure.”  


A multi-stage migration approach can often begin by integrating new DCS components with new and existing I/O devices. As I/O is one of the most significant investments in an automation upgrade, I/O drops can be replaced in a phased manner over time allowing for spare parts capture from decommissioned drops, phased implementation aligned with plant outage limitations and staggered financial investment.


Another consideration is the need to integrate the DCS system with the existing enterprise systems.  “Customers want more than an effective implementation of the Level 2 automation system,” says Wood.  “They often want improved data capture and the conversion of that data into useful knowledge presented in desktop KPI dashboards that can be utilized at the manufacturing execution level and/or the enterprise ERP level.”


 


The User Interface


A DCS system is a hub of a processor’s operations monitoring key variables such as flow, applied temperatures, pressure, level and material conveying/handling.  The operator user interface brings all the data that is collected from production equipment and the controllers process and present it in a highly “human factored” manner for an operator, generating trends, alarms, etc.   


The NovaTech D/3 interface, for example, displays real time process information in a complete customer-oriented graphical human-machine interface (HMI).  Custom graphics, built using dynamic objects from an extensive library, make it easy for the operator to control the process, enter information, and interact with sequence programs.


Standard Operating Proce­dures, maintenance records, and other information are also available in desktop application formats.  The information can be viewed using common Web browsers to display data from multiple plant sites from anywhere in the world. 


 


A Migration Path into the Future


A DCS replacement is a significant investment that is designed as a long-term contribution to operations. Two key considerations are the system’s migration path and the overall DCS lifecycle cost.


Whether the search for a control system replacement was caused by system limitations or an existing system being “dead ended” by the supplier, process manufacturers want to avoid this situation happening in the future. When considering a project or supplier, the new system should be scalable, flexible and able to upgrade to future releases on an ongoing basis to leverage system updates and improvements.


The D/3 system, for example, was introduced in the early 1980’s.  As a testament to its longevity and flexibility, Wood says the system can still be upgraded with applications written to run on the current version.  Hardware has to be upgraded, of course, but a complete “rip and replace” is not required.  The company refers to it as an evergreen solution based on its demonstrated commitment to protecting the customer’s migration path.


The total lifecycle cost of ownership needs to be factored in any DCS or control system migration or replacement project.  The financial investment in replacing a control system encompasses more than the initial outlay for new hardware, software and engineering services. Process manufacturers need to also consider recurring maintenance, service support and upgrade costs that they will incur over what can easily be a 20-year or more lifespan. 


“A DCS sits on top of an inherently dynamic processing environment made more so as new equipment is added, production lines are expanded, and as issues like obsolescence and cybersecurity present new challenges over time,” explains Wood.  “That is easier to navigate if there is a well-defined system life cycle plan and migration path forward that includes a carefully thought-out execution plan for success.”


About the Author


 


Stephen Armstrong is a Tustin, Calif.-based freelance writer. He has researched and written about industrial technologies, healthcare, automotive and international trade for the past 15 years.

Did you Enjoy this Article?

Check out our free e-newsletters
to read more great articles.

Subscribe Now

Taking an Incremental, Multi-Stage Approach When Upgrading Aging DCS Systems


By Stephen Armstrong, Freelance Industrial Writer


As Distributed Control Systems (DCS) age, there can be increasing risks to the process manufacturer.  An old or obsolete DCS system may no longer be supported by the original supplier, spare parts may no longer be readily available, and system performance issues may begin to appear.  With some DCS systems now decades old, system users often know they need to upgrade but find the task daunting given the cost and potential for disruption of operations while the new system is brought online.


Even if process manufactures have installed newer equipment alongside legacy components, there can be considerable challenges maintaining disparate legacy systems, associated spare parts and the different skill sets required to support multiple control system platforms.  This can lead to “islands of automation” that diminish the effectiveness of a user to integrate, control and optimize the entire process from beginning to end.  It may be that the system user has simply outgrown the existing control system due to increased production demands and/or newly added processes.


“Most process manufacturers are looking to maximize their automation investments and run them as long as they can before upgrading or replacing,” explains Dwight Wood, Vice President of Global Sales for Owings Mills, Maryland based NovaTech LLC Process Division whose D/3 DCS system solution was introduced 38 years agoas the first hybrid batch and continuous control architecture.  “A number of process manufacturers have come to us with I/O, controllers and even servers that are 30 to 40 years old.”


When process manufacturers ultimately decide to move forward on an upgrade, however, they often find that their DCS supplier has implemented a new generation of technology that lacks a cost and mission effective migration path to update the existing system often requiring a rewrite of applications programming or a complete “rip and replace.”


Fortunately, ripping and replacing a dead-ended DCS system is not required. 


“Addressing the vulnerabilities that are present with a legacy DCS does not always require a disruptive all-at-once approach,” says Wood.  “For a plant of any scale running at or near capacity, taking down processing lines for any amount of time can be extremely expensive in terms of lost production and business impact.”


Instead, many engineering, operations and procurement teams are opting for a multi-stage implementation over a total system overhaul by phasing in newer DCS servers, controllers and applications.  This approach can be more affordable and less disruptive, while still allowing gaps, points of pain and cybersecurity risks to be addressed immediately.


 


A Multi-Stage Approach


The process typically begins with a consultation and “deep dive” into the current system and application, said Wood. “We begin the process diagnostically to identify the pain points, gaps, operating challenges, and any other potential risks in the current process and control system implementation.  This supports a more targeted approach that focuses on areas of improvement that can bring the greatest impact in terms of operations and addressing risk exposure.”  


A multi-stage migration approach can often begin by integrating new DCS components with new and existing I/O devices. As I/O is one of the most significant investments in an automation upgrade, I/O drops can be replaced in a phased manner over time allowing for spare parts capture from decommissioned drops, phased implementation aligned with plant outage limitations and staggered financial investment.


Another consideration is the need to integrate the DCS system with the existing enterprise systems.  “Customers want more than an effective implementation of the Level 2 automation system,” says Wood.  “They often want improved data capture and the conversion of that data into useful knowledge presented in desktop KPI dashboards that can be utilized at the manufacturing execution level and/or the enterprise ERP level.”


 


The User Interface


A DCS system is a hub of a processor’s operations monitoring key variables such as flow, applied temperatures, pressure, level and material conveying/handling.  The operator user interface brings all the data that is collected from production equipment and the controllers process and present it in a highly “human factored” manner for an operator, generating trends, alarms, etc.   


The NovaTech D/3 interface, for example, displays real time process information in a complete customer-oriented graphical human-machine interface (HMI).  Custom graphics, built using dynamic objects from an extensive library, make it easy for the operator to control the process, enter information, and interact with sequence programs.


Standard Operating Proce­dures, maintenance records, and other information are also available in desktop application formats.  The information can be viewed using common Web browsers to display data from multiple plant sites from anywhere in the world. 


 


A Migration Path into the Future


A DCS replacement is a significant investment that is designed as a long-term contribution to operations. Two key considerations are the system’s migration path and the overall DCS lifecycle cost.


Whether the search for a control system replacement was caused by system limitations or an existing system being “dead ended” by the supplier, process manufacturers want to avoid this situation happening in the future. When considering a project or supplier, the new system should be scalable, flexible and able to upgrade to future releases on an ongoing basis to leverage system updates and improvements.


The D/3 system, for example, was introduced in the early 1980’s.  As a testament to its longevity and flexibility, Wood says the system can still be upgraded with applications written to run on the current version.  Hardware has to be upgraded, of course, but a complete “rip and replace” is not required.  The company refers to it as an evergreen solution based on its demonstrated commitment to protecting the customer’s migration path.


The total lifecycle cost of ownership needs to be factored in any DCS or control system migration or replacement project.  The financial investment in replacing a control system encompasses more than the initial outlay for new hardware, software and engineering services. Process manufacturers need to also consider recurring maintenance, service support and upgrade costs that they will incur over what can easily be a 20-year or more lifespan. 


“A DCS sits on top of an inherently dynamic processing environment made more so as new equipment is added, production lines are expanded, and as issues like obsolescence and cybersecurity present new challenges over time,” explains Wood.  “That is easier to navigate if there is a well-defined system life cycle plan and migration path forward that includes a carefully thought-out execution plan for success.”


About the Author


 


Stephen Armstrong is a Tustin, Calif.-based freelance writer. He has researched and written about industrial technologies, healthcare, automotive and international trade for the past 15 years.

Did you Enjoy this Article?

Check out our free e-newsletters
to read more great articles.

Subscribe Now

© 2019, Best Brothers Group. All rights reserved.

Tags: AgingApproachDCSIncrementalMultiStageSystemsUpgrading
Admin

Admin

Canada 🇨🇦

0
Confirmed
0
Deaths
0
Recovered

Stay Connected

  • 1.4k Fan
  • 3 Follower
  • 35 Follower
  • 131 Follower

Popular Post

    Follow Our Page


    For all queries regarding print editions of BBG Architecture Life, including change of address, change of payment details requests and back issues, please contact +1-888-224-8688. Email: [email protected]
    • About US
    • Terms of use
    • Cookie Policy
    • Privacy Policy
    • Advertising guide

    Recent News

    Accessibility advocates say Peggy’s Cove viewing deck will ensure safe access for all - Halifax

    Accessibility advocates say Peggy’s Cove viewing deck will ensure safe access for all – Halifax

    January 24, 2021
    • Best Brothers Group
    • BBG Security Cameras
    • BBG Hub Home Automation
    • BBG Renovations
    • BBG Construction
    • BBG Business Partnership
    • BBG I/O Marketing
    • Security Cameras GK
    • Automatic Door Depot
    • About US
    • Terms of use
    • Cookie Policy
    • Privacy Policy
    • Advertising guide

    © 2018 BBG Architecture Life - supports the architecture industry on a daily news by Best Brothers Group.

    No Result
    View All Result
    • Interiors
    • Design
    • Technology
    • Projects

    © 2018 BBG Architecture Life - supports the architecture industry on a daily news by Best Brothers Group.

    Login to your account below

    Forgotten Password?

    Fill the forms bellow to register

    All fields are required. Log In

    Retrieve your password

    Please enter your username or email address to reset your password.

    Log In