Key Considerations for Scoping Reinstrumentation Projects

Copyright © Yokogawa Corporation of America

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Key Considerations for Scoping of Reinstrumentation Projects

Hyonsook Kang Industry ConsultantRetired from Shell – PM/EM

December 13, 2016


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Host: Josh PerryMarketing [email protected]

Presenter: Hyonsook [email protected]

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Key Considerations for Scoping of Reinstrumentation Projects

Hyonsook Kang Industry ConsultantRetired from Shell – PM/EM

December 13, 2016

Modernize or Maintain?

• Are the right people involved – business, projects, plant?

• Is the cost of maintaining the old system worth spending? What is the total cost of ownership?

• How many more years can the existing system last? Can the capability and productivity of the old system be improved?

• Is it safe to operate?• How much will it cost to migrate the system?• What are the benefits and value added features of

the new system?• Downtime for migration and disruptions to operation

and maintenance?• How will future regulations influence operations in

the future?

Top 3 Drivers for Reinstrumentation Projects

• Obsolescence– DCS– SIS– Operator Stations– Field Instrumentation & Wiring

• Safety, Industry Regulations & Compliance

– SIS Regulation– Environmental Compliance Monitoring

• Operational Excellence– Risk of Aging Workforce – Advanced Process Control– Cyber Security

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Obsolescence – Automation Component Lifecycle

Safety, Industry Regulations/ Compliance

• SIS regulations – IEC 61511 becoming more stringent. Different parts of the world not allowing the grandfathering of the existing systems (separation of BPCS & SIS)

• Environmental Compliance Monitoring • Modular Process Automation – Operational

safety.

! Careful consideration of how a possible accident could affect the Owner’s Company in terms of workforce safety, equipment damage and loss of reputation

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Average Dollar Loss per Major Incident by Cause in $MM

Challenges for Operational Excellence

Risk of Aging Workforce – losing senior operators due to retirement. How to fill the gap with increase automation and modular procedure automation

Advanced Process Control – increase throughput in plant for more effective use of capital. Average increase of 4-10% depending on the unit

Cyber Security – as moving towards a “connected enterprise”, moving operations to the shore during emergencies (for offshore), how to protect the networks from these hackers and malware infections.

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People over Age 65

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Typical APC Costs & Benefits

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Cyber Security

• Industrial plants are moving toward the “connected” enterprise and enjoying the merits of connection to information systems

• The control systems installed 10-20 years ago may have obsolete security measures due to long term operation and sophisticated new attacking techniques

6 Steps to Successful Reinstrumentation

Field Survey

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Implementation of Best Practices and Recommendations

System Architecture

Project Scope Identification

• Identify the big pieces

• Explore all the opportunities and do a proper risk analysis

• Maintain a vision of what constitutes success

Reuse of Existing Infrastructure

years


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Obsolescence Dilemma

System & Security Requirements

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Cyber Security Operations & Maintenance

APC

• Increase overall control stability and throughput

Operator Effectiveness

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Control Room Upgrade

• Well designed control room will create synergy and flow in the control rooms. Human centered design philosophy prioritizes safety, health, and comfort.

• Central Control Room Philosophy – increase in operator effectiveness and breadth of operator control and improve communications.

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Modular Procedural Automation

• Automate Procedures to help mitigate risks of aging workforce for typical manual operations.

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Benefits of Operator Training System

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Human Machine Interface Benefits

Time shortening of monitoring cycle

Time shortening of malfunction detection

Prevention of mistaken judgment or maloperation

Reduction of operators’ eyestrain or workload

Inheritance of operation skills


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Alarm Management

DCS/SIS Scope


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Different Upgrade Scenarios

Step by Step Upgrade: component base upgrade unlike a full upgrade. For example, HMI is upgraded without stopping the controllers, or upgrade of controllers in an area of the unit without stopping other controllers.

Competitor System Upgrade: Yokogawa has developed a comprehensive system migration strategy to address competitor systems including Honeywell, ABB, Emerson, Invensys, Siemans, etc, utilizing special marshalling panels and adapter cables to connect terminal panels of existing legacy systems and database conversion tools.

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Different Upgrade Scenarios

• Field Instrument Replacement: intelligent field instruments and process analyzers accumulate diverse field information including process values and diagnostics.

Questions??


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Additional Resources

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Download our Re-Instrumentation eBook to Learn More on This Topic

Key Considerations for Scoping Reinstrumentation Projects

Engineering

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