Paul Stewart Marathon
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Transcript of Paul Stewart Marathon
Management of legacy control systems
Paul Stewart, Automation and Control for Energy Conference, May 2011
Marathon Integrated Oil and Gas Company overviewUpstream
Oil and Gas Exploration
Oil and Gas production
Oil sands mining
LNG
Shale gas
Downstream
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Refining
Marketing
Transportation
Distribution
World wide operations
3
Brae area infrastructure
4
Brae Alpha - 1984
Photo
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Brae Bravo - 1987
Photo
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East Brae - 1993
Photo
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Typical control systems on an Oil and Gas Installation
ESD
Safety Instrumented Function logic solvers
F&G
DCS
MCS
SCADA
Gas Turbine control systems
Machinery control, sequence logic
Machinery protection, vibration monitoring
Compressor Anti‐Surge protection
Flow Metering
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legacy control systemLegacy – from the past
A system whose development is complete
A control system which is not a current product
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Obsolete
A product or system is considered obsolescent when an end of life date has been announced
A product or system is considered obsolete once it is no longer available from the original manufacturer, even though parts or components may still bethe original manufacturer, even though parts or components may still be available in the supply chain
Obsolescence is inevitable and requires effective management to reduce the business impact
Ineffective obsolescence management can result in difficulty obtaining spares or support
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Standards
IEC 62402:2007 (BS EN 62402) Obsolescence Management – Application guide
Gives guidance on establishing a framework for obsolescence management
Covers the following areas:‐
Design of new products
New technology insertion into existing products
Support and maintenance of legacy products
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Reasons for keeping legacy systems
The system works satisfactorily and it is therefore difficult to justify replacement.
The costs of redesigning or replacing the system are prohibitive because it is large and/or complex.large and/or complex.
The system requires close to 100 percent availability, so it cannot be taken out of service without a significant impact on production.
The way that the system works is not well understood. This is common on legacy systems where it is likely that the original designers of the system have left the organisation and the system design has either not been fully documented or documentation has been lost.
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Reasons for replacing a legacy control system
The system is unreliable.
The system is unsupportable either by the OEM or after market service providers.
h i ll i h i i lif hi h i ffi i l l k iThe installation has a remaining life which is sufficiently long to make it unlikely that obsolescence can be overcome without replacement of the system.
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Obsolescence management process
Effective management of obsolescence is essential to ensure an optimum
balance between reliability, availability and cost‐efficiency.
Identify – Critical control systems are assessed to identify obsolescence issues
Mitigate – Select and implement the most appropriate obsolescence strategy for each system.
Monitor – Carryout periodic re‐assessments, monitor effectiveness of strategy
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Identify
Control Systems are assessed to identify any obsolescence issues
Hardware, software, documentation, support contracts and competency shall be assessed with respect to obsolescence
A ll i i d f h b d li iAn overall assessment is carried out for each system based on a qualitative approach using a risk matrix and shall take in to account probability and severity of obsolescence. A risk category of low, med or high shall be assigned to each system
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Risk Matrix
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Mitigation strategies
A reactive or proactive obsolescence strategy shall be selected for each of the control systems
Unlikely that one solution will be applicable to all systems, likely to be a combination of solutions across an installation depending on risk to thecombination of solutions across an installation depending on risk to the business, cost, where the system is in it’s lifecycle. replacement, migration/upgrade and life extension
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Reactive obsolescence strategy
Do nothing until the need arises
Suitable only where impact on safety, environment or business is low
This is a positive decision to do nothing
Recovery options:‐
Product search by contacting OEM, after market suppliers, contacts within the industry (other Oil and Gas Operators)
Repair by specialist electronic repairers
Cannibalisation from redundant equipment
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Cannibalisation from redundant equipment
Proactive obsolescence strategies
Replacement
Migration
Upgrade – brought up to date by replacement of obsolete items.
Life extension of existing equipment
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Monitor
The obsolescence assessments on critical instrumentation and control systems is repeated periodically
Active dialog with manufacturers and suppliers to establish end of life dates for systemsfor systems
Monitor obsolescence strategy for effectiveness
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Life extension
The Service Life Extension Program (SLEP), was developed in the 1980s toThe Service Life Extension Program (SLEP), was developed in the 1980s to extend the service life of the US Navy’s aircraft carriers. The concept subsequently expanded to all of the US Navy’s life‐extension programs for ships, aircraft, and combat systems including the NASA Space Shuttle program
SLEP considers factors including safety, reliability, supportability, performance, and cost reduction
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Life extension
Review each of the following areas to understand what is required to extend the
life of the system
Hardware
Software
Supplier management
Training
Technical support
documentation
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Hardware
Lifetime buy from OEM
Aftermarket resellers
Repair
Reverse engineer
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Software
Backups
Ability to modify software
Software emulator to overcome obsolete software or hardware
Well constructed and annotated code to enable reverse engineering
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Spares Management
Clear spares management strategy
Accurate bill of materials
Onsite spares
Offsite spares
Periodic testing of stored spares to ensure they are serviceable
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Competency
Suitably trained and experienced staff on site.
Mixture of formal training, mentoring and hands on experience to build up a skills set.
A i kf i h UK Oil I d kill i i iAgeing workforce in the UK Oil Industry, skills retention is important
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Documentation
Up to date Operation and Training manuals
Maintenance manuals
As built drawings
May be an opportunity to obtain design info for end of life products from OEM
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Supplier Management – Contract award and structure
Sole source or tender?
Good quality contract structure – CRINE, LOGIC standard contracts
Contracts must comply with corporate standards, EU procurement regulations, Oil d G UK l h i d f dOil and Gas UK supply chain code of conduct.
Market conditions – where does the balance of power rest?
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Supplier Management – Managing Performance
Supplier and Purchaser feedback through FPAL process.
Use of KPI’s, metrics, penalty clauses and bonus structure
Hold periodic review meetings
Build an effective working relationship with key suppliers
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Compressor Vibration and Temperature control upgrade
Original CML system
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Compressor Vibration and Temperature control upgrade
Replacement Rockwell XM system with Panelview
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LM5000 gas turbine control system
Replacement control system at FAT
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DCS migration
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East Brae metering system
OEM migration path enabled replacement of flow stream microcomputers with new generation micros
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East Brae metering system
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Questions
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