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Solution in Focus

ICS Modernization Strategy

Solution in Focus

ICS Modernization Strategy

by keystonecntrl
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ICS Modernization Strategy

Intelligently address your aging control system with a modernization roadmap to certainty.

Overview

The Keystone Controls migration strategy is designed to help industry leaders in power & mining make strategically aligned & forward-looking decisions with regard to management of their aging control systems.

With our data driven methodology, we bridge the gap between technical requirement & business strategy, facilitating a conversation between all stakeholders to deliver the most appropriate plan of attack unique to each facility.

Modernization Roadmap

Forethought and careful planning are required to minimize the impact and cost of automation system obsolescence.  To achieve this, it is vital that each plant have a documented automation system life cycle strategy, containing a long term overview plan for the automation system.

In order to establish a baseline for automation system life cycle management, this modernization strategy (and resulting roadmap) provides a step-by-step procedure to take control of a facilities automation system. The strategy is designed to transition facility operators from a state of unknown, in-actionable subjective anecdotes to a state of hard and fast metrics that make the decisions for us.

It establishes a system for continual improvement with which facility operators can maintain control upon a structured framework, providing measurable and objective intelligence for effective and ongoing project selection and scoping.

Informed Decisions

Make informed control system life cycle decisions with actionable data.

Reduce Costs

Reduce system support costs for multiple, aging system technologies.

Extend Life

Extend the life of your existing control system, replacing it only when its really necessary.

Strengthen valuable relationships

Strengthen services relationships with a trusted control system partner.

Optimize life cycle costs

Improve control system total cost of ownership.

Remove Uncertainty

With real data, remove uncertainty in your budgeting process.

Why Modernization?

An aging Control System should be approached with the philosophy that the end user should preserve all of the existing assets that are maintainable, and continue to offer value.  We must evaluate the components of a control system and determine which make sense to replace and which make sense to preserve. This avoids making an unnecessary investment, and assures maximum return on investment.

A robust modernization strategy addresses issues, mitigates risks and identifies opportunities for improvement for aging and obsolete control systems.

When to consider Modinization?

When this happens:

  • Plant trip and alarm systems are unreliable and/or inadequate.
  • Production is inflexible and start-up time is lengthy.
  • Business systems lack meaningful production data.
  • Obsolete system support costs continue to increase.
  • Difficulty in maintaining skills for obsolescence support due to employee turnover

When you’re missing these:

  • Integration of production information with business systems for more informed and timely decisions.
  • Integrating predictive maintenance practices to focus your maintenance resources, saving time and money.
  • Providing actionable field service alerts to operations and maintenance to minimize disruptions to production.

Benefits

  • Informed Decisions- Make informed control system life cycle decisions with actionable data.
  • Reduce costs- Reduce system support costs for multiple, aging system technologies.
  • Improve life cycle costs- Improve control system total cost of ownership.
  • Extend life- Extend the life of your existing control system, replacing it only when its really necessary.
  • Remove Uncertainty- With real data, remove uncertainty in your budgeting process.
  • Eliminate unplanned production loss- Eliminate unplanned production losses from process upsets and trips due to system interruption.
  • Maximize system investment: Maximize system investments and assets, both physical and intellectual.
  • Strengthen relationships: Strengthen services relationships with a trusted control system partner.

The New System should:

  • Offer compelling value- Offer a compelling value proposition and a path to operational excellence.
  • Preserve hardware investment- The system should require minimized hardware investment, and wiring modification, commensurate with risks and improvement opportunities identified.
  • Preserve existing control system investment- The system should preserve graphics, and control strategies.
  • Minimize or eliminate downtime– Modernization work must cause as little disruption as possible to operation.
  • Minimize training cost– Minimize the learning curve for maintenance engineers to take on the new system.

Key Deliverables

  • Conditions assessment– a conditions inventory is a delimited list of issues, risks and opportunities.
  • Risk analysis and mitigation– a comprehensive risk inventory (including opportunities) and a set of control measures upon which project options will be determined.
  • Project options and quantified financials– a crucial component of the modernization strategy is actionable intelligence. Here, a project inventory is created, each with a unique risk and financial profile for consideration and selection.
  • Business case– a comprehensive business case (project defense) for the selected modernization strategy is prepared in order for budgets approval, and for management buy in.
  • Modernization road-map- most often, modernization projects involve a series of micro projects over a period of time. The modernization road-map lays out the months and years ahead to arrive at certainty.
  • Life cycle management plan- the game plan to stay on top of an automation system when the modernization project has achieved its objectives.
  • Obsolescence management plan- if applicable, the obsolescence management plan lays out a precise plan of attack for the trouble free maintenance and support of obsolete automation equipment.

Modernization Paradigms

The Phased Migration

A phased migration aims to minimize downtime and risk, while providing a tangible and compelling business value proposition that will have a real economic impact on your business. It involves a gradual migration over a predefined period.

In this way, it allows end users to evolve the components of their legacy systems that will have the greatest impact on their operations, while preserving the components that have not yet outlived their useful lives.

  • Minimal loss of production
  • Minimal risk
  • Lower project costs
  • Minimal commissioning and startup
  • Preserves investment in existing control systems assets
  • Upgrades easily implemented at opportune times
  • Savings from reduced work and resource demands

The Rip and Replace

The rip and replace, or “vertical migration” is characterized by a single project event where the legacy system is removed and the target system is installed.

This tends to be the default approach to control system life-cycle management, but, as with any project initiative, the project selected must be supported by a compelling business case and value proposition.

  • Greater loss to production
  • Increased risk
  • Higher project costs
  • Long commissioning and startup periods
  • Requires significant hardware changeout
  • Requires significant shutdown and planning
  • Significant complexity overheads
ICS Modernization Strategy

Be Informed to make the right decisions with confidence.

Life Cycle approach

Keystone’s preferred approach to Control System life cycle management incorporates a philosophy of continuous improvement & operational excellence.

The term life cycle implies a beginning, middle and end. In fact, process automation can continually evolve via regular upgrades to new components. Doing so precludes the need to ever entirely replace a system. Through an ongoing evolution process that includes continuous evaluation, selective upgrades and business driven enhancements, its possible to always own a system that continues to grow, perform and provide increasing value.

Approximately 20% of system owners take a strategic life cycle approach to their control system. The rest do nothing or are strictly reactive, making changes only as needed to correct problems.

Presented with the potential for continually improved productivity and performance, why don’t more process owners take a lifecycle approach to proactively manage process automation?  In most cases, it’s because of a lack of actionable information. Taking a strategic life cycle approach & making decisions on a micro level (system evolution) rather than a macro level (rip and replace) requires business case information that proves difficult to quantify for the non-specialist.

“Experience has shown that organizations adopting a lifecycle approach to the automation systems realize 10 to 30% reduction in the system maintenance costs” ABB- Maximize process automation life cycle

Managed properly, with the help of third-party experts, a process control system can provide continually higher levels of performance throughout its life. Rather than degrading over time, it can be maintained in a way that vastly extends its longevity and continually increases its performance.

With a comprehensive process automation maintenance program in place, the process owners have a well-defined path forward.  Through regular upgrades and routine maintenance, their system can literally evolve over time and may never require a wholesale upgrade or replacement.

Resources

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