CCUG 2013 Meeting Control System Upgrades and Retrofits Arthur L. - - PowerPoint PPT Presentation

CCUG 2013 Meeting Control System Upgrades and Retrofits

Arthur L. Mayclin, PE

Calpine Corporation Manager, I&C Engineering

1

Agenda

• Control system overview
• Scope
• Procedure
• Legacy Status
• Technical Specification
• Key Points

2

Control System Overview

• The basic control system is an intermediary between process variables and controlled variables. The

most simple case is level control for a tank. The control system reads the indicated level (process variable), compares it against the desired level (setpoint), and opens a valve (controlled variable) to adjust.

Level Indication (Process Variable) Tank Pump Control Valve (Controlled Variable) Discharge Valve Tank Level Setpoint DCS Control Algorithm Source Supply Process Discharge Process Demand

3

Control System Overview

• These variables interface to the control system via input/output (I/O) modules, which connect to

processors, where the control logic resides. Human machine interface (HMI) computers provide the interface between operators or programmers, and the control system.

Level Indication (Process Variable) Tank Pump Control Valve (Controlled Variable) Discharge Valve Source Supply Process Discharge Process Demand Processor I/O Rack Interface I/O Rack Interface I/O Rack Interface DI Module Interface Module DO Module AO Module AI Module Spare HMI DCS Automation Processor Station DCS I/O Rack Tank level setpoint generated in HMI and stored in processor

4

Control System Overview

• In general, an upgrade is performed by the same vendor and replaces only the outdated parts
• f the control system: Be it HMIs (software), processors, network equipment or all. A

retrofit is the replacement of the entire system, which includes I/O modules.

Processor I/O Rack Interface I/O Rack Interface I/O Rack Interface DI Module Interface Module DO Module AO Module AI Module Spare HMI DCS Automation Processor Station DCS I/O Rack

Upgrade Retrofit

5

Scope

• Upgrades:
• Will encompass HMI computers and software.
• May include processors and network equipment (including serial links).
• 3 to 6 month schedule (engineer and build), and 1 to 2 weeks to install.

Processor I/O Rack Interface I/O Rack Interface I/O Rack Interface HMI Automation Processor Processor I/O Rack Interface I/O Rack Interface I/O Rack Interface Automation Processor EWS Root Switch Root Switch

6

Scope

• Retrofits:
• Will encompass all components to the field terminations.
• May include determ and reterm of field connections.
• 6 to 9 month schedule (engineer and build), and 2 to 4 weeks to install.

Processor I/O Rack Interface I/O Rack Interface I/O Rack Interface HMI Automation Processor Processor I/O Rack Interface I/O Rack Interface I/O Rack Interface Automation Processor EWS Root Switch Root Switch DI Module Interface Module DO Module AO Module AI Module Spare DCS I/O Rack Valve Transmitter

7

Procedure – Risk Analysis

Impact of Risk Probability of Occurrence Low Low High High L

• w

L e v e l R i s k M e d i u m L e v e l R i s k H i g h L e v e l R i s k 1 2 3 4 Regions:

• 1. Critical Importance
• 2. High Importance
• 3. Moderate Importance
• 4. Low Importance
• Probability of Occurrence: Occurrence being equipment failure and/or process interruption. Heavily

influenced by historical data. Operating hours per year is also a factor.

• Impact of Risk: Safety or monetary impact.

8

Procedure

Process Flow Chart for Control System Retrofits or Upgrades

Notes Scheduling Budgeting Validation Analysis

Control System Supportable Control System Meets Operational Needs Hold to Next Budget Cycle Cost Justified for Current Budget Cycle

No No Yes Yes

Like Systems in Fleet Budgeted

No Yes

Group Like Systems for Single Bid RFP Upgrade or Retrofit RFP or Sole Source

Yes No Upgrade Retrofit Note 1: Supportable includes the availability of spare parts as well as technical support services. Note 2: Operational needs includes the ability to operate properly, add logic, or system expansion for plant upgrades. Note 3: Like systems are those that are capable of being upgraded or retrofitted by the same vendor.

Note 1 Note 2 Note 3 Note 4

Note 4: For some upgrades, a sole source is justified since a competitive bid is impossible. Note 5: The RFP procedure would consist of a technical specification, including training, installation, and project completion dates. For Spring outage installations, costs may be incurred over two budget cycles.

Note 5

9

Legacy Status

• Always Verify with the OEM
• Emerson WDPF (ten year support commitment):
• Level-8: January 2012
• Q-Line I/O: January 2018
• Emerson Ovation (five year support commitment):
• Release 3.2: May 2014
• Release 3.3: July 2015
• Release 3.5: October 2017
• Siemens TXP:
• All releases no longer supported.
• Network gear no longer supported.
• ET200M I/O supported (no end date published)

10

Legacy Status

• Millennium Control System
• Fanuc 90-70 (new parts not being manufactured).
• Field I/O no longer supported.
• Mark VI (some cards not available new)
• Software!
• Toshiba D-EHC
• HMI computers no longer supported (as well as the NCCX and Processors for

C900 system).

• Mark V:
• Hardware no longer supported
• HMI additions required.
• Mark VI:
• Formal support to 2018 with exceptions:
• Processor and communication cards
• Network equipment
• Software

11

Legacy Status

• Siemens T-3000:
• All versions supported but significant development ongoing
• ET200 I/O still standard
• Application Server virtualized but all previous versions supported
• Scalance network switches (recommend X-300 managed)
• Woodward
• 501, 505, Netcon are all legacy but can still be supported if spare parts are

available (knowledge is still available).

• Allen Bradley
• PLC5 legacy but spares can be found
• SLC supported
• ControlLogix, CompactLogix, and MicroLogix are now standard
• GE Fanuc
• Fanuc 90-70: No new parts
• Fanuc 90-30: Supported

12

Technical Specification

• Topics:
• Scope
• Overview
• Furnished by Seller and Buyer
• Codes, Standards or Regulations (if pertinent)
• Equipment Specifications (what it is)
• Number of HMIs, number of monitors, mounting, etc.
• Links
• Network
• Technical Requirements (how it works)
• Trending, alarming, logging, diagnostics, failure modes, accuracy,

redundancy, etc.

• Execution
• Project management
• Schedule
• FAT

13

Technical Specification

• Topics:
• Execution (continued)
• Installation and commissioning (coordinate with schedule)
• Ancillaries
• Training
• Options (what you may add if the price is right)
• Critical Issues (ensure they are covered sufficiently):
• Commissioning, since available time is always a factor.
• Equipment protection (all trips and protective settings)
• Equipment operation (primary control devices)
• Indications (if time permits)
• Project Management. Ensure the seller provides overall on-site

management during installation and commissioning (especially for turn-key retrofit covering both BOP and turbines).

14

Key Points

• A vendor’s quote is targeted at reducing their risk!
• A technical specification enforces what you require, not what the vendor is

willing to sell you. Include it in the contract or reference it in the PO.

• Full documentation is essential to prevent assumptions.
• Accurate I/O count by type and location.
• Logic diagrams.
• Electrical schematics and wiring diagrams.
• Serial link delineation (integration with other systems).
• A turn-key project prevents the vendor from blaming others for delays.
• Installation and testing will occur during an outage when people are

busy with other projects.

• Equipment may be required to remove and install control cabinets.
• Laydown and storage area may be required for electronic equipment

(sheltered from the elements).

15

Key Points

• Verify key dates (schedule):
• Kick-off and transfer of all pertinent documentation.
• Design review (prior to hardware or software freeze).
• Hardware and Software FAT.
• Equipment shipped to site. Once equipment arrives at site, liability

for damages shifts to the buyer.

• If schedule slips, have Seller store the equipment (added cost is

worth it).

• Mobilization at site and scheduled completion.
• Breakdown and schedule all activities at site to ensure they mesh

with other work ongoing at that time.

• Murphy rules! Provide contingency where possible.
• The FAT is free training but limit interference with the vendor once on site.
• Hold back as much money for final payment as possible.

16

Key Points

• Cost adders:
• Contractor support for evaluation and review
• Technical specification
• Bid evaluation
• Hardware Design
• Logic
• FAT support
• Commissioning support
• Cabling additions
• Fiber optic
• Electrical
• Links
• HVAC
• Furniture

17

Key Points

• Upgrade only if absolutely necessary:
• Existing system:
• Burn in complete, with all bugs worked out
• Support personnel trained
• Known history of issues to fall back on
• Operator familiarity
• Spare parts (unless the lack of them is a reason to upgrade)
• Board level repair can extend spare part lifetimes

considerably.

• New system:
• Punch list!
• Warrantee period!
• New manuals and training
• Patch path just beginning