Taking advantage of newer process control system technologies

Operators of large production plants rely on the smooth operation of manual and automated process control systems to deliver results and maintain plant uptime. Modern technology and the constant need to further automate and centralise processes has resulted in legacy systems becoming outdated and, in some cases, obsolete.

It’s clear that businesses want to achieve operating efficiency, but sometimes don’t see the value or need to upgrade process control systems. What new technologies are available on the market? Can older systems be upgraded without a complete overhaul? And what will your business achieve with an upgrade?

New technologies available when upgrading

The days of dealing with unintelligent controls that use vulnerable cabling are gone. Modern process control systems can incorporate over a million I/O points with intelligent control and high-speed fibre backbones to bring real-time plant control, monitoring and trending.

Wiring savings

In years gone by, hazardous areas such as those in chemical plants presented costly obstacles to the deployment of process control systems. Expensive cable protection and costly wall penetrations once limited control cabling in these high-risk areas. Leaps in technology now allow controllers to send their signals wirelessly to an access point outside of the hazardous area with no penetrations or cable protection required.

The cost of mixing old with new

Older process control systems are often costly to service due to the lack of spare parts and a diminishing number of subject matter experts. The natural progression from this expensive situation is an upgrade to a control system that incorporated better supported, up-to-date technology.

The upfront cost of completely upgrading legacy process control systems can be daunting, so a common alternative is to implement newer systems in some areas to coexist with older systems.

Ironically, this type of site set-up can often end up costing more in maintenance, problem solving and lengthy downtime when things go wrong.

Focus on user-friendliness

Advances in software technology now make the management of process control systems user-friendly. Once the initial set-up of a software package takes place, users are able to intelligently scale their process controls using ‘drag and drop’ functionality. Users can also monitor specific controls in real time, troubleshoot faulty plant without leaving the workstation and process batch jobs on the fly.

Servicing cost savings

Graphical user interface design is as easy as using in-built graphics or can be as detailed as custom-designed backgrounds and icons for easy discrimination. The do-it-yourself approach gives site operators ultimate control over their system, reducing the cost of servicing and call-outs when new equipment is added or removed.

Control of the site’s critical plant can be managed from a single workstation on site or remotely using wireless links and wide area networks (WANs). Remote management of process control systems could immediately reduce servicing and callout fees because a technician can maintain or evaluate a piece of plant or machinery from an off-site office.

Detailed security

A more detailed security regimen can also be integrated within modern process control systems. User interfaces can be set up to allow only a certain amount of plant control or programming per user depending on their privileges. This level of control, also complemented with extensive logging and monitoring, not only maintains integrity, but allows for flexibility.

Portability reducing costs

Sites requiring portability and decentralised monitoring can take advantage of smartphones and tablets to manage the process control systems on site. High-resolution graphics can be teamed with ultrafast 802.11n wireless connectivity to securely monitor plant and process controls in real time.

This technological feat is a godsend for sites where plant and equipment may be hundreds of metres apart during servicing and inspections. Technicians can use a tablet or laptop to interrogate equipment, view logs and fix problems while physically at the piece of plant, as opposed to constantly moving between the plant and central control system.

Are these technologies only available when upgrading the entire system or can they be added into an existing system?

Some organisations become discouraged when they realise the amount of work and planning required when upgrading an entire process control system. Most organisations try to run as close to optimal efficiency as they can, meaning that extended downtime - even to optimise efficiency - further affects business.

Progressive control system upgrades

There are processes in place for upgrading entire systems in organisations where systems can’t be switched off at the same time for an overhaul. Staged upgrades allow the old process control system to operate in unison with the new process control system for the duration of an upgrade, meaning business can still take advantage of new process control systems.

Where an entire system makeover can’t be achieved due to costs or timing limitations, newer process control systems can be integrated and operate over a proprietary system protocol along with the legacy system. While this type of solution often causes bottlenecks and increases maintenance costs, it is an alternative measure for organisations upgrading in progressive steps.

During the upgrade phase, sites can operate process controls via two systems simultaneously to allow for redundancy and familiarity. Operators can be trained on the new system, while still processing and performing critical functions on the old system. Once the new system is ready, the old system can be phased out and removed.

Whole system upgrade benefits

Ideally, process control systems should be upgraded as a whole to immediately see cost savings and operational advantages.

Aside from long-term cost savings, organisations will spend less money on training and mitigate risk by overhauling systems in one sitting, as opposed to progressively over time.

Each organisation is different and requires a customised plan for achieving success during an upgrade. It’s well worth investing in a specialist consultant that is able to accurately estimate transition timing and determine the best way to move forward. An entire system upgrade shouldn’t be attempted without due thought, consideration and consultation.

Partial upgrade vs replacement

Investing in future reliability

Don’t be surprised if you see the cost of maintaining and servicing your older process control system continuously rising. Also, don’t be surprised if you find the number of technicians specialising in your particular process control system decreasing. As legacy systems become older, they’re costlier to maintain and support exponentially diminishes. As time goes by, these problems will grow exponentially, so the implementation of an up-to-date control system will be an investment in the future reliability of the plant.

Production and productivity benefits

Upgrading the technology behind your organisation’s critical process control system is a logical step forward to reducing operating costs and eliminating the risk associated with aged hardware and outdated software. Cost savings can immediately be seen in areas where limited process reporting and forecasting, or inaccurate controls, can hold up production.

Intuitive graphical user interfaces, faster system response, higher quality reporting and ultimate scalability are just the start of advantages seen when upgrading older process control systems. These advances free up the time of operators, returning productivity to your business.

While the upgrade process can be costly and time consuming at face value, the end result is a more productive workplace, a decentralised control system and fewer maintenance requirements. Upgrading really is a logical step forward.