The Legacy Automation Playbook. How to Proactively Manage Your Legacy Industrial Control System

Transcription

1 The Legacy Automation Playbook How to Proactively Manage Your Legacy Industrial Control System

2 A Troubled Legacy? As industrial control technology continues to advance, legacy production equipment may begin to show its age. Critical electrical components may have become obsolete, leaving them unsupported and unable to be replaced. Essentially, such components become dead ends for continuous improvement. However, the mechanical components of electrical systems will have plenty of productive life left when proper preventive maintenance is performed. This guide will provide helpful tips for dealing with legacy systems proactively in order to stay productive and maintain your competitive edge. 2

3 Who Should Follow This Playbook? The Legacy Automation Playbook is designed to help plant managers and maintenance managers handle or avoid the types of emergencies that result when legacy control systems experience failure or degraded performance. If you re responsible for key production equipment older than 10 years, you should be considering the risks involved and understand how to mitigate them. Maintenance personnel are often too busy to keep track of which devices are still available and which have been retired. That is, until a controller fails and it s impossible to find a replacement. So, what happens when a critical system goes down and you don t have a spare? If it s no longer available, you ll need an ebay account and a little luck. To avoid finding yourself in a tight spot, try implementing the tools and tactics outlined in this Legacy Automation Playbook. The team at Digitronik Labs applies them every day, helping manufacturers plan and execute control system upgrades and retrofits for their critical production equipment. When Is Equipment Considered Legacy? Any system with an older model PLC, HMI, motion controller, drive, etc. with limited features, lack of availability, and increased risk of failure is considered a legacy system. However, certain situations merit special consideration, such as: 1. Critical equipment with no backup This refers to any process bottleneck in which downtime would drop productivity to zero. 2. Machine tools from vendors who no longer support the system Oftentimes, companies that sold an original system no longer support it, or they may be out of business entirely. 3. Old systems with limited communication capability In these scenarios, continuous improvement efforts, such as plant data collection and remote monitoring, may be difficult or impossible to achieve. 4. Desire for additional features or capabilities Legacy systems may lack key functionalities that would improve productivity or flexibility. 3

4 What Are My Options? There are three main options when it comes to dealing with legacy control systems: do nothing, manage the situation, or upgrade the system. 1. Let It Ride Your first option, and arguably the most popular, is to do nothing. Some managers may choose this option because it has the lowest upfront cost (free!), while others may not be aware of the risks associated with legacy control systems in the first place. Unfortunately, it may be only a matter of time until these users find out the hard way. Doing nothing often winds up being the most expensive option of all. PROS Fits into any budget Production continues uninterrupted (at least, until a failure event occurs) No re-training required CONS Highest-risk option Downtime may be measured in days or even weeks Recovery support from a system integrator will include emergency markups 4

5 2. Plan Ahead In other situations, users cannot afford to do nothing, but the cost of a full control system upgrade is out of reach. With a risk mitigation plan, you ll be prepared with the tools and resources you need to deal with failure or degraded performance events quickly and efficiently, minimizing the cost of downtime. A typical risk mitigation plan is comprised of the following: Maintenance kit This will include a laptop PC with the proper programming software, communication cables, and anything else you may need to diagnose and repair an issue with a controller. Program backup Batteries can fail and devices can be destroyed, so don t let the program and configuration vanish into the ether. Digital documents System prints, operating manuals, and other key documents are also included in risk mitigation plans. Spares Ensuring you have spare parts available in advance eliminates the stress of tracking them down in an emergency. PROS Significantly reduces the risk associated with legacy systems Facilitates additional enhancements to the system Less costly than a full upgrade CONS Still limited by functionality and reliability of the legacy system Efficacy of the plan is dependent on internal skillset Investing in obsolete technology may not be the best choice 5

6 3. Beat the Odds Proactive managers will find opportunities to replace legacy hardware in order to reduce the risk of failure, ensure necessary spares are available, and augment key processes with new capabilities and increased efficiency. Instead of the major capital expenditure associated with a full replacement system, consider modernization as your first option. A new control system is a fraction of the cost of a brand new piece of equipment, and you can even integrate new features and functionality to enhance performance, taking your operation to the next level. Modernization can allow for: The best way to mitigate the risk and limitations associated with critical legacy control systems is to upgrade them with modern devices and employ engineering best practices (e.g., modernization). Peace of mind Trouble areas are eliminated before they cause bigger problems Increased efficiency Optimizing process controls and operator interfaces lets equipment set new records for productivity Reduced cost Robots and vision systems unlock new possibilities for automation PROS Less costly than a brand-new machine or line Opportunity to add other improvements in tandem Support and spare parts become readily available CONS Considerably more expensive than the other options Usually results in some downtime during the upgrade Requires updates to training and maintenance procedures 6

7 What Industries Benefit Most from Control System Modernization? Automotive Oil and gas Life sciences Mining and minerals Glass and ceramics Food and beverage Packaging Large-scale printing What Types of Issues are Resolved by Control System Modernization? Production downtime is an extraordinary expense. Whether working with logic controllers, operator interfaces, motion components, or other critical devices in manufacturing and other industrial sectors, equipment that is inactive for days, hours, or even mere minutes can lead to huge revenue loss. The following are examples of issues that modernization can fix: Missing functionality or features Failed equipment Outdated or obsolete components Quality issues Troubleshooting difficulties Unidentifiable system problems Recurring alarms or warnings Critical systems that can t go down Operator-induced errors These techniques can help determine which systems may carry the most risk: Control panel inspection and inventory Component obsolescence study Electrical thermography identifying components with abnormal temperatures that signal imminent failure Unsupported software (e.g., PCs running Windows XP) Process data and alarm history analysis to identify trends and diagnose root cause 7

8 A Proactive Investment in Your Company s Future Once you know you re a good candidate for modernization, how can you apply it to your operations in order to address obsolete or outdated equipment? Executing a modernization project with internal resources is always an option, but many companies struggle to find the time for even modest improvement projects, much less a complete system overhaul. Your in-house controls and electrical engineers already have their hands full with day-to-day operations, leaving little bandwidth for the intense effort required to replace a control system and resume revenue-generating activities. Attempting an upgrade without the proper expertise, planning, and resources will inevitably result in frustration, extended downtime, and, ultimately, loss of revenue. Partnering with a system integrator is usually the best option; they will have the skills and experience necessary to guide you through the entire process, reducing risk and allowing you to maintain focus on operations. What Is the Turnaround Time for a Modernization Project? Will It Impact Production? Turnaround time for control system modernization is highly variable; in general, projects usually span three to six months, with two to 10 days of downtime during the integration phase. Upgrades can be performed during planned downtime or non-business hours. For the most critical systems, a process to minimize or even eliminate downtime may be developed. 8

9 Example Process for Control System Modernization 1. Catalog every electronic device in the system 2. Download and back up the program for each device 3. Identify which devices are obsolete 4. Identify which devices have the highest risk of failure 5. Research replacements for key devices 6. Review electrical schematics for the existing system, and plan how the new system will integrate with the panel and field wiring 7. Determine program compatibility, then convert or rewrite each program 8. Test the new program in simulation to ensure system behavior is correct The best way to diagnose your problem and estimate project turnaround time is to bring professionals in-house to inspect your device or system in person. Digitronik Labs offers up to one half day of free consulting and assessment of legacy systems, which includes a detailed recommendations report for your specific issue. How Do I Get Started? If you re unsure where to start or still wondering if you even need to it s best to rely on the experts. We ll carefully review your process and develop tailored system specifications to meet your unique needs. 9

10 About Us Digitronik Labs works with manufacturers and machine tool builders, to bring industrial control and monitoring systems to new heights. We partner with you to optimize your process control, data collection systems, system safety, and operator workflow. Our team will get your equipment up and running faster, keep it running longer, and maximize its value to the plant. Our purpose is customer satisfaction. We always deliver the highest quality workmanship, in both a timely and responsive way. Supplementary support is provided to make sure our solutions live up to the Digitronik name. We don t stop until the job is done right. Add: Tel: Web: St. Paul Street Suite 6D, Rochester, NY (585) contact@digitroniklabs.com