A Lessons Learned Discussion of Digital Control Upgrades

How to Make Sure Your Digital

Upgrade is Over-Budget, Over -

Schedule, and Everyone’s Vacation

Gets Cancelled

Major Topics

• The Phases of a Digital Control Project

• Examples of How things can go Wrong

• Discussion

3

Slide 4

Major Phases of a DCS ProjectSales/Proposal

Phase ManagementPhase Design

Phase

ImplementationPhase Testing

Phase Startup/Commissioning

What is…..

5

6

The Sales/Proposal Phase

• Request For Quote• Competitive Bid

Process• Proposals• Awarding of Contract• Purchase Order

The Management Phase

7

• Assemble Project Team• Hold Kickoff Meeting• Develop Schedule• Project Specification

Finalized; Requirements Created

• Develop Plans

Project Management Plan

Quality Assurance Plan Etc, etc, etc

AND……

The Management Phase (cont…)

Slide 8

DESIGN INPUTExamples:• Process Description• P&ID Drawings• Existing Logic and Function Drawings• Procedures• Alarms, setpoint, scaling information• I/O Database

Project I/O Database

Slide 9

Project I/O Database

Slide 10

Database

I/O Load (Drawings) Wiring Diagrams

Control Database New Control Drawings Software Design Description

Hardware Test Procedure Site Testing

Process Graphics Graphic Documentation

Historian

Reporting

Other Systems Documentation

Software Test Procedure Site Testing Site Procedures

The Design Phase

11

BEGIN

DESIGNFREEZE

• Design Input continues

END

• Design Calculations• System Design Drawings• I/O Database• Failure Modes and Effects

Analysis• Testing Plans• Traceability Matrix

The Implementation Phase

12

• Application Software Control/Graphics/Historian/Reports

• Test Cases and Procedures

• Updated Design Drawings Possible

• Dry Run Testing

The Testing Phase

13

• Pre-Testing (Vendor Test)• Factory Acceptance

Testing (Customer Test)• Corrections and Retest• Changes

The Startup/Commissioning Phase

14

• YOUR system now