Mon 14.50 Automation Hot Cut Over ABB APC9

John Jones, 19th September 2011, APC9 IChemE, York Conference
Keeping the Plant on-line during an

Automation Hot Cutover
ABB Group
September 18, 2011 | Slide 1
Requirement For Change !

Pneumati
c Control
Obsolete
Panel
Control
Obsolete
Computer
Control Systems
Poor
Reliability
Poor
Information
Flow
ABB Group
Poor Control
Room
Environment
Existing Control System
High
Maintenance
Costs
Upgraded Automation System

Field bus
Maintenance
Systems
Enabling
Infrastructure
Optimisation
MIS
Integrated Control & Information System

APC
Safety
Systems
Labs
ABB Group
Evolution of Control Systems Upgrade

The DCS
New Generation
The PLC
A = Panel to DCS -> lower complexity
B = DCS to DCS -> Higher complexity
The first industrial

control computer
system
The PID Controller

Watt Governor
1788
1922
Panel
1959
1968 1975 1996
2000
Pneumatic / Electronic
Early DCS
ABB Group
2011
Time
Modern DCS
Why do you want to upgrade ?
ABB Group
Drivers:
Obsolescence
Maintenance / Reliability issues
Productivity / Quality
Functionality
Profitability - Business demands
System capacity limits
Automation Upgrade Road Map

Requirement
for
change
Feasibility /
Migration
study
On-line
FEED
Detail Design &

Enabling work
Cut Over
Procedures
Shutdown
Cut Over
Detail Design
Decommissioning
Pre Shutdown
work
Shutdown
Installation
Test &
Commission
ABB Group
Upgraded
Automation
System
Shutdown Window,
Advantages
Potential reduction in time for the control system upgrade
Perceived Easy option
Reduced risk & cost
Plant buy-in
Disadvantages
Shutdowns are for maintenance/overhaul activities
DCS will always become the critical path another reason why shutdowns
get extended!
Process Cold/black start up on a new DCS system
Control system brought on-line immediately!
No fallback
Plant modifications/projects happening impact on new DCS
ABB Group
On-Line
Advantages
No requirement for an shutdown window
Reduction of risk
Limited, or no impact on the plants production
Ability for a phased implementation over a period of time in line with

Business requirements
The plant does not have to be restarted after an extended shutdown on

a new control system
Benefit from the new DCS system NOW rather than having to wait for a
shutdown
Disadvantages
Need to plan for an extended period of time compared with a shutdown
Will have 2 systems running in parallel during cutover
More effort is required to ensure the cutover is successful
ABB Group
Perceived more expensive than a shutdown
Automation Upgrade Road Map: Hot Cut Over

Requirement
for
change
Feasibility /
Migration
study
Detail Design &
Enabling work
Cut Over
Procedures
FEED
Cut Over
Detail Design
Decommissioning
Pre Shutdown
work
Shutdown
Installation
Test &
Commission
ABB Group
Upgraded
Automation
System
Feasibility / Migration study
Purpose :
Understand the plant (As is)
Determine where the plant wants to be (2B)
Gap Analysis of As-is Vs 2 B
How will they get there - options
ABB Group
How & When ?
Migration study activities
Existing Automation system ( & Plant if necessary) is surveyed
Options are investigated
URS (User Requirements Specification) produced
Issued to Automation vendors
Tender analysis performed
Commercial
Technical
Recommendation of options
Budget estimate of project cost
Project programme produced
ABB Group
FEED stage
Chosen migration path validated
Site surveyed to validate proposed solution path
Documentation gathered/quality
Cutover points - confirmed
Identification of How it will be done with regards the location of the new
DCS equipment
System rationalisation addressed - graphics, redundant areas
Safety - voltages, process
Technical issues resolved with Automation vendor
Estimate refined
Critical loops identification - criteria
Identify enabling work if required
Implementation strategy/plan on-line cutover plan
ABB Group
FEED - On-Line Upgrade

Criticality Review (1st Risk Assessment)
Loop by loop assessment of importance / availability
Allocate each loop a criticality grading based upon grading scale developed
for project
Systems implementation review what can not be done on-line?
Identify enabling work if required
Enabling work
Work required to allow cutover on-line System Hardware / Process
Implementation plan for enabling work
Some design now or later (shutdown driven)?
ABB Group
End of FEED review - Is everything still OK ?
ABB Group
Implementation strategy still valid in-line with migration study.
Plant operations no changes
Business buy-in
On-Line Upgrade Detail Design
ABB Group
Documentation gathered
Enabling I/E Design
I/E design
Cabinet design
Cutover points
Ancillary systems design e.g. UPS, lighting,

H&V
Cable routing
Control room design - including nonautomation hardware e.g. F&G, Telecoms,

CCTV
Interconnection wiring
DCS vendor liaison
Detailed plan
Pre and Hot Cutover procedures
Reviews
Reviews / Risk Assessment
ABB Group
Loop Critically Review
Risk Analysis Study
Implementation Strategy Review
Cut-Over Methods Review
Hazcon Reviews
Training and Validation Requirement Review
Detail design reviews
Failure Mode Effect Analysis (FMEA) Review
Ensure that each step in the procedure was the

correct step to be made and in the correct order
Ensure that there is a fallback position available for

every step
To guarantee that if all the steps are followed in the

correct order then the result would be a successful
cutover of the loop
Highlight any design or construction/commissioning

problems that may occur
Highlight any tools or specialist equipment that may be

required during the cutover
Measurement Function & Control Complexity
Legacy code issues
Eccentricities of system
Poor documentation of
control schemes
Potential requirement to
reverse engineer system.
ABB Group
On-Line Cutover procedures
What are they ?
ABB Group
Pre-Cutover procedure
Hot Cutover procedure
Hot Cut Over Methodology
ABB Group
Pre Cutover Procedure

Key stage, risk assessment - Go / No-Go for Hot Cutover
Does the new system mimic the old system? no surprises!!
Cutover point confirmation
Format is a detailed line by line checklist
Ensures loops are operational prior to cutover
Ensures graphics details and alarm pages are correct
Ensures Loop configuration details are correct, including

ranges, alarm settings, titles, controller actions etc.
Check existing plant equipment associated with the Cutover

operates correctly
ABB Group
Example: Test manual bypass valves, Do manual hand

jacks work?, etc.
Typical Analogue Input Pre Cutover Procedure

Method statements that detail loop testing requirements prior to Hot Cutover
Prerequisites
Work control permit in place.
Ferrule & termination details

are in accordance with loop
diagrams.
Procedure
Check DCS configuration, using

data from the project database
Confirm knife edge terminals
within DCS cabinet are open.
Disconnect signal source &

open knife edge terminals in
DCS cabinet.
Confirm primary control button

on the DCS faceplate links to the
correct graphic.
Suppress DCS alarm.

New transmitter, impulse
lines & secondary isolation
valves are installed in
accordance with hook-up.
Connect relevant signal source at the

transmitter cutover point as shown on
the loop diagram & hook-up.
Completion
Remove DCS alarm suppression.
New cables are installed,

ferruled & terminated, tight &
secure
New transmitter, impulse

lines & secondary isolation
valves are installed in
accordance with hook-up
Close knife edge terminals in

DCS cabinet.
Simulate transmitter input signal to the DCS confirm
the following:
Correct representation of DCS graphic
Process alarms active on DCS, if applicable
Bad PV alarm activates on high & low signal
Correct representation on graphic
ABB Group
Complete & sign relevant

section of loop control
documentation.
Hot Cutover Procedure

Written procedure to allow the safe transfer of the existing
system to the new whilst on-line
ABB Group
Standard procedure
Complex / bespoke procedure
Format is a detailed line by line checklist
Hot Cutover procedures need to be reviewed using FMEA

process
Typical Analogue Input Hot Cutover Procedure

Method statements that detail loop testing requirements to complete the Hot Cutover, inclusive of any prerequisites
and post cutover testing.
Prerequisites
Procedure
Pre-cutover loop tests are complete.
Ensure DCS input point is displayed on

the DCS.
Work control permit is current and

applicable to the loop detailed.
Confirm the existing loop is stable,

record the PV.
Record the DCS PV.
Confirm the DCS and

existing PVs are similar, if
not find out why before
moving onto next procedure.
Completion
A copy of the loop diagram is
available for reference.
Identify the field instrument, with

process, isolate & blow down lines.
Confirm no leaks from isolations.
DCS loop isolations are complete, i.e.

knife edge terminals are open.
Carry out any work identified on the field

hook-up.
All relevant test certificates are in

place.
Confirm DCS input tag is reading zero.
Connect the DCS signal by closing the

appropriate knife edge terminals
DCS alarm suppression is removed
Correct PPE available
ABB Group
With process & using the works

procedure, open isolation valves putting
process onto the transmitter, confirm no
leaks.
Complete & sign changeover

notification label(s) and fix to
appropriate locations.
Complete & sign relevant

section of loop control
documentation.
Develop detailed Pre & Hot Cutover packs
Work Packages for Pre cutover and Hot cutover
Good clear and simple check sheets
ABB Group
Typical sections:
Purpose
Prerequisites
Procedure
Completion
For each type of generic loop develop a detailed method
Involve those who are to perform actual cut-over
Identify the equipment required - special tools, chocks etc.
Test the methods on none critical loops
Perform trial run and follow up with review
On-line Cutover stage
Cutover team
DCS / System Engineer
Process Operator / FLM
Technicians / Electrician
Project Designer
Pre Cutover activities:
Follow pre cutover procedures
loops to be cutover as soon as possible
Hot Cutover activities:
ABB Group
Cut-over team, managed by Commissioning Manager

comprising:
Follow plan and Cutover procedures !!!
Hot Cutover implementation Main Plan & Daily Activities
Main Cutover Plan
Master overall status of cutover
Plan down to loop level
Details sequence for cutover

including daily cutover activities.
Daily Cutover Activities
Short meeting held prior to start in control room

of cutover team to ensure:
Plant is operating normally
Resources are all in place
Plan usually MS Excel spreadsheet

based.
Multiple columns can detail
associated information i.e. loop
diagram details
Confirm all documentation is in place
Relevant operator training completed
Control/Safety system platform is fully

operational
Multiple work fronts pre cutover &

cutover
Check feedback from overnight shifts
Impact of any other work in area
Permit to work situation
ABB Group
Toolbox talks
Reservations / punch listing
Update end of day report
Decommissioning
ABB Group
Leave old system operator station running for a period of

time - to be used for reference purposes
Can you pull the plug ????
On-line Upgrade - Success factors!
Ensure business understands inherent risks
Operations buy-in to deliver
The project process used
The review process undertaken
The documentation quality
The implementation strategy for cut-over
The cutover team resource
The cutover methods developed
Cutover methods followed
Enabling work
Training
ABB Group
It is very important to remember...

Plants are process driven NOT
Engineering driven! & Operations is
always King!
ABB Group
ABB Group

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John Jones, 19th September 2011, APC9 IChemE, York Conference

Keeping the Plant on-line during an

Requirement For Change !

Existing Control System

Upgraded Automation System

Integrated Control & Information System

Evolution of Control Systems Upgrade

The first industrial

The PID Controller

1968 1975 1996

Why do you want to upgrade ?

Maintenance / Reliability issues

Profitability - Business demands

System capacity limits

Automation Upgrade Road Map

Detail Design &

Potential reduction in time for the control system upgrade

Perceived Easy option

Reduced risk & cost

Shutdowns are for maintenance/overhaul activities

Process Cold/black start up on a new DCS system

Control system brought on-line immediately!

Plant modifications/projects happening impact on new DCS

No requirement for an shutdown window

Limited, or no impact on the plants production

Ability for a phased implementation over a period of time in line with

The plant does not have to be restarted after an extended shutdown on

Need to plan for an extended period of time compared with a shutdown

Will have 2 systems running in parallel during cutover

More effort is required to ensure the cutover is successful

Perceived more expensive than a shutdown

Automation Upgrade Road Map: Hot Cut Over

Feasibility / Migration study

Understand the plant (As is)

Determine where the plant wants to be (2B)

Gap Analysis of As-is Vs 2 B

How will they get there - options

How & When ?

Migration study activities

Existing Automation system ( & Plant if necessary) is surveyed

Options are investigated

URS (User Requirements Specification) produced

Issued to Automation vendors

Tender analysis performed

Budget estimate of project cost

Project programme produced

Chosen migration path validated

Site surveyed to validate proposed solution path

Cutover points - confirmed

System rationalisation addressed - graphics, redundant areas

Safety - voltages, process

Technical issues resolved with Automation vendor

Critical loops identification - criteria

Identify enabling work if required

Implementation strategy/plan on-line cutover plan

FEED - On-Line Upgrade

Loop by loop assessment of importance / availability

Systems implementation review what can not be done on-line?

Identify enabling work if required

Work required to allow cutover on-line System Hardware / Process

Implementation plan for enabling work

Some design now or later (shutdown driven)?

End of FEED review - Is everything still OK ?

Implementation strategy still valid in-line with migration study.