Parijat Hot Cutover Tool NGSH-10103
Overview: Many control systems are getting old without improvements or approaching end of their life. These plants should start migration to a new control system before issues start to occur.
Two common approaches for a migration:
- Offline (cold) cutover; complete replacement at once. Requires plant control system shutdown.
- Online (hot) cutover; migration without plant shutdown.
A hot cutover is an approach of replacing the old control system while the plant is operational. The old and the new control systems operate simultaneously, and the new system is cutover point by point, loop by loop.
Hot Cutover requires intense Planning with plant operations to Install, Commission and Integrate New Control Systems with the Existing Systems without taking sections of the running Plant into Shutdown mode.
PCI (Parijat Controlware, Inc.) Hot Cutover Tool: PCI HCT is a temporary use tool needed only during the cutover time. Preferably work with one controller I/O rack at a time. If multiple racks need to be simultaneously worked on, multiple tools use is advisable.
Allows user to safely migrate to a newer control system without having any or minimal downtime. For some I/O’s an online migration can be an issue because of their critical nature to the process. Disconnecting these critical control loops can result in shutdown which could be critical to the process conditions. In these situations, PCI Hot Cutover Tool proves its value; it can take-over even some of the critical loops, while maintaining optimal control of the process.
Various possibilities:
- I/O Panels using
- Existing
- New
- Old Controllers I/O update w r t logic scan
- Synchronous
- Asynchronous
- System options
- Same as existing vendor’s products
- Different vendor’s products
- Use some different custom configurations in new system
Assumptions
- The whole system is powered by the same AC power supply. If not, the AC phase of all power supplies must synchronize. If DC power supply used, ignore this note.
- Old controller logic is editable and editors are available. It should support relocatable I/O & SW forcing of I/O. If no, consult with PCI.
- New controller(s) programs fully tested/debugged in lab. This also supports forceable, relocatable real I/O. If no, please consult PCI.
- Both controllers can survive rack faults
- DO, AO wiring must have some nude conductor exposure or connection terminals accessible (in some cases only).
- Both old & new controllers allow high speed and voluminous data transfers.
- Must evaluate all possibilities and keep backup plans in place and ready.
HCT connects parallel to existing (old) control system and verifies connection to control loops of the module or rack to be operated on, and ready to read & write with both controllers using PCI HCT app.
Advantages of PCI HCT
- Marshalling panels Terminal strips not required. Use the terminals of I/O modules themselves. Allows reuse of existing control panels
- Once process started, it is relatively easy to reverse.
- Safe and controlled hot cut-over
- Maximum efficiency
- Minimization of human errors and risks
- Strong Financial Benefits, where there is less Downtime and Less Production Downtime/Loss.
- Generally independent of the type of existing or new control system HW.
- HCT saves time, reduces risk, eliminates expensive plant shutdowns
- Hot cutover allows for complete commissioning and testing with real process values before the cutover.
- Reduces project costs by eliminating the need to have additional equipment for process signal simulation
- Presents significant reduction in project lifecycle costs.
- Uses the physical signals rather than a communication protocol.
- The amount of I/O that can be moved during a hot cutover is unrestricted.
- As it is not vendor-specific, this technique can be used with almost any platform from any supplier, or a group of vendors (Please see minimum requirements).
- Control systems work independently with all hardware types from a remote SCADA system, remote I/O, to a DCS / PLC system.
- Multiple platforms can be migrated at the same time.
- Any combination of analog, discrete, isolated, non-isolated, high side, low side, 4-wire loops, 2-wire loops, pulse signals, 0-20V & 4-20 ma devices, powered signals and all kind of standard control system I/O.
Why use it?
Customers Choose to Migrate their Control System for some reasons. Some of them are following
- There are a lot of Control Systems that are approaching the end of their life.
- OEM declaring obsolescence of the product or going out of business. 3. The Lack of Production Data is also a big reason; some Facilities Expand, and they need more reliable and Extended IO Control Units, but the facility can’t shut down to incorporate these changes.
- Add more flexibility and to Overcome Reduction in Production capacity. More Modules can be added in the future if the Production capacity gets bigger.
- To get rid of Old control system, less Production Capacity, and sometimes add a Redundancy System if the facility is Critical to Shut Down like a Power Plant.
- To Minimize the High Maintenance Costs, need to adapt to use more state of art solutions.
- Advanced Process Control.
- Minimizing Waste.
- Optimizing products based on market conditions.
Process sequence explanation
The process starts with an initial study/report of inventory of all processes and related instruments that will be affected by the migration. Define the critical loops and perform the necessary hazard and operability studies. Identify new control hardware (PLC, I/Os, Switches, Power supply, etc.) to match existing control system. Identify any new additions or changes required.
Share the existing editable control logic with wiring diagrams. Share the desired new control system make/model. Share existing & new system architecture. Rest will be discussed with you.