system platform - building re-usable standards presenter: dries van schalkwyk control systems...
DESCRIPTION
Introduction ▪ Control Systems Integration ▪ Standards Development – Key in CSI ▪ Standards Developed Exxaro Sublime Technologies Mittal Kumba Iron Ore Others ▪ Standards Used SAB Miller Nestle OthersTRANSCRIPT
System Platform - building re-usable Standards
Presenter: Dries van SchalkwykControl Systems Integration
Agenda
IntroductionIntroduction
Definition of StandardsDefinition of Standards
WhyWhy Develop Standards?Develop Standards?
ConsiderationsConsiderations
Lessons Learnt & SummaryLessons Learnt & Summary
HowHow do we do it?do we do it?
Introduction
▪ Control Systems Integration▪ Standards Development – Key in CSI▪ Standards Developed
• Exxaro• Sublime Technologies• Mittal• Kumba Iron Ore • Others
▪ Standards Used• SAB Miller• Nestle• Others
Agenda
IntroductionIntroduction
DefinitionDefinition ofof StandardsStandards
WhyWhy Develop Standards?Develop Standards?
ConsiderationsConsiderations
Lessons Learnt & SummaryLessons Learnt & Summary
HowHow do we do it?do we do it?
Definition of “Standards”
▪ Pre-developed PLC, SCADA, A2 Code
▪ Bottoms Up Approach• Schematics -> PLC Code -> A2 Obj Models ->
SCADA• Linked to Equipment Types (incl Brands)
▪ Documented▪ Starter Pack
• Schematics, PLC Code, ArchestrA objects, SCADA graphics of various objects
• Documentation
Agenda
IntroductionIntroduction
DefinitionDefinition of Standardsof Standards
WhyWhy Develop Standards?Develop Standards?
ConsiderationsConsiderations
Lessons Learnt & SummaryLessons Learnt & Summary
HowHow do we do it?do we do it?
Why develop standards?
▪ Client – Reduced TCO!• Save on Engineering Cost(New Projects & Expansions) e.g 41%
saving• Reduced Commissioning Time
Project What? By Whom Commissioning TimeGG2 Beltfilter (PLC 07) New SCADA and PLC CSI & Client 2 DaysGG2 Beltfilter (PLC 08) New SCADA and PLC CSI & Client 2 DaysWet Sub New SCADA and PLC and Panels CSI & Client 2 DaysA Sub New SCADA and PLC and Panels CSI & Client 5 DaysD Sub New SCADA and PLC and Panels CSI & Client 3 DaysB Sub New SCADA and PLC and Panels CSI & Client 4 DaysMAN TAKRAF Stacker 813 New MCC, Cabling, PLC, SCADA, Instrumentation CSI & Client 6 DaysGG3 New SCADA and PLC CSI & Client 3 DaysGG4 New SCADA and PLC and Panels CSI & Client 3 DaysGG5 New SCADA and PLC CSI & Client 3 DaysD8 Outloading New SCADA and PLC and Panels CSI & Client 4 Days
Avalloy furnace rebuild Full instrumentation rebuild and recommission CSI & Client 4 WeeksSAB Cellars Polokwane New PLC and SCADA CSI & Client 3 WeeksSAB Brewhouse New PLC and SCADA CSI & Client 5 days (FV Temp control running in 4 hours)
New Greenfields Control Systems CommissioningProject What? Commissioning TimeSublime Technologie Furnace CSI & Client 8 weeks of which part was beneficial use
Letseng Diamonds Diamond PlantCSI & Bateman for Client (CSI did all PLC panels, PLC, 13 weeks of which 4 weeks on full production
Char ExtentionsCSI & EICON & XL Projects for Client
Project running abour 2 years, commissioning about 3 weeks
New Brownfields Control Systems Commissioning (2007/8):
Why develop standards?
▪ Client – Reduced TCO!• Ease of Maintenance• Lower Training Cost• Centralised Enterprise SOP
▪ Reduced Risk
Why develop standards?
▪ The value to the SI• Control over automation principles• Competitive Advantage with customer• Relationship with customer – Trusted Advisor• Paid Services for SI • Customer Commitment• Save on Engineering – Time = Money e.g 41% saving• Better planning and estimation = On-Time Delivery• Automation of activities, e.g. Macros• Risk Mitigation
Agenda
IntroductionIntroduction
DefinitionDefinition of Standardsof Standards
WhyWhy Develop Standards?Develop Standards?
ConsiderationsConsiderations
Lessons Learnt & SummaryLessons Learnt & Summary
HowHow do we do it?do we do it?
Approach to Develop Standards
▪ Project Approach• Identify Scope (Equipment models)• Schedule – Project Plan (1-3W/obj)• Budget• Strong Quality Control
▪ Strong PM▪ Client involved – Joint Team▪ Detailed documentation ▪ Wonderware SA involved
• Advice• Best Practices Document
How do we do it?
▪ Get Corporate buy-in▪ Think Wide▪ Technical Skills▪ Training▪ Team approach SI/Customer▪ Keep things Simple▪ Simple to Complex derivations▪ Group head offices & IT
• Antivirus• Patch Management, service packs,• Security, disaster recovery, group policies
Agenda
IntroductionIntroduction
DefinitionDefinition of Standardsof Standards
WhyWhy Develop Standards?Develop Standards?
ConsiderationsConsiderations
Lessons Learnt & SummaryLessons Learnt & Summary
How do we do it?How do we do it?
Other considerations
▪ Risk to the SI!▪ Standards = Foundation of Projects▪ Stds must be easy to Rollback
• Download PLC Code, A2 objects, SCADA• Commission
▪ Standards ownership – not SI IP▪ Size of Customer
Agenda
IntroductionIntroduction
DefinitionDefinition of Standardsof Standards
WhyWhy Develop Standards?Develop Standards?
ConsiderationsConsiderations
Lessons Learnt & SummaryLessons Learnt & Summary
How do we do it?How do we do it?
Lessons Learnt
▪ Right Resources (SI & Customer)▪ Bench Test Thoroughly
• Comms Turnaround Time• Scalability• Cycle Times• Test against H/W
▪ Highly Detailed FAT ▪ Take no shortcuts▪ Enforcement Body at End user ▪ Change Control▪ Hierarchical derivations▪ Wonderware Audits
Conclusion
► You MUST Standardise
► It saves $$$$ for SI and Customer
► It helps in building relationships
Conclusion
►Questions???
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