Professional Documents
Culture Documents
Automation Project: Survival Guide
Automation Project: Survival Guide
SURVIVAL GUIDE
Ideas to help
you land on
your feet
TABLE OF CONTENTS
| 2
| 3
| 4
| 5
| 6
http://awgo.to/028
Organization: Project Management Institute
| 7
Close
Lifecycle Methods
Waterfall
Agile
Spiral
Design V
Other
Internal
Kickoff
Requirements
Development
Site
Acceptance
Test
Factory
Acceptance
Test
Traceability
Specification
Design
Subsystem
Integration Test
Unit/Module
Unit/Module Test
Development
Project management V model, courtesy Control System Integrators Association.
also important to make sure the right
people attend the FAT; that includes
the lead operator and maintenance
tech, not just the manager.
6. Follow programming standards.
Make sure that in-house programmers,
system integrators and OEMs use the
same PLC programming standards,
such as OMAC and PackML. Theres
nothing worse than custom code that
has to be reworked at the last minute
to make it compatible with a plants
existing systems. Multiple approaches
to programming can cost a company
millions of dollars.
| 8
Four IT Standards
You Should Understand
Imagine a world without electrical
standards, such as 110 V at 60 Hz, or
220 at 50 Hz, or a world where every
phone had a different type of connection and required a different type of
switchboard. Just as these standards
are critical to the basic functioning of
electrical equipment, there are also IT
standards used daily to ensure optimal
functioning of production systems in
the process industries.
There are four production-related IT
standards of special interest to the
processing industries:
Tcontrol;
he ANSI/ISA 88 standard on batch
95 standard for MES
Tand
he ANSI/ISA
ERP-to-MES communication;
The ANSI/ISA 99 technical reports
in industrial cyber security; and
The new ANSI/ISA 106 technical
report on procedure automation.
These standards and technical reports
define the best practices for imple-
menting automated and manual control on the systems that reside above
the PLC (programmable logic controller) and DCS (distributed control
system) level, and which perform the
basic control that keeps production
running. These four standards all share
a common view of a production facility, providing a consistent terminology
that makes it easier to compare plants
within a company and across companies.
The ANSI/ISA 99 reports define structures and policies for designing effective and secure networked production
facilities.
The new ISA 106 reports define
the procedural control strategy for
continuous production during upsets,
switchovers, and other types of process changes.
| 9
Four Considerations
for Upgrades & Migrations
Regardless of whether you want to
increase productivity or shorten timeto-market, attaining success in these
areas depends on the application of
suitable automation technologies in a
batch processing plant. Following are
the principal steps involved in assessing your plants technology to gauge
whether a technology upgrade or
migration is in order:
the efficiency and produc Etivity
ffectofonplant
personnel.
Need for continuing support of the
legacy system; and
| 10
DEFINE IN DETAIL.
Successfully implementing a DCS project requires that all stakeholders
(operations, maintenance, project team, vendor, management, etc.) have
a clear definition of what they want from the system. In both upgrading
and installing new DCS systems, the best tip is to keep the end in mind.
Good up-front engineering pays dividends. Automation technology can
only assist us if we know what the needs are. Maintenance must know
what reports and information they really require to do their work. Operations must be completely sure how they operate and what is the best
way to do it. Dont assume anything. Write everything down thats actually required and all the things the technology can do. Be very specific.
In the end, the best DCS is the one that best satisfies all the important
requirements in the plant. Writing and signing this definition document
should be the first step in any project.
| 11
6. Good links. Distributed control systems are only as good as their communications links. Choose a very solid and
reliable link between processing units.
7. FAT is where its at. Make sure
you do a comprehensive and
detailed factory acceptance testing (FAT) test before cutover. FAT
involves experienced operations
people interacting with engineering
to validate graphics and verify that
instruments in the configuration
exist and will remain in service.
8. Use single server. Base the selection of a DCS system on its redundant
capability. A single server system is
preferred. Pay attention to the hardware license for client and server to
avoid delays during a system or hard
disk crash. Care must also be taken in
selecting appropriate layered switches
for communication. Make sure you
properly configure trends and history
data for future analysis.
| 12
13 Suggestions for
Control System Migrations
As anyone who has been involved
in a control system migration will
tell you, its never an easy process.
Whether its an upgrade, expansion,
stepwise migration or rip-and-replace, the bigger and more complex
the project, the more fraught with
tension and risk. To help you get
through the project with your sanity
intact, Automation World readers
share their recommendations and
suggest pitfalls to avoid:
1. Determine strategy. Your migration strategy will depend on which
type of automation youre dealing
with: scripts, workflow tools, policybased orchestration, configuration
or control systems. The different
activities that can be automated
(provisioning, maintenance, proactive incident response, production
execution, etc.) and the different
degrees of automation (automating
just a few actions, partial workflows
or end-to-end) will determine your
strategy in terms of resources, time
scale, production stops, etc.
2. Virtualize first. Automation
upgrades or migrations need to be
scheduled properly in terms of system commission date to extend the
warranty or for a vendors obsolete
notice date. The best practice is to
| 13
| 14
| 15
| 16
| 17
Conduct review
Dand
ecommissioning:
obtain required authorization
before decommissioning a safety
system. Ensure that the required
safety functions remain operational
during decommissioning.
Safety Lifecycle IV:
Ongoing Functions
Certain functions are ongoing. Examples include managing functional
safety, planning and structuring the
safety lifecycle, and performing periodic safety system verification and
safety audits over the whole lifecycle.
Specific activities include:
safety, safety
Massessment,
anage functional
and safety audit:
Identify the management activities
that are required to ensure that
the functional safety objectives are
met.
Bottom Line:
A Requirements Definition
Readers should note that the standards define requirements for safety
management, rather than system
development. Not all safety lifecycle
phases will be relevant to every application; management must define
which requirements are applicable
in each case. The standards do not
prescribe exactly what should be
done in any particular case, but guide
management toward decisions and
offer advice.
| 18
| 19
| 20
| 21
can be hijacked
Cafter
ommunication
it has been initiated (does not
can be
Preplayed
arts of atocommunication
a target, even if the at-
can be listened to
Cbyommunication
third parties anywhere along the
communication chain.
can have data
Cinjected
ommunications
into them by an attacker.
The communication can be interrupted or jammed.
a valid
Acommunications
n attacker can impersonate
node and gain
access to the underlying communications medium.
| 22
2. Control multicast traffic. When implementing wireless technology in factory automation projects, be aware of
any multicast traffic coming from PLCs
or producer devices. Multicast traffic is
handled differently than unicast traffic
by wireless access points. Multiple
devices can receive multicast traffic,
while unicast is destined for only one
| 23
DO YOUR HOMEWORK.
Extensive planning is complete, timelines and schedules are determined,
budgets and ROI calculated and all the textbook preparations and
considerations have been met. What could go wrong? Plenty! Always
vet your system integrator. Get references, see a system designed and
implemented by them in use, visit their factory and, most important, run
credit checks and investigate their financial health. Nothing is more destructive than having an integrator run out of money before the project
has been completed.
careful if you get a much lower price
than expected or than others have
quoted.
| 24
| 25
16. Are they open? Select an integrator that is open to your requests
and ideas. Beware of someone that
constantly pushes back. If you hear
14. Test the team. Verify the integrators capabilities by giving a test to the
personnel who will perform the work
on your project. Make sure those people are listed in the contract, including
fallback or substitute candidates.
15. Do they have business skills?
Look beyond technology expertise
or project experience to consider an
| 26
These are comprehensive PDF e-books jam-packed with tips, pitfalls to avoid, and best
practices for implementing automation in the areas of factory and machine automation,
continuous process, and batch process.
awgo.to/factory
awgo.to/batch
CONTINUOUS PROCESS
PLAYBOOK
awgo.to/continuous
DOWNLOAD THE PLAYBOOK!