Polyethylene Plant Upgrade: New DCS and Centralized Servers
Modernization: Implementing PLC Vx Rail Hosts and updating an outdated Honeywell DCS, SCADA system, a safety manager system, and network cables at a petrochemical plant
Overview
InnoTech upgraded a client’s outdated Honeywell equipment and coaxial network in three stages, ensuring operational reliability and efficiency. Challenges included last-minute construction changes and vendor delays, but the team adhered to timelines, avoiding disruptions. The upgraded system now supports faster data transmission, centralized servers for operational congruency and space efficiency, and enhanced process control, securing the client’s operational future.
Situation
The client had soon-to-be-obsolete Honeywell equipment and a communication network still operating on coaxial cables. This infrastructure needed a facelift, and the client wanted it completed with ample time to fully test and prepare their equipment and facility, to establish confidence for the future.
Risks
The client and their facility would soon be at risk due to their outdated infrastructure. They would soon no longer be able to find support or spare parts for it. These risks included the ability:
- to maintain control of their plant,
- to make changes to plant systems,
- for their equipment to communicate,
and ultimately result in a substantial loss of revenue for the client.
Why InnoTech?
The client chose InnoTech over the competition because of our pre-established relationship and track record of high-quality work on their facility.
Actions Taken
The team completed this project in 3 stages, beginning with the simulator infrastructure package which involved installing all the hardware. The new hardware in the cabinet designs would be powered using:
- network switches,
- centralized servers (PLC Vx Rail cluster hosts),
- and power supply infrastructure (replacing the old UCN and LCN connections with an ethernet network and fiber cables)
The next stage was the virtualization package. During this stage, the team installed and configured software in the virtualized machines, and plugged-in all the cables. Then, they tested everything to ensure that it was ready to go for the implementation stage.
Finally, the hardware was implemented and migrated; the old hardware and cables were removed, and the equipment was tested and commissioned. Then, during the plant turnaround, the hardwired machines were moved to the virtualized machines.
Alongside the installation of the virtualized centralized servers, the team also upgraded the client’s outdated Honeywell Plantscape SCADA system to the Experion Process Knowledge System (PKS) and replaced the outdated Honeywell FSC with a Safety Manager (SM).
Challenges
The team faced challenges along the way with last minute changes to the construction packages, delayed communication with a third-party vendor, and limitations with cable lengths. These challenges ultimately put stress on the project timeline, but the team managed to issue the final package just in time, avoiding the need to redo the risk assessment and reschedule the migration.
Results
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The client now has a new system with supported hardware that will run more efficiently, can be serviced, and new parts can be procured for. |
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These virtualized clusters allow for the plant to have interfaces that connect to this centralized server, rather than having servers at each workstation, freeing up space in the control room. |
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The upgraded communication network and equipment sends and receives data and commands faster which increases the efficiency of the client’s processes. |
DISCUSSION QUESTIONS
Have you considered auditing your facility for any equipment that has become obsolete? This best practice helps mitigate risks to processes and production, especially before it is nearly, or is, too late.
This may seem like more work to add to your plate, at InnoTech Engineering we provide Health assessments for OT (Operational Technology) system hardware, software, cybersecurity level threats, configuration, and standardization. Focus on what you do best, leave the OT to us.