What are some strategies for upgrading control systems during their lifecycle?

Here are a few thoughts: 1- Focus on not just the initial costs but the overall lifecycle costs. 2- Assess the control system's longevity, considering the manufacturer's track record in handling product obsolescence. 3- Implement best practices for control system migration, such as ensuring compatibility and minimizing downtime, to modernize systems without disrupting ongoing operations.

Control Systems migrations is always an thoughtful decision and shall be based on the below key strategic points : 1.Continous of Evolution of the System to latest Technology/Platform/Features 2.Maintain the current Intellectual property of the customer databases across Migration 3.New Features helping customer to achieve/move towards bigger goals of Digital Transformation/Connected Systems/Sustainability. 4.One another key aspect is Training/Usability needs of the Operators/System Engineers of the Plant. 5.Most important maintaining overall Control Fidelity of the system.

Below are few points to consider: 1. Detailed analysis of Current Pain Points 2. End of lifecycle (EOL) of components and and in case software what are technology being used and when it is getting over from Support point of view. 3. Explore all possible options but with current state of control system we may have less option as we are not having fully interchangeable or Interoperable option available. 4. Do include learning curve as pointer in your planning so that Operator and Engineers have training and learning post migration.

1) Upgrade should not be done just because the vendor recommends for the same. 2) If the maintenance team is confident on the system performance and availability one should never think of upgrades even if vendor says that he will stop support of the system 3) Availability of spares is a key factor as most of the vendors stop supporting old hardware and if spares is not an issue then the migration plan can be dragged to the maximum 4) If migration program is decided then it should be planned strategically so that cost, schedule, and availability is not compromised.

1. Define the goals in terms of downtime, other KPI and communicate to all stakeholders( Operation, Maintenance,3rd party supplier and Control system company) 2. Measure defined goals , post migration. 3. Some of benefits may be in short term and few may be long term. Better capture both. 4. Align with business need . 5. As technologies are evolving so when defining goals have brainstorm and if required take external or subject matter expert input to ensure that goals are realistic and measurable and solving business problems.

It crucial to develop a detailed upgrade plan that includes objectives, timelines, budget, and resources. The plan should also address any system downtime required and how it will be managed to minimize operational impact. It would be prudent to design the new system in phases to ensure continuous operation during the transition.

L’approche doit correspondre aux objectifs définis mais doit également être choisie par rapport au coût financier que représente cette mise à niveau.

Upgrade approach is related to goals and objectives. If having long term goal then you must consider architectural view in your consideration as we know once control system is installed then it goes for next 2 decades. In this case if required have training or hands on system in place and mitigate the risks by evaluating the application migration and know how of team from asset owners if you seen some of companies are using Open Process Automation (OPA) system as a training system and post evaluation asset owners will adopt. If planning to upgrade due to short term point of view identify the area which need to be changed or upgrade. E.g is it network or control application or front end due to enhanced feature.

Training is key for maintenance teams. Provide comprehensive training for all users on the new system to ensure they are comfortable and proficient in its use.

Cross functional engagement is crucial. Engage all stakeholders as early as possible in the process, including management, IT staff, end-users, and external vendors or consultants. This will help ensure that all needs are considered, potential issues are identified early, and there is buy-in across the organization. While the technology is a crucial enabler in control systems upgrades , the change must be holistic, involving strategy, culture, customer focus, data management, process reengineering, skills development, and security. It's a journey that impacts all areas of a business

My challenge is to catetory in 3 levels 1. Legacy 2. Obsolete 3. Active Client and Vendor Notice let them manage their stagtegy follow to 3 category.

Execute the items 1, 2, and 3 above before purchasing anything. Understand your likely upgrade pathway in the planning stage. Not when you already have half a million dollars in committed purchase orders. Begin with the desired results, and work backward through upgrades which are currently beyond the budget, personnel, production demand, or space constraints.