Re: [foxboro] A good news story.
- From: Tadeo Armenta <tadeoarmenta@xxxxxxxxx>
- To: foxboro@xxxxxxxxxxxxx
- Date: Mon, 23 Aug 2010 13:47:12 -0700 (PDT)
Congratulations,
Biggest upgrade i've heard so far. You guys must get serious vacations now!!!
Regards
________________________________
De: "Bud.Kahovec@xxxxxxxxx" <Bud.Kahovec@xxxxxxxxx>
Para: foxboro@xxxxxxxxxxxxx
Enviado: lun, agosto 23, 2010 1:41:36 PM
Asunto: [foxboro] A good news story.
I just wanted to convey a good news story and give kudos where due.
A successful DCS upgrade with GREAT support from site personnel, Cybertech
Automation, Chemco Electric Contractors, Invensys (service and customer support
group), and others.
I could name names but they all know who they are and it would make this very
long.
Below is a brief summary of our major DCS upgrade, which has given us a system
that has met and exceeded our expectations in most cases.
Yes, we had a few disheartened days and nights but now have a very capable
system, thanks to an excellent team, hard work and a good product.
I read bad press often about FDSI FBMs, but they have done the job for us (25+
FBM230, 15+ FBM231, 10+ FBM232).
In converting approximately 40 gateways we only had to use one FBM224, and we
did this to achieve better redundancy than we had previously.
Windows (and I am an old UNIX guy, but not too too old), F/ZCP270, MESH all is
working well.
DCS Upgrade Summary
(All numbers are approximations)
Schedule
* First meeting April 2007
* Plant running on Upgraded DCS June 2010
* Engineering on-boarding June 2008 (infrastructure planning begins)
* Testbed ordered November 2008 (GW conversion begins)
* 100% GW soft I/O mapping testing 6-8 months
* CP database testing 2-3 months (test compile every sequence)
Scope
* SW V6.5.X to 8.4.X
* 40+ CP60 to ZCP270, 22750 hard I/O (+7 - ZCP270 expansion)
* 300+ Vertical baseplates (2250 FBMs)
* 20+ GW30B (serial) to 15+ FCP270 (FBM230/231), 19500 soft I/O total
serial & mb+
* 20+ MB+ to FCP270 (FBM232) (+1 - FCP270 expansion)
* 30+ Unix WP to Windows WP (+10 expansion)
* 10+ Unix AWs to Windows AW (+2 expansion)
* 2 A series fibre MESH switches (9 ATS) to 4 N3, 6 N1, 6 A Star MESH
switches (+2 N1, 6 A expansion)
* 3500+ Graphics converted
* 21000+ Overlays converted
* 125+ scripts (50 lines average)
* Maintain ICC due to focus on hardware only
* No scope on FF FBM221
* 5+ NR&D MEB-RT used where MB+ network could not be replaced due to end
device (MEB P even looks better) interface to FBM232
* 10+ SST Xlink (DN to MB+) changed to Bridgeway AB7603 (DN to Enet)
interfaced to FBM232
* 6 persons full time, 4 persons part time for 2 years for engineering
design, documentation, testing, etc.
Notes
* Testbed (re-used in system, approximately 10% of total cost)
* Control station loading reduced by 60%
* Checkpoint time reduced from 20-30 minutes to 10-20 seconds
* No Cyan IPC connection issues due to the 100 IPC limit of 270s
* Footprint reduced by deleting 1x8 cells containing ATS, DNBT, FONBE in
CCR
* Footprint remained the same in rack rooms due to adding baseplates and
power for FDSI gateways where 1x8's were removed
* FDSI gateways worked well (only one case the new FDSI module had to be
replaced by a FBM224, due to redundant port configuration with the end device.)
* Many custom driver options are available or can be built (expensive,
but effective)
* GWs connected to 15 various end devices (PLCs, analyzers, VFD,
Multilins, HMIs, RTUs, etc.)
* Single user Windows ICC vs. multiple user Unix ICC not an issue due to
fast checkpoint times.
* MESH backbone upgraded hot prior to turnaround
* WPs were upgraded hot prior to turnaround
* CPs, baseplates, GWs, AWs all upgraded during turnaround (28 days,
24hr/day, 30 people)
Thanks to our project team,
bud/
Bud Kahovec, PMP
Project Lead
Shell Projects Group
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_______________________________________________________________________
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Systems (formerly The Foxboro Company). Use the info you obtain here at
your own risks. Read http://www.thecassandraproject.org/disclaimer.html
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