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![Page 1: A Lessons Learned Discussion of Digital Control Upgrades How to Make Sure Your Digital Upgrade is Over- Budget, Over - Schedule, and Everyone’s Vacation.](https://reader035.fdocuments.us/reader035/viewer/2022081513/56649e2a5503460f94b182fc/html5/thumbnails/1.jpg)
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A Lessons Learned Discussion of Digital Control Upgrades
How to Make Sure Your Digital
Upgrade is Over-Budget, Over -
Schedule, and Everyone’s Vacation
Gets Cancelled
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Major Topics
• The Phases of a Digital Control Project
• Examples of How things can go Wrong
• Discussion
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Slide 4
Major Phases of a DCS ProjectSales/Proposal
Phase ManagementPhase Design
Phase
ImplementationPhase Testing
Phase Startup/Commissioning
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What is…..
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The Sales/Proposal Phase
• Request For Quote• Competitive Bid
Process• Proposals• Awarding of Contract• Purchase Order
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The Management Phase
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• Assemble Project Team• Hold Kickoff Meeting• Develop Schedule• Project Specification
Finalized; Requirements Created
• Develop Plans
Project Management Plan
Quality Assurance Plan Etc, etc, etc
AND……
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The Management Phase (cont…)
Slide 8
DESIGN INPUTExamples:• Process Description• P&ID Drawings• Existing Logic and Function Drawings• Procedures• Alarms, setpoint, scaling information• I/O Database
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Project I/O Database
Slide 9
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Project I/O Database
Slide 10
Database
I/O Load (Drawings) Wiring Diagrams
Control Database New Control Drawings Software Design Description
Hardware Test Procedure Site Testing
Process Graphics Graphic Documentation
Historian
Reporting
Other Systems Documentation
Software Test Procedure Site Testing Site Procedures
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The Design Phase
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BEGIN
DESIGNFREEZE
• Design Input continues
END
• Design Calculations• System Design Drawings• I/O Database• Failure Modes and Effects
Analysis• Testing Plans• Traceability Matrix
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The Implementation Phase
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• Application Software Control/Graphics/Historian/Reports
• Test Cases and Procedures
• Updated Design Drawings Possible
• Dry Run Testing
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The Testing Phase
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• Pre-Testing (Vendor Test)• Factory Acceptance
Testing (Customer Test)• Corrections and Retest• Changes
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The Startup/Commissioning Phase
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• YOUR system now
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