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Management of legacy control systems

PaulStewart,AutomationandControlforEnergyConference,May2011

Marathon Integrated Oil and Gas Company overviewUpstream OilandGasExploration OilandGasproduction Oilsandsmining LNG Shalegas Downstream Refining Marketing Transportation Distribution2

World wide operations

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Brae area infrastructure

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Brae Alpha - 1984Photo

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Brae Bravo - 1987Photo

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East Brae - 1993Photo

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Typical control systems on an Oil and Gas InstallationESD SafetyInstrumentedFunctionlogicsolvers F&G DCS MCS SCADA GasTurbinecontrolsystems Machinerycontrol,sequencelogic Machineryprotection,vibrationmonitoring CompressorAntiSurgeprotection FlowMetering

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legacy control systemLegacy fromthepast Asystemwhosedevelopmentiscomplete Acontrolsystemwhichisnotacurrentproduct

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ObsoleteAproductorsystemisconsideredobsolescentwhenanendoflifedatehas beenannounced Aproductorsystemisconsideredobsoleteonceitisnolongeravailablefrom theoriginalmanufacturer,eventhoughpartsorcomponentsmaystillbe the original manufacturer, even though parts or components may still be availableinthesupplychain Obsolescenceisinevitableandrequireseffectivemanagementtoreducethe businessimpact Ineffectiveobsolescencemanagementcanresultindifficultyobtainingspares orsupport

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StandardsIEC62402:2007(BSEN62402)ObsolescenceManagement Applicationguide Givesguidanceonestablishingaframeworkforobsolescencemanagement Coversthefollowingareas: Designofnewproducts Newtechnologyinsertionintoexistingproducts Supportandmaintenanceoflegacyproducts

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Reasons for keeping legacy systemsThesystemworkssatisfactorilyanditisthereforedifficulttojustify replacement. Thecostsofredesigningorreplacingthesystemareprohibitivebecauseitis largeand/orcomplex. large and/or complex. Thesystemrequirescloseto100percentavailability,soitcannotbetakenout ofservicewithoutasignificantimpactonproduction. Thewaythatthesystemworksisnotwellunderstood.Thisiscommonon legacysystemswhereitislikelythattheoriginaldesignersofthesystemhave lefttheorganisationandthesystemdesignhaseithernotbeenfully documentedordocumentationhasbeenlost.

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Reasons for replacing a legacy control systemThesystemisunreliable. ThesystemisunsupportableeitherbytheOEMoraftermarketservice providers. Theinstallationhasaremaininglifewhichissufficientlylongtomakeit h i ll i h i i lif hi h i ffi i l l k i unlikelythatobsolescencecanbeovercomewithoutreplacementofthe system.

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Obsolescence management processEffectivemanagementofobsolescenceisessentialtoensureanoptimum balancebetweenreliability,availabilityandcostefficiency.

Identify Criticalcontrolsystemsareassessedtoidentifyobsolescenceissues Mitigate Selectandimplementthemostappropriateobsolescencestrategy foreachsystem. Monitor Carryoutperiodicreassessments,monitoreffectivenessofstrategy

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IdentifyControlSystemsareassessedtoidentifyanyobsolescenceissues Hardware,software,documentation,supportcontractsandcompetencyshall beassessedwithrespecttoobsolescence Anoverallassessmentiscarriedoutforeachsystembasedonaqualitative A ll i i d f h b d li i approachusingariskmatrixandshalltakeintoaccountprobabilityand severityofobsolescence.Ariskcategoryoflow,medorhighshallbeassigned toeachsystem

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Risk Matrix

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Mitigation strategiesAreactiveorproactiveobsolescencestrategyshallbeselectedforeachofthe controlsystems Unlikelythatonesolutionwillbeapplicabletoallsystems,likelytobea combinationofsolutionsacrossaninstallationdependingonrisktothe combination of solutions across an installation depending on risk to the business,cost,wherethesystemisinitslifecycle.replacement, migration/upgradeandlifeextension

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Reactive obsolescence strategyDonothinguntiltheneedarises Suitableonlywhereimpactonsafety,environmentorbusinessislow Thisisapositivedecisiontodonothing Recoveryoptions: ProductsearchbycontactingOEM,aftermarketsuppliers,contactswithinthe industry(otherOilandGasOperators) Repairbyspecialistelectronicrepairers Cannibalisationfromredundantequipment Cannibalisation from redundant equipment

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Proactive obsolescence strategiesReplacement Migration Upgrade broughtuptodatebyreplacementofobsoleteitems. Lifeextensionofexistingequipment

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MonitorTheobsolescenceassessmentsoncriticalinstrumentationandcontrolsystems isrepeatedperiodically Activedialogwithmanufacturersandsupplierstoestablishendoflifedates forsystems for systems Monitorobsolescencestrategyforeffectiveness

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Life extension

TheServiceLifeExtensionProgram(SLEP),wasdevelopedinthe1980sto The Service Life Extension Program (SLEP), was developed in the 1980s to extendtheservicelifeoftheUSNavysaircraftcarriers.Theconcept subsequentlyexpandedtoalloftheUSNavyslifeextensionprogramsfor ships,aircraft,andcombatsystemsincludingtheNASASpaceShuttleprogram SLEPconsidersfactorsincludingsafety,reliability,supportability,performance, andcostreduction21

Life extensionRevieweachofthefollowingareastounderstandwhatisrequiredtoextendthe lifeofthesystem Hardware Software Suppliermanagement Training Technicalsupport documentation

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HardwareLifetimebuyfromOEM Aftermarketresellers Repair Reverseengineer

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SoftwareBackups Abilitytomodifysoftware Softwareemulatortoovercomeobsoletesoftwareorhardware Wellconstructedandannotatedcodetoenablereverseengineering

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Spares ManagementClearsparesmanagementstrategy Accuratebillofmaterials Onsitespares Offsitespares Periodictestingofstoredsparestoensuretheyareserviceable

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CompetencySuitablytrainedandexperiencedstaffonsite. Mixtureofformaltraining,mentoringandhandsonexperiencetobuildupa skillsset. AgeingworkforceintheUKOilIndustry,skillsretentionisimportant A i kf i h UK Oil I d kill i i i

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DocumentationUptodateOperationandTrainingmanuals Maintenancemanuals Asbuiltdrawings MaybeanopportunitytoobtaindesigninfoforendoflifeproductsfromOEM

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Supplier Management Contract award and structureSolesourceortender? Goodqualitycontractstructure CRINE,LOGICstandardcontracts Contractsmustcomplywithcorporatestandards,EUprocurementregulations, OilandGasUKsupplychaincodeofconduct. Oil d G UK l h i d f d Marketconditions wheredoesthebalanceofpowerrest?

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Supplier Management Managing PerformanceSupplierandPurchaserfeedbackthroughFPALprocess. UseofKPIs,metrics,penaltyclausesandbonusstructure Holdperiodicreviewmeetings Buildaneffectiveworkingrelationshipwithkeysuppliers

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Compressor Vibration and Temperature control upgradeOriginalCMLsystem

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Compressor Vibration and Temperature control upgradeReplacementRockwellXMsystemwithPanelview

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LM5000 gas turbine control systemReplacementcontrolsystematFAT

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DCS migration

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East Brae metering systemOEMmigrationpathenabledreplacementofflowstreammicrocomputers withnewgenerationmicros

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East Brae metering system

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Questions

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