Controller Optimization

Key Facts

Location: Offshore Gulf of Mexico
Client Challenge: Experiencing unreliable control system operations
Technology: ControlLogix & PlantPAx (Studio 5000)
Size of System: 4 Integrated AB Process Control Systems (1756‐L75 version 20.058 kit 2), 3 Redundant Pairs and 1 Simplex System, Multiple stand-alone RIO panels servicing each controller, ControlNet integrated IO, Ethernet integrated Safety IO (SIL 2), Ethernet integrated package based sub-systems
Project Duration: On Going

Scope of Project

We performed a thorough analysis of the infrastructure and code in various systems on an offshore facility. This included PCS, SIS, ESD, and FGS systems. Our goal was to find ways to make the control system operate more smoothly and reliably. After studying the systems, we came up with solutions to reduce operational risks and increase reliability.

Approach

Examine backups from different controllers in the system to identify factors that could lead to reliability issues, unnecessary alarms, and trips caused by overloading. Additionally, pinpoint inefficient programming techniques that may disrupt communication. After analysis, propose recommendations and discuss various integration options with client approval. Conduct hardware firmware upgrades and optimize application programming to enhance memory availability and communication capacity. This aims to mitigate risks such as program task scan overruns, spurious trips due to controller overloading, and prioritize code execution based on priority.

Client Benefits

Increased availability reduced the risk of unnecessary disruptions or communication loss, ensuring consistent process visualization. The project progresses in phases: analysis, optimization implementation, verification and validation of modifications, and commissioning of revised application code. These stages ensure a seamless transition, ultimately delivering a more dependable system to the client – one they can rely on to perform as intended.