PlantPAx Upgrade

Key Facts

Location: Offshore Gulf of Mexico
Client Challenge: Current control system, the Wonderware InTouch HMI, has a tag count cap of 60K, and the current system is running to the limit.
Technology: ControlLogix & PlantPAx (Studio 5000)
Size of System: 3 Integrated AB Process Control and Safety Systems (1756‐L85EP version 34.01), 2 Redundant Pairs (PCS/PSS) and 1 Simplex System (Gateway), 21 stand-alone RIO panels servicing each controller, Total 3000 I/O counts and 400 HMI screens, Ethernet integrated Control IO and Safety IO (SIL 2)
Project Duration: 18 months

Scope of Project

This major design and integration project involves updating over 300 wiring drawings to accommodate I/O module replacements, locational changes, and communication module type changes. Additionally, it includes configuring the PCS/PSS & Gateway PLC system on the PlantPAX platform in line with the Functional Design Specification (FDS). The project entails replacing the existing Wonderware InTouch HMI system with Allen Bradley FactoryTalk HMI to address tag count and graphics limitations. Furthermore, the development of approximately 400 HMI screens and their interlinking is part of the scope, with an IO count of approximately 3000 tags.

Approach

To effectively execute the project, a systematic approach is crucial. Begin by updating wiring drawings, configuring process control and safety systems to meet PlantPAx FDS specifications, and developing HMI screens in phases with a prioritized focus. Coordinate closely with the client to conduct thorough factory acceptance testing (FAT) and manage hardware firmware upgrades for compatibility with new modules, conducting customer witnessed testing to address any concerns. Meticulously document all processes, including system documentation and crating and shipping PLC hardware for overseas transport. Maintain regular communication with stakeholders, providing updates and meetings as needed to ensure alignment throughout the project lifecycle.

Client Benefits

The client has benefited from upgraded operational efficiency, streamlined processes, improved reliability, enhanced user control, and confidence in system functionality, supported by comprehensive documentation for long-term management and maintenance.