Replacement of a Legacy HMI as the First Step In a MultiPhase Control System Migration

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• Replacement of a Legacy HMI as the First Step In
  a Multi-Phase Control System Migration

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• Independent Control Systems Integrator
• More than 100 control and IT engineers
• Experience in implementing/supporting virtually
  all commercially available DCS and PLC/SCADA
  systems
• Eight offices in the Mid-Atlantic, New England,
  and Gulf Coast

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Mittal Steel Corporation Sparrows Point,
Maryland 68 Inch Hot Mill

• Critical Operation in Large Integrated Steel Mill
• In continuous operation since 1947
• 1990 Retrofit
• Installed two new Stein Haurty Walking Beam
  Furnaces
• Installed new Moore Products High Level
  Link/Local Instrument Link control system
• Manufactures feedstock for all site finishing
  operations
• Typical end uses
• Structural steel
• Tin cans
• Truck frames
• Appliances

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Legacy System Architecture

• A total of 103 Moore Products Local Instrument
  Link (LIL) Controllers and Communication Devices
  on Three Expanded LIL Networks
• Model 352 Single Loop Digital Controllers
• Model 353 Multi-Loop Controllers
• Model 383 Multi-Point Display Stations
• Model 324 Programmable Sequence Controllers
• Model 321 Link Expansion Satellites
• Model 320 Independent Computer Interfaces
• Link Expansion Satellites Connect Three Expanded
  LILs to a High Level Link (HLL)
• ACS Consoles on HLL
• Model 2.5 ICI on HLL to Communicate with Level 2
  Supervisory Control System

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Legacy Architecture Diagram
Applied Control Engineering, Inc.
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Problems

• ACS Consoles
• Occasional failures and intermittent problems
• Engineering console being used for spare parts
• No other source for spare parts
• Model 324 Programmable Sequence Controllers
• Occasional failures in I/O cards and power
  supplies
• Retired equipment being used for spare parts
• No other source for spare parts

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Problems (Contd)

• ICI 2.5
• Single point interface to VAX
• No spare parts available
• Link Expansion Satellites
• Single points of failure with no spare parts
  available
• HLL interface is most likely point of failure
• Other LIL Devices
• Very reliable
• Technically obsolete, but can be replaced or
  repaired

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Consequences of Device Failures

• ACS Consoles
• Failure of one very inconvenient, but
  operations could continue
• Failure of two shut down entire hot mill (and
  therefore entire plant)
• Model 324 Programmable Sequence Controllers
• Failure of one shut down the associated furnace
• ICI 2.5
• Loss of level 2 interface
• Operations could continue, but less efficient

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Consequences of Device Failures (Contd)

• Link Expansion Satellites
• Failure of one LES shutdown of one furnace
• Failure of any two LESs shut down entire hot
  mill
• Other LIL Devices
• Failure might shut down a furnace zone
• Minor and temporary impact on operations

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Migration Plan

• Phase I Console Migration to Siemens PCS7 OS
• Interface to LILs through ICI 320s
• Customized solution to mimic ACS operation
• Parallel Console Operation During Prove-Out
• Phase II Replace PSCs with Siemens PCS7 AS
• Removes controllers that have highest failure risk

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Migration Plan (Contd)

• Phase III Replace Level 2 Interface
• Removes ICI 2.5
• Phase IV Replacement of Remaining LIL Controls
• Can be accomplished one device at a time
• Final system is a integrated PCS7 DCS solution

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Customer Requirements

• Phase I Implementation Without Downtime
• Closely Mimic ACS Navigation and Control
• Navigate to screens by entering screen numbers
• Navigate between furnace A and furnace B lower
  level screens without moving through screen
  hierarchy
• Control using fixed window no pop-ups
• Final Migration to a Distributed Control System
• Single Database
• Common HMI/Control engineering tool

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Project Team

• Wayne Medoff Mittal Steel
• 68 Hot Mill Process Engineer
• Vince Danna Mittal Steel
• 68 Hot Mill Instrument Technician
• Rob Duke Applied Control Engineering
• Process Control Engineer
• Dave Erby Applied Control Engineering
• Process Control Engineer
• Alex Shields Applied Control Engineering
• Project Manager

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Phase I Architecture

• Redundant PCS7 OS Servers
• Also act as client stations
• Connect ICI 320s to each Local Instrument Link
• Two on each LIL for redundant communications
• Spare devices used no capital cost
• Parallel Operation of ACS and PCS7 OS Until Final
  Acceptance

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Phase I Architecture Drawing Parallel Operator
Stations
Applied Control Engineering, Inc.
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Tag Database Creation Flow Chart
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Objective Single Database with All Console and
Tag Address Information

• Uploaded ACS configuration
• Used MYCAD to obtain dBase format database
• File contained animation information, but only
  HLL addresses
• Uploaded LES configuration
• Printed configuration to text file
• Converted information to Excel
• Imported into dBase tables
• Combined ACS and LES Information
• Merged through a series of queries
• Result combined ACS/LES database with all
  console and LIL address information

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Objective Extract ACS/LES Information to Create
File that can be Imported into PCS7 Database
Automation Utility

• Identify ACS/LES parameters that will be required
  for PCS7 OS configuration
• Assign required parameters to elements within
  structures
• LIL_DISC
• LIL_ANLG
• LIL_LOOP
• Develop application to query ACS/LES database and
  manipulate and map required information to proper
  format for import
• Default values
• Addressing information
• Data extrapolation
• Non-global information

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Combined ACS/LES Database
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Point Template
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Press the magic button to build PCS7 points
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Then A Miracle Occurs
Applied Control Engineering, Inc.
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Import File for the OPC DBA
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Not really a miracleLots and Lots of code
behind the magic button
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Tag Database Creation Flow Chart
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PCS7 OS OPC Database Automation Utility

• Imported files produced by migration tool into
  the OPC DBA
• Block icons not used (attributes, including
  symbol type, could not be assigned)
• Screen hierarchy defined
• Tags are assigned primary graphics

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PCS7 OPC DBA Utility
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PCS7 OPC DBA Utility
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LIL OPC Server Limitations

• No file import capability
• Cannot copy devices or folders
• Scaling for all analog tags had to be entered
  manually
• Not supported for devices other than the 353
  (although it communicates to all LIL devices)

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LIL OPC Server Configuration

• Create one of each type of device as template
• Manually enter device name
• Manually create subfolders
• Manually create elements
• Manually scale analog tags
• Create instances of device templates
• Manually enter device name
• Manually create subfolders
• Copy elements into subfolders from device
  template
• Manually scale analog tags

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LIL OPC Server Configuration
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LIL OPC Server Configuration
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Discrete Point Communication Issues

• Problem
• PCS7 OS recognized LIL OPC Server discrete tags
  as integers values (based on bit location)
• Some discretes (those above the 8th place in the
  word) would never toggle to True.
• Solution
• Read into PCS7 as integers
• Treat zero values as False
• Treat any non-zero value as True

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PCS7 OS Customization

• Animation Using Legacy Database Parameters
• Visibility
• Color
• Decimal Places
• Action
• Navigation
• Hot Key for immediately jumping to a screen
  number, regardless of position in hierarchy
• Scripting to modify left/right navigation buttons
  to move to same screen on other furnace
• Control
• Embedded window rather than pop-ups
• Populated by discrete, analog, or loop faceplate
  as appropriate

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Typical Process Graphic
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Animation of Number of Decimal Places
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The PCS7 OS Request Queue

• Behavior
• PCS7 Request Queue jam-packed when any screen
  using symbols was used
• PCS7 Request Queue jam-packed when global alarm
  acknowledgement configured

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The PCS7 OS Request Queue

• Consequences
• No Operator request can be processed until queue
  clears
• Waits could be as long as 10 minutes
• If queue got too full, system would freeze-up,
  requiring a re-boot

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The PCS7 OS Request Queue

• Solution
• Wherever possible, reconfigure screens to direct
  addressing vs. use of symbols
• Add functionality to screens to reduce the need
  for picture window functionality
• Add a line in the system registry to change the
  polling time for the request queue
• Add a line in the system registry to change the
  polling time for alarms

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Project Status

• Configuration complete
• PCS7 OS operating in parallel to ACS consoles
• Turnover after operator and maintenance training
  completed

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Final Phase I Architecture
Applied Control Engineering, Inc.
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Contact

• Alex Shields
• Project Manager
• Applied Control Engineering, Inc.
• The Mill at White Clay
• 700 Creek View Drive
• Newark, DE 19711
• alex.shields_at_ace-net.com
• 302-738-8800 (office)
• 443-745-3363 (cell)

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