After many years of use, the TPS (Total Plant Solution) control system will cause many potential hidden dangers due to the aging of the system. Proactively upgrading TPS is critical to ensuring that equipment can meet growing demand and enable efficient operations. How to be safer, more stable, and more cost-effective is the core topic that users are concerned about.
Sinopec Shanghai Gaoqiao Petrochemical Co., Ltd. (hereinafter referred to as "Gaoqiao Petrochemical") is committed to the innovation and development of various high-end petrochemical products, and has been introducing foreign advanced technology and equipment for many years, promoting cleaner production and improving the ability of comprehensive utilization of resources. In the TPS control system upgrade, Takahashi Petrochemical adopted Honeywell remote upgrade technology to upgrade the system in a safer and more economical way, improving the safety and stability of the system. This is also Honeywell's first TPS system ELCN/EUCN upgrade in China.
Upgrades: Imperative
The TPS control system can be regarded as the "brain" of the industrial facility, controlling the operation of the entire plant installation. By collecting various parameters, issuing instructions after calculation and processing, and directing the operation of the execution equipment, the automatic control of the factory is realized. As the third generation of products developed by Honeywell after the DCS control system, the TPS control system has been operating safely and stably for more than 20 years, and its product quality is well-known in the industry. After many years of operation, the old control system will face some challenges to a greater or lesser extent.
Software security is at great risk
The operating systems configured at the time of the construction of the TPS control system were mostly Windows 2000, Windows XP, and Windows 7, and Microsoft gradually stopped supporting the previous operating system. Vulnerabilities in abandoned software systems are found gradually, but without patches. Older control system virus protection services are also not available from major antivirus vendors.
The old and new software and hardware are incompatible
The TPS control system has a long life cycle, and users cannot install the old version of the software after purchasing a new PC device.
The network architecture can't match the new requirements
The network architecture of the TPS control system is mostly based on coaxial cable, with poor anti-interference ability and low network speed, and will be eliminated in 2025, and spare parts cannot be obtained.
With the continuous upgrading of software and hardware systems and the continuous improvement of industrial safety level, in order to avoid the loss of using old control systems to plant operations, it is particularly important to upgrade TPS control systems with advanced technology to improve operational efficiency and performance. Users are faced with the direct choice of replacing the entire system at a higher cost and instability or a safer and more cost-effective TPS control upgrade.
Online Upgrade: No Stopping
It is imperative to upgrade and maintain the TPS control system. Upgrades that can only be implemented at the user's site must be stopped first, resulting in increased costs and uncertainty about the outcome. Rather than betting on the individual level of the engineer on this important process, is there a more efficient, simpler, and more reliable way to maintain the customer's financial benefits while ensuring the safety of the operation?
In response to Gaoqiao Petrochemical's upgrade requirements for safety, stability, long-term, full-load production, and optimized production, Honeywell's technical team suggested and implemented the ELCN/EUCN upgrade solution, which can support users to upgrade online without stopping. During the implementation process, due to the user's concern about the possible fluctuating impact of the upgrade during the production process, Honeywell was required to complete the control system upgrade within a week at the same time as the equipment was overhauled.
Honeywell implemented a semi-online upgrade based on the specific requirements of Takahashi Petrochemical. Because the network interface module, operation station and controller of the control system are all redundant configuration, the redundant equipment is replaced by a power failure first, and the data synchronization is done, and after the switching, the newly replaced redundant equipment is brought online, and then the old equipment is replaced by a power outage to do data synchronization. In this way, Honeywell has helped Takahashi Petrochemical to upgrade and optimize from the operator station to the network interface module to the controller.
More efficient
The ELCN/EUCN upgrade method can be used to achieve non-stop online upgrade, and the overall upgrade time is about 1/10 of the replacement of the entire system solution. If the scheme of replacing the entire system is adopted, the upgrade time not only includes preliminary preparation, manual conversion of the database and various tests, but also needs to carry out a series of complicated work such as system disassembly, rewiring, and re-dotting tests for about a month on site, as well as a series of complicated work such as joint debugging, verification control, logic and screen display after the preparation of the system program, before it can be put into production. The ELCN/EUCN upgrade method can avoid the above complex work.
More economical
The original control IO card is fully compatible with the new system, and Honeywell guarantees full lifecycle supply, so that the user's original assets are not wasted.
Safer
Compared with replacing the entire system, the ELCN/EUCN upgrade method does not need to replace the wiring and other equipment accessories, and the source code can be manually changed after the upgrade, and the database conversion can be automatically completed, with an accuracy rate of up to 100%, which greatly reduces the security risk of the upgrade.
More stable
For users of Honeywell equipment, after the ELCN/EUCN upgrade, its past operating parameters (given values, PID parameters, logic point settings, etc.) can be completely inherited without any changes after restarting. The upgraded DCS system is fully compatible with the current mainstream operating systems, specifications and protocols.
It is worth mentioning that the ELCN/EUCN upgrade method is used to upgrade the control system, because it is also a new software and hardware, its performance and effect reach the level of a new system, which ensures the long-term operation of the equipment and the full load production performance.
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