The plant was equipped with an ABB MOD 300 Distributed Control System
. Although this system had been a steady performer for more than 20 years, it was aging, and system reliability problems were leading plant managers to assess whether it was time to evolve to a current technology platform such as ABB System 800xA. Managers knew that to make an informed upgrade decision, they would need accurate information about whether they could obtain critical parts for the MOD 300 System, for which obsolescence notifications were first issued in the mid-1990s.
The Parts Fingerprint provided plant personnel with the information they needed about the availability of critical system spares. This assessment showed that parts replacement could be problematic by identifying critical high-risk parts that would be difficult to source.
In addition to helping to justify a control system replacement, the Parts Fingerprint laid the foundation for improved parts management by supplying a complete parts inventory, and listing all current spares along with information about their condition. ABB found that a large portion of existing spares were open, untested or needed repair, and recommended actions to rectify the site inventory.
The Parts Fingerprint additionally identified and evaluated the plant‘s gaps in spare parts coverage, and categorized the gaps into high-, medium- and low-risk groups to facilitate planning. The Fingerprint identified 48 parts where gaps existed; most were high-risk spares that should be stocked on-site for fast access. ABB provided information on costs and sourcing, including refurbished and third-party sourcing, to eliminate gaps and bring inventory to recommended levels.