Modernizing your control systems isn’t just a technical option; it’s a business necessity for staying competitive, relevant, and innovative. This ARC Advisory Group whitepaper on Modernization delivers help you understand the strategic imperative for unlocking value through modernization. Read this report to discover how modernization opens the door to modern technologies like AI, digitalization, and advanced cyber security, explore stepwise vs. rip-and-replace strategies, and learn best practices.
Executive Overview
The imperative for control system modernization is driven by the critical role these systems play in enhancing reliability, operational efficiency, and safety in industrial environments such as power generation plants, chemical plants, life-sciences manufacturing, and oil refineries. Control systems act as the "brain" of a plant, continuously collecting and processing data from numerous sensors and devices to provide operators and process engineers with a comprehensive view of the plant's condition. The main goal of the control system is to create the most autonomous facility possible. This real-time data enables reading of important process parameters coming from field devices like temperature, pressure, or flow. Operators continuously keep an eye on upcoming alarms and are enabled to manually adjust control parameters ensuring plant uptime, optimal process performance, better product quality, reduced waste, and lower energy consumption. Additionally, centralized monitoring and latest control strategies reduce operational cost. Furthermore, smart connections to field devices reduce the need for local maintenance in hazardous areas. Hence, a modern DCS can significantly enhance the overall plant performance and safety.
Modernizing distributed control systems (DCS) is crucial for addressing inefficiencies inherent in outdated version of control system hardware and software and older “legacy” systems, which often lack advanced functionalities and are more vulnerable to cyber-attacks. Further, these systems show a decline in reliability and availability as they age. The high maintenance costs associated with aging hardware and software, coupled with the difficulty of finding replacement parts, drive up operational costs and increase the risk of downtime. Modern systems offer better reliability, lower maintenance costs, and enhanced and current cybersecurity features, making them a more cost-effective solution in the long run.
Modernizing is crucial for addressing inefficiencies inherent in outdated control systems that lack advanced functionalities, are more vulnerable to cyber-attacks, and over time show a decline in reliability and availability due ageing components. The high maintenance costs associated with aging and the risk presented by unsupported versions of control systems hardware and software lead into difficulties of finding compatible replacement parts and requires software upgrades to support more current replacement parts, drives up operational costs, and increases the risk of unplanned downtime. Modern systems running on supported versions offer better reliability, lower maintenance costs, and allow the us of enhanced cybersecurity features, making them a more cost-effective solution in the long run. Running on outdated operating system which can no longer be patched clearly open the door for cyber attacks which are in recent years more and more conducted on-site.
Modernization also creates an environment that is more attractive to younger workers. This makes it easier to find and retain staff. Depending on the application, changes that can only be accomplished with a performant modern system are needed to operate the plant with less staff because retiring employees may not be easily replaced due to labor shortages.
Table of contents:
- Executive Overview
- The Imperative for Control System Modernization
- Integrating Modern Technologies for Optimal Business Performance
- Recommendations
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