Rarely do municipal governments readily part with the $100,000 or more required for a full plant automation upgrade.  Nevertheless, your automation system won’t last forever.  So rather than trying to eat the elephant all in one bite, carve it up into smaller portions for consumption over time.  Here is a step by step plan you can use.  

Step 1- Quantify the cost of doing nothing.

There is a cost associated with avoiding and delaying system upgrades. Failure of obsolete components or out of production hardware will cause lengthy and unscheduled system down time. System outages may not bring production a halt, but the increased man-hours required to keep things running without full automation has a price tag. While that cost doesn’t hit the capital budget, it does impact the operating budget.

Produce a Systems Asset Report that identifies the current status of all hardware and software components in relationship to its product lifecycle. Identify items that are obsolete, out of production, lack suitable replacement parts, require high maintenance and subject to high failure rate. Highlight the system wide consequences and budgetary impact of failure of each non-current component. 

You can do it yourself or have us provide you with a comprehensive Systems Asset Report as part of a Control Systems Checkup.  (Order Control Systems Checkup) 

Furthermore, keeping your automation systems up to date will save money, make your operations more efficient and increase system capacity. A well designed and well run SCADA system frees up operators so they can focus their attention more efficient use of plant resources. Older systems require more hands on involvement and so there is less opportunity for process and resource optimization. These lost opportunities are real and identifiable costs associated with holding on to older less capable technology.

Step 2- Always have a plan

Next design the system that you ultimately want to have so that you can build it incrementally.  Set 1-year, 3-year and 5-year goals.

Consider emerging standards as part of your plan including: Upgrades to comply with ISA/IEC 62443 Cyber Security standard, NIST SP800-53 and the ISA-112 SCADA Standard. 

Your plan should include a go-to list of projects that move you toward your goal. This list should clearly identify your weakest links and upgrades that provide the greatest returns. Your weakest links include: obsolete hardware/software, slow serial networks, failing systems, inadequate SCADA Security. Your greatest returns will be realized from adding High Performance HMI, SCADA optimization to new process areas, and adding remote visibility and access. If you can find areas where your weakest links and greatest returns overlap, these will become your top priorities. 

Step 3- Publish the plan

There is great value in having a documented plan. It helps your team to understand the goal so they can cooperate in achieving it. A documented plan helps keep you focused on the target. A documented plan builds confidence in your stake holders as they are able to see the ROI benefits of investing towards a better future rather than paying again for a decaying past.

Step 4- Implement the plan with available resources 

With a plan in place, you will position yourself to implement your dream system while replacing failed and obsolete items. As one politician put it, “never waste a crisis”. So don’t just patch up a failing system when you can use the same operating budget to build your new system.

Instrulogic can help every step of the way.

SINCE 1990, InstruLogic has built a track record of innovative solutions for municipal, industrial, and federal clients. As experienced designers and consultants in the field of instrumentation and controls, our team of specialists approach every project with a proven ability to engineer complete systems for any application.  InstruLogic can help you every step of the way. Request an @no Charge Consultation.