Q: What if a user has “1 for 8” controller redundancy in a currently installed control system. What type of redundancy will be available when the user migrates to Experion?A: Migration to Experion will improve redundancy to “1 for 1.” This new level of redundancy greatly increases the control system’s uptime.
Q: What about users who employ Extended Operator Stations as their primary operator interface. Will they still have multiple databases to maintain after migrating to Experion?A: The database management problems of the past will no longer be an issue for users. Experion consolidates multiple databases into one, easy-to-manage database for all data types.
Q: Will the user have trending comparable to the existing BOS/EOS box trending?A: No, it will be better! Box trending is a limited snapshot of the process variable and can only be updated with operator intervention. Experion trending goes far beyond box trending and provides truly useful history information to the operator for analyzing and controlling the process. All trend data is presented to the operator with the capability to zoom, pan and select specific trend data in real time. Data points to be trended can also be selected and grouped together “on the fly” to facilitate real time process analysis.
Q: Do users need to improve and automate their reporting to meet new requirements? Will the migration to Experion help?A: Yes. In addition to the larger number and type of reports available, a key new feature is the ability to have the reports electronically transmitted via the plant network to all interested parties. No longer will you need to have an operator or engineer manually read the printed reports, perform additional calculations and then create new reports to pass along. Additionally, you can set the system up to automatically post all data to an Excel spreadsheet for automated data manipulation, analysis and distribution.
Q: What kinds of totally new control capabilities will be available following migration to Experion?A: Experion provides improved control capability such as model-based controls, integrated loop and logic capability for improved process-constraint control. Experion implements cross unit controls in easy to use software instead of clumsy hard wiring between controllers.
Q: What if a user wants to simply “copy” existing control schemes over to Experion without making any changes?A: Control Match services are available that simply duplicate the controls that were running in an existing system into Experion. All point types and standard algorithms of the Extended Controller can be easily migrated.
Q: How quickly can the physical migration to new controllers occur at the plant/mill site?A: The typical time for the physical migration to occur is 2 to 4 hours. Much less time is needed if you are migrating a small system. There are two reasons for the short downtime: the migration kit is a plug-and-play design, and I/O checkout can be quite efficient. To make the physical changes, all you have to do is disconnect cables, remove a few screws per assembly, install new assemblies, then connect or reconnect cables. All the new cables and assemblies are tested and verified in the factory before shipment. Assuming all your existing I/O and cables were operational and correct before the migration, there is very little room for error in the physical upgrade process.
Q: Is additional cabinet space required for the new Experion controllers?A: Typically, no. In most cases the new control system can be mounted into the existing TDC 2000 cabinets.
Q: Are calibration and test points available in the migration kits for on-going maintenance?A: Yes, calibration and test points are provided.
Q: Do the migration kits have any active components on them such as CPUs, networking and the like?A: No, all Signal Match migration hardware is created using passive components. This greatly increases reliability, longevity and reduces the number of possible fault paths.