Because distributed control systems control so many connected devices, total replacements were once the order of the day when upgrades became necessary. New technology and service approaches are making rip and replace a thing of the past.
While upgrading a control system is no easy task—no matter how it’s done—the good news is that the rip-and-replace process once common to this undertaking is no longer a requirement.
“Addressing the vulnerabilities that are present with a legacy DCS does not always require a disruptive all-at-once approach,” says Dwight Wood, vice president of global sales for NovaTech, whose D/3 DCS system was introduced 38 years ago. “For a plant of any scale running at or near capacity, taking down processing lines for any amount of time can be extremely expensive in terms of lost production and business impact.”
Conrad Oakey, vice president, strategy and communications for NovaTech, notesthatmany engineering, operations and procurement teams are now opting for a multi-stage implementation to phase in newer DCS servers, controllers, and applications. “This approach is more affordable and less disruptive, while still allowing gaps, points of pain and cybersecurity risks to be addressed immediately,” he says.
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