In the Pulp & Paper industry, end users face an increasing need to modernize their aging automation systems to deal with obsolescence, mounting cybersecurity risks, and effectively leverage new digital technologies. This article explores the needs and justifications for modernization (both obvious and hidden) and the keys to a successful modernization project.
Just how old is your aging control system?
When it comes to industrial control systems, many Pulp & Paper mills today are still running technology and software from 15 to 30 years ago. We routinely speak with clients whose systems predate the turn of the century. This reliance on outdated technology poses significant cybersecurity and operational risks, alongside challenges related to obsolescence and ongoing support. Many facilities operate multiple distributed control systems (DCS) and programmable logic controllers (PLCs), complicating the support of these obsolete systems. Managing even one outdated system is demanding; dealing with several can become an unsustainable burden.
Obsolescence is a problem, but what else are you missing out on?
Most end users know the struggles of obsolescence all too well. Often, they invest in costly support contracts only to face inadequate service and responsiveness from manufacturers. A significant shortage of experienced plant staff and integrator partners means it’s a toss-up of how you will bring new inputs & outputs (I/O) into the system, of who will work on new plant expansions or even simply how you will troubleshoot something that has stopped working in your 20+ year old automation environment. Maintaining adequate staffing levels is increasingly challenging as experienced personnel retire or leave. Meanwhile, newly hired operators and control system engineers are eager to work with and learn with modern technology.
During discussions with clients from the Pulp & Paper industry, a common challenge is managing outdated control systems. We certainly agree that moving away from obsolescence is critically important to enhance their cybersecurity posture, lower their operating costs and decrease risks to their business. However, we also emphasize another compelling reason to modernize; specifically, that a current generation DCS enables them to embrace emerging technologies such as data analytics, Artificial Intelligence (AI) and Machine Learning (ML) which is much more expensive, risky and complex to do using older DCS and PLC technologies.
Modernization as a stepping stone in your digital transformation journey
Unless you’ve been cut off from the world since your last control system modernization, you’ve been hearing buzz terms like Industrial Internet of Things (IioT), Industry 4.0, artificial intelligence (AI), machine learning (ML), and data analytics. Does your control system infrastructure enable you to leverage these technologies, or are you trying to find creative ways to bypass what should be your greatest enabler to digital transformation?
Modernizing with Emerson's DeltaV system unlocks a comprehensive range of capabilities that drive operational excellence. The big technology focus in today’s industrial world is about connectivity of data and ensuring it can get to the right place for decision support. Directly within your control system environment, there are already potential benefits from updated high-performance graphics for your operators. Additionally, other digital projects that many clients are seeking to implement are real-time process optimization, predictive maintenance, and energy management. There is an entire range of process simulation-based solutions that are focused on operator training and enabling offline testing of critical scenarios.
Where to begin?
Many end users simply get overwhelmed by the complexity and cost of modernization, or otherwise fail to justify the business value over other investment opportunities. The first piece of advice to deal with the scope of the challenge is to break down your control system into smaller, more manageable chunks, and to build a roadmap of where you are trying to go.
Most people think first about hardware. Your control system is composed of workstations, controllers, I/O cards, terminal strips, and a mess of wiring, signal conditioning hardware and connection points. Should you rip everything out and replace it with brand new equipment?
In a complete “rip & replace” solution, Emerson’s industry leading Electronic Marshalling technology has proven itself as a best-in-class solution as it provides flexibility down to the individual I/O channel, offers a huge range of different input types to simplify and consolidate your I/O, and is highly scalable so you can start small and add new I/O as your modernization efforts progress.
What if “rip & replace” is not for you?
While a “rip & replace” solution is certainly a clean approach and immediately brings your control system up to speed, it’s also the most capital intensive at the beginning leading many Pulp & Paper clients to choose an alternate approach. So what other options are there?
Emerson’s DeltaV system grants you the flexibility to move in phases and target particular areas of the system first, while distributing the cost intensity of your modernization journey over time. This portfolio of solutions is called DeltaV.Connect.
Consoles (Human Machine Interface - HMI)
As you might expect, the hardware that goes obsolete the fastest in your control system are your computer workstations and displays. Many clients experience failed monitors, hard drives, network cards or even disc drives (yes, they still exist).
Depending which legacy control system you have, it may be possible to connect new DeltaV workstations with the DeltaV LiveTM HMI graphics platform directly to your existing controllers. This allows existing non-Emerson controllers to continue executing their code, while adding a modern look & feel to your operator interface, and the option to implement high-performance graphics concepts. This delays the eventual replacement of other system components until such time that it makes sense to also begin moving controllers and I/O to native DeltaV hardware.
Controllers (CPU)
Many clients are surprised to find out that DeltaV Controllers can connect to their existing non-Emerson I/O cards from a variety of manufacturers. DeltaV IO.Connect introduces DeltaV controllers with a direct interface to an entire I/O subsystem and is attractive to many end users because the initial capital costs are reduced by up to 40+% when keeping the existing I/O cards and wiring in place. The cutover to the new system and the required shutdown window are very short, and once complete the entire process logic is running on DeltaV. Now operators have not only modern graphics, but also the horsepower of modern controllers and control system logic, allowing operational benefits to start being realized right away.
Controller Programming: avoid reinventing the wheel
Replacing your controllers of course means also modernizing your control system programming. So, does that mean you have to rewrite your programming from scratch? Far from it!
The DeltaV solution offers an easy way to move software from old systems to the DeltaV system using a tool called DeltaV RevampTM. This tool, powered by AI, can automatically convert about 70% of the basic setup, which can cut initial costs by up to 15%.
Here's how it works: Revamp takes backup files from your old system, analyzes them, and creates reports showing details like input/output counts and card types. This reduces the effort needed for conversion and lowers the risk of cost estimation errors.
Advanced analytics are used to create logic diagrams and a searchable database of the applications. AI matches existing logic with a library of past projects to find repeated patterns in the system. By simplifying work and streamlining processes, the digital workflow ensures a smooth, error-free data path, allowing for earlier testing and easier project completion.
What’s important for modernization besides my choice of technology?
The right choice of technology and approach for your modernization is essential, and the decision is not easy to navigate alone. Choosing a good modernization partner is equally important and will have a long-term impact on the operation of your facility.
A good modernization partner should guide you on your automation journey by ensuring you understand how automation technology choices will impact you in the future, will ensure that your system can scale and adapt to your changing needs, and provide a digital foundation for whatever comes next. Laurentide Controls is proud to partner with many customers in Eastern Canada each year to help modernize their operations, and to bring Emerson’s world-class technology so end users can have an evergreen system that they leverage to gain a competitive edge.
When considering your choice of partner, ask them about their experience with both legacy and modern systems, their level of access to modernization tools and factory support, ask for references to speak with previous clients of theirs to see how their experience has been, and inquire what role they will play for you after the project is complete.
Globally, Emerson’s DeltaV system is used to modernize over 400 control systems each year and can interface in various ways to solutions from all major manufacturers. Laurentide Controls provides local, long-term partnership for system modernization, and has been in operation for over 60 years helping industry thrive in Eastern Canada. We look forward to hearing from you about how we might assist in your next control system modernization project.
