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tech.com The Great I/O Migration By Dell Williams M
any processors, even those with mod- ern distributed control systems (DCS), a system of sensors, con-
trollers, and associated computers that are distributed throughout a plant, continue to operate with outdated input/output (I/O) components. I/O transfer information be - tween computer main memory and the out- side world. Despite its long-term contribu- tion to operations, I/O is one of the most sig- nificant investments in an automation upgrade. Justifying the risk and expense of I/O upgrades to management is a challenge, and often, it is easier for processors to delay upgrades year after year. “While a phased approach to migrat-
ing from older systems to newer technol- ogy is preferred, we find it is often diffi- cult for processors to determine just when and how to make the switch to modernized I/O,” says Mike Davis, process product manager for NovaTech Automation, a Pennsylvania-based auto - mation provider. “Some of the old sys- tems are still reliable and that is a major part of the problem. Engineers want the latest and greatest, but it can be hard to justify the costs.” According to Davis, the decision to
modernize should be based on whether a processor can continue to operate reli- ably and safely with the existing system. Key considerations include whether spare or replacement parts are still available, whether system performance
issues are beginning to appear, and the avail- ability of training and support required to keep legacy systems and subsystems running. The impact and cost of an unexpected shut- down should also be considered. “Many process manufacturers come to
us with I/O, controllers and other compo- nents that are 30 to 40 years old,” explains Davis. “As I/O ages, there can be increasing risks. 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.”
However, the challenge in migrating I/O
is that there is not just one solution. Different approaches and even custom solu- tions are required depending on the type of I/O being replaced. Fortunately, there are products and services designed to assist in modernizing I/O systems while minimizing downtime.
How to Migrate An I/O migration typically begins by
upgrading to the latest version of the existing DCS system, if needed, which serves as the hub of a processor’s operations monitoring key variables such as flow, applied tem- peratures, pressure, level, and material conveying/handling. A detailed site survey is critical to
determine the scope of the upgrade. Will the existing cabinets be used, or will new cabinets be required? Can the exist- ing I/O be retrofitted with conversion kits from the original manufacturing? Will the I/O require wiring or use inter- face boards? Will new communication controllers be required? To modernize I/O on its D/3 DCS,
NovaTech typically installs 8000 I/O, a highly reliable I/O system with a full range of module options. Within each 8000 Series node, up to 64 I/O modules can be supported, with 4 to 32 channels per module. The 8000 Series has fully integrat-
Control cabinet after a Novatech upgrade. Continued on next page
July, 2022
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