Bailey dcs upgrade 1

[data74]

We have a bailey system running close to 7000 tags on site. We intend to replace it as it has close to 12 years worth of support.Anyone out there has gone through the same process?? I have two ideas in mind:

1. Change to clgx plc
2. Install an ABB interface to the current system.....preferably an 800xA system
3. DeltaV system

Any ideas out there??

 

[controlnovice]

On a 7000 point system, I recommend going for quotes and investigating each of their offerings. Limit the DCS/PLC vendors to 3, possibly 4, to make your review easier for you.

Costs on a 7000 point system can differ up to 40%, so it's worth taking a look at multiple vendors. You also need to have intimate conversations with each vendor to understand their systems offerings and capabilities. A 10-20% cheaper vendor may not have all of the tools that fit your plant and personnel. For a 20year investment, this 10-20% up front savings may cost you more in the long run.

Using US$1000 per I/O point when designing a new system.... Add the vendors costs and your internall engineering, and it will come out to be about $1000/point. So, for 7000 points, it'll be US$6-8MM.

A 20-40% difference in cost between vendors is money you can't afford to give up without a comparative bid!



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[ScottyUK]

What kind of process are you trying to control? DeltaV is a great batcher, but might not be first choice for a continuous process.

Add Foxboro's I-A system, Emerson's Ovation, Honeywell's product (name escapes me - sorry) and perhaps Siemens PCS to your list of possibles.


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If we learn from our mistakes I'm getting a great education!

 

[data74]

Our process is a pulp and paper in Southern africa. Is the plc option out of the question???

 

[JLSeagull]

You may prefer a DCS with batch controllers if you address controls, display etc. If this is a plant modification with limited down time, consider including the programming or configuration for the controls, displays etc. within the scope. For regulatory work with a clone of a previous unusual product configuration I saw a system mentioned with much less hardware and including configuration. The cost was far greater for the system configuration and checkout to cover a short cycle to remove the old and replace with new. Some suppliers have software to do the typical initial configuration but great config time for a custom or clone of existing package that is comcplex. You may also want to buy the new hardware using remote buildings that can be set on site before the shutdown / turnaround etc.

 

[controlnovice]

ABB has a lot of experience with pulp and paper. I'm sure the other major players do as well.

PLCs are not out of the question and many have good offerings. In North America, it seems Rockwell (Allen-Bradley) has captured a large portion of the market. Don't know the players in S. Africa.

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[gtwreck22]

Data74,
First off I will state that I do work for ABB in the US. I hope you or other users will not take this as a sales pitch. I'd hate for you or any other user to replace your system for the wrong reasons. Support timeframe is no longer an issue for your Bailey system. Have you heard that ABB as of November 2010 announced that the Bailey system will be supported indefinitely? Additionally in April, ABB announced new products and development activities at all levels for the Bailey system under the name Symphony Plus. There is a path forward for all levels of your system. Hope this has not offended. Good luck with whatever you choose to do!