"In the limited time available, it would have been impossible to migrate this system using traditional methods."
— Daniel Morales, Automation Manager, Braskem, secure DIN-rail, Glen Pfeifer, controls, control systems
For Braskem, the truly critical-path time savings afforded by Electronic Marshalling was in the system installation and commissioning. With this approach, once the new CIOCs are in place field technicians can quickly land the existing field wiring on any available I/O channel without regard to type. Subsequently, each channel is given its appropriate character by simply plugging in the appropriate type of characterization module, or CHARM. The mapping of each I/O point to the appropriate controller in the system is done through the DeltaV system software with very little effort. In the end, Electronic Marshalling can save time and prevent mistakes just when the migration team is under the most pressure to get the plant back up and running.
HCD in the Details
While Electronic Marshalling represents a conceptually different approach to doing automation projects, Emerson's focus on human-centered design (HCD) also is apparent in the smallest implementation details that can streamline system installation and commissioning tasks. For example, the DeltaV CIOC itself has been designed for ease of use, both in physical installation and its software tools. Components snap together with secure DIN-rail latches and interlocking carrier connectors; a series of 96 I/O channels can be connected to a DIN-rail in a matter of minutes.
No tools are needed to remove a CHARM or CHARM terminal block from the baseplate. Upon initial insertion, CHARMs are sensed by the system, automatically creating the I/O definition in the DeltaV configuration database. Also, upon initial insertion of a CHARM, each terminal block is "self-keyed" such that the wrong type of CHARM cannot be mistakenly inserted without removing and manually resetting its terminal block (again, without tools). CHARMs also can be partially ejected to a stand-by position, disconnecting the field wiring from the system to perform field maintenance actions or to remove power to a field device. Activating the CHARM latch ejects the CHARM to the stand-by position. Closing the latch locks the CHARM in place and isolates the field wiring for field work.
For Glen Pfeifer, controls specialist for chemicals manufacturer E.R. Carpenter LP, a recent control system retrofit at its Pasadena, Texas, facility "worked out wonderfully" with Electronic Marshalling technology. The modernization project involved new DeltaV control and safety instrumented systems for two units, each consisting of 550 I/O points.