Operating any industrial asset inevitably presents various challenges over time. In the case of an oil and gas production plant, common challenges arise when production begins to decline, making it crucial to minimise maintenance and upgrade costs to maintain profitability. However, neglecting to keep the control system up to date is never a wise investment. A modern control system offers enhanced performance, improved cybersecurity, and greater availability of spare parts. These factors are essential for maintaining high production levels and uptime, emphasising the importance of investing in system upgrades for long-term success.
Running older control systems can pose significant risks to businesses. One of the main concerns is that the equipment becomes unserviceable and prone to faults. This can result in costly downtime and disruptions to operations.
Additionally, the software used in older control systems is often outdated, making it more vulnerable to cyber security risks. Hackers are constantly evolving their techniques, and outdated software may not have the necessary security measures to prevent unauthorised access or data breaches. Therefore, it is crucial for businesses to prioritise regular updates and maintenance of their control systems to mitigate these risks. By not running the latest, correct software, businesses are putting themselves at greater risk of cyber-attacks and compromising the integrity of their operations. It is important to stay proactive and ensure that control systems are up to date to protect against potential vulnerabilities.
In addition to the risks posed by unserviceable equipment and outdated software, another major drawback of running older control systems is their lack of operator-friendliness. These systems often have complex interfaces that can be difficult for operators to navigate and understand. Also, operators are usually trained on the latest softwares, as training won't be available on old product, which creates an issue with running legacy software. This can lead to errors and inefficiencies in operations, as operators struggle to make sense of the system's controls and functions.
In contrast, modern control systems are designed with user-friendliness in mind, featuring intuitive interfaces that are easy to navigate and comprehend. By upgrading to more operator-friendly control systems, businesses can improve the efficiency and effectiveness of their operations, ultimately leading to enhanced productivity and reduced downtime.
Based on our expertise, the only time we might not recommend completing a control system upgrade would be based on the assets lifecycle. If the asset will be permanently shut down within a very short timeframe, then it might not be necessary to do the upgrade, as long as safety is maintained.
Overall, upgrading control systems is a necessary step for businesses to stay secure, efficient, and competitive in today's rapidly evolving technological landscape.
It all starts with completing an evolution study. This includes evaluating everything in the control system, including considering whether to upgrade everything, or if it is better to use a phased approach. An evolution study will also explain how to best upgrade with minimum disruption to operations.