Navigating the Transition from DeltaV Operate to DeltaV Live: Key Challenges and Solutions

Transitioning from DeltaV™ Operate to DeltaV™ Live offers life sciences manufacturers numerous benefits but can also come with challenges. These challenges may arise from a range of factors, including legacy system compatibility, training, validation, production demands and lack of facility downtime, and system integration. Here are some common obstacles companies face during the transition process and actionable strategies to overcome them.

Key Challenges in Transitioning to DeltaV Live:

1. Legacy System Compatibility
Problem: Older DeltaV versions (prior to 14.LTS) may require significant upgrades to be compatible with DeltaV Live.
Solution: Prioritize an initial assessment of current systems and plan for incremental upgrades to minimize disruption. Upgrade plans should be aligned with production schedules.
 
2. Training and Change Management
Problem: Operators and engineers accustomed to DeltaV Operate may struggle with adopting the new DeltaV Live interface.
Solution: Develop a comprehensive training plan with hands-on workshops and simulation environments. Begin training early, ideally during the integration phase, to ensure smooth adoption.
 
3. Data Migration and Display Conversion
Problem: Migrating data and converting displays from DeltaV Operate to DeltaV Live can be time-consuming and prone to error.
Solution: Utilize Emerson’s conversion services, and schedule regular validation checks to ensure data integrity during the migration.
 
4. System Integration and Downtime
Problem: Downtime during the system upgrade and DeltaV Live integration can disrupt production schedules.
Solution: Plan upgrades during scheduled downtimes or production cycles to minimize impact. Establish contingency plans in case of unexpected delays.

Best Practices for a Smooth Transition

Transitioning to DeltaV Live is a significant and complex process that requires careful planning and execution. To ensure a successful transition, it's essential to follow best practices that help you avoid common pitfalls, mitigate risks, and achieve optimal results. Here are some key best practices to guide you through your DeltaV Live upgrade:

Engage with a Partner with Experience Early in the Process

One of the most crucial steps in ensuring a smooth transition is to engage with a partner who has a deep understanding of both DeltaV systems and the unique needs of life sciences manufacturing. An experienced partner can guide you through the initial stages of the transition, from system evaluation and requirement analysis to selecting the best conversion methodology for your organization.

By involving an expert partner early in the process, you can ensure a thorough understanding of your current system’s architecture, identify necessary upgrades, and align the transition plan with your operational objectives. Their experience will help you navigate through the complexities of the conversion, addressing any specific needs related to system functionality, scalability, and future-proofing.

Furthermore, an experienced partner brings invaluable knowledge about regulatory compliance, industry standards, and best practices. They can help ensure that your transition to DeltaV Live will meet both current and future regulatory requirements, minimizing potential compliance issues and reducing the risk of costly mistakes down the line.

Use Parallel Testing and Simulation Environments to Minimize Risk Before Going Live

Testing is a critical part of any system upgrade, especially in regulated environments like life sciences manufacturing. Parallel testing allows both the legacy DeltaV Operate system and DeltaV Live to run simultaneously, providing an opportunity to assess system performance, identify potential issues, and ensure that the new system meets operational requirements without disrupting production.

Simulation environments are also essential for this stage, as they replicate real-world conditions, allowing for testing under the same load, stress, and performance scenarios the system will face in production. This ensures that DeltaV Live functions as expected and gives your team the opportunity to address any issues before the final deployment.

This proactive testing approach minimizes the likelihood of system failures or unexpected delays, increasing confidence that DeltaV Live is ready for full deployment. Engaging with an experienced partner can add value in helping set up and manage these test environments to ensure thorough and effective validation.

Create an Incremental Upgrade Schedule that Aligns with Production Demands and Regulatory Requirements

Proper planning and timing are essential in the DeltaV Live transition process, particularly when aiming to minimize disruptions in production while meeting industry regulations. A strategic incremental upgrade schedule breaks the process into manageable phases, allowing for system upgrades to proceed without halting operations or jeopardizing regulatory compliance.

Each phase should be carefully planned to accommodate production cycles, training schedules, and validation activities. Considering strict regulatory requirements in the life sciences industry, it’s important to integrate necessary validations, such as Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), into the timeline to avoid costly delays and compliance issues.

An incremental approach also optimizes resource allocation, allowing team members to focus on specific tasks at different stages of the upgrade, such as system testing or staff training. This leads to a smoother, less disruptive transition while maintaining production schedules. Working with an experienced partner can help streamline this process by advising on the best times for upgrades and ensuring the right steps are taken at each phase.