Y2K PROBLEMS

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Y2K PROBLEMS SOLUTIONS IN EMBEDDED
SYSTEMS ( FOR PLANT PROCESS INDUSTRIES )
BY ETT
CORP. LTD. NEW DELHI INDIA

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Helping Our Clients Become More Profitable Into
The 21st Century
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Embedded System Risk Is So Much
Greater!
There Are Hundreds of Computers and
Applications Times Hundreds of Thousands of Lines
of Code
IT
F A C T O R Y
There Are Thousands of Devices and Applications
Times Thousands of Lines of Code Times Hundreds
of Proprietary Operating Systems
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There Are Four Y2k Issues

• Cost
• Time
• Risk
• Location

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The Unchangeable Schedule

• Negotiations 1 Month
• Inventory Assessment 3 Months
• Conversion Planning 1 Month
• Remediation 2 Months
• Whats Left? -2 Months

98.1
98.2
98.3
98.4
99.1
99.2
99.3
99.4
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The Third Issue Is Risk!

• Y2k poses a significant threat to the safety of
  plant personnel.
• Y2k poses a significant threat to a plants
  ability to maintain its production levels.
• Y2k poses a significant threat to the
  continuation of a plants insurance coverage.

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The Fourth Issue Is Location
Dates Are Everywhere!

• Control Hardware

• Vendor Software

• Embedded Systems

• In -House Developed
• Programs

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• The Red Zone
• Before 1975 , most of the hardware is okay , but
  the software
• is very suspect.
• Between 1975 1995 , the hardware aswell as the
  software
• is suspect.
• After 1995 most equipment aswell as the software
  is okay.

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We Found Problems With ...

• Sensors Analyzers
• Laboratory Equipment
• Programmable Control Systems
• Embedded Systems
• SCADA Systems
• Distributed Control Systems
• Human-to-Machine-Interfaces (HMIs)
• Networks
• Operating Systems
• Third Party Applications
• Computers

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Where Are The Greatest Problems?

• Usually this code is
• Very,very custom
• Not documented
• Riddled with dates
• And it was
• Written 10-15 years ago
• Written in an obscure vendors language
• Written by an engineer who is long gone
• Written only for you

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• We found Dates in ...
• storage , transfer , output calculation
• Storage of dates occur in
• Data historians trending
• Alarm event logging
• Sequence of events recorders
• Lot /part number tracking
• Maintenance Databases
• Calibration information stored on smart sensors

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• Transfer of dates found in
• Recipe and batch processing
• Laboratory Information Management Systems
• Process information management systems
• Dates embedded in bar codes
• PLC programming

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• Output of dates found in
• Notifications
• Billing/Invoices
• Printed schedules
• Orders
• Compliance documents
• Change management documents

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• Calculation of dates found in
• Specific operations by day (
  startup/shutdown
• routines , report generation , scheduling
  etc.)
• Counters that span the Year 2000 rollover
• Energy management systems
• Expiration dates
• Comparison

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This Is The Potential Effect Of Y2K
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Here Is A Real Life Example

• We took a leading SCADA package and reset the
  date and time ahead to 1145 PM on December 31,
  1999.
• When the clock crossed into never, never land,
  i.e. January 1, 2000, the SCADA package stopped
  running.
• If that SCADA application were running a plant,
  then the plant might also stop running.

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See What We Mean?!
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Our Approach To Y2k?
Plant Y2k Is A Full Spectrum Y2k Solution Set
...

• Plant
• Y2k

Designed Specifically For Manufacturing
Companies
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What is Plant Y2k?

• Method Y2k
• Inventory Y2k
• Compliance Y2k
• Search Y2k
• Manage Y2k
• Millenium Services

Its A Suite of Integrated Products and
Services Designed To Significantly Reduce Your
Time and Cost To Achieve Y2K Compliance
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Method Y2k

• . A comprehensive methodology that specifically
• addresses Year 2000 compliance for manufacturing
  
• process industries. Comprises of four stages
• Assessment
• Analysis
• Conversion Planning
• Implementation

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Method Y2K

• Assessment Guides you
  through
• defining organizing your Year 2000
  project

• Analysis Helps
  you in
• understanding your technical
  vulnerabilities
• and how system failures can
  affect your
• company bottom line

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Method Y2K .

• Conversion Planning Identifies quickly
  the
• mission critical applications using the
  results
• of analysis phase and develop strategy

• Implementation This is the
  final initiative in
• bringing your plants systems into
  compliance
• and incorporates various conversion
  projects

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Inventory Y2k?

• Inventory Y2k is a structured language, front end
  inventory tool.
• It allows our engineers to take a complete
  inventory of a manufacturing system using a
  consistent approach.
• This inventory will contain the vendor, the
  product, its age, and the revision level of each
  component inside the manufacturing system(s).

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Compliance Y2k?

• Compliance Y2k is an on-line, internet, linked
  repository of product compliance statements.
• This database will provide device analyses rated
  as either compliant, non-compliant, or suspect.
• It also contains testing and detailed evaluations.

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Typical Compliancy Report
Plant Y2K Product Report
Vendor Name Microsoft Product Name
Windi\ows for Workgroup 3.11 Item Class
OS Product Version 3.11 Platform DOS Model
Number n/a Product Description Windows
Operating Systems Report Revision 3 Report
Date 3/16/98 104424 AM Vendor Statement
Microsoft Windows File Manager displays an
incorrect date if the file is created with a date
of January 1, 2000 or later Vendor Statement
Reference 10224 Plant Y2K Analysis Microsoft
Windows for Workgroup version 3.11 will handle
dates correctly until the year 2108. However,
the File Manager will incorrectly display the
date of a file if it was created with a date
of 2000-01-01 or later. Dates will be
displayed as 0 instead of 00. This occurs
because is the next ASCII character after 9.
This error may cause application problems. The
problem can only be fixed by upgrading to
wWindows 95 or NT.

Impact class name Non- Compliant Known Date
Problems File Manager will display date
incorrectly after 1999-12-31.
I
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What Is Search Y2k?

• Manufacturing hardware should not be ignored but
  it generally represents only 20 of the plant Y2k
  problem.
• Over the years, your plants have created
  thousands of blocks of code using PLC Logic, DCS
  Configurations, FORTRAN, BASIC, and PASCAL.
• Search Y2k is a software library of date search
  engines (called DSEs) designed to search for
  dates inside the code of specific process
  equipment, software, and applications.

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Manage Y2k

• Y2K Summary Report
• System Summary Report
• Non-Compliant Systems Reports
• Suspect List
• Schedule and Document Further Actions

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Y2K ProgramWithout Plant Y2k
15 - 56 Weeks
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Y2k Program With Plant 2k
9 - 41 Weeks
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A Major Improvement

• Plant Y2k can reduce cost
• It reduces time
• It can reduce risk
• It can reduce errors

15 - 56 Weeks
A 30-40 Reduction In Time
9 - 41 Weeks
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Risk Analysis for Y2K
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Action Plan

• Select an experienced external agency having
  proper tool set and methodology ( ETT and Plant
  Y2K )
• Focus on Survival as a goal - not perfect
  compliance
• Get Legal opinions on your Warranties other
  liabilities
• Begin NOW - the clock is still ticking

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The CLOCK is Still Ticking
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For Details , please contact Mr. A.K.Tiwari ,
Deputy General Manager ETT Corporation Limited (
A. Govt. of India Enterprise ) 15/48 , Malcha
Marg Chanakya Puri , New Delhi -110 021,
India Phone no 6883979, 6119724 Fax
6879748 E- mail ettakt_at_del2.vsnl.net.in
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Thank you