How do you manage DCS configuration changes and backups to avoid data loss or corruption?

Utilizing a virtual computer architecture for a DCS system can offer myriad benefits, especially in terms of disaster recovery and ease of making backups Fast Recovery: In the event of a disaster, virtual machines can be recovered more quickly than physical servers. Snapshot and Rollback: Virtual environments have the capability to take snapshots of the entire system at specific points in time. In a disaster scenario, the system can be rolled back to a known good state, ensuring business continuity with minimal data loss. Offsite Backups and Replication: Virtualization facilitates easier and more efficient offsite backups and replication, providing additional data protection and disaster recovery capabilities

I love to my challenge myself so I made two forms, first for my self for any DCS software modifications (including Windows, Antivirus, Microsoft, third part relevant applications) updates and hardware modification (new workstation, new monitor, optimizing existing program/graphics). And second is for operation team logic, cause and effect, program, graphics changes, adding/deleting instruments, motors, custom formulas, reports modification, alarms, trends configuration etc. I implement both of these modifications after assessment, taking backups, work method statement and of course with management approval. I tie these requests with OEM built-in help, manuals and my own SOPs.

One thing i found that we should always take backup before any changes done in the DCS on a regular basis. For that can use deferent tools available like media and methods, such as external hard drives, cloud storage, or encryption software. And also we should label and store your backups properly to avoid any data loss.

In my experience we would run a difference report between new code to be loaded and existing code before loading. Then we would run a variance report on changes in variables and consolidate before loading the new code. All code loads are also kept on a server for backup for the DCS

Scheduled backups and upgrades. This will ensure you have the freshest revision of any changes available to trace your steps...

Critical configuration changes or installation of updates or upgrading firmware should be planned and done during the plant shutdown. Else implement following OEM manuals, ReadMe Instructions, work method statements and SOPs during daytime after discussion and in presence of all relevant manpower.

Based on my own experience, the modifications never really corrupt your program or files but your storage devices might bring in viruses or malware based on where the have been used. That is the reason, back-ups are stored in dedicated paths and storage devices never shared on other systems. You also ensure you back-up before any modification and also back-up afterwards and label the files appropiately with dates and possibly time of action. Ensure access points to the system are protected (locked) as well. You will always have the chance to validate your changes/modifications before download/upload to the the system and this should help pick-up any error in your logic build but not the virus. Ensure you have a functional antivirus too

We all DCS Engineers know that we should take backup before and after modifications but ignore this important question: What if modifications corrupt the DCS database? Can we recover it on a running plant? I believe DCS Backup restoration should be testing during planned shutdown or before first startup and document the results.

You should regularly test the backup and restore procedures to ensure they are working as expected and identify any issues that may arise. Additionally, it is essential to ensure that backups are stored securely and off-site to protect against data loss due to disasters or hardware failures.

Don't forget to take backup before modifications and right after modifications. Also update relevant documents (SOPs, I/O List, Instrument Index, Trainings etc.) and drawings (System Architecture, Panel/JB Wiring Diagrams etc.) after modifications. Appended of course, Train Operators and Technicians about the modifications.

Implement version control: Implement a version control system to manage DCS configuration changes. This ensures that you have a history of all changes made to the system and allows you to roll back to previous configurations if necessary. Use change management software: Use change management software to control and track configuration changes. This software can help ensure that changes are authorized and adequately documented. Limit access to configuration tools: Limit access to configuration tools to authorized personnel only. This helps prevent unauthorized changes to the system.

So much has been discussed and shared on this topic. It almost covered everything. However the thing which I would like to stress on is the media used to save backup data. I would recommend saving the data on a safer media which is CD or DVD. We have faced a scenario where the external drive used to save the important data failed. Fortunately we had an earlier version saved on a DVD. Though it required a later update implementation, but it is better than starting from scratch. All devices used to take backup aren't hundred percent foolproof, like CD or DVD can also get scratched on the surface rendering it susceptible to damage, but it is always better to have one just in case. Backup is a redundancy option, but it should be a safer one.

1st-any jobs on DCS should be covered by work order & PTW. 2nd-routine backup should be in ICSS. At any given time you're assured that you have the latest backup in case you need to do a disaster recovery. 3rd- any DCS modification should be covered by MOC, Memorandum of Changes, where all the requests and justifications for modifications are indicated plus the risk involve and what are the necessary precautions needed to minimize the risk, including backup & restoration in case the modification wasn't successful. This job includes Methods / Engineering and supported by DCS vendor. 4th- raise a work order to proceed with PTW, again all risks and procedure will be discussed Last- Backup, implement modification then test. Backup. Monitor

Based on my experience, there is need to record DCS software version along with installed updates/patches/hotfixes even hardware specifications etc. while taking backup because it must match when you are restoring as per some OEM. Also note, there are different types of back and restoring methods accordingly. Better to take backup of each type as per DCS OEM recommendations and if possible automate the backup.

1. If DCS is PC based then make hdd backup or perform "Ghost." Trust me, all the backup inside the PC, including the application program can be wiped out by virus infection. A Ghost backup can restore the entire hdd. 2. If DCS is server based then make a physical external hdd drive backup by replacing 1 of its system disk in Raid 1 configuration by a new hdd. You have now a physical hdd backup. 3. Perform routine project based PLC backup. 4. DCS System has its own backup procedure. Know those procedures. Sometimes you have several procedures like version control, thus, perform all of them. 5. All external backups should be at least 2 copies and stored in different locations 6. Enter the backup jobs as routine PM in CMMS.