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School of Engineering and Energy

‘‘ A report submitted to the School of Engineering and Energy, Murdoch University in partial fulfillment of the requirements for the degree of Bachelor of Engineering.’’

Name: Fee Boon Tang

Academic Supervisor: Dr Gareth Lee, Murdoch University

Industry Supervisor: Paul Jones, Engineering Manager of Motherwell Automation

Unit Code& Name: ENG450 Engineering Internship

Document: Final Year Report

Status: Final

Due Date: 21/09/2012

Date Submitted: 21/09/2012

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1. ABSTRACT

This report is submitted as a final requirement for an engineering internship which was undertaken at Motherwell Automation, Perth. The main aim of the internship is to provide exposure to engineering design and technical competencies and to develop practical skills such as time management, communication skills, networking skills and troubleshooting skills. The practical skills learned in the internship prepared student to adapt in real engineering jobs after graduated from university.

The project was dealing with the upgrade of the software and hardware for YARA Fertilizer Company’s Inert Gas Generator section. The main reason of the upgrade is to ensure that the plant can be operated with the latest versions of software and hardware available in the market, replaced the non standard redundancy software and also to enhance machine reliability.

An upgrade from the GE 90-30 system to the RX3i PACSystem requires an in depth understanding of every hardware component. In establishing a basis for the required modification, hardware components, layouts, architecture and configuration of the control were thoroughly explored.

An upgrade to redundancy requires additional hardware components which caused some issues at the beginning. During the upgrade, the non-standard software has been replaced and code reconfigured for all additional redundant hardware. An industrial Ethernet switch was also replaced due to compatibility issues with the latest RX3i PACSystem Ethernet Module.

Control solutions design was required to provide the system with redundant power supplies, CPU with hot standby redundancy, dual Genius Bus Controller, Reflective Memory X-Change Modules (RMX) and Ethernet Modules.

Time management was crucial in completing the project, as significant technical challenges were faced in the course of completing the project. Moreover there is a need to manage stress whilst working on the project and concurrently doing reports and presentation slides for the school.

On the basis of this final report, it is the author’s belief that the internship objectives have been successfully fulfilled by the project undertaken at Motherwell Automation. Finally, the experience gained has also benefited the author in terms of enhancing the troubleshooting skills and stress management.

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2. ACKNOWLEDGEMENT

It was such an honor and a great privileged to be part of Motherwell Automation over

the past sixteen weeks of my internship. The knowledge that I have gained over this

period has given me much confidence to working with experienced engineers from

different disciplines. I am extremely appreciative to Motherwell Automation and

Murdoch University for providing me with such a wonderful opportunity and for

enormously enriching my experience in my quest to becoming a successful engineer.

This internship program will not be a success without the full support given to me by

Paul Jones, Engineering Manager at Motherwell and all the multi-disciplined and highly

experienced engineers, especially Jeff Hunter, Scott Spurway and Khang Zen Sim who

had been particularly patience and keen to answer all my questions and queries with

regards to the project that I did. Last but not least, I would like to take this opportunity

to acknowledge and thank Dr Gareth Lee, my Academic Supervisor for the help and

support that he had given me throughout the internship.

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3. TABLE OF CONTENTS

1. Abstract ............................................................................................................................................................................ 2

2. Acknowledgement ....................................................................................................................................................... 3

3. Table of Contents ......................................................................................................................................................... 4

3.1 List of Figures......................................................................................................................................................... 6

3.2 List of Tables .......................................................................................................................................................... 7

3.3 Version Control ..................................................................................................................................................... 8

3.4 Referenced Documents ...................................................................................................................................... 8

3.5 Glosarry of Terms and Abbreviations .......................................................................................................... 8

3.6 Definitions ............................................................................................................................................................... 9

4.0 Introduction ............................................................................................................................................................. 11

4.1 Document Introduction .................................................................................................................................. 11

4.2 Background on Motherwell Automation ................................................................................................. 11

5. Internship Work Placement Summary ............................................................................................................ 12

5.1 Internship Objectives ....................................................................................................................................... 12

5.2 Time Management ............................................................................................................................................ 12

6. System Functional Overview ............................................................................................................................... 13

7. Design Requirements .............................................................................................................................................. 13

7.1 Control Solution Requirement ..................................................................................................................... 13

7.1.1 Redundant Power Supply ...................................................................................................................... 13

7.1.2 Redundant CPUs ........................................................................................................................................ 14

7.1.3 Dual Genius Bus Controller ................................................................................................................... 15

7.1.4 Redundant RMXs ....................................................................................................................................... 16

7.1.5 Redundant Ethernet Module ................................................................................................................ 17

7.2 Core Network Configuration ........................................................................................................................ 18

7.3 Hardware Requirements ................................................................................................................................ 20

7.4 Hardware Installation Overview ................................................................................................................ 21

8. Technical Review ...................................................................................................................................................... 24

8.1 Hardware .............................................................................................................................................................. 24

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8.1.1 Power Supply .............................................................................................................................................. 24

8.1.2 Central Processing Unit (CPU) ............................................................................................................. 26

8.1.3 Reflective Memory Xchange (RMX) ................................................................................................... 32

8.1.4 Genius Bus Controller ............................................................................................................................. 37

8.1.5 Ethernet Interface Module .................................................................................................................... 43

8.2 Software ................................................................................................................................................................ 47

8.2.1 GE Proficy Machine Edition .................................................................................................................. 47

8.2.2 Cimplicity ..................................................................................................................................................... 47

9. Design Modification ................................................................................................................................................. 48

9.1 PLC Code Modification .................................................................................................................................... 48

9.1.1 Code Modification for Genius Bus Controller ................................................................................ 48

9.1.2 Code Modification for Ethernet Redundancy ................................................................................ 51

9.1.3 Code Modification for Power Supply Monitoring ........................................................................ 52

9.2 PLC Hardware Configuration ....................................................................................................................... 53

9.2.1 Comparison of Overall Hardware Configuration for Both PLCs ............................................ 53

9.3 Human Machine INTERFACE (HMI) modification ............................................................................... 59

9.3.1 Points Comparison ................................................................................................................................... 59

9.3.2 Existing Login Page Vs New Login Page .......................................................................................... 61

10. Design Testing ......................................................................................................................................................... 65

10.1 FAT Document ................................................................................................................................................. 65

10.2 Internal Testing ............................................................................................................................................... 65

10.3 FAT Test .............................................................................................................................................................. 67

11. Conlusion ................................................................................................................................................................... 69

12. Internship Review .................................................................................................................................................. 69

13.0 Bibliography .......................................................................................................................................................... 70

14. Appendix .................................................................................................................................................................... 71

Appendix A .................................................................................................................................................................. 71

Appendix B .................................................................................................................................................................. 73

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3.1 LIST OF FIGURES

Figure 1 Reschedule of Task ..................................................................................................................................... 12

Figure 2 Redundant Power Supply ........................................................................................................................ 14

Figure 3 The Redundant CPU.................................................................................................................................... 14

Figure 4 A Dual Genius Bus CONTROLLERS ....................................................................................................... 15

Figure 5 Redundant RMXs ......................................................................................................................................... 16

Figure 6 Local Active Status Bits ............................................................................................................................. 17

Figure 7 Redundant Ethernet ................................................................................................................................... 17

Figure 8 Updated LAN Configuration .................................................................................................................... 18

Figure 9 FAT Lan Configuration .............................................................................................................................. 19

Figure 10 Redundant Power Supply ...................................................................................................................... 24

Figure 11 The Power Supply ..................................................................................................................................... 25

Figure 12 Insulation Stop Position ......................................................................................................................... 26

Figure 13 Multiple Drops Serial COnnection...................................................................................................... 27

Figure 14 The Front Panel of The Cru320 CPU ................................................................................................. 28

Figure 15 Sweep Sequence ........................................................................................................................................ 31

Figure 16 CPU LED State & Description ............................................................................................................... 32

Figure 17 RMX Transfer List ..................................................................................................................................... 34

Figure 18 The Input and Output Transfer List (GE,GFK 2308, 2009) ...................................................... 35

Figure 19 The Redundant RMX Module ............................................................................................................... 35

Figure 20 The Genius Bus COntroller (GBC) ...................................................................................................... 37

Figure 21 Genius Bus Controller and Drops ....................................................................................................... 38

Figure 22 The Hardware Configuration of Genius Bus Controllers and Drops ................................... 39

Figure 23 Genius Bus Controller Setup ................................................................................................................ 40

Figure 24 The Genius Bus Role Switch Template............................................................................................. 40

Figure 25 The Ethernet Modules ............................................................................................................................ 44

Figure 26 Set Temporary IP Address .................................................................................................................... 45

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Figure 27 Status bits of the Ethernet Modules (GEGFK2224F, 2007) ..................................................... 46

Figure 28 The Cimplicity Workbench ................................................................................................................... 47

Figure 29 The Existing Logic for Genius Bus redundancy ............................................................................ 48

Figure 30 Existing Locked blocks to be Removed ............................................................................................ 49

Figure 31 A Dual Bus Interface Template ............................................................................................................ 49

Figure 32 the GB_Config Template ......................................................................................................................... 50

Figure 33 The GB_Config Setup ................................................................................................................................ 50

Figure 34 RMX Transfer List ..................................................................................................................................... 51

Figure 35 Ethernet Role Switching Code ............................................................................................................. 52

Figure 36 Power Supplies Monitoring (HMI) .................................................................................................... 52

Figure 37 The Power Supply Status on HMI ....................................................................................................... 52

Figure 38 Existing Login_form.cim ......................................................................................................................... 61

Figure 39 Modified Login_form.cim ....................................................................................................................... 62

Figure 40 The Primary Window .............................................................................................................................. 62

Figure 41 Project Shortcut ......................................................................................................................................... 63

Figure 42 CimView Commands ................................................................................................................................ 63

Figure 43 Task Manager execution Setup ........................................................................................................... 64

Figure 44 Ethernet Redundancy Code with Flaw ............................................................................................ 66

Figure 45 Perfect Ethernet Redundancy Code .................................................................................................. 66

Figure 46 Initial Version of FAT Test Login Page ............................................................................................. 67

Figure 47 Finalized Login Page ................................................................................................................................ 68

Figure 48 Editing of ENGG Mode Password ....................................................................................................... 68

3.2 LIST OF TABLES

Table 1 Hardware Requirements ............................................................................................................................ 20

Table 2 Summarize of The Hardware Functionality that used ................................................................... 24

Table 3 STatus Bits of RMX Module (GE,GFK 2308, 2009) ........................................................................... 33

Table 4 The DESCRIPTION OF RMX'S LEDs ........................................................................................................ 36

Table 5 Reserved Status Address for Genius BUs Template ........................................................................ 41

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Table 6 Specific Status Address for for GBC A and GBC B on Primary and Secondary COntroller ............................................................................................................................................................................................... 42

Table 7 Comparison of PLCs Hardware Configuration Setup ..................................................................... 53

Table 8 Comparison of genius Bus Controller Setup ...................................................................................... 54

Table 9 Hardware Configurtion Setup for Ethernet Modules ..................................................................... 57

Table 10 Exisiting Points that being deleted ...................................................................................................... 59

Table 11 New Created Points ................................................................................................................................... 60

Table 12 Commands and Description ................................................................................................................... 63

3.3 VERSION CONTROL

Version Date of Submission Description

1.0 12/11/2012 Draft Report

2.0 19/11/2012 Final Report

3.4 REFERENCED DOCUMENTS

Reference Document Title Revision

1. Engineering Internship Project Plan 1

2. Engineering Internship Progress Report 1

3.5 GLOSARRY OF TERMS AND ABBREVIATIONS

Terms/Abbreviation Description

PLC Programmable Logic Controller

SCADA Supervisory Control and Data Acquisition

FAT Factory Acceptance Testing

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SAT Site Acceptance Testing

GE General Electric

HMI Human Machine Interface

Yara Yara Pilbara Fertilizers Pty Ltd Burrup Site

I/O Input or Output

GBC Genius Bus Controller

CPU Central Processing Unit

RMX Reflective Memory Xchange

LED Light Emitting Diode

PME Proficy Machine Edition

FOBOT Fibre Optic Break Out Tray

GNIUS Genius Network Interface Unit

ICMP Internet Control Message Protocol

LIS LAN Interface Status

SBA Serial Bus Address

3.6 DEFINITIONS

Active Unit The unit that is currently controlling the process

Backup Unit The hot standby unit that synchronized with active unit. Backup unit

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will take over control in the event of active unit failure.

CPU Redundancy

Two CPUs that have been configured to control the same process. Only one PLC CPU will be active at a time.

Critical Component

Components that acquire or distribute I/O data or that are involved in execution of the control logic solution

Genius Dual Bus

Two Genius Bus Controller on each PLC that been used to control the same Input and output.

Genius Hot Standby

The hot standby Genius Bus Controller that will take up the control of I/O in the event of other Genius Bus Controller failure

Hot Standby A system that running actively with the active unit without sending the output. Hot standby unit will take over control when the active unit failed.

Primary Unit Primary Unit is the preferred unit to run the system in the redundant setup.

Secondary Unit Secondary Unit is configured as backup unit in the redundant setup.

Transfer List Transfer list is the list that contained the predefined data that need to be synchronized between active unit and backup unit. The transfer list is selected in the hardware configuration for the redundancy CPU.

PME Proficy Machine Edition is the programming Interface for PLC

Cimplicity Cimplicity is the SCADA software that used to develop Human Machine Interface (HMI).

ENGG Station The Engineering station

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4.0 INTRODUCTION

4.1 DOCUMENT INTRODUCTION

The internship which runs over a period of one semester provides students an opportunity to apply knowledge that he or she learned in school into the real engineering world by contributing to the project assigned. Valuable experience and knowledge were gained from the experienced engineers as a result of this internship. This report is aimed at providing detailed information of the project completed as part of the internship at Motherwell Automation.

Enclosed in this report are the project completion stages which include the aims of the project, the design requirements, the technical review for all the hardware and the software used, design implementation, testing, commissioning detailed, problem solving skills and project evaluation. Thorough explanation and in depth information on the decisions made can be found on each section of this report.

4.2 BACKGROUND ON MOTHERWELL AUTOMATION

Motherwell Marketing Pty Ltd or popularly known as Motherwell Automation aspires to provide the best control engineering services for the clients by optimizing the operational performance by increasing throughput and efficiency of existing assets or by implementation and support of new facilities. Through excellent project management skills and by employing high quality engineering practices, the company achieves success.

Motherwell Automation has business throughout Australia and Asia by supplying products and services to the industry ranging from mining & resources to food & beverage. In addition, they are also the major distributor and registered warranty repair and support centre for GE intelligent platforms. On top of that, Motherwell also provides training on Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition (SCADA) systems for the clients on either software or hardware. (Motherwell Automation, 2012)

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5. INTERNSHIP WORK PLACEMENT SUMMARY

5.1 INTERNSHIP OBJECTIVES

Skills on applying theoretical knowledge into practical work situations can be developed through an internship and the skills and techniques acquired during internship are directly applicable to the careers when graduated. Moreover, being exposed to the real engineer world, aptitude towards engineering career can be tested before undeviating commitments are made. (Department of Management) On the basis of this definition, the key outcomes through the internship at Motherwell Automation are:

- Work experience in programming and HMI design field based on the supervision by two experienced engineers.

- Readiness to face project challenges and determination to become successful engineer upon graduation.

- Enhanced problems solving skill enhanced through involvement in a real project.

5.2 TIME MANAGEMENT

Time management is vital in order to complete a project on time and on budget. Through stringent time management on every stage of the project and rescheduling of the project plan when unexpected problems occur, good control towards the status of the project can be achieved. A task schedule for Yara Pilbara Fertilizers Pty Ltd Burrup Site (Yara) project was created and can be found in Appendix A. Due to the unexpected issue that surfaced during the shipment of devices from the client Company to Motherwell, rescheduling of the tasks was required. All of the RX3i CPUs were broken during the shipment and up to 4 weeks were required to get the Central Processing Unit (CPU) replaced. Figure 1 shows that in order to reduce the effect of the unforeseen issue on the overall project schedule, the hardware redundancy configuration task was rescheduled significantly earlier than originally planned.

FIGURE 1 RESCHEDULE OF TASK

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6. SYSTEM FUNCTIONAL OVERVIEW

The system is made up by a single Central Process Unit (CPU) module, a redundant power supply module, a redundant Genius Bus Controller module (GBC), a redundant Reflective Memory Xchange (RMX) and a redundant Ethernet Module on each PLC. Each module has its own specific role to play to ensure the operability of the system.

The CPU processes all the logic and it communicates with other modules via backplane while GBC is the interface between CPU and the remote I/O. Moreover, Cimplicity, the HMI interface communicates with PLC through Ethernet module and synchronizing between the active and slave CPU is done through RMX module. The detail of the functionality of each of the module will be covered in section 8. Technical Review.

7. DESIGN REQUIREMENTS

The design requirements of the YARA Upgrade project as requested by the client were to upgrade the existing hardware to a newer version due to current equipment’s limited time span and obsolescence of hardware. Redundancy function for Power supply, Ethernet module, GBC and RMX needs to be added to secure the system by giving two or more points of failure. In terms of software, the non standard redundancy software needs to be replaced. The existing Genius bus redundancy code was written by engineers from India and it was locked. This means a password is required to view the code in the locked block. There were no ways to unlocked blocks and consequently, the standard General Electric (GE) Dual Genius Bus redundancy template need to be chosen. Due to the increased number of devices used for redundancy functionality, the PLC System Configuration for the control system need to be updated and the compatibility issues between the modules used should be confirmed before any decision on the upgrade is made. The existing Local Area Network (LAN) configuration should also be changed to accommodate the new redundant Ethernet modules.

7.1 CONTROL SOLUTION REQUIREMENT

The final control solution design was required to provide the redundancy for power supply, CPU, dual Genius Bus controller, RMX and Ethernet module.

7.1.1 REDUNDANT POWER SUPPLY

With the redundant power supply functionality and in the event of one power supply failure, another power supply is able to seamlessly taking over the role by powering the entire system. This will prevent the loss of power to the other modules which might lead to dropping of Input/Output (I/O) on the site. In this project, each PLC rack was setup with two power supply for power supply redundancy functionality as shown in

Figure 2.

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Figure 2 Redundant Power Supply

7.1.2 REDUNDANT CPUS

Two CPUs allow the process to continue operating when one of the CPU fails or stops working. In the hot standby CPU redundancy, the active CPU will actively control the process while the backup CPU will be synchronized with the active CPU and take over the control when the active CPU fails. Both CPU must be in the same family for redundant function and control will switch to back up CPU once failure on active unit being detected. CPU redundancy is part of the requirement in this project thus as shown in Figure 3 , two PLC rack are being setup to provide the CPU redundancy functionality. Data between master CPU and slave CPU is synchronized via RMX modules.

FIGURE 3 THE REDUNDANT CPU

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7.1.3 DUAL GENIUS BUS CONTROLLER

As shown in Figure 4 there will be two GBC seating on each set of CPU. As mentioned before GBC is the interface between CPU and remote I/O. Dual Genius Buses provide cable redundancy for the controller to remote I/O devices and a template was required as a starting point to implement the dual Genius Bus Controller application for RX3i family. When the GBC A on the PLC A drops off, PLC B GBC A will take over control and the control will switch over to PLC B Bus B if its PLC B GBC A is unhealthy. In the case of three point failure (PLC A GBC A failed, PLC B GBC A failed and PLC B GBC B failed), master control will role switch back to PLC A GBC A. In a nutshell, with the correct configuration of GBC, the I/O will need to undergo a 4-point failure of GBC before it is dropped off.

FIGURE 4 A DUAL GENIUS BUS CONTROLLERS

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7.1.4 REDUNDANT RMXS

By using the RMX module on the high speed optic fiber network, data can be shared between the CPUs so that the backup CPU is updated with current status and can take over as controller immediately in the event of master CPU failure. Complete RMXs between redundant CPU consists of one RMX modules on each CPU connected with the high speed optic fiber cables. The transmitter of the active unit is tied to the receiver of the backup unit and vice versa. Redundant RMXs were installed on the CPU for RMX redundancy purpose. The RMX 2 on each PLC will take over control automatically when either of the RMX1 failed. Slave PLC needs to be power cycled after the unhealthy status of RMX 1 being solved to recover the RMX communication with active PLC. There are four RMX modules used in this project to ensure redundancy as shown in Figure 5.

FIGURE 5 REDUNDANT RMXS

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7.1.5 REDUNDANT ETHERNET MODULE

Cimplicity is the software used to design the HMI pages. Figure 6 shows that Cimplicity is set up to communicate with the master PLC, thus when PLC A is master PLC, its local active bits will be checked and communication between PLC and Cimplicity is done via PLC A Ethernet LAN A or LAN B. When the %S35 in the PLC is not checked, Cimplicity will recognized the PLC as failed PLC and communication channel will swing to PLC B. Similar to the other redundancy module, two Ethernet modules which were configured in each PLC provide two points failure for LAN communication between PLC and HMI (Cimplicity) as shown in Figure 7. The communication channel will swing to Ethernet LAN B automatically if Ethernet LAN A failed. In the event of two point failure, the communication between Cimplicity and PLC will be discarded until the Ethernet LANs issue is fixed or the master PLC is switched from PLC A to PLC B.

FIGURE 6 LOCAL ACTIVE STATUS BITS

FIGURE 7 REDUNDANT ETHERNET

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7.2 CORE NETWORK CONFIGURATION

FIGURE 8 UPDATED LAN CONFIGURATION

Due to the compatibility issue with the latest Ethernet Module, the Ethernet switches need to be replaced and Figure 8 shows an updated version of the LAN configuration. The redundancy Ethernet modules provide network redundancy functionality for the Operation Station to control the PLC while supporting the redundancy for ENGG Station where Cimplicity HMI will be placed on. There are redundant Ethernet modules for each PLC and the primary Ethernet modules on each PLC the IP address of 3.0.0.1 for PLCA and 3.0.0.2 for PLCB while the secondary Ethernet modules for each PLC will be configured with the IP address of 192.0.0.1 for PLC A and 192.0.0.2 for PLCB. The Ethernet modules with the IP address of 3.0.0.1 and 3.0.0.2 will be used by the PME during programming period to communicate between laptop and PLC while the IP address of 192.0.0.1 and 192.0.0.2 will be connected and used for Cimplicity HMI screens editing. More information on PME and Cimplicity can be found on Section 8.2.1

GE Proficy Machine Edition and Section 8.2.2 Cimplicity. All of the Ethernet modules will be used for SCADA and PLC communication which explained in Section 7.1.5.

Both the Operation Station and the ENGG station’s desktop have two Ethernet cards. The Ethernet Cards will be configured with the IP address of 3.0.0.50 and 192.0.0.50 for the Operating Stations and IP address of 3.0.0.51 and 192.0.0.51 for the ENGG Stations and one of the Ethernet Cards was attached to Switch One and another was attached to Switch Two. Switch one handles the IP address of 3.0.0.X while Switch two deals with IP address of 192.0.0.X. Moreover, both the PME software and Cimplicity software will be

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loaded on both desktops so that in the event of desktop failure, both of the software environments can be run on same desktop while getting the broken desktop changed.

Figure 9 shows the photo hardware setup of the LAN Configuration diagram used during the Factory Acceptance test (FAT).

FIGURE 9 FAT LAN CONFIGURATION

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7.3 HARDWARE REQUIREMENTS

Table 1 summarises the hardware required and used in the project.

TABLE 1 HARDWARE REQUIREMENTS

Module Description Quantity

IC964CHS016 RX3i 16 slot universal base 2

IC695SPA140 RX3i power supply, Multifunctional 120/240VAC, 125VDC 30W Power Supply

2

IC695CRU320 Redundant CPU, 1GHz, 64MB of memory, 2 serial ports, occupies two slots on system base.

2

IC695RMX128 RX3i Redundant Memory Exchange Module. 2MB of user shared memory.

4

IC694BEM331 RX3i Genius Bus Controller (supports I/O and Datagram’s).

4

IC695ETM001 Ethernet module, 10/100Mbps, 2 RJ45 connections, One IP address occupies one slot on system base.

6

VMICBL-000-F5-001

Fiber patch cables for Redundant Memory Exchange modules, custom length, or other suitable patch cables.

4

DPS-1-240-24 Power supply, 115/230VAC input, 24VDC 240W output 1

Moxa IMC-101-M-ST

Fiber optic to Ethernet converter 4

Moxa EDS-205 Ethernet switch, 5 port, including PSU 4

Note: Two of the IC695ETM001 Ethernet modules and two of the VMICBL-000-F5-001 Fiber patch cables were used in the Ethernet upgrade project.

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7.4 HARDWARE INSTALLATION OVERVIEW

A maximum of two hours were allowed for the changeover of GE-IP 90-30 PLCs at Yara Pilbara Fertilizers Pty Ltd Burrup Site (Yara) from a GE-IP 90-30 platform to the GE-IP RX3i PACSystem platform as the fully start up of IGG system required 4 hours. Thus, a changeover from GE-IP 90-30 platform to the GE-IP RX3i PACSystem platform will be performed. Before shutting down the GE-IP 90-30 platform, GE-IP RX3i PACSystem it must be ensured that it is ready to start up by running the GE-IP RX3i PACSystem with output disable switch turn on and compare the every single digital outputs, analog outputs and double confirm that the current value of the register is being uploaded from GE-IP 90-30 platform to GE-IP RX3i PACSystem platform.

The change over work was to be undertaken without causing unscheduled production downtime and minimizing disruption to the site operation. Detailed planning was required for hardware installation before any actual work had been carried out on site. During site visit, a check list which can be found in Appendix B was prepared to ensure the requirement for the setup of the new system is met. As an example, two more power supply sources should be installed before the commissioning as redundant power supply was configured in the PACSystem. The procedure for changing over from the GE-IP 90-30 to GE-IP RX3i PACSystem is given as follows:

Install Fiber Converter in IGG PLC Panel/ Control Room Panel

Procedure:

1. Remove existing Ethernet switches from panel

2. Drill holes for Din rail and install DIN rail in panel.

3. Mount Fiber Converters on DIN rail in panel.

4. Wire in the 2 wires from the power supply to appropriate terminal on converter.

5. Plug in power supply pack and turn on.

6. Confirm unit powers up correctly.

Install Ethernet Switch in IGG PLC Panel/ Control Room Panel

Procedure:

1. Mount Ethernet Switch in IGG PLC panel on new DIN rail.

2. Wire in the 2 wires from the power supply to appropriate terminals on switch.

3. Plug in power supply pack and turn on

4. Confirm unit powers up correctly.

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Fiber Connectivity Test

Procedure:

1. Install fiber optic patch lead to Moxa Fiber converter located at base of PLC cabinet.

2. Install Cat 5E patch lead between MOXA fiber and Ethernet switch.

3. Install fiber optic patch lead to MOXA fiber converter located at base of Control Room Cabinet

4. Install Cat 5E patch lead between Moxa Fiber converter and Ethernet switch.

5. Attach Ethernet capable device to each Ethernet switch to confirm connection by data transfer of large files between both devices.

For the installation of the PACSystem RX3i PLC A and PLC B, a pre-start work is required to ensure the smooth change over and risk minimization. To changeover from 90-30 PLC A and PLC B to RX3i PLC A and PLC B, a step by step procedure needs to be carried out to ensure that the operation on the site is not being affected. The 90-30 PLCs will be power off one by one and he RX3i PLCs will be started up after the 90-30 PLCs is being power down.

Changeover of PLCs

1) Ensure that the 90-30 PLC A is the master and changeover of PLC will start on 90-30 PLC B and RX3i PLC B.

2) Upload the initial value from the 90-30 PLC and export it to an external file. Open the RX3i hardware configuration project and import the initial value into it.

3) Check and ensure that the output of both PLC is similar.

4) Ensure that 90-30 PLC A is running as master and stop the 90-30 PLC B.

5) Power down PLC B and isolate the circuit breaker. Ensure that PLC B loses all power and use the Multimeter to ensure that the correct circuit breaker is power off.

6) Ensure that SCADA and DCS screens are still connected and working properly.

7) Remove the Genius bus module from 90-30 PLC B.

8) Remove the Ethernet cable from 90-30 PLC B to RX3i PLC B.

9) Once again ensure that the SCADA and DCS screens are still healthy.

10) Remove the old PLC B from the rack.

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11) Mark and drill holes for RX3i PLC B as RX3i PLC B will be placed at the rack beside of current 90-30 PLC B.

12) Install the new PLC B rack and setup the RX3i PLC B on that rack.

13) Install the Cat 5e cables from RX3i PLC B Ethernet module to Ethernet switch.

14) After the changeover of PLC B is done, load the initial value from 90-30 PLC, export it and import it to RX3i PLC B. Ensure that the power supply of PLC B is not turn on.

15) Repeat step 3 to step 15 to change over from 90-30 PLC A to RX3i PLC A.

PLCs start up procedure

1) Connect up the fiber patch leads to RMX modules on both PLC

2) Install Genius bus module terminal blocks into new Genius modules on new PLCs.

3) Switch the power supply for PLC A follow by PLC B. Ensure that the outputs are disabled.

4) Ensure that SCADA screens have live data and system is healthy and ready to be restarted.

5) Cooperate with operator to startup the plant.

6) Enabled the outputs of PLC A and PLC B.

7) Test all the code and make sure it works properly. Carry out the testing on pumps and valves and ensure that SCADA has control of I/O.

8) Check PID values and ensure that PID values have been transferred in.

9) Check PLC fault tables for errors to get the errors issues solved.

10) Carry out the role switch test for RMXs.

11) Do the redundancy check for Genius Bus Controllers

12) Test the redundancy check for Ethernet Module.

13) Hand back the system to production for full system start up.

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8. TECHNICAL REVIEW

The purpose of this review is to finalize the design related issues and the technical criteria. This review also shows the description of the design and component “features” as exploring the ways of achieving the client’s goals and objectives.

8.1 HARDWARE

TABLE 2 SUMMARIZES THE HARDWARE FUNCTIONALITY USED IN THE PROJECT.

Hardware Role

Power Supply module Supply the power to all of the modules

Central Processing Unit (CPU) module Process logics and communications

Reflective Memory Xchange (RMX) module Synchronize the data between the active CPU and backup CPU

Genius Bus Controller (GBC) module The interface between CPU and Input/Output

Ethernet Modules The communication path between software (PME and Complicity) and the CPU

8.1.1 POWER SUPPLY

The Client had requested design of a system that does not tolerate down time. Thus the redundant power supply configuration was considered. The base plate of each CPU module was designed to have two power supplies as per client requirements and this is shown in Figure 10.

FIGURE 10 REDUNDANT POWER SUPPLY

There are three main reasons in considering power supply redundancy (GE, GFK2399D, 2011):

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a) Load Sharing

In certain situation, a single power supply is not enough to run the system continuously. The shortage of power supply might lead to insufficient power capacity which in turn might cause damage to the equipment. Using redundant power supply, the ON/OFF switch must always be in the ON position to prevent system disruption. If disruption occurred, the PLC logic and hardware configuration are reloaded to resume the aborted operation.

b) Power Supply Redundancy

The redundant power supply is used above the minimum requirements to power up the system. If for some reasons there is a failure in one of the units, the other one will seamlessly take over to prevent power loss. Moreover, through this arrangement, the damaged unit can be replaced without taking the machine down. This is also known as hot swapping.

c) Power Source Redundancy

With the setup of power source redundancy, the basic redundancy for power supply is provided plus power source redundancy. Two power supplies must be connected to different power sources to provide power source redundancy. In this case, the individual power supply can be removed without affecting the operation of the system as long as the minimum power requirement for the system is met.

FIGURE 11 THE POWER SUPPLY

Figure 11 shows there are 4 LEDs which indicates the condition of the power supply.

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a) Power: This Light-emitting diode (LED) is green when the backplane is supplied with power and it is amber when the power supply switch is in off mode.

b) P/S Fault: The LEDs will turn red when insufficient voltage was supplied to the backplane.

c) Over temperature: The light will turn to amber color when the operating temperature of the power supply hit the maximum set point.

d) Overload: This LED will lit when its capability to provide power supply to other modules is almost exceeded or exceeded.

In the event of any fault that occurs, the CPU fault table will log the error. Moreover, if overloading occurs, over current protection will shut down the power supply. The power of the power supply will be sustained 20 ms when there is an interruption of power source and once overloaded issues is solved, the power supply will return to its normal stage. The door of the power supply must be closed all the time to prevent accidental shock hazard.

Insulation stop position is shown by the red arrows in Figure 12, ensures that the wire is properly wired up. If the wire is too short or it is not inserted fully into the terminal, no power will be passing through the device. A minimum of 9mm should be stripped off from the wire and up to 11mm is acceptable. (GE GFK2413D, 2011)

FIGURE 12 INSULATION STOP POSITION

8.1.2 CENTRAL PROCESSING UNIT (CPU)

The PAC System RX3i CPU is a smart device which is able to perform real time processing and communicates with a wide variety of devices. The CPU communicates with the programmer and the HMI devices via serial Series Ninety Protocol (SNP) and is able to communicate with Input/output (I/O) over a dual backplane bus. The RX3i universal backplane uses a dual bus that provides high speed Peripheral Component Interconnect (PCI) for fast throughput of new advanced I/O and serial backplane which simplified the migration of the existing series 90-30 I/O. (GE, GFK-2514M, 2012)

The Proficy Machine Edition which could be installed either in a desktop or laptop computer will initiate all the communications and the slave CPU will respond to the master’s requests. Commands and data will be sent to the PLC and the data can be retrieved from the PLC as well. The details of the SNP protocols during communication

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will be handled by the SNP driver while application programmer will be focusing on the application software. There are two different of types of SNP protocol. The SNP Master Slave Implementation is one of the SNP protocols which uses a Terminate and Stay Resident (TSR) implementation, but an additional TSR driver must be installed. On the other hand, the linked library implementation is another type of SNP protocol; a link must be produced between SNP driver libraries with the CPU. The link can be a point to point connection through RS422 or multi drop serial port connection. In the multi drop serial ports connection, host devices will be the master while other devices will be configured as slaves which shown in Figure 13.

FIGURE 13 MULTIPLE DROPS SERIAL CONNECTION

A Redundant system is made up of two redundant units. Each hot standby (HSB) redundancy unit can be configured with using one Redundancy CPU, one Redundancy Memory Xchange (RMX) module as a redundancy link. (GE, GFK2308F, 2010)

The CPU is in built with

- 64 Mbytes of battery backed memory - 64 Mbytes of non volatile flash user memory - a configurable data and program memory - support programming in Ladder diagram, structured text, function block

diagram and C language - have the functionality to auto locate symbolic variables, - Two serial ports (RS-485 and RS-232) can be found on CPU hardware as shown

in Figure 14 The and it can be configured through PME and five different configuration of port mode can be chosen.

- Ethernet communication via the rack based Ethernet Interface Module is supported.

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A specific protocol for communication will be set when the port mode is defined.

Modbus RTU Port Mode: Modbus RTU slave protocol is applied meanwhile communication with SNP master is allowed.

Message mode: With the message mode C runtime library functions are required to enables the C language block to perform the communication.

Serial I/O Mode: This shall be chosen if COMMREQ functions are preferred. SNP slave Mode: This setting only reserved for SNP master communication. Available Mode: This setting is not be used by PLC firmware.

FIGURE 14 THE FRONT PANEL OF THE CRU320 CPU

Hot standby CPU redundancy provides a back up for the current CPU to prevent interruption of the process in the case of failure of primary CPU. The primary CPU actively controls the process while the secondary CPU synchronized with the primary CPU and takes over control upon failure of the primary CPU. Synchronization will only happened when both CPUs are in run mode. The logic solution in each CPUs will run in parallel, however only the output from the active unit will be used. The synchronization of data is being transferred via the RMX modules. The control will automatically switch to the secondary CPU when any fault is detected on the primary CPU. Otherwise, switching of control can be done via the toggle switch on the RMX modules. Transfer list must be setup in both PLCs to ensure correct synchronization. Transfer of data occurs twice per sweep which is before and after the logic is solved. The details of how the data being transferred will be covered in the later stage.

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Both CPUs must be from the same controller family. The run or stop mode of the CPU can be toggled by either using the three position RUN/STOP switch or by the programming environment and CPU status is indicated on the CPU module. The Run/Stop switch function can be configured from PME and with the Run/Stop switch enabled button on the hardware. Stopping or running of the CPU can be done via the CPU interface or from PME. Moreover, online editing function through the programming windows allows easy logic modification to a running program. Fatal fault on the system will stop the CPU from processing and the diagnostic variable will be set and logged in the fault table. Operators need to resolve the problems that lead to fatal fault and power cycle the PLC. The current position of the Run/Stop switch and its configuration can be read through the Read Switch Position (Switch_Pos) function by program it in logic.

The RX3i supports most of the series 90-30 modules and thus the existing system can be upgraded without affecting the panel wiring and the conversion from the existing GE-IP 90-30 logic to the GE-IP RX3i PAC System. This functionality enhances the smooth transition from the existing program to the new PACSystem. PME Logic Developer PLC programming software is used to program the CPU. On power up and periodically, the CPU will verify the hardware on its rack and make sure it is tallied with the hardware configuration that was downloaded from the PME. If the physical configuration is not the same, the differences will be reported to the CPU alarm processor and fault response can be seen on the physical interface as well as the fault table in the PME.

The PACSystem provides the interface with intelligent devices such as its Ethernet interface and its Genius I/O system. When the hardware configuration of the intelligent devices is downloaded to the CPU, the unique module ID for each module will be used by the CPU to determine the correct type of communication with the given module. If the CPU could not find the correct module ID corresponds to the modules physically, a system configuration mismatch fault will be generated. The diagnostic data in the PACSystem can be obtained either through the bus controller which provides the module’s diagnostic data to the CPU or through the CPU’s I/O scanner subsystem which generates the diagnostic bits based on the data provided by the modules. Diagnostic bits are derived from diagnostic data and it shows the current status of the specific module. Diagnostic bit is set when fault detected and clear when the fault is cleared.

The priority of the tasks in the CPU was determined by the sweep mode. Sweep is a sequences of operation for performing internal housekeeping, obtaining data from the input device, executing the application program, sending the result to output device and communicating task to perform self test.

The sweep mode will allocate time for each task and the parameters can be modified depending on the selection of sweep mode which changes the operation of the controller communication window, the backplane communication window and the background window. The data from the input device can be obtained through input scan. During housekeeping, the sweep will update the system (%S) bits, timer values, determining mode of the sweep and the polling of expansion racks to prepare for the start of the sweep. Polling ensures that sufficient electrical power is being supplied to the expansion rack and configuration of the modules on the rack is being processed in the controller communication window. In the application program task execution which

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is also called the logic window, the CPU solves the logic and creates a new set of output data whenever the last logic is being executed.

The new output result will be written to the bus controller and output modules. If the CPU is in run mode and it is configured to perform a background checksum calculation, the background checksum is performed at the end of the output scan. The default setting for the number of words to checksum is performed at the end of the output scan. The default setting for the number of words to checksum each sweep is 19. If the words to checksum each sweep is set to zero, this processing is skipped. The background checksum helps ensures the integrity of the user logic while the CPU is in run mode. The output scan is not performed if a program has an active suspend I/O function on the current sweep.

The controller communications window services the onboard Ethernet and serial ports. Moreover, it also reconfigures the expansion racks and individual modules during the sweep. The highest priority is given to reconfigure up to the total time that is allocated to this window and normally a few sweeps are needed to complete the reconfiguration. After that, communication with intelligent devices such as Ethernet modules and Genius Bus Controller will be executed through the backplane communication window. Depending on the configuration of the mode setup, the background communication window will be executed from run to completion by default and if limited mode is chosen, the backplane communication window will only execute until the maximum time that allocated to the window per scan. In the final stage, CPU will carry out a self test to verify the checksum for the CPU operating system software. In the event of abnormal sweep, watchdog timer timeout value will be triggered, the OK LED on CPU will blink and halt the CPU operation.

A fault is logged on the fault table when the watchdog timer is triggered. In halt mode, only programmer can communicate with CPU and power must be cycled on the backplane of CPU. (GE GFK2222R, 2012)

When the CPU is about to stop from the PME, a window will pop up which provides an alternative to the user to choose the operation of the CPU while in stop mode. With the I/O scan enabled, the input and output scan will be performed for each sweep and with the I/O scan disabled, the input and output scans are skipped. In the stop mode, communication with the programmer and intelligent modules continue but the logic will not be executed. If I/O scan is enabled, the output and input of the I/O will therefore still be scanned and passed to the intelligent modules.

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FIGURE 15 SWEEP SEQUENCE

The CPU will perform a checklist when it transitions from stop to run mode.

There are three different types of sweep mode which can be configured from the PME. The default of the sweep mode is normal mode. Under normal mode, the PLC sweep will execute as quickly as possible and the sweep time is dependent on the logic program and the respective window timer values. The logic window will be executed from run to complete while communications and background windows can be set to either run to complete or executed in limited mode. Similarly, in constant sweep mode, the sweep time is fixed and the logic window will be executed from run to completion however each sweeps will only be started at user specified constant sweep time and the communications and background windows will only be executed if there are left over time before the next sweep begin. In contrast, the constant window mode will alternate between the three windows from “run” to “completion” mode. The sweep time is varied due to the difference in program logic execution and the value of the window timer.

The PACSystem CPU supports a wide variety of user memory that contains in the application program and hardware configuration such as registers (%R), bulk memory (%W), analog inputs (%AI), analog outputs (%AQ) and managed memory. Managed memory consists of symbolic variables and the I/O variables. By using symbolic variables, more memory is allowed to be used and the I/O variables are similar to the symbolic variables but it is mapped to the input and output in the hardware configuration.

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FIGURE 16 CPU LED STATE & DESCRIPTION

8.1.3 REFLECTIVE MEMORY XCHANGE (RMX)

The Memory Xchange module is used to pass data to another Memory Xchange module through high speed fiber network. By using reflective memory technology, predetermined data can be sent to the nodes that are connected by a fiber optic daisy chained loop. The daisy chained loop is setup by connecting the transmitter of one node to the receiver of another node. Setting up the RMX module as redundant link requires four RMX modules as indicate as Figure 5.

The RMX modules can only be used in the main rack which has location indexed by 0 to a maximum of 6 RMX modules and it supports hot insertion and removal. However, during the hot insertion or removal, the network will be disrupted and the connection between redundant RMX modules will lost. The connection can be reconnected through power cycle the secondary Unit if the primary unit is in control if only one OK LED is switched off. If both the OK LED of the redundant RMX module is switched off, power cycles both redundant rack and the RMX module should be restored. When there are redundant RMX modules in a system, the RMX will switch to another link automatically when it detects the lost of another RMX module link so that the CPUs can remain synchronized.

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The current operating state of the RMXs can be obtained from % S33 to %S39 and %SB18. Table 3 shows the important status bit for the RMX.

TABLE 3 STATUS BITS OF RMX MODULE (GE,GFK 2308, 2009)

To be noted, %S are the system bits which cannot be overridden or altered. It will display as OFF mode when there are not configuration being stored and STOP or RUN mode when configuration is downloaded to the system.

When RMX is used in a redundant CPU, the configuration parameter for CPU shall be set to enable so that RMX serve as redundancy link instead of general purpose reflective memory. When RMX serves as the redundant link, it ensures that the backup units received the latest status of the active unit by via the predetermined transfer list. With the latest status of predetermined data, logic in both CPUs can run in parallel.

Data is being transferred from the active PLC to the RMX module through the backplane bus and being sent from the RMX module to the RMX receiver which is located on backup PLC. The data received by the RMX will be passed to the CPU via backplane bus as well. The size of a single data packet can be varied from 4 bytes to 64 bytes and will only accepted by the RMX module if the data is valid and the data packet is not originates from itself. The RX3i can support up to 6 RMX and when up to two RMXs is daisy chained, reflective memory hub should be used. Reflective memory hub can ensure that when error is detected on one of the nodes, the fault on that node will not affect other nodes.

The LED on the RMX module will be lit when it received its own test data packet. A test packet will be sent out when there is configuration of the module and the aim of the test

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packet is to ensure that the transmitter of the all nodes on the rings is enabled. Moreover, the role switch which is located on the module itself serves the function as manual CPU role switching button. The role switch is a spring loaded two position switch which by default rests in the Off position and to prevent unintentional CPU role switching happened, the role switch need to be latch for at least 1 second and it will de-bounced upon releasing.

Each data packet will be sent twice to prevent corruption or missing of data packet during the transfer and the configuration can be setup through the redundant transfer mode operation which can be found from the PME. When the redundant transfer mode operation is set to enable, the backup data packet will be resent if errors were found in the data packets or else the backup data packet will be discarded. If errors are detected on both the original and backup data packet, the data packet will be completely removed from the network. Setting up of redundant reduced the error in sending data by 50% however longer transfer rates are required.

Flooding of rogue packets on the network can cause a big disaster. A rogue packet is a data packet which could not be recognized by any of the nodes in the chain, thus this data packet will be passing around indefinitely. A rogue packed might be formed if the packet is being altered on the non originating node or when there is malfunction of originating node thus originating node could not recognize its own packet and removed it. In addition, rogue packet might also be caused by the broken board or overly harsh operating environment and the ideal way to solve this problem is to replace the whole board. In RMX modules, rogue packet master can also be configured in hardware configuration to prevent the circulating of rogue packet. Rogue master will alternate the rogue packet and when rogue packet circulated through rogue master for second time, it will be recognized and removed by rogue master. Only one rogue master is allowed in every network.

In the predetermine transfer list setup, it is broken down into two part which is input transfer list and output transfer list.

FIGURE 17 RMX TRANSFER LIST

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The input transfer list is sent right after the input is scanned during the sweep. In a sweep, the input will be scanned once and so for the output. An output transfer list will be sent after the logic is executed. There are no logic required for activate the transfer list, however proper configuration is required.

FIGURE 18 THE INPUT AND OUTPUT TRANSFER LIST (GE,GFK 2308, 2009)

The two ports at the bottom are the optical transceiver port “TX” is the transmitter port and “RX” is the receiver port. In Figure 19, the RMX module has eight LEDs which show its current status. The description of the LEDs light is shown in Table 4.

FIGURE 19 THE REDUNDANT RMX MODULE

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TABLE 4 THE DESCRIPTION OF RMX'S LEDS

LED Label Description

OK On indicates the module is functioning properly.

LINK OK When used as a redundancy link, On indicates the link is functioning properly. When not used as a redundancy link, ON indicates the module is configured

SIG DETECT ON indicates the receiver is detecting a giver optic signal.

OWN DATA ON indicates the module has received its own data packet from the network at least once.

LOCAL READY On indicates the local unit is ready

LOCAL ACTIVE On indicates the local unit is active.

REMOTE READY On indicates the remote unit is ready.

REMOTE ACTIVE On indicates the remote unit is active.

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8.1.4 GENIUS BUS CONTROLLER

The Genius Bus Controller (GBC) is an interface between I/O and the PLC. The GBC can handle up to 31 devices and provides Genius global data communication, background communication and control of the I/O data up to 128 bytes on 31 devices. A Genius bus system consists of Genius Bus Controller, Genius I/O, Genius I/O power and carrier.

FIGURE 20 THE GENIUS BUS CONTROLLER (GBC)

As shown in Figure 20, the Genius Bus controller has two LEDs which indicate its current status. LEDs will turn on after it is powered up and through COM OK LED, status of the Genius Bus Controller can be known. It will consistently turned on when the bus is working properly, blinking when there are intermittent bus errors and the LED will turned off when the bus is failed or when it is not being configured.

The GBC controller passes the data between PLC and remote devices through two asynchronous activities which the Genius bus scan will communicate with the every single devices on the bus from bus 0 to bus 31 and communicate to the CPU through the CPU sweep. Communication between the GBC and CPU is through the on-board RAM and a serial backplane interface. The data sent via the Genius bus will be placed in the onboard RAM of the CPU and when the CPU sweep is executed, the data on the Onboard RAM will be transferred to the CPU via the serial backplane. Similarly, the output of the CPU will be placed on on-board RAM through the serial backplane when the CPU sweep executed. When the GBC received the token on Genius bus, the GBC will transfer the

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output from the onboard RAM and sent to other drops via the data package which also known as token. A complete cycle of token among the drops on the Genius bus is called Genius bus scan.

During the Genius bus scan, the Genius bus controller will broadcast global data to the devices and update the outputs on the devices if permitted and it will also receive the error messages from the devices and send to the CPU so that they will appear in fault table. Moreover, the GBC can also receive the data sent from all of the devices. The period for Genius bus scan depends on the number of devices that he GBC deals with, the speed of Genius bus communication, and the use of global data and datagram communications. The data transferred from the devices to the GBC is broadcast data and devices can broadcast the data to the GBC whenever the device has the communication token. The communication token will be passed to another device after a specific broadcast sign off message sent. Whenever the PLC executed, all the data global data, input data and status bit of the GBC will be read by the PLC. On the other hand, data sent by the GBC to devices are non-broadcast message, only specific devices with the correct ID will receive the messages. When setting up the configuration of the GBC, either %I or variable memory can be used to map the 32 status bits of the GBC.

The terminating resistor should be connected to the same location at the starting and ending of the bus as shown in Figure 21. With the terminating resistor, the upper block of the GBC can be removed without losing the control on the bus.

FIGURE 21 GENIUS BUS CONTROLLER AND DROPS

Hardware configuration for the GBC and devices should be set up in the PME software. As an example, Figure 22 shows the hardware configuration of the device that placed on drops 1, 2 and 3 as Generic I/O and the SBA 30 and 31 is the Genius Bus control. With the setup as control, global data can be transmitted and as for Generic I/O it is configured for data receiving but not controlling.

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FIGURE 22 THE HARDWARE CONFIGURATION OF GENIUS BUS CONTROLLERS AND DROPS

When the GBCs were set up as a redundant controller, a specific template is required. With the redundancy in Genius bus, it provides the backup to the Genius communication so that in the event of losing a link, the remote node switch can switch to another bus and this guards against the loss of I/O which can might lead to the site’s shutdown. Similar to single Genius bus, dual Genius bus can accommodate up 29 remotes and the drops 30 and 31 will act as the redundant controller. The amount of inputs that can be sent and output received depends on the type of the Genius and drops. For VersaMax, 128 bytes of input and output are allowed.

The RX3i PACSystem can provide up to 32768 bytes of discrete output (%Q), 32640 bytes for the Analog Outputs (%AQ), 32768 bytes discrete inputs (%I) and 32640 bytes analog inputs (%AI). (All addresses are shown in decimal number form). For the template that was given by GE, up to 7500%I and %I10000 are been configured for use in the Dual GBC redundancy. In order to setup the hardware configuration of the Genius bus properly by using the dual Genius Redundancy template, I/O address of the Bus Network Interface, address for GBC for Bus A, GBC for Bus B, and the set up file “GB_Config” which coordiantes the addressing between Bus A and Bus B. For redundant CPU application, the setup for redundant GBC A and GBC B on backup CPU will be exactly the same as active CPU. The Genius network interface will sent the status of its input (%I and %AI) from the lowest to highest to controller and similarly , the controller will sent its output (%Q and %AQ) from lowest to highest addresses to the Genius Network Interface Unit. Hardware configuration is extremely important as the communication between the Genius Network Interface Unit (GNIU) and Genius bus controller will not be operate properly if the communication between GNIU and GBC does not achieve the agreement.

As shown in Figure 23 below, each GNIU have 8 parameters to be setup. Input reference address is the address where the %I/%AI of the devices will be stored and output reference is where the source address of the outputs ( % Q or %AQ) will be sent to the GNIU. Length is the total number of bits between the lowest input address and highest input address.

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FIGURE 23 GENIUS BUS CONTROLLER SETUP

The %I address for Bus B must have 10000(decimal) added to the bus A address and 5000 added to %AI. The output address (%Q or %AQ) for bus A and bus B should be similar as both bus are controlling the same output. The input list as shown in Figure 24 in the structure text block “GB_Config” should be setup according to the input that is used. The “GB_Config” block will transfer the input status to bus B if there is failure of bus A. Losing both bus will affect the control of bus towards the I/O and I/O will either go to zero or hold the last state depends on the setup in hardware configuration. In the “GB_config” block , the “GB_Config_Done” is the flag that indicate that dual genius bus template will be used. “GB1_HIGHEST_SBA” is the highest number of SBA that being used while “GB_Matrix” shows that the amount of SBA that are used. “GB1_GBCA_Slot” and “GB1_GBCB_Slot” indicate the slot number of the GBCs on the hardware itself. The “GB1_IOFF[01]” indicates the starting address of input %I for Genius bus A. The “GB1_ILEN[01]” indicates the total of the length for the input mentioned above and similarly for analog input (%AI) which can be found on third column and its length on fourth column. The default address for Ethernet status address is %I which conflicts with the starting address of digital input (%I), thus the status address of the Ethernet input shall change so that it does not fall in the list of address that being reserved for dual GBC.

FIGURE 24 THE GENIUS BUS ROLE SWITCH TEMPLATE

The dual Genius Bus redundancy template comes with fixed status reference for bus A and bus B which it was %I31001 for bus A and %I32001 for bus B. Moreover, it also

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used certain variable references for internal operation. The Genius Dual Bus Block will determine which bus shall be used. All the reserved status address for Genius Bus Controller switching is listed in Table 5.

Table 5 Reserved Status Address for Genius BUs Template %I00001 to %I7500

Allocated to the digital inputs to GBCA

%I10001 to %i17500

Allocated to the digital inputs to GBCB. If %I is higher than 17500, it will not work with the template.

%I31001 to %I31256

Used for GBC status on Bus A

%I32001 to %I32256

Used for GBC status on Bus B

%Q All address can be used

%AI0001 to %AI3200

Allocated to the analog input to GBCA

%AI5001 to %AI8200

Designated for analog input to GBCB

%AQ All address can be used

%G1025 to %G1280 %M32043 to %M32050 %R8001 to %R8060

All this address are reserved for redundant bus switching

“RoleSw_Enable” variable’s initial value should be changed from Off to On so that role switch will be done automatically when the active controller cannot communicate with the devices while backup controller is able to do it. The GBC will switch from Bus A active unit to Bus A backup unit while role switching the active controller. When Bus A backup unit Bus A drops off as well, the GBC will switch to Bus B. When Bus B backup unit also experience the drop off, GBC will switch back to active unit Bus B. An important note to add is that all the rest of the logic should be placed after the Genius bus role switching logic or blocks. The specific status bits for GBC A and GBC B on both primary and secondary controller are listed in

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Table 6.

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TABLE 6 SPECIFIC STATUS ADDRESS FOR FOR GBC A AND GBC B ON PRIMARY AND SECONDARY CONTROLLER

Status Bits in Both Controllers

%I310001 to %I310032 GBC bus A status bits, one bit per device

%I31002 Status bits for SBA 1

%I31031 Status bits for GBC30 in secondary controller when dual Genius bus is used in redundant system

%I31032 Status bits for GBC31 in Primary Controller

%I32001 to %I32032 GBC bus B status bits, one bit per device.

Status bits in Primary Controller

%G1025 Only the GBC in the primary controller is on Bus A.

%G1026 Both the primary and secondary controller is lit on Bus A

%G1027 Only GBCB on the primary controller is running

%G1028 Both the primary and secondary controller is lit on Bus B

%G1029 All SBAs are on primary controller GBC A

%G1030 All SBAs are on primary controller GBC B

Status bits in secondary controller

%G1041 Only the GBC in the secondary controller is on Bus A

%G1042 Both primary and secondary controller are on Bus A

%G1043 Only the GBC in the secondary controller is on Bus B

%G1044 Both primary and secondary controller are on Bus B

%G1045 All SBAs are on Secondary controller Bus A

%G1046 All SBAs are on Secondary controller Bus B

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8.1.5 ETHERNET INTERFACE MODULE

Computer running the TCP/IP (Information Sciences Institute, University of Southern California, 1981) version of programming software such as the PME and Cimplicity software are able to communicate with the Ethernet interface through TCP/IP. The program can be downloaded to the CPU via an Ethernet interface at greater speed and the Ethernet interface is the server, the PME software acts as a client which sends the requests to server.

The two auto sensing Ethernet port 10BaseT or 100Base TX are used for connection to either 10 Base T or 100 Base TX IEEE 802.4 (IEEE, 2012) network with the speed of 10Mbps or 100 Mbps. Although there are two network ports, every Ethernet module only have one interface to the network which means only one Ethernet IP address is allowed. On the Ethernet Interface, there are seven LEDs that indicate the status of the Ethernet module as well as the status of the link as indicate as Figure 25.

a) Ethernet Module OK (EOK): This LED will be ON and flashing for all normal operations and when hardware failure occurs the EOK LED will be flashing in a two digit error code implicate the failure of the hardware.

b) LAN online (LAN): This LED will be blinking when there are data received and transmitted to and from Ethernet Interface. If either of the port is healthy and connection of the Ethernet port is available the LEDs will stay on. LEDs will only changed to OFF when there is no connection through the Ethernet port or when the firmware is updating.

c) Log Empty: Log Empty LED will turn on if the Ethernet interface is operating in a normal mode. It will turn off or blinking when some event happened and the error can be view through Station Manager Interface.

d) Two Ethernet network activity LEDs (LINK): The LINK LED will lit when there are physical linkage between the network and network port. When the traffic of the network detected, the LED will blink.

e) Two Ethernet network speed LEDs (100): indicating the network speed. It will turn on when the network speed is tally with the port transmission rate.

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FIGURE 25 THE ETHERNET MODULES

The Ethernet interface will automatically detect the type of port when the Ethernet cable is plugged in via the in-built embedded switch. Two different devices that need to work in two different speed can be attached into the port and Ethernet interface will adjust according to type of devices. Moreover, each port will also select the types of cables automatically when the cable is plugged in. Cables can be in either straight through or crossover cables (National Instrument, 2002).

In order to ensure that the Ethernet interface is communicating with devices, the PING can be used to test the devices by sending an Internet Control Message Protocol (ICMP) echo request message and waiting for the reply from devices. If there is reply from the devices, it is indicate that the connection between Ethernet Interface is working and configured properly with devices. The PING is a type of program which is used on the TCP/IP network to test the communication.

The Ethernet module should be configured through the PME module before it can be used. Permanent IP address can be assigned and download to the Ethernet module via serial cable and store it in CPU or setting the temporary IP address to the Ethernet module through Set Temporary IP Address Utility.

The rack-based Ethernet Interface (ETM001) comes with dual RJ-45 ports which are connected through an auto sensing switch. An IP address is required for each Ethernet module and temporary IP address can be assign over the network with the Set Temporary IP Address Utility or the IP address can be download to CPU through serial cable. Before Set Temporary IP Address Utility is used, the user must ensure that the CPU is in stop mode and is not scanning the outputs. The setup will not be processed

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until the CPU is stopped and the utility can be used if the network travels across hubs or switches but not router. The Set Temporary IP address can be found under Utility tab and MAC address of the Ethernet module is required and a temporary IP address needed to be keyed in to setup a temporary IP address. The temporary IP address will not be retained after power cycle and to set a permanent IP address, the hardware configuration of the Ethernet modules must be setup properly and need to be downloaded to the module itself. Figure 26 shows the Set Temporary IP Address programming interface.

FIGURE 26 SET TEMPORARY IP ADDRESS

Moreover, when configuring the Ethernet module, a block of memory or I/O variables should also be set up for Ethernet Interface status bits. The LAN Interface Status (LIS) bits will occupied the first 16 bits of the block and channel status will occupied the another 64 bits. The channel status will not be displayed if the LIS bit is not set.

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FIGURE 27 STATUS BITS OF THE ETHERNET MODULES (GEGFK2224F, 2007)

As shown in Figure 27, the Bits stated below is the essential bits that normally will be used either in programming or designing the HMI.

Bit 1 (Port 1A full duplex) : This bit will be set to 1 when port 1A is set to full duplex and 0 when it is half duplex. The mode of operation is set automatically by Ethernet Interface and this bit only valid if Bit 13 which is LAN OK bit is set to 1.

Bit 2 (Port 1A 100Mbps): this bit will be set to true when bus on Port1A is operating at 100Mbps.

Bit 3 (Port 1B full duplex): Similarly to bit 1, but this is applied on Port1B.

Bit 4 (Port 1B 100Mbps): similar to bit 2 but it depends on Port1B.

Bit 6 (Redundant IP address active): When redundant IP address is configured, this bit will set to 1, if not it will be set to 0.

Bit 13 (LAN Ok): This bit will be set to 1 when the communication on the network is healthy. It will be changed to 0 if network is unhealthy and switch back to 1 if the network becomes healthy again.

Bit 16 (LAN Interface Ok): This bit checks the communication between Ethernet Interface and PLC. CPU will set the bit to 0 if there is no communication between Ethernet Interface and PLC and setting the bit to 0 will lead to loosing of all other Ethernet Interface Status bits.

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8.2 SOFTWARE

8.2.1 GE PROFICY MACHINE EDITION

The GE Proficy Machine Edition (PME) is the software used to program the PLC in any range from GE-IP 90-30 to GE-IP RX7i PACSystem which includes the major PLC system used in this project, GE-IP RX3i PACSystem.

A training course on PME was given by a professional trainer to familiarize the student with the GE programming environment. With the programming skills that the author learned during the ENG305 PLC unit in Murdoch University, adapting to new software environment was rather easy. The challenge programming an upgrade system is the requirement to fully understand the new and existing hardware and the diagnostic bits which are essential in programming role switching functionality.

8.2.2 CIMPLICITY

Cimplicity collects data from the PLC and displays it on the screen. Moreover, it also acts as a control which triggers output of the PLC. As shown in Figure 28, Cimplicity workbench is where editing of screen, setting up of communication path and its relevant data and viewing can be done. The screen for the project is imported and changes on the screen were done with points added so that the status of the PLC modules can be monitored through Cimplicity with the alarm event created to alert operators in the event of fault.

FIGURE 28 THE CIMPLICITY WORKBENCH

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9. DESIGN MODIFICATION

9.1 PLC CODE MODIFICATION

9.1.1 CODE MODIFICATION FOR GENIUS BUS CONTROLLER

This section describes the work done by the author on the existing and modified code for the upgrade of the GE-IP 90-30 PLC system to the new RX3i PLC system. The IGG original code was written by an external vendor to perform the redundancy control on Genius Bus Controller and was deleted as the logic blocks for Genius Bus Controller switching was locked and password is required to view the content in the block. Hence, the GE standard template for Dual Genius Bus Controller was used. As shown in Figure 29 and Figure 30, the items in red boxes are the code blocks to be removed. As shown in the Figure 29, RED_SW locked block are calling other blocks as well, thus all the block that relate to RED_SW as indicated in Figure 30 will be removed.

FIGURE 29 THE EXISTING LOGIC FOR GENIUS BUS REDUNDANCY

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FIGURE 30 EXISTING LOCKED BLOCKS TO BE REMOVED

GE has supplied a Genius Dual LAN template which has been set up to accommodate 10 Serial Bus Address (SBA)’s drops and it is GE’s latest philosophy on how to handle “Dual Genius LAN Switching” and CPU redundancy. The “a_Dual_Bus_Interface” block must be dragged from the template as shown in Figure 31 be inserted to the logic window before any other user code.

FIGURE 31 A DUAL BUS INTERFACE TEMPLATE

The template will only work properly if the setup for template and hardware configuration for Genius Bus Controllers is correct. Under the “Dual_Genius_Bus” template, double click on the “GB_Config” template as shown in Figure 32 and setup the GB configuration template to match with the project requirement. Figure 33 detailed meaning for every single parameter that needs to be setup.

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FIGURE 32 THE GB_CONFIG TEMPLATE

FIGURE 33 THE GB_CONFIG SETUP

Moreover, the RMX transfer list is also essential during the Genius Bus Controller’s switching in order to synchronize the data between the master and slave on every sweep so that correct information is displayed. Steps to setup the RMX transfer list can be found under Section 8.1.3 Reflective Memory Xchange (RMX). In addition, steps to setup the Genius Bus template can be found in Section 8.1.4 Genius Bus Controller. Figure 34 indicates the setup for RMX transfer list and Genius bus template.

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FIGURE 34 RMX TRANSFER LIST

9.1.2 CODE MODIFICATION FOR ETHERNET REDUNDANCY

The Ethernet module redundancy code was written to provide a four point failure to SCADA. Either of Ethernet module A and B or both of the LAN connecting to the module failed, this code will perform a role switch and the master will swing to PLC B with the condition that all the Genius Bus controller are healthy. The Ethernet role switch will be disabled if any of the Genius bus controllers are not healthy. Role switch might lead to failure of the I/O if the Genius Bus controller is not in healthy mode and it might lead to

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the shutdown of plant. Figure 35 shows the logic that been put in for Ethernet role switch when all of the Genius Bus controller are healthy.

FIGURE 35 ETHERNET ROLE SWITCHING CODE

9.1.3 CODE MODIFICATION FOR POWER SUPPLY MONITORING

Figure 36 is the code written for power supply’s alarm monitoring to display on the HMI . The display screen for power supply can be found in Figure 37. The HMI will be alarmed if power supply becomes faulty and power supply can be replaced immediately. Redundant power supplies provide two point of power supply failure to each PLC and this lower the probability of I/O failure.

FIGURE 36 POWER SUPPLIES MONITORING (HMI)

FIGURE 37 THE POWER SUPPLY STATUS ON HMI

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9.2 PLC HARDWARE CONFIGURATION

9.2.1 COMPARISON OF OVERALL HARDWARE CONFIGURATION FOR BOTH PLCS

The difference between the hardware configuration of the existing GE-IP 90-30 System and the GE-IP RX3i PACSystem is shown in Table 7. All the modules were updated to the newer version and redundancy functionality of power supply and the RMX modules were added to the new GE-IP RX3i PACSystem.

TABLE 7 COMPARISON OF PLCS HARDWARE CONFIGURATION SETUP

GE-IP 90-30 System GE-IP RX39 PACSystem

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The setup for the Genius bus in the primary and secondary CPU will be exactly the same and therefore, the setup will not be listed twice. Table 8 shows the comparison between the hardware configuration of Genius Bus Controller Setup for GE-IP 90-30 system and GE-IP PACSystem. GE-IP RX3i PACSystem used different status reference type due to the Genius Bus Controller role swithching template requirement. Matching of hardware configuration setup between the GE-IP 90-30 System and the GE-IP RX3i PACSystem can be differentiated through color code. TABLE 8 COMPARISON OF GENIUS BUS CONTROLLER SETUP

GE-IP 90-30 System GE-IP RX3i PACSystem GBC1

GBC2

GBC 1 I/O Setting

GBC 1

GBC 2

GBC 1 I/O setting

SBA1

SBA2

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GBC 2 I/O setting:

SBA3

SBA30

SBA31

GBC2 I/O setting:

SBA1

SBA2

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SBA3

SBA30

SBA31

The status address of the Ethernet module was in variable mode while the status address of the GE-IP 90-30 system was in %I form. During the upgrade, the change should be minimized to ensure the operability of the site before and after upgrade is the similar. However, the status address for the GE-IP RX3i PACSystem must be changed because %I01905 and %I02017 are reserved for Genius Bus Controller role switching template.

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Refer to Table 9 for the setup of Ethernet modules for GE-IP 90-30 System and GE-IP RX3i PACSystem. Similar to the Genius Bus Controller, the setup for the Ethernet Modules for primary and secondary system will be exactly the same, thus, it will not listed twice. Table 9 Hardware Configurtion Setup for Ethernet Modules

GE-IP 90-30 System GE-IP RX3i PACSystem Status Address for Ethernet module 1 and its IP address

Status Address for Ethernet module 1 (in variable mode) and its IP address

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Status address for Ethernet module 2

Status Address for Ethernet Module 2

An additional function of the GE-IP RX3i PACSystem is that the RMX module transfer list can be setup so that the data can be synchronized between the master CPU and the slave CPU. In this project the total output used is setup in the transfer list so that the slave controller can be updated with the latest output status. Figure 33 The GB_Config Setup showed the setup of the RMX module transfer list for Primary PLC. The setup for RMX module transfer list for Secondary PLC is the mirror image of Primary PLC. The details of the input transfer point and output transfer point of the RMX module hardware configuration setup can be found in Section 8.1.3 Reflective Memory Xchange (RMX).

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9.3 HUMAN MACHINE INTERFACE (HMI) MODIFICATION

The upgrade of the hardware leads to changes in the logic and with this some points need to be removed or added to ensure the HMI page works as before. A significant modification was made to the existing HMI Login page compared to the existing Login with the aim to bring up more information that happens on site. It was found that, with the existing license key owned by the client, there is no room to allow for more information on the modules to be displayed on the HMI screens. However, after discussion with the client, a decision was made to upgrade the 300 points license key to 700 points. Section 9.3.1 Points Comparisonshows the points deleted and added and the reasons for deleting and adding explained.

9.3.1 POINTS COMPARISON

TABLE 10 EXISITING POINTS THAT BEING DELETED

Existing bits that being deleted

DIAG_STATUS_P1_C1 : Point that are not being used

DIAG_STATUS_P1_C2 : Point that are not being used

DIAG_STATUS_P2_C1 : Point that are not being used

DIAG_STATUS_P2_C2 : Point that are not being used

LANA_DROPS : Point that show which LAN is the master and is operating in existing system. This point is being removed due to changes in Ethernet Module status bits.

LANB_DROPS : Point that show which LAN is the master and is operating in existing system. This point is being removed due to changes in Ethernet Module status bits.

GBCA_STATUS : Point show the status of Genius Bus A on PLC A and PLC B in existing system. This point is being removed due to changes in Genius Bus controller Module status bits.

GBCB_STATUS : Point show the status of Genius Bus B on PLC A and PLC B in existing system. This point is being removed due to changes in Genius Bus controller Module status bits.

PLC_STATUS : show the status of PLC A and PLC B in existing

system. This point is being removed due to changes in Genius Bus controller Module status bits.

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TABLE 11 NEW CREATED POINTS

New points which been created

MODEP1 : Status of PLC A ( healthy bits, master/slave)

MODEP2 : Status of PLC B (healthy bits, master/slave)

STATUSP1C1 : Ethernet status on PLC A LAN A

STATUSP1C2 : Ethernet status on PLC A LAN B

STATUSP2C1 : Ethernet status on PLC B LAN A

STATUSP2C2 : Ethernet status on PLC B LAN B

DATASOURCE : Indicate which Ethernet LAN is taking control

PLCAGBCA31_STATUS : Genius Bus Status ( LAN A )

PLCAGBCB31_STATUS : Genius Bus Status ( LAN B )

PLCBGBCA30_STATUS : Genius Bus Status ( LAN A )

PLCBGBCB30_STATUS : Genius Bus Status ( LAN B )

DROP1LANA : healthy bit of drop1 on LAN A

DROP1LANB : healthy bit of drop1 on LAN B

DROP2LANA : healthy bit of drop2 on LAN A

DROP2LANB : healthy bit of drop2 on LAN B

DROP3LANA : healthy bit of drop3 on LAN A

DROP3LANB : healthy bit of drop3 on LAN B

PLCAPOWER1 : indicate the status of the Power Supply1

Module on PLC A

PLCAPOWER2 : indicate the status of the Power Supply2

Module on PLC A

PLCBPOWER1 : indicate the status of the Power Supply Module

on PLC B

PLCBPOWER2 : indicate the status of the Power Supply Module

on PLC B

ALARMDROP1 : virtual points that used for drop1 disconnected

alarming

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ALARMDROP2 : virtual points that used for drop2 disconnected

alarming

ALARMDROP3 : virtual points that used for drop3 disconnected

alarming

PLCARMX_LR : indication of PLC A RMX Local Ready LED

PLCARMX_LA : indication of PLC A RMX Local Active LED

PLCARMX_RR : indication of PLC A RMX Remote Ready LED

PLCARMX_RA : indication of PLC A RMX Remote Active LED

PLCBRMX_LR : indication of PLC B RMX Local Ready LED

PLCBRMX_LA : indication of PLC B RMX Local Active LED

PLCBRMX_RR : indication of PLC B RMX Remote Ready LED

PLCBRMX_RA : indication of PLC B RMX Remote Active LED

9.3.2 EXISTING LOGIN PAGE VS NEW LOGIN PAGE

The differences between the existing Login_form.cim and the new Login_form.com are shown in Figure 38 and Figure 39. In the existing Login_form.cim only status of PLC , GBC and drops were shown however in the modified version of Login_form.cim, the status of PLC, Ethernet status and its current communicating LAN, Genius Bus Controllers and its drops status, power supplies as well as RMX bits will be shown.

FIGURE 38 EXISTING LOGIN_FORM.CIM

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FIGURE 39 MODIFIED LOGIN_FORM.CIM

Maximized, Captive and No Exit Functionality

Figure 40 is the primary window that will be executed when the shortcut for the project as shown in Figure 41 was clicked. When the primary window is executed, the maximized, Captive and no exit function will be triggered.

FIGURE 40 THE PRIMARY WINDOW

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FIGURE 41 PROJECT SHORTCUT

The maximized, captive and no exit function can prevent the user from exiting the primary window in any way. Three commands as highlighted in Figure 42 are required to be added in to the properties of the project shortcut (Figure 41).

FIGURE 42 CIMVIEW COMMANDS

Table 12 explains each of the commands functionality introduced to the modified version of Primary page shortcut. The only way to execute the primary page is through the “Login” button.

TABLE 12 COMMANDS AND DESCRIPTION

Function Description

alwaysmaximized This function is to maximize the CimView window and user will not be able to resize the window.

captive Captive code will shut down the Explorer when the primary window is opened. These prevent the user to go below the primary window.

noexit When no exit is triggered, the screen could not be closed and the shortcut key(ALT+F4) to close the screen will also be removed

Clicking the Login button on the primary page will execute the Login_form.cim and the “Launch Task Manager” which can be found in the modified Login_form.cim as shown in Figure 39 will only pop out when “Engg Mode” is pressed and correct password was keyed in. The function of “Lunch Task Manager” was the only way to execute from the primary window and this is done via mouse up event as shown in Figure 43 which executes the window task manager.

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FIGURE 43 TASK MANAGER EXECUTION SETUP

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10. DESIGN TESTING

10.1 FAT DOCUMENT

Factory Acceptance Test is also known as FAT. The aim of the FAT document is to describe a method for verifying the correct operation of the proposed upgrading prior to field installation in order to gain acceptance from Client. To achieve this, Motherwell has proposed the use of the GE-IP RX3i platform configured as a redundant pair and the RX3i system will interface directly with the existing GE-IP Versamax Genius input/output modules. If project design requirements are met, the FAT document will be submitted for customer review. The FAT will be carried out once customer satisfied with the design. The FAT document will be produced for each of the Yara upgrade project. As mentioned before, the first project deals with the upgrade of the Yara IGG PLC while the second project deals with the small scale of upgrade on Yara CPU project.

The FAT document for upgrading of hardware and software for Yara IGG included the tests for the following sections:

- Testing of 90-30 PLC with I/O attached - Testing of RX3i PLC with I/O attached which include the technique of swap over

from 90-30 PLC to RX3i PLC.

The FAT document of the Ethernet module upgrade for Yara CPU consists of the hot insertion of Ethernet module in the primary and secondary PLC.

Each section in the FAT document included the detailed steps to test the redundacy of the system.

10.2 INTERNAL TESTING

Internal testing is the pre-FAT which used the FAT procedure document. The aim of the internal testing was to ensure the consistencies of the result and eliminate all the problems or errors either on the logic implemented or screen designed before the FAT was carried out. Any minor problems or errors during the FAT might leave a bad impact on the customer thus internal FAT is crucial to ensure FAT works as expected.

Some issues were discovered during the internal testing and there are described below:

Problem 1:

There was a flaw on the role switch code for the Ethernet redundancy. The logic was initially written so that when both of the Ethernet LANs on either PLC drops out, the role switches from one PLC to another would occur. The logic works perfectly however, it was discovered that the I/O devices will drop out if role switch is executed when the either of the GBCs on the opponent site was not healthy. Consequently, the code was modified to ensure that if any of the GBCs are not healthy, role switch of PLC due to the faulty Ethernet LAN will be disabled. Figure 44 shows the initial logic and Figure 45 shows the final logic implemented.

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FIGURE 44 ETHERNET REDUNDANCY CODE WITH FLAW

FIGURE 45 PERFECT ETHERNET REDUNDANCY CODE

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10.3 FAT TEST

The FAT test was performed by Jeff Hunter and the author at the Motherwell Office with a client representative from Yara. The entire test required to prove the redundancy function of the RX3i power supply, the RMX modules, the Ethernet module and the Genius bus controller were carried out. Once the FAT test was completed successfully, the client will signed off the FAT document. Any test failure was recorded in the Abnormal Operation section and completed overnight. If it is unable to be completed overnight, it will be included in the outstanding items list. Moreover burn in test which was required to leave the modules to turn on for at least 48 hours and still remain healthy was also be carried out.

During the FAT test, the client requested changes to the arrangement for the Login page and requested for more information to be displayed on the screen. Under the client supervision, the engineer responded to the questions from client and fulfilled the client’s request on the spot whenever possible. As an example, changing of the display of the screen and adding the RMX LEDs from Figure 46 to Figure 47 were requested. The engineers responded to the request and got the page done on the spot.

FIGURE 46 INITIAL VERSION OF FAT TEST LOGIN PAGE

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Figure 47 Finalized Login Page

Furthermore, the password for the ENGG mode was changed upon client’s request. Changing of the password can be done easily by changing the variable data. “SUPERPASS” is the variable which stored the password of the ENGG mode and it can be edited by right click on the variable and select the “Point Control Panel”, refer to Figure 48.

FIGURE 48 EDITING OF ENGG MODE PASSWORD

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11. CONLUSION

This project is about the upgrade from the GE-IP 90-30 Series Control system to the PACSystem RX3i. As a precursor to the work undertaken and to address the objectives of the projects, some questions were raised by the engineers that were involved in the project. These are:

a) Does the new upgrade enable the use of existing I/O configurations? b) What modification on the logic (code) is required? Existing logic shall be remain

the same unless necessary. c) Can the non standard Genius Bus redundancy code being replaced? If Yes, How? d) How was the upgrade of the Control system affect the SCADA page? Any big

changes required due to the upgrade? e) Will the upgraded code works exactly the same as existing code?

The RX3i PACSystem is so flexible that it maintains the same I/O investments while upgrading. The I/O does not have to be modified to accommodate the RX3i system since its footprint is the same as series 90-30. The existing series 90-30 can be used to migrate to the RX3i which has better throughput and more capacity. The RX3i system’s backplane is 250 times faster than the series 90-30 serial bus. The RX3i support redundant power supplies to ensure high availability.

The only code replaced was the non-standard Genius Bus role switching code. The status bits reserved for the standard Genius Bus role switching template were not used in the project and therefore did not cause any issues. No significant changes were required, but the Login page of the SCADA had to be modified significantly due to the request from the client. More alarms were put into the system so that they trigger for alerting the operators in the event of device failure. The upgraded system will work exactly the same as the existing system and on top of that, it also provides more points of failures to protect the I/O from failure.

12. INTERNSHIP REVIEW

The engineering internship outcome provides the opportunity to understand the fundamental technical skills and principles of control systems engineering and their application to complex open-ended engineering tasks and problems. From the day to day involvement with the project, the author has developed and enhanced her technical and problem solving skills.

During internship, technical experience and understanding of the knowhow were developed in the areas of:

a) PLC programming, specifically in GE Machine Edition Software. b) HMI design specially in GE Cimplicity environment c) In depth understanding of GE-IP 90-30 System and GE-IP RX3i PACSystem and

its hardware. d) Better understanding of networking and IT systems.

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13.0 REFERENCES

Department of Management. (n.d.). Internship in. Retrieved 09 15, 2012, from Internship Objectives: http://www.intech.mnsu.edu/mgmtintern/objectives.htm

GE GFK2222R. (2012, January). CPU Reference Manual. Retrieved 10 1, 2012, from http://support.ge-ip.com/support/index?page=docchannel&id=S:DO186&actp=search

GE GFK2413D. (2011). PACSystems RX3i. In Power Supply, 120/240VAC or 125VDC, 40 watts (p. June). GE.

GE, Genius Bus Template. (2012, April 23). RX3i Dual Bus Genius Quick Start. Retrieved 10 5, 2012, from GE Intelligent Platforms Automation Support: http://support.ge-ip.com

GE, GFK2308F. (2010, july). Hot Standby CPU Redundancy User's Manual. Retrieved 09 16, 2012, from GE Intelligent Platforms Automation Support: http://support.ge-ip.com/support/resources/sites/GE_FANUC_SUPPORT/content/staging/DOCUMENT/2000/DO2255/en_US/9.0/GFK2308F.pdf

GE, GFK2399D. (2011). PACSystem RX3i IC695PSA140. In Multipurpose 120/240 VAC or 125VDC Power Supply, 40 Watts (p. June). GE.

GE, GFK-2514M. (2012, June). PACSYStems RX3i IC695CRU320-EH. Retrieved 09 14, 2012, from GE Intelligent Platforms Automation Support: http://support.ge-ip.com/support/resources/sites/GE_FANUC_SUPPORT/content/staging/DOCUMENT/2000/DO2241/en_US/21.0/GFK2514M.pdf

GE,GFK 2308. (2009, july). PACSystem Hot Standby CPU Redundancy User Guide GFK2308. Retrieved 10 5, 2012, from GE Intelligent Platforms Automation Support: http://support.ge-ip.com/support/index?page=docchannel&id=S:DO2255&actp=search

GEGFK2224F. (2007). GFK2224F. GE Fanus Intelligent Platforms.

IEEE. (2012). Advancing Technology for Humanity. Retrieved 12 1, 2012, from IEEE.org: http://www.ieee.org/index.html

Information Sciences Institute, University of Southern California. (1981, September). Transmissison Control Protocl. Retrieved December 1, 2012, from Darpa Internet Program: http://www.ietf.org/rfc/rfc793.txt

National Instrument. (2002, 04 02). KnowledgeBase. Retrieved 12 01, 2012, from What are the differences between a standard CAT 5 Ethernet Cable and a crossover cable: http://digital.ni.com/public.nsf/allkb/34C3163EFAC9F30E86256B8F0060AD0C

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14. APPENDIX

APPENDIX A

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APPENDIX B

Site Checklist

Site checklist listed all the hardware(cables and etc) required and double confirm with the system upgrade requirement.

1) Check Power Supply cables log enough to reach back the power supply [ Confirmed, is long enough]

2) Check existing Genius Bus cables to ensure that it is long enough to reach the new GBC destination [confirmed]

3) Check size of Gap between RMX module [1 meter]

4) Check and measure the length of fiber optic that are required [1 meter]

5) Ask client about alarming of Power Supply faulty bits [Yes, alarm message shall be bring up when there is fault in power supply]

6) Check Control Room IGG “PC” + Fiber leads [checked]

7) Request for Din rail to mount media converter and switches [requested and confirmed that Din rail will be ready before commissioning]

8) Ask if require new CAT5 cables [ yes, client will prepare the new CAT5 cables]

9) Check IP addresses of PC’s for control room and substation [ confirmed]

10) Confirm that whether the access data base for data report is still required? [No, it can be removed]

11) Confirm with the client about the upgrade of the Cimplicity points number. [ Yes, point number will be upgrade form 300 points to the next level which is 700 points] Note: not enough points to create the alarm for RMX, Power Supply and Ethernet module thus upgrade is suggested.

12) Request for the the replace of single GPO with Doubles for extra Ethernet LAN. [Requested]

13) Confirm that is the Alarm database still needed? [Yes, the alarm database shall be remained]

14) Confirm the shutdown time that is available for the upgrade. [2 hours maximum]

15) Request to setup a PC from control room next to the PLC for CPU Ethernet upgrade. [Yes, this will be arranged]

16) Confirm the date for FAT test. [ Confirmed, 7th of November]

17) Confirm the date for commissioning. [Confirmed, 26th November is the earliest available date as plant will be very busy on startup before 26th November]

18) Ensure that the Modbus link to SCADA is read only. [Confirmed]