Maintenance Programming

Problems

Plant processes and equipment often change, requiring new solutions which must then be integrated with an existing automation system.

Solutions

Install, Replace, or Modify Communication Networks

• Upgrade Siemens Tiway network to a TCP/IP network.
• Create new DH+ network to allow SCADA system to communicate with a Thermal Oxidizer.
• Install wireless network to allow mass flow meter to communicate via radio modem.
• Install and program converters to allow PC to gather data via TCP/IP-to-Modbus network.
• Install and program new scanners and adaptors to create a Remote I/O network.
• Install leased-line modems for a master-slave DF1 network.
• Install and program communication cards so various PLCs can communicate via Modbus to gas chromatographs, power management relays, chemical injection skids, flow meters, and variable speed drives.
• Install various routers, switches, and firewalls to manage TCP/IP network.
  

Replace Relay-based Controls with PLC-based Controls

• Flare ignition system.
• Refrigeration compressor operation at an LTS plant.
• LACT shipping sequence for an oil pipeline.
• Gas compressor operation.
• Fire pump control.
• Hydroelectric dam flood-control sequence.
• Vapor recovery compressors with lead-lag sequencing.
  

Install Additional PLCs onto Existing Automation Networks

• Three expansion PLC bases for new instrumentation at an urban oil lease.
• New PLC for motor control and alarm annunciation at an Amine Plant.
• New PLC for a Thermal Oxidizer.
• Fifty-three PLCs for a water injection system.
• New PLC for a CO2 plant.
• New PLC for a LACT (custody transfer) skid.
• Three new PLCs to control an assembly line at an automotive plant.
• New PLC for a vapor recovery system.
• New PLC for a chemical injection skid.
  

Install Additional Field Equipment and Integrate with PLC and HMI

• Meteorological station to monitor atmospheric conditions to meet air quality standards.
• Analog input/output cards and PID loops for process control.
• Fire, combustible gas, and toxic gas monitoring systems.
• Variable speed drives for motor control.
  

Modify PLC Ladder Logic

• Add programming to calculate gas and liquid flow rates based on differential pressure across orifice plate, taking into account temperature, pressure, and specific gravity correction.
• Re-create ladder logic documentation for databases that have become corrupted.
• Create new controls which allow Operators to test their safety devices under controlled conditions without shutting down their plants.
• Modify the programming for a driller's console on an offshore drilling rig.
  

Provide Detailed Electrical Drawings

• PLC drawings
• Control Panel drawings
• Interconnection drawings
• Motor control drawings
• Networking drawing

Results

• Increased product quality.
• More productive employees.
• More reliable equipment.
• Better able to document environmental compliance.

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Details

PLCs:

• Allen Bradley: SLC500, PLC5, MicroLogix and ControlLogix families
• Direct Logic: 06 series, 205 series, and 405 series
• Siemens: TI 545

HMIs:

• Wonderware: InTouch 7.11 through 9.5
• Iconics: Genesis

Remote Alarming:

• Wonderware: SCADAlarm 6.0 (to operator pagers)

Data Historian:

• Wonderware: InSQL Server

Other Components Integrated through SCADA:

• ABB RTU - gas chromatograph data
• ABB TotalFlow - 6713 flow meter
• DetTronics - flame detection panel
• Lantronics - protocol converters
• Honeywell - corrosion monitor
• Meteorological Station
• Micro Motion - mass flow meter
• MDS - frequency-hopping radios
• Motorola - 202T modem
• Moxa - Ethernet switches, routers
• MSA - combustible and toxic gas detection panel
• Multilin - power management relay
• Notifier - fire alarm panel
• PCAnywhere - remote PC access
• ProSoft communication modules - 3150-MCM, MVI46-MNET, MVI46-MCM
• SCADApack - Daniels gas chromatograph data
• Security Camera (web enabled)
• SonicWall - hardware firewall
• Systron Donner - fire detection panel
• United Security Products AD-2000 - paging equipment
• Variable Speed Drives
  • Allen Bradley
  • Centrilift
  • Toshiba
  • WEG
• YZ - NJEX 7300G chemical injection skid

Operating Systems:

• WindowsNT service pack 4
• WindowsXP service pack 2
• Windows 2003 Server, mirrored hard-drives, with RAID-3 protection

Networking, Protocols, and Drivers:

• AB1784KT (Data Highway Plus driver)
• ABTCP (AB Ethernet driver)
• CTI-2572 (TI Ethernet driver)
• DF1
• DSData (OPC and DDE communication driver)
• KEPDirect (OPC Server)
• Modbus RTU
• RSLinx
• WWRSLinx
• TCP/IP
• K-Sequence
• EIA-568A
• RS-232
• RS-485