2007-20C0000 Rev A MAMS Description of Operation.doc

DESCRIPTION OF OPERATION

Integrated Machinery Alarm and Monitoring System, Tank Gauging System, and

Valve and Pump Automation

(MAMS)

Swath Program

VT Halter Marine Prepared for VT Halter Marine, Inc.

900 Bayou Casotte Parkway

Pascagoula, MS. 39581

Prepared by

Robichaux Automation and Control, Incorporated

Point of Contact Information

Dennis Robichaux, PhD

504-733-6891 dennis.robichaux@raaci.com

September 2, 2009 Rev A 2007-20C0000

T. Robichaux 10/2/08

T.Robichaux 10/26/09

Proprietary Notice

This document contains proprietary information and shall be used only in the best interest of Robichaux Automation and Control, Inc. No portion of this document may be reproduced or disclosed without the written approval of Robichaux Automation and Control, Inc.

TABLE OF CONTENTS

General Overview

Description of Operation

72.1 Visual Display Units

92.2 Remote IOs (RIO)

102.3 Engineer Alarm Panel and Stateroom Alarm Panel

112.4 Ethernet Networks

122.5 Software – MMI

132.6 Software – Control Algorithms

132.6.1 Console Operations

142.6.2 Attendance Monitor

142.6.3 Assistance Needed

142.6.4 MAMS Controls

142.6.5 Power Monitoring

152.7

EOT

152.8 Drop – In Equipment at FWD and AFT SCC

162.9 Tank Level Indicators

162.10 Miscellaneous

1 General Overview

Operation of the machinery alarm and monitoring system and tank gauging system (MAMS) provided by Robichaux Automation and Control, Inc. (RAACI) for the Swath program is described throughout this document. The MAMS is a computer based system consisting of the following visual display units (VDU): 5 workstations and 1 engineer alarm panel, all connected together over an Ethernet network. The VDU’s provide the operators and crew with a man machine interface (MMI) for both controlling and monitoring the plant. There are two Siemens 317-2DP PLCs physically located in the engineer’s operating station (EOS). These PLCs are responsible for gathering I/O data from the Remote IOs (RIO’s) and for performing control algorithms. Only one of the two PLCs is in control at any given time. The two PLCs negotiate control location via heartbeats between them. The MAMS consists of several RIO’s strategically located throughout the vessel so as to minimize cabling to field transducers. The RIO’s are networked back to the EOS using redundant Profibus Serial communications links.

The following page illustrates the MAMS system provided by RAACI. This diagram will be referenced throughout the description of operation.

Figure 1 System Diagram 2 Description of Operation

Refer to Figure 1 – System Diagram throughout description below.

2.1 Visual Display Units

The MAMS consists of five visual display units (VDU’s) –

EOS Console Workstation FWD SCC Workstation #1 (Pilothouse) AFT SCC Workstation #2 (Pilothouse) ACS Workstation Chief Engineer’s Workstation In addition, the MAMS includes remote monitoring at the following location - Mess Alarm Panel The pilothouse and EOS workstations are ABS approved 2.2 GHz Pentium computers. Each includes 1 GB Ram, 80 GB data logging hard drive, CD-RW/DVD, 8 GB flash drive and Windows XP Professional.

The pilothouse and the EOS workstations each include an ABS approved Comark 19” LCD. The Comark displays are dimmable to complete darkness.

In addition a Siemens 5.7” touchpanel is provided in the Mess for remotely alarming engine room alarms as required by ABS.

All VDU’s, including the remote alarm panel, are the man machine interface (MMI) to the MAMS. The VDUs include graphical screens for monitoring and controlling the various MAMS equipment. The MAMS MMI includes a menu toolbar for navigating through the screens. Each screen includes a mini alarm summary window for alerting the operator to the most recent alarms. The MMI was developed by RAACI using Wonderware Intouch software.

Each of the workstations and alarm panel run the MAMS MMI software developed by RAACI. The MAMS data represented on the various MMI’s is retrieved from the PLCs over the Ethernet network. In addition, any control actions initiated on the MMI at the EOS Console, pilothouse, and/or Chief Engineer’s VDU is propagated over the Ethernet network to the PLC in control at the time of the control action. In addition to running the MAMS control algorithms, the PLCs also run other software. The PLCs handle modbus serial communication with the Cat PL1000E modules at each propulsion main engine, and modbus serial communication with the Cat EMCP 3 modules at each ship service generator.

The PLCs run the MAMS control algorithms and various communication drivers developed by RAACI with the Step 7 software by Siemens.

At any given time either of the EOS Console PLCs will be in control of the MAMS plant. The PLC in control will handle polling the RIO’s and the various serial equipment for data, commanding control actions, running control algorithms, and updating the various MMIs. The PLCs negotiate control based on heartbeats existing between the two PLCs over a dedicated network interconnection. The PLC in control keeps the backup PLC in sync using the dedicated network interconnection. The MAMS MMI software will alert the operator of which PLC is in control at all times. An alarm will sound notifying the operator that a PLC has taken control away from the other PLC. Because of the synchronization between the two PLCs over the dedicated network interconnection, hot back ups are bumpless.

The EOS Console PLCs each include an Ethernet communications processor card within their respective racks. The Ethernet communication processor card in each connects to the workstations and the remote alarm panel. The Pilothouse, ACS, EOS and Chief’s workstations are networked over a redundant Ethernet 100Mbps network via Ethernet hubs. The Ethernet hubs are connected to both PLC’s in the EOS console. Each network connection is monitored for status and alarmed in the event of a failure. The Ethernet hub includes isolated links so that a failure on one network hub will not affect the entire network.

The EOS Console PLCs each include a profibus communications processor card within their respective racks. The Profibus communications processor card in each EOS PLC rack is used as a dedicated interconnection of the two PLC’s for hotbackup redundancy purposes. The two PLCs communicate with each other over this link, thereby keeping the reserve in a state which allows a seemless switchover in the event of a failure to the master.

The EOS Console PLCs also include “on-board” profibus ports for connecting to the MAMS RIO. The MAMS RIO profibus network is a redundant daisy chain to each of the RIO enclosures. Within several of the remote IO racks are serial expander cards for serial communicating with the Cat PL1000E modules using modbus.

2.2 Remote IOs (RIO)

There are a total of 5 RIO’s strategically placed throughout the vessel for interfacing with the various MAMS I/O.

· 2007-20A6150 – Main Machinery Room Port Side Aft RIO

· 2007-20A6200 - Main Machinery Room Stbd Side Aft RIO

· 2007-20A6050 – Main Machinery Room Port Side Fwd RIO

· 2007-20A6100 – Main Machinery Room Stbd Side Fwd RIO

· 2007-20A2000 – EOS Console The RIO’s are located so as to minimize transducer cabling. The RIO’s are each connected in a redundant daisy chain fashion back to the EOS Console PLCs using two Profibus copper cable pairs. The Profibus redundant channels are distributed throughout the vessel to each RIO. Since there are two separate Profibus cables to each RIO, a single failure will not disable an RIO.

Each RIO is powered by battery backed up 24VDC from the EOS Console.

The RIO’s include a variety of I/O cards for interfacing with different transducers including digital inputs, digital outputs, relay outputs, RTD inputs, 4-20mA inputs, analog outputs, and serial. The digital inputs are wired in fail safe mode – closed is normal and open is alarm. The analog inputs are calibrated prior to delivery and do not need to be re-calibrated periodically or field calibrated. Refer to the RAACI schematics for transducer hook-up information.

· 2007-20A6150 – Main Machinery Room Port Side Aft RIO

· Emergency Generator Monitoring

· Ship Service Generator Monitoring

· Steering Gear Monitoring

· Reduction Gear Monitoring

· Tank Level Monitoring

· Modbus Serial Network: Port Propulsion Main Engine (Cat PL1000E)

· Sea Water

· Water Tight Doors

· 2007-20A6200 - Main Machinery Room Stbd Side Aft RIO

· Ship Service Generator Monitoring

· Steering Gear Monitoring

· Reduction Gear Monitoring

· Tank Level Monitoring

· Modbus Serial Network: Stbd Propulsion Main Engine (Cat PL1000E)

· Sea Water

· Water Tight Doors

· 2007-20A6050 – Main Machinery Room Port Side Fwd RIO

· Tank Level Monitoring

· Fire and Bilge Pump Monitoring

· Water Tight Doors Monitoring

· Bow Thruster Monitoring

· HVAC Monitoring

· Ballast Valve ASI Network Monitoring and Control

· 2007-20A6100 – Machinery Room Stbd Side Fwd RIO

· Fire Main Monitoring

· Tank Level Monitoring

· Bilge Monitoring

· Water Tight Door Monitoring

· Ballast Valve ASI Network Monitoring and Control

· 2007-20A2000 – EOS Console RIO

· Battery and Power Supply Monitoring

· Switchboard Monitoring

· EOT Failure Monitoring

· Emergency Generator Monitoring

· Shaft RPM Signals

· Engine RPM Signals

2.3 Engineer Alarm Panel and Stateroom Alarm Panel

There is one engineer alarm panel (EAP):

· Mess Room (5.7” Touchpanel) There is one stateroom alarm panel (SAP):

· Chief Engineer’s Horn The EAP and SAP alert the crew to machinery plant alarms as required by ABS. The alarms flash when activated and sound with a constant tone. The Fire alarm flashes when activated, but sounds a unique warble tone.

If an alarm at the EOS remains unacknowledged for 2 minutes, then the Assistance Needed Alarm will indicate and sound at the EAP and SAP.

The alarms at the EAP and SAP are acknowledged at the EOS Console. The alarms can not be acknowledged from the EAP or SAP directly. However the EAP or SAP horn can be silenced from the EAP or SAP.

The Chief Engineer alarm panel includes a 19” workstation and LCD and alarm horn. The horn works independent of the workstation. Thus the workstation can fail and the alarm horn will still sound.

Each alarm panel includes two horn test buttons, which test the two different tones – machinery plant alarm and fire. These buttons should be exercised periodically to ensure continued operation of the panel.

The stateroom alarm panel includes a watch call feature. The operator can use the MMI at any workstation to call either the chief engineer or the assistant engineer. The operator selects the engineer at the workstation MMI, and the SAP watch call indicator at the alarm panel will illuminate in green and the horn will sound. The engineer can acknowledge the watch call at the SAP by pressing the Watch Call Ack pushbutton.

The EAP/SAP panels are powered with battery backed up 24VDC derived at the SCC.

2.4 Ethernet Networks

The MAMS uses two independent Ethernet networks for normal communications. The MAMS will alarm on the MMI a failure of any of the Ethernet channels.

The redundant Ethernet networks, Ethernet Network #1 & #2 are dedicated to communication with the following devices:

· All MAMS VDU’s In the event of a communication failure on one of the Ethernet lines, the MAMS will automatically switch communications over to the respective backup Ethernet line. The operator will receive an alarm describing the failure of the communications Channel.

All VDUs are connected to the EOS PLC’s via the Ethernet network. Each VDU Ethernet cable is wired to Ethernet hubs located in the EOS console. The Ethernet hubs are wired independently to the two PLC’s located in the EOS console. For increased survivability the Ethernet hub includes isolated Ethernet ports. A failure in one cable (either to a VDU or to the EOS console) does not affect the remaining Ethernet VDU network.

The Ethernet hub is intelligent in that each message is confirmed before retransmission including bit retiming and bit oversampling. Corrupt messages are removed from the network at the hub.

The VDU Ethernet network is configured as illustrated below in the System Diagram.

2.5 Software – MMI

A number of mimics are included to reflect the actual plant and the corresponding location of monitoring points. Mimics are included in detail for each system as well as overview mimics for ease of use.

The individual alarm displays are typically gray while in a normal state. The alarm displays flash yellow and sound an audible horn when an alarm is active. The alarm continues to flash and sound until acknowledged by the operator. If the alarm condition persists, after it is acknowledged by the operator, the indicator displays steady in yellow and the horn is silenced. A normal condition returns the indicator to gray. Each new alarm reactivates the audible horn and flashes yellow the respective alarm window.

All control functions available on the MMI are password protected. There are several levels of password protection with the administrator password and chief engineer password having full system access and control.

Each screen includes a mini alarm summary window in the bottom right hand corner. The mini alarm summary window alerts the operator to the most recent six alarms. Those six alarms appear on the screen simultaneously in a tabular format. In addition, the operator has the ability to scroll, with the up and down arrows, throughout all active alarms. Each alarm includes the alarm name and type, the time and date of occurrence. If the alarm print is red it means that the alarm is active and unacknowledged. If the alarm print is blue it means that the alarm has returned to normal but is not acknowledged and if the alarm print is black the alarm is active and acknowledged. Alarms activate independently of one another, meaning one alarm will not prevent or inhibit another from occurring. The system is not limited as to how many alarms can occur or be active simultaneously. All alarms include visual indication, as well as audible. The machinery space includes beacons and horns to alert the operator in the machinery room to an active unacknowledged alarm at the EOS Console.

Miscellaneous screens are included with the MAMS system for viewing alarm logs, system status/communication status, operator rights and logging into the system.

The various screens allow the operator to monitor all parameters coming into the MAMS including pressures, temperatures, tank levels, and status indications. In addition, the screens give the operator the ability to control the various MAMS equipment. Controls may include pumps and valves.

2.6 Software – Control Algorithms

The EOS PLCs run the MAMS control algorithms developed by RAACI with the Step 7 software by Siemens. Only one PLC is running the algorithms at any given time. The other PLC monitors the “in control” PLC and takes over in the event of a failure. In the event of a failure the failed PLC should be repaired and restored to its normal operating state. The newly replaced PLC will now act as a back up PLC.

2.6.1 Console Operations

The MMI includes pushbuttons for periodically testing the horn. The horn test pushbutton will audibly sound the horn in a constant tone. The operator should periodically use the test buttons to confirm the functionality of the horn. Horn test at the EOS console will also test the horns and beacons in the machinery space.

The acknowledge pushbutton can be used to acknowledge alarms on the MAMS MMI. Alarms acknowledged at one workstation do not acknowledge alarms at other workstations with the exception of the EOS console. The MAMS MMIs in the EOS console will acknowledge the active alarms at all other MMIs.

2.6.2 Attendance Monitor

The operator is required to periodically “check-in” by pressing the Engineer Report PB every 30 minutes. If the operator has not pressed the Engineer Report PB within the past 25 minutes, the Engineer Report PB will flash and the horn will sound. If the operator has not pressed the Engineer Report PB within the past 30 minutes, an additional 5 minutes from the time that the Engineer Report PB began flashing, the Failed To Report indicator will flash and the horn will continue to sound. In the event of a Failed To Report condition, the assistance needed horns will also sound and the assistance needed indicators on the EAP/SAP’s will alarm.

2.6.3 Assistance Needed

The MMI includes an Assistance Needed pushbutton. The assistance needed pushbutton activates the assistance needed and the assistance needed alarms at the EAP and SAP.

2.6.4 MAMS Controls

The MMI includes several pump and valve controls. These pumps and valves include:

· Ballast Valve ASI Network Monitoring and Control

· Fire Pump Controls

· Sea Water Pump Controls

· Main Engine Start/Stop Control

· Bilge System Controls

2.6.5 Power Monitoring

The MAMS system monitors the 24VDC distribution system and provides alarms for battery low voltage and power failure. The MAMS MMI is configured to alarm on low battery voltage. The following power monitoring is included:

· 24V MISSION EQUIPMENT Power Supply - Low Voltage

· 24VDC Bridge Equipment Battery Charger 24BCP1A – Fault

· 24VDC Bridge Equipment Battery Charger 24BCP1A - Low Voltage

· 24VDC Bridge Equipment Battery Charger 24BCP1B – Fault

· 24VDC Bridge Equipment Battery Charger 24BCP1B - Low Voltage

· RIO PORT, AFT POWER FAILURE ALARM

· RIO PORT, FWD POWER FAILURE ALARM

· RIO STBD, AFT POWER FAILURE ALARM

· RIO STBD, FWD POWER FAILURE ALARM

· Emer. Genset 12VDC Battery Charger 12BC4 – Fault

· Emer. Genset 12VDC Battery Charger 12BC4 - Low Voltage

· EOS Alarm System Emerg. Power Fail-Alarm

· EOS Alarm System Normal Power Fail-Alarm

· Port Engine Rm 24VDC Battery Charger 24BC2 – Fault

· Port Engine Rm 24VDC Battery Charger 24BC2 - Low Voltage

· Port EOT Power Failure

· SCC Alarm System Emerg. Power Fail-Alarm

· SCC Alarm System Normal Power Fail-Alarm

· STBD Engine Rm 24VDC Battery Charger 24BC3 – Fault

· STBD Engine Rm 24VDC Battery Charger 24BC3 - Low Voltage

· Stbd EOT Power Failure

· BT Control Volt 24V DC-Failure

· BT Emergency Supply 24V DC –Failure

· Scientific 30 K VA SCUPS 1 – Summary Alarm

· Scientific 30 K VA SCUPS 2 – Summary Alarm

· Scientific 30 K VA SCUPS 3 – Summary Alarm

· UV PURIFIER POWER AVAILABLE

2.7 EOT

Also included with the MAMS system on the Aft SCC is the Port and Starboard engine order telegraph (EOT). There are EOT’s located at the Aft SCC and the FWD SCC.

2.8 Drop – In Equipment at FWD and AFT SCC

Drop-in equipment is provided for both the FWD and AFT SCC consoles. This equipment includes two LCDs, computers and a redundant power panel in the FWD SCC and one LCD and computer in the AFT SCC. All control and monitoring functions provided at the EOS Console are also provided at the SCC consoles. The control functions are password protected.

The FWD SCC also includes Port and Starboard EOT’s. The FWD SCC EOT’s operate in conjunction with the AFT SCC EOT’s.

2.9 Tank Level Indicators

The RAACI MAMS MMI includes tank level indications at all workstations. This tank level monitoring includes fuel oil tanks, fresh water, lube oil, dirty oil tank, etc.

The RAACI MAMS monitors the various tank levels through RIO’s throughout the vessel. The tank level is then linearized in the MCC PLCs Step 7 software.

2.10 Miscellaneous

The RAACI MAMS includes six machinery space horns and beacons. Alarms at the MAMS will sound the console horns as well as the machinery space horns and illuminate the machinery space beacons.

RAACI

Robichaux Automation and Control, Incorporated

Rev A 2007-20C0000

Rev A 2007-20C0000

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