RAACI IMAMS TGS VPA MAMS.pdf

OPERATING MANUAL

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

504-834-1167 dennis.robichaux@raaci.com

October 15, 2009 Rev -

2007-20T0000

REV Description of Change Signature and Date

RAACI

R o b i c h a u x A u t o m a t i o n a n d C o n t r o l , I n c o r p o r a t e d

REV - 2007-20T00002

- Released for Production Darryl Case

DR

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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.

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TABLE OF CONTENTS

1 Introduction 6 2 General Overview 6

2.1 Redundancy 7

3 Description of Major Hardware 9

3.1 Visual Display Units 9

3.2 PLCs 10

3.3 Remote IOs (RIO) 13

3.3.1 Input/Output Modules 16

3.3.1.1 SM331 AI 8x12 16

3.3.1.2 SM332 AO 4x12 18

3.3.1.3 SM321 DI 32x24VDC 19

3.3.1.4 SM322 DO 16x24VDC/0.5A 19

3.4 Engineer Alarm Panel and Stateroom Alarm Panel 19

3.5 Profibus Networks 20

3.5.1 Profibus CP342-5 21

3.5.2 ET200M Interface Module IM153-2 22

3.6 Ethernet Networks 25

3.6.1 Ethernet Communications Processor CP-343-1 Lean 26

3.7 Serial Networks 29

3.8 Equipment at EOS Cabinet 31

3.8.1 Sonalert 31

3.8.2 Misc 31

3.9 Drop – In Equipment at FWD and AFT SCC 31

3.10 Tank Level Indicators 32

3.11 Miscellaneous 32

4 Description of Software 32

4.1 Software – MMI 32

4.2 Software – Control Algorithms 33

5 Description of Operation 33

5.1 System Start-up 33

5.2 System Shut-down 35

5.3 Console Operations 36

5.4 Attendance Monitor 36

5.5 Assistance Needed 36

5.6 MAMS Controls 36

5.7 Power Monitoring 37

5.8 Mimic Screens 37

5.8.1 Navigation Bars 37

5.8.1.1 Security 39

5.8.2 Typical Data Displays 43

5.8.3 Typical Alarm Windows 44

5.8.4 Typical Dynamic Valve Controls 46

5.8.5 Typical Dynamic Pump Controls 46

5.8.6 Typical Data Entry Control 47

5.8.7 Automated Ballast Control 49

5.8.8 Mess Alarm Panel 54

5.8.9 “PROPULSION” Menu 54

5.8.9.1 “PORT MAIN ENGINE” Screen 55

5.8.9.2 “STBD MAIN ENGINE” Screen 55

5.8.9.3 “CANARD AND STEERING” Screen 56

5.8.9.4 “REDUCTION GEAR” Screen 56

5.8.9.5 “BOW THRUSTER” Screen 57

5.8.10 “BILGE/BALLAST” Menu 57

5.8.10.1 “BILGE ALARMS” Screen 57

5.8.10.2 “BALLAST TANKS” Screen 58

5.8.10.3 “BALLAST PORT” Screen 59

5.8.10.4 “BALLAST STBD” Screen 59

5.8.10.5 “AUTOMATED BALLAST” Screen 60

5.8.11 “ELECTRIC PLANT” Menu 62

5.8.11.1 “SHIPS SERVICE GENERATOR - PORT” Screen 62

5.8.11.2 “SHIPS SERVICE GENERATOR - STBD” Screen 63

5.8.11.3 “BUS - TIE MAIN DISTRIBUTION” Screen 64

5.8.11.4 “EMERGENCY GENERATOR” Screen 65

5.8.12 “INSULATION MONITORS” Screen 65

5.8.12.1 “POWER SUPPLY” Screen 66

5.8.13 “AUXILLIARIES” Menu 67

5.8.13.1 “SEAWATER PUMP” Screen 67

5.8.13.2 “FIRE” Screen 68

5.8.13.3 “WASTE” Screen 68

5.8.13.4 “OIL TANKS” Screen 69

5.8.13.5 “POTABLE WATER” Screen 69

5.8.13.6 “WATERTIGHT DOORS” Screen 69

5.8.13.7 “MISC (MSD, REFR, AIR)” Screen 70

5.8.14 “SYSTEMS” Menu 70

5.8.14.1 “RIO STATUS – PORT AND STBD” Screen 71

5.8.14.2 “RIO STATUS – EOS” Screen 74

5.8.14.3 “COMMUNICATION STATUS” Screen 75

5.8.14.4 “PLC REDUNDANCY” Screen 76

5.8.14.5 “AS-i COMMUNICATION STATUS” Screen 77

5.8.14.6 “ALARM SUMMARY” Screen 78

5.8.14.7 “EVENT HISTORY” Screen 78

5.8.14.8 “LOG ON” Screen 79

5.8.14.9 “TRENDING” Screen 79

5.8.14.10 “POINT CONFIGURATION” Screen 80

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1 Introduction This document describes the hardware, software and operation of the machinery alarm and monitoring system and tank gauging system (MAMS) provided by Robichaux Automation and Control, Inc. (RAACI) for the NOAA SWATH program. The reader should be familiar with the general operation of Microsoft Windows operating systems.

2 General Overview The MAMS is a computer based monitoring and control system. It consists of several visual display units communicating with a redundant pair of Siemens PLC’s, which are communicating with several remote I/O devices and several Caterpillar serial communication links.

Included in the system are six visual display units (VDU), which include four 19” LCDs with workstations, one multifunction stateroom computer and one engineer alarm panel, all connected together over an ethernet network.

The VDUs 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 redundant 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 by monitoring each other’s heartbeats. The MAMS consists of several RIOs strategically located throughout the vessel so as to minimize cabling to field devices. The RIOs are networked back to the EOS using redundant Profibus Serial communications links.

The advantages of the RAACI MAMS include the following:

A uniform comprehensive system that assumes all control and monitoring functions and minimizes interface problems.

A modular design that simplifies maintenance and expansion problems.

An increase in system availability and operational reliability through the utilization of standard Off the Shelf Siemens components designed for offshore use.

An increase in system reliability due to the redundant processors and redundant serial networks.

Reduced installation costs due to the remote I/O (RIO), by reducing cabling.

Ease of operation due to the well-designed Man Machine Interface (MMI).

An open communications system that allows communication with other computer systems such as the Caterpillar CAT PL1000E and CAT EMCP 3.3.

2.1 Redundancy

Fault-tolerant design refers to a method for designing a system so it will continue to operate, at a reduced level (also known as graceful degradation), rather than failing completely, when some part of the system fails. The term is most commonly used to describe computer-based systems designed to continue more or less fully operational with, perhaps, a reduction in throughput or an increase in response time in the event of some partial failure. That is, the system as a whole is not stopped due to problems either in the hardware or the software. A structure is able to retain its integrity in the presence of damage due to causes such as fatigue, corrosion, manufacturing flaws, or impact.

Each component, in turn, can continue to function when one of its subcomponents fails, this will allow the total system to continue to operate.

Redundancy means having backup components which automatically "take over" should one component fail. Providing fault-tolerant design for every component is normally not an option. In such cases the following criteria may be used to determine which components should be fault-tolerant:

How critical is the component?

How likely is the component to fail?

How expensive is it to make the component fault-tolerant?

Hardware fault-tolerance sometimes requires that failed parts can be changed out with new ones while the system is still operational. Such a system implemented with a single backup is known as single point tolerant, and represents the vast majority of fault-tolerant systems. In such systems the mean time between failures should be long enough for the operators to have time to fix the failed devices before the backup also fails. It helps if the time between failures is as long as possible, but this is not specifically required in a fault-tolerant system.

The RAACI MAMS utilizes this redundancy by using redundant PLCs, redundant communications interface components and redundant communications cabling.

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

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3 Description of Major Hardware Refer to Figure 1 – System Diagram throughout the description below.

3.1 Visual Display Units

The MAMS consists of five visual display units (VDU’s) with operator monitoring and control capability and one VDU with monitor only capability.

The five VDU’s with operator monitoring and control capability are at the following locations:

EOS Console Workstation FWD SCC Workstation (Pilothouse) AFT SCC Workstation (Pilothouse) ACS Workstation Chief Engineer’s VDU

The VDU with monitor only capabilities are at the following location:

Mess Alarm Panel

The full graphic environment of the VDUs can be operated by the touch of a finger at the Mess Alarm touch-screen panel or a mouse/track ball at the other stations. Quick access to all ships information is available with the clear and easy to understand screen presentations. Ships functions can easily be controlled and monitored because the operator can see on the screens what is actually happening in the system.

The pilothouse, ACS and EOS workstations are ABS approved 2.2 GHz computers. Each includes 1 GB Ram, 80 GB data logging hard drive, CD-RW/DVD, 8 GB flash drive, two Ethernet ports for communication with the redundant PLC’s, and Windows XP Professional operating system.

The displays for the pilothouse, ACS and EOS workstations each include an ABS approved 20” LCD. The displays are dimmable to complete darkness.

The Chief Engineers VDU is an OptiPlex 360 Minitower base computer, with an Intel Celeron Processor 440, 2 GHz, 512 K, 800 MHz FSB. It has a 1.0 GB DDR2 Non-ECC SDRAM, 800 MHz. The hard drive is 80 GB 7200 RPM SATA 3.0 Gb/s and 8 MB Data Burst. It has a 16X DVD +/- RW SATA Roxio creator. The monitor is a 20” wide screen flat panel. The computer has two Ethernet com ports for communication with the redundant PLC’s, and Windows XP Professional operating system.

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

All VDU’s including the remote alarm panels 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 pull down menu system 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, VDUs and alarm panels run the MAMS MMI software developed by RAACI. The MAMS data represented on the various MMIs is retrieved from the PLCs over the Ethernet network. In addition, any control actions initiated on the MMI at the EOS Cabinet, Pilothouse, ACC, and/or Chief Engineer’s VDU is propagated over the Ethernet network to the PLC in control at the time of the control action.

3.2 PLCs

Processing is accomplished with a redundant pair of Siemens CPU317-2DP PLCs, of the Simatic S7-300 family.

The PLCs run the MAMS control algorithms and various communication drivers developed by RAACI with the Siemens’ Step 7 software. The PLCs handle Modbus serial communication with the Cat PL1000E modules at each propulsion main engine and the Cat EMCP3.3 modules at each of the two ship service generators. The PLCs also handle the AS-I communications for the ballast valves.

At any given time either of the EOS Cabinet PLCs will be in control of the MAMS plant.

The PLC in control will handle polling of the RIOs and the various serial and AS_I equipment for transferring data, commanding control actions, running control algorithms, and updating the various MMIs. The PLCs negotiate control based on the 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 as to which PLC is in control at all times.

An alarm will sound notifying the operator if one 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 and change over are bump less.

The EOS Cabinet PLCs include Ethernet communications cards within their respective racks. The Ethernet communications cards connect to the VDU Ethernet network. The VDUs are networked over an Ethernet 100 Mbps network via two Ethernet Hubs. Each VDU has two dedicated Ethernet communication links to the Ethernet hubs. The hubs are located in the EOS cabinet. One Ethernet hub is connected to each PLC in the EOS cabinet. Each network connection is monitored for status and alarmed in the event of a

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communication failure. The Ethernet hubs include isolated Ethernet links so that a failure on one network will not affect the entire Ethernet network.

The EOS Cabinet PLCs also include “on-board” profibus ports for connecting to the MAMS RIO’s. 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 communication with the Cat PL1000E and EMCP 3.3 modules using Modbus or AS-I communications with the ballast valves.

In order for the PLCs to communicate with each other and with the other components in the system they must be assigned a unique address. The addresses of the PLCs are set in the Step 7 software by the programmer.

The memory modules in the PLCs are SIMATIC Micro Memory Cards (MMC). MMCs can be used as load memory and as portable storage medium.

Note:

These CPUs do not have an integrated load memory and thus require a SIMATIC Micro Memory Card for operation.

The SIMATIC Micro Memory Card ensures maintenance-free and retentive operation of the CPUs.

Caution!

Data on a SIMATIC Micro Memory Card can be corrupted if you remove the card while it is being accessed by a write operation. In this case, you may have to delete the SIMATIC Micro Memory Card on your PG, or format the card in the CPU.

Never remove a SIMATIC Micro Memory Card in RUN mode. Always remove it when power is off, or when the CPU is in STOP state, and when the PG is not writing to the card. When the CPU is in STOP mode and you cannot determine whether or not a PG is writing to the card (e.g. load/delete block), disconnect the communication lines.

Figure 3.2.1.3.1

General error and status displays of the CPU 317-2DP are shown in Table 3.2.1.3.1.

Table 3.2.1.3.1

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Table 3.2.1.3.2 shows the LED status of the CPU317-2DP.

Table 3.2.1.3.2

Table 3.2.1.3.3 shows the Bus Error LED status of the CPU317-2DP.

CPU LED designation Color Meaning 317-2DP BF1: red Bus error at interface1 (X1) 317-2DP BF2: red Bus error at interface1 (X1)

Table 3.2.1.3.3

Mode selector switch settings are shown in Table 3.2.1.3.4.

Mode Selector Switch Settings

Table 3.2.1.3.4

3.3 Remote IOs (RIO)

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

2007-20A2000 – EOS Console RIO 2007-20A6050 - Forward Port Side RIO

2007-20A6100 – Forward Starboard Side RIO 2007-20A6150 – Aft Port Side RIO 2007-20A6200 – Aft Starboard Side RIO

The RIOs are located so as to minimize field device cabling. The RIO communications are connected in a redundant daisy chain fashion back to the EOS Cabinet 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 a RIO.

Each RIO is redundantly powered by 24 VDC from the 24 VDC Distribution Systems at the EOS Console. The vessels normal 120 VAC Distribution Panels provide power for the primary 24 VDC power supply, the vessels emergency 120 VAC Distribution Panels provide power for the secondary 24 VDC power supply and the EOS provides a 24 VDC battery backup, all for powering the RIOs.

The RIOs include a variety of I/O cards for interfacing with different field devices, such as transducers, switches, relays, control valves, etc. These include digital inputs, digital outputs, relay outputs, RTD inputs, 4-20mA inputs, analog outputs, AS-I links and serial links. The digital inputs are wired in fail safe mode – a closed contact is normal and an open contact is alarmed. 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.

The following are the five RIO units with their control and monitor functions:

2007-20A2000 – EOS Console RIO

– Power Supply Monitoring

– Emergency Generator Monitoring

– Battery Voltage Monitoring

– Switchboard Monitoring

– EOT Monitoring

– Fire Monitoring

– Reefer Locked In Monitoring

– Horns/Beacons Control

– Bridge Wing Instruments Control

– Modbus Serial Interface for Engine and Shaft 2007-20A6050 – Forward Port Side RIO

– Port Fire/Bilge/Ballast Pump Monitoring and Control

– Port Bilge Level Monitoring

– Port Draft Monitoring

– Port Tank Level Monitoring

– Bow Thruster Monitoring

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– Port Watertight Door Monitoring

– Port Fuel Oil Transfer Monitoring and Control

– Port Fresh Water Pump Monitoring

– Port Ventilation Monitoring

– Port Canard Monitoring

– Port power Supply monitoring

– Port Misc. Systems monitoring

– Port AS-I Valve Monitoring and Control 2007-20A6100 – Forward Starboard Side RIO

– Starboard Fire/Bilge/Ballast Pump Monitoring and Control

– Starboard Bilge Level Monitoring

– Starboard Draft Monitoring

– Starboard Tank Level Monitoring

– Starboard Watertight Door Monitoring

– Starboard Fuel Oil Transfer Monitoring and Control

– Starboard Fresh Water Pump Monitoring

– Starboard Ventilation Monitoring

– Starboard Canard Monitoring

– Starboard Supply monitoring

– Starboard Misc. Systems monitoring

– Starboard AS-I Valve Monitoring and Control 2007-20A6150 – Aft Port Side RIO

– Port Bilge Pump Monitoring

– Emergency Generator Monitoring

– Port Draft Level Monitoring

– Port Ships Service Generator Monitoring and Control

– Port Reduction Gear Monitoring

– Port Steering Gear Monitoring

– Port Tank Level Monitoring

– Port Sea Water Pump Monitoring & Control

– Port Watertight Door Monitoring

– Port Bilge Level Monitoring

– Port Bilge Pump Monitoring and Control

– Port Main Engine Monitoring and Control

– Port Battery Monitoring

– Modbus Interface for Port Main Engine and Ships Service Generator 2007-20A6200 – Aft Starboard Side RIO

– Starboard Bilge Pump Monitoring

– Starboard Draft Level Monitoring

– Starboard Bilge Monitoring

– Starboard Ships Service Generator Monitoring and Control

– Starboard Reduction Gear Monitoring

– Starboard Steering Gear Monitoring

– Starboard Tank Level Monitoring

– Starboard Sea Water Pump Monitoring & Control

– Starboard Watertight Door Monitoring

– Starboard Bilge Level Monitoring

– Starboard Bilge Pump Monitoring and Control

– Starboard Main Engine Monitoring and Control

– Starboard Battery Monitoring

– Modbus Interface for Starboard Main Engine and Ships Service Generator

3.3.1 Input/Output Modules

The MAMS utilizes four different I/O class modules in this system:

The Analog Input (AI) modules are Siemens type SM331, 8 channel, 12 Bit resolution, Isolated, for Voltage or Current inputs, P/N 6ES7331-7KF02-OABO.

The Analog Output (AO) modules are Siemens type SM332, 4 channel, 12 Bit resolution, Voltage or Current outputs, P/N 6ES7332-5HD01-OABO.

The Digital Input (DI) modules are Siemens type SM321, 32 channel, 24 Volt DC inputs, P/N 6ES7321-1BL00-OAAO.

The Digital Output (DO) modules are Siemens type SM322 16 channel, 24 Volt DC, 0.5 Amp outputs, P/N 6ES7322-1BH01-OAAO.

The CPU processes the analog values in binary (digital) form only. Therefore the analog input modules convert the analog process signal into digital form and the analog output modules convert the digital output value into an analog signal.

3.3.1.1 SM331 AI 8x12

The analog input module SM 331 AI 8 x 12 bits has the following characteristics:

8 inputs in 2 channel groups Measured-value resolution; settable per group (depending on the integration time set) o 9 bits + sign o 12 bits + sign o 14 bits + sign

Measuring method selectable per channel group:

o Voltage o Current o Resistors o Temperature

Arbitrary measuring range selection per channel group Programmable diagnostics

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Programmable diagnostic interrupt Two channels with limit monitoring Programmable hardware interrupt when limit has been exceeded Isolated against the backplane bus interface Isolated against load voltage (except when at least one coding key is inserted in position D)

To reduce electrical interference, twisted-pair shielded cables should be used for the analog signals. The shield of the analog signal cables should be grounded at both cable ends. If there are potential differences between the cable ends, an equipotential bonding current can flow over the shield, which leads to an interference of the analog signals. In such a case, you should ground the shield at one end of the cable only.

The following measuring methods for the input channels can be set:

Voltage measurement Current measurement Resistance test Temperature measurement

The measuring range for an analog input is determined by jumpers on the card. The measuring range module jumpers are preset to “B” (voltage; ± 10 V) when the module is supplied. When replacing a SM 331 AI 8 x 12 card, you have to change the measuring range module jumpers to the corresponding setting. The old card should be used to determine how to set the jumpers.

Default settings of the SM331 AI x 12 Using measuring Range Modules

Table 3.3.1.1.1

The analog input module SM 331 AI 8 x 12 bits has diagnostics indicators on the card.

Table 3.3.1.1.2 shows diagnostics for the SF LED of the SM 331 AI 8 x 12 module.

Table 3.3.1.1.2

3.3.1.2 SM332 AO 4x12

The analog output module SM 332 AO 4 x 12 bits has the following characteristics:

A 4 Output channels The individual output channels can be programmed as o Voltage outputs o Current outputs

Resolution 12 bits Programmable diagnostics Programmable diagnostic interrupt Programmable substitute value output Isolated against backplane bus interface and load voltage

To reduce electrical interference, twisted-pair shielded cables should be used for the analog signals. The shield of the analog signal cables should be grounded at both cable ends. If there are potential differences between the cable ends, an equipotential bonding current can flow over the shield, which leads to an interference of the analog signals. In such a case, you should ground the shield at one end of the cable only.

Each output channel of the SM 332 AO 4 x 12 bits can be configured individually.

Therefore, separate parameters for each output channel can be assigned. The outputs can be connected as voltage or current outputs, or they can be disabled.

The analog output module SM 332 AO 4 x 12 bits carries out a wire-break check only for current outputs. The analog output module SM 332 AO 4 x 12 bits carries out a short-circuit test only for voltage outputs.

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The analog input module SM 332 AO 4 x 12 bits has diagnostics indicators on the card.

Table 3.3.1.3.1 shows diagnostics for the SF LED of the SM 332 AO 4 x 12 bits module.

Table 3.3.1.2.1

3.3.1.3 SM321 DI 32x24VDC

The digital input module SM 321 DI 32 x 24 VDC has the following characteristics:

32 inputs, isolated in groups of 16 24 VDC rated input voltage Suitable for switches and two / three / four-wire BEROs (proximity switches).

Each channel has an LED indicating the status of the channel. When the LED is lit the input to that channel is active, or true.

3.3.1.4 SM322 DO 16x24VDC/0.5A

The digital output module SM 322 DO 16 x 24 VDC/0.5 A has the following characteristics:

16 outputs, isolated in groups of 8.

0.5 A output current.

24 VDC rated load voltage.

Suitable for solenoid valves, DC contactors and indicator lights.

Each channel has an LED indicating the status of the channel. When the LED is lit the output of that channel is active, or true.

3.4 Engineer Alarm Panel and Stateroom Alarm Panel

There is one engineer alarm panel (EAP) located in the Mess Room (5.7” Touch-panel) and there is one stateroom alarm panel (SAP) located in the Chief Engineer VDU (20” computer monitor).

The EAP and SAP alerts 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.

The SAP indicates all alarms that occur. The EAP indicates only alarms as required by ABS. When a horn at a location is disabled the MMI will still update with alarms but the horn will not sound. However, the Fire alarm, engineer’s call and assistance needed alarm will always sound the appropriate horn regardless if the horn is disabled.

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

The alarms at the EAP and SAP are acknowledged at the EOS Cabinet. The alarms can not be acknowledged from the EAP or SAP directly.

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

The stateroom alarm panel includes an inactive sleep mode where the alarm panel display automatically darkens during inactivity.

The stateroom alarm panel includes a watch call feature. The operator can use the MMI at any workstation to call the Chief Engineer or the mess room. The operator selects the desired engineer at the workstation MMI and the EAP/SAP watch call indicator at the alarm panel will illuminate in green and the alarm horn will sound at the appropriate station Chief Engineer and the Mess. The engineer can acknowledge the watch call horn at the EAP or SAP by pressing the SILENCE HORN pushbutton.

The EAP panel is powered with 24 VDC derived at the EOS RIO.

3.5 Profibus Networks

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

Physically, PROFIBUS is an electrical network based on a shielded twisted pair or an optical network using fiber optic cable. The RAACI MAMS system uses shielded twisted pairs.

The distributed peripheral I/Os (DP) allow you to use a large number of analog and digital input/output modules in the immediate vicinity of the process in a distributed configuration.

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The main redundant Profibus networks, Profibus DP Network #1 & #2 are dedicated to communication with all of the MAMS RIO’s.

In the event of a communication failure on one of the Profibus lines, the MAMS will automatically switch communications over to the respective backup Profibus line. The operator will receive an alarm describing the failure of the Communications Channel.

3.5.1 Profibus CP342-5

??The CP 342-5 communications processor is designed for operation in a SIMATIC S7- 300 programmable logic controller. It allows the S7-300 to be attached to a Profibus system. The PLCs are connected to each other via the CP 342-5 communications processor card. This dedicated link is used for hot back.

The different combinations of the four LEDs on the front panel indicate the status of the communications processor:

Table 3.5.1.1

3.5.2 ET200M Interface Module IM153-2

When a system is set up, it is common for the inputs to and outputs from the process to be incorporated centrally in the automation system. If there are inputs and outputs at considerable distances from the programmable controller, there may be long runs of cabling which are not easy to follow, and electromagnetic interference may impair reliability.

Distributed I/O devices are the ideal solution for such systems:

The control CPU is located at a central location The I/O devices (inputs and outputs) operate locally on a distributed basis.

The powerful Profibus DP with high data transmission speed ensures that the control CPU and the I/O devices communicate smoothly.

The distributed I/O device, ET 200M, is a modular DP slave. The ET 200M has the configuration technology of the S7-300 automation system and consists of an IM 153-2 and I/O modules of the S7-300 as described above Figure 3.5.2.1 below shows the front view of a typical ET200M IM153-x module.

Figure 3.5.2.1

Each of the MAMS RIOs uses a redundant pair of ET200M IM153-2’s. The IM153-2 is the communications link between the PLC and the RIO.

In order for the PLC to communicate with the RIOs, each of the RIOs must have a unique bus address. The bus addresses can be set with the DIP switches on the front of the IM153- 2’s (see Figure 3.5.2.2 below).

The switches represent one 8 bit byte of binary information, starting at 0 from the bottom to 64 at the top (8 switches). The switch is “On” when moved to the right and “Off’ when moved to the left. The switch in the figure below is set for an address of 3 (the sum of 1+2=3).

Figure 3.5.2.2

The interface modules have diagnostics indicators. Table 3.5.2.1 shows the status and error displays of the IM 153-2.

LED's

SF BF/BF1 ACT ON Meaning Remedy Off Off Off Off No voltage on the IM 153-2 or there is a hardware fault with the IM 153-2.

Switch on the power supply module or replace the IM 153-2.

* * * On There is voltage on the IM 153-2. The IM 153-2 is functioning.

On Off Off Off The IM 153-2 is undergoing a hardware reset after switching on.

On On Off Off The operating system update is running.

Off Flashes

0.5 Hz

Off Off The operating system update has concluded successfully.

On Flashes

0.5 Hz

Off Off External error, e.g. unsuitable operating system or SIMATIC Micro Memory card

Use a suitable operating system for the update.

On Flashes

2.0 Hz

Off Off Internal error, e.g. when writing the update files.

Repeat the update process.

If the LEDs indicate an error, the internal memory is faulty.

* Flashing Off On IM 153-2 is incorrectly configured-no data exchange is taking place between the DP master and the IM 153-2.

Causes:

1) PRIFIBUS is incorrect.

2) Faults on the bus.

1) Check the IM 153-2.

2) Check the configuration and parameterization.

3) Check the PROFIBUS address on the IM 153-2 and in the STEP 7 project. 4) Check the cable length with reference to the baud rate.

5) Check the settings for the terminating resistors.

* On Off On No connection to the DP master (search baud rate).

Causes: 1) The bus communication via PROFIBUS DP to the IM 153-2 has been interrupted.

Check the bus configuration.

1) Check to see if the bus connector/ FOC is inserted properly. 2) Check whether the bus cable/FOC to the DP master is defective.

3) Switch off and on the on/off power switch for the 24 VDC on the power supply.

On Flashing Off On The configured structure of the ET 200M doesn't tally with the actual structure of the ET 200M.

Check the configuration of the ET 200M to see if a module is missing, faulty or if there is a non-configured module.

Check the configuration (e.g.

with COM PROFIBUS or STEP 7.

On Off Off On Inadmissible PROFIBUS On the IM 153-2 set a valid address. Is the SF LED of an SM/FM also lit?

1) If so: Error or diagnosis in an S7-300 module.

2) If not: IM 153-2 is faulty.

address (1 to 125).

Check the SM/FM with the diagnostics. Replace the S7- 300 module or the IM 153-2 or contact your Siemens representative.

* Off On On The IM 153-2 is exchanging data with the DP master and the I/O modules of the ET 200M. In redundant mode this IM 153-2 is the active one of the ET 200M.

* Off Off On There is voltage on the IM 153-2. In redundant Mode this IM 153-2 is the passive one, i.e. no data exchange with the I/O modules.

Flashes 0.5Hz

Off Off On In redundant mode, this IM 153-2 is the passive, and is not ready for a fault-free changeover (e.g. associated CPU in stop mode).

Switch the H system to redundant mode.

Flashing Flashing Flashing Flashing The IM 153-2 in the current operating mode is not compatible with the redundant

IM 153-2.

Information on compatabilities between the versions of IM 153- 2 can be found in ET 200M Operating Instructions, 02/2006, EWA-4NEB7806006-02 07.

* Not relevant.

** After the transition to the redundant mode the SF LED flashes for a further 20 seconds.

Table 3.5.2.1

3.6 Ethernet Networks

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

The Ethernet hubs provide electrical isolation/bus segmentation which increases system availability.

The VDU Ethernet network is configured in a star structure as illustrated in the System Diagram figure and the typical diagram below.

Figure 3.5.1

3.6.1 Ethernet Communications Processor CP-343-1 Lean

The CP 343-1 Lean communications processor is designed for operation in an S7-300 programmable logic controller. It allows the S7-300 to be attached to Industrial Ethernet. Each of the PLC’s has one of these modules for communications with the RIO’s.

Figure 3.6.1.1 below shows a typical CP-343-1 Lean

Figure 3.6.1.1

The display on the front panel consists of 5 LEDs that indicate the operating mode and display the communication status.

Figure 3.6.1.2

LED’s displaying the CP operating mode.

The different combinations of the LED’s on the front panel indicate the operating mode.

SF

(Red)

Run (Green)

Stop (Yellow)

CP Operating Mode

On Off On Starting up after power-up

The start-up behavior differs depending on the configuration as follows:

-Ethernet cable inserted.

After a few seconds, the CP also signals the existing connection to ITP/TP with the link LED. The CP then changes to Run Mode.

-Ethernet cable not inserted.

After 10 seconds the CP changes to the “Ready to begin Firmware download” status.

or

Stopped (STOP) with errors.

In this state the CPU or intelligent modules in the rack remain accessible using PG functions.

Off On Off Running (RUN).

Off Blink On Starting up (STOP to RUN).

Off On Blink Stopping (RUN to STOP).

Off Off Blink Ready to begin firmware download (this mode is active for approximately 15 seconds).

This mode is activated after the “Starting up after power on” mode if the Ethernet cable was previously removed.

During this phase, the Ethernet cable must be inserted again and the firmware download started.

On Off Blink Waiting for firmware update (CP currently has an incomplete or incorrect firmware version).

Off Off On Stopped (STOP) In the STOP mode configuring and performing diagnostics on the CP remain possible.

Table 3.6.1.1

LED Display of the CP Communication status

The front panel also includes LED’s that provide information about the status of the CP interface to the industrial Ethernet.

LED Meaning Link LED (Green) On: Indicates an established connection to TP RX/TX LED (Green) Flashing: CP sending/receiving via TP

Table 3.6.1.2

3.7 Serial Networks

In order for the PLC to communicate with the various Caterpillar machinery on the vessel, a communications processor is required to “translate” the Caterpillar language to the PLC language and vice versa. The MAMS uses the Siemens CP 341 for this purpose. Each RIO that communicates with the Caterpillar equipment has a CP 341 in its rack. These CP 341’s query the Caterpillar devices (PL1000E for the Main Engines and EMCP 3’s for the Ships Service Generators) and wait for a response from the devices. Each device has a unique address so the PLC will know which device is responding.

Another RIO located in the EOS uses the CP 341 to communicate with some equipment that does not require a query and response. In this instance, the CP 341 sends specific information in a broadcast. This system does not require any specific address.

The CP 341 communication processor allows the exchange of data between programmable controllers or computers by means of a point-to-point connection. In a point-to-point connection the CP 341 communication processor forms the interface between the programmable controller and a communication partner. In a point-to-point connection with the CP 341, the data is transmitted serially.

In serial transmission, the individual bits of each byte of information are transmitted one after the other in a fixed order.

The MAMS uses the CP 341 – RS 422/485 for Modbus interface with the Caterpillar engines.

Figure 3.6.1 shows the positions of the module elements on the front panel of the CP 341 communications processor.

Figure 3.6.1

The following LED indicators are located on the front panel of the CP 341:

SF(red) Error TxD(green) interface transmitting RxD(green) interface receiving

The display elements of the CP 341 provide information on the CP 341. The following display functions are distinguished:

Group alarm LED – SF (red) Fault has occurred or re-parameterization is in progress.

Special LED – TXD (green) Sending active; lights up when the CP 341 is sending user data via the interface.

Special LED – RXD (green)Receiving active; lights up when the CP 341 is receiving user data via the interface.

The group alarm LED SF always lights up after POWER ON and goes out after initialization. If parameterization data has been generated for the CP 341, the SF LED again lights up briefly during re-parameterization. The group alarm LED SF lights up whenever the following occur:

Hardware faults Firmware errors Parameterization error or no parameterization Breaks (receive cable between CP 341 and communications partner becomes disconnected)

The CP 341 has three operating modes:

STOP - When the CP 341 is in STOP mode, no protocol driver is active and all send and receive requests from the CPU are given a negative acknowledgment.

The CP 341 remains in STOP mode until the cause of the stop is removed (e.g.

break, invalid parameter).

Re-parameterization - For re-parameterization, the protocol driver is initialized. The SF LED is on during re-parameterization. Sending and receiving are not possible, and send and receive message frames stored in the CP 341 are lost when the driver is restarted. Communication between the CP and the CPU is started afresh (active message frames are aborted). At the end of the re-parameterization, the CP 341 is ready to send and receive.

RUN - The CP 341 processes the requests from the CPU. It provides the message frames received by the communications partner to be fetched by the CPU.

3.8 Equipment at EOS Cabinet

Drop-in equipment is provided for the EOS Cabinet. The equipment includes a VDU, the redundant PLCs, the RIO and a redundant power panel. The VDU provides the man machine interface to the MAMS. In addition, the following controls and indications are included on the console:

3.8.1 Sonalert

Also included on the EOS cabinet is a sonalert that annunciates when an alarm occurs in the alarm and monitoring system. At the same time the machinery space horns/beacons annunciate in the engine room, cargo room and bow thruster room.

3.8.2 Misc

Miscellaneous equipment is provided by the customer and installed inside of the EOS cabinet.

3.9 Drop – In Equipment at FWD and AFT SCC

Drop-in equipment is provided for both the FWD and AFT SCC consoles. This equipment includes an LCD and computer in each console. All control and monitoring functions provided at the EOS Cabinet are also provided at the SCC consoles. The control functions are password protected.

The FWD and AFT SCC console also includes a sonalert that annunciates when an alarm occurs in the alarm and monitoring system. They also include Port and Starboard EOTs.

The SCC EOTs operate in conjunction with the ACS Cabinet EOTs.

3.10Tank Level Indicators The RAACI MAMS MMI includes tank level indications at all workstations. This tank level monitoring includes fuel oil tanks, ballast tanks and some miscellaneous tanks.

The RAACI MAMS monitors the various tank levels through RIOs throughout the vessel.

The tank levels are then linearized in the EOS PLCs.

3.11Miscellaneous The RAACI MAMS includes six machinery space horns and beacons, a Sonalert at the Mess EAP and a Sonalert at the Chief Engineers Workstation. Alarms at the MAMS will sound the console horns as well as the machinery space horns and illuminate the machinery space beacons. Various RIOs control the six machinery space horns and beacons and the EAP and SAP sonalerts.

4 Description of Software

4.1 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 nine alarms. Those nine 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. Active, unacknowledged alarms appear on the alarm summary window in red letters. Active, acknowledged alarms appear with black letters. Each alarm includes the time and date of occurrence, the type of alarm, the value, the limit and the name of the alarm. 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 Cabinet.

Miscellaneous screens are included with the MAMS system for viewing alarms, system status/communication status 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.

4.2 Software – Control Algorithms

The EOS PLCs run the MAMS control algorithms developed by RAACI with the 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.

5 Description of Operation

5.1 System Start-up

This start-up procedure is for a completely cold start-up. Ensure that the Normal 120 VAC and the Emergency 120 VAC supply to the EOS Console and the Forward Bridge Console Circuit Breakers are energized.

At the EOS Work Station: Close circuit breakers A1-CB1 and A2-CB1 to apply redundant 120 VAC power to the two 24 VDC power supplies. Close circuit breaker A1-CB2 to apply the 24 VDC battery back-up to the system. Close CB A1-CB3 to apply power to the Internal Distribution to PLC #1 and Hub #1 through A6-F1, PLC #2 and Hub #2 through A6-F2, The EOS Remote RIO through A6-F3, the EOS computer and LCD through A6-F4, the Port Aft Remote RIO through A6-F5, the Starboard Aft Remote RIO through A6-F6, the Port Forward Remote RIO through A6-F7 and the Starboard Forward Remote RIO through A6-F8. Set both PLC Mode Selector switches to “RUN”. Push the start push button on the computer. Push the start push button on the LCD monitor. The computer will boot up into the MMI system.

At the SCC Work Station: Close circuit breakers A1-CB1 and A2-CB1 to apply redundant 120 VAC power to the two 24 VDC power supplies. Close circuit breaker A1-CB2 to apply the 24 VDC battery back-up to the system. Close CB A1-CB3 to apply power to the Internal Distribution to SCC computer and LCD #1 through A2-F1, SCC computer and LCD #2 through A2-F2, The ACS computer and LCD through A2-F3, the Mess Alarm Panel through A2-F4, the Port Bridge Wing RPM meters through A2-F6 and the Starboard Bridge Wing RPM meters through A2-F7. Push the start push button on the Forward computer. Push the start push button on the Forward LCD monitor. The computer will boot up into the MMI system. Push the start push button on the Aft computer. Push the start push button on the Aft LCD monitor. The computer will boot up into the MMI system.

At the ACS Workstation: Close circuit breaker A1-CB1 to apply redundant 24 VDC battery backed power to the ACS computer and LCD. Push the start push button on the computer.

Push the start push button on the LCD monitor. The computer will boot up into the MMI system.

At the Port Aft RIO Panel: Close circuit breaker A2-CB1 to apply redundant 24 VDC battery backed power to the two IM153-2 Modules, the Internal Distribution, the Digital Input Field Contacts through A2-F1 and the Relay Output Field Control through A2-F2.

At the Starboard Aft RIO Panel: Close circuit breaker A2-CB1 to apply redundant 24 VDC battery backed power to the two IM153-2 Modules, the Internal Distribution, the Digital Input Field Contacts through A2-F1 and the Relay Output Field Control through A2-F2.

At the Port Forward RIO Panel: Close circuit breaker A2-CB1 to apply redundant 24 VDC battery backed power to the two IM153-2 Modules, the Internal Distribution, the Digital Input Field Contacts through A2-F1, the Relay Output Field Control through A2-F2, the AS-i power supply #1 through A2-F3 and the AS-i power supply #2 through A2-F4.

At the Starboard Forward RIO Panel: Close circuit breaker A2-CB1 to apply redundant 24 VDC battery backed power to the two IM153-2 Modules, the Internal Distribution, the Digital Input Field Contacts through A2-F1, the Relay Output Field Control through A2- F2, the AS-i power supply #1 through A2-F3 and the AS-i power supply #2 through A2-F4.

At the Chief Engineers Work Station: Push the start push button on the computer. Push the start push button on the LCD monitor. The computer will boot up into the MMI system.

The Mess Alarm Panel will boot up into the MMI system when power is applied to the SCC Work Station.

5.2 System Shut-down

Generally, a complete system shut-down will not be necessary. If for some reason a complete system shut-down becomes necessary, set the mode Selector switches on the PLCs to “STOP”. At the each work stations open the “SYSTEMS” page and open the “LOG ON” page (see 5.8.1 to log on to the system). Touch the “EXIT WINDOW VIEWER” button and wait for the program to close. Touch the operating system “Start” pushbutton in the lower left hand corner (Figure 5.2.1). A drop down menu will appear.

Touch the “Turn Off Computer” pushbutton (Figure 5.2.2). A pop up will appear in the center of the screen. Touch the “Turn Off” pushbutton (Figure 5.2.3). The computers will close all applications and shut themselves down.

Note: The above procedure must be followed or damage to the hard drive and\or the Run Time license may result!!

Once these computers are shutdown any and all circuit breakers in the system can be opened to remove power and completely shutdown the system.

Figure 5.2.1 Figure 5.2.2 Figure 5.2.3

5.3 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 cabinet will also test the horns and beacons in the machinery space.

The acknowledge pushbutton can be used to acknowledge alarms on the MAMS MMI.

Each MAMS MMI has an Acknowledge pushbutton. Alarms acknowledged at one workstation do not acknowledge alarms at other workstations with the following exceptions:

1. The Acknowledge pushbutton on the Fwd SCC MMI will acknowledge the alarms at the Aft SCC console MMI and vise versa.

2. The Acknowledge push button at the MAMS MMI in the EOS Cabinet will acknowledge the horns at all of the other locations, including the engine room horns and beacons. However, the active alarm must be acknowledged at each work station to clear the screen. If the EOS is not acknowledged within two minutes, the Chiefs horn will sound.

5.4 Attendance Monitor

When the engine room is attended 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 will alarm. The time can be adjusted from the default of 30 minutes up to 60 minutes with the “SET DEAD MAN TIMER” pushbutton on each screen.

5.5 Assistance Needed

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

5.6 MAMS Controls

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

Fire/Ballast/Bilge Pump Controls and associated Valve…