Maintenance Management Assistance (MMAC)

for Wafa Desert Plant & Pipelines

Technical Report

2A-150-JD-801
Investigation of the situation when the both
instrument air compressors (NG-01) operates
simultaneously

Document No:

2014-MMAC-TR-031/IAS

Rev. Comments Prepared by Checked by Date

1 Issued for information Adrian N. MEM 01.07.2014
 2014-MMAC-TR-031/IAS

TABLE OF CONTENTS

1. EQUIPMENT DESCRIPTION ........................................................................................................ 3

2. HISTORICAL DATA ....................................................................................................................... 3
3. WORK DESCRIPTION ................................................................................................................... 4
4. ACTIONS AND INVESTIGATION ................................................................................................ 4
5. CONCLUSIONS............................................................................................................................... 5
6. RECOMMENDATIONS .................................................................................................................. 8
7. REFERENCES ................................................................................................................................. 9

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1. Equipment Description
Tag Number : 2A-150-JD-801
Functional Unit : 2A-150-KC-001A/B
Area : NG-01
Equipment Description : Siemens PLC S7-200
Serial number :

2. Historical Data
The simultaneously occurrence in the local panel of the instrumental air
compressors of the following indication:
- Compressor A – “Main” local indication (ULKC 01A-5M);
- Compressor B – “Main” local indication (ULKC 01B-5M);

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3. Work Description
On 28th April 2014, the responsible for the ECS and the Instrumentation team
start the investigation on this subject.

4. Actions and Investigation

1. The power supply checking in the PLC cabinet;

2. The reset one by one of the both PLCs, by STOP command from the local
CPU button.

3. Start one by one of the both PLCs, by RUN command from the local CPU
button

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5. Conclusions
The redundant communication between the PLC S7-200 (A & B), it is based on
the PPI port and it hasn’t a specialized card for the synchronization. For this
reason, any disruption in the communication or commands can affect the data
communication between PLCs.
The causes of this event can be understood with the following pictures:

Any changing in the PLC-B OK status, due un-properly commands, can inhibit
the synchronization of the PLC-A with PLC-B.
Moreover, at this situation is added the internal clock for cross-over of the
compressor by time can generate a cross reference loop that will keep the active
PLC in between sequence.

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The module for changing compressors (active and standby) on time.

The memory bit of the changing action.

The program checks the changing possibility.

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The alternative changing (Set/Reset) of the M7.4, generated by the PLC cycles,
will get the alternative activation of the MAIN lamps for both compressors.

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Lamp “Main A” on the

local control panel

Lamp “Main B” on the

local control panel

6. Recommendations
The main recommendation is to respect the requests from the Instrumental air
compressor Operation Manual (see attachment).
Regarding the best practice PLC S7-200 functionality:
1. For the prevention of any CPU’s cumulative errors, shall be included in the
Preventive Maintenance procedure, a special activity for the saving of the
alarms on the field portable workstation (PG) and for the testing of the

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PLCs changeover capability;

2. According with the instruction from the Operation Manual recommended
combinations are:
- Auto mode: Main/Standby;
- Manual mode (for maintenance): Main/Standby.

To prevent any other combination it is more safety to use a single switch button
(with different internal contacts) for Auto A + B and Manual A + B or a common
software connection in the PLC for both signals. In this manner, the both air
compressors will be only in MAN or AUTO mode.
3. To avoid a long functionality of the compressors in other operation mode
than AUTO, this situation can be software added in one of the existed DO-
Remote contact signalization:
- General Alarm (K10);
- Status (K11);
- PLC error (K16);
4. The un-synchronization phenomenon can appear frequently due external
or internal causes and the redundant PLC can’t make the switchover in
time. For this reason the PLC network can be upgraded to MPI or Profibus
connection and the synchronization can be made more accuracy.

7. References

1. Control Narrative and Interlock and Sequence Flow Diagram PNE-J-52-S-N-

0502-00-F2;
2. A.2B.2C.2D.2E-150-XX-010 WIRING AND SCHEMATIC DIAGRAM PNE-J-
52-X-N-0801-00-F1;
3. 2A.2B.2C.2D.2E-150-XX-010 PLC Sequence Ladder Diagram PNE-J-52-D-
N-0555-00-F1;

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