Contents

Abstract…………………………………………………………………………………...……i

Acknowledgements…………………………………………………………............................ii

Contents................................................................................................................ 1
CHAPTER 1: ATTACHMENT AT HWANGE POWER STATION ....................................3
1.0 Introduction.................................................................................................. 3
Zimbabwe Power Company.............................................................................6
Safety, Health and Environment Policy............................................................7
Quality Policy Statement.................................................................................7
1.2 History of Hwange Power Station.................................................................8
1.3 Company’s Core Business............................................................................9
1.4 Major Customers...........................................................................................9
1.5 Profile of Management Team......................................................................10
1.5.1Organisational Structure........................................................................10
[2] Fig 1.0 ZPC Organizational Structure.......................................................11
1.5.2 Zimbabwe Power Company Information Technology Structure............11
1.6 Conclusion..................................................................................................12
CHAPTER 2: COMPUTER NETWORKING AND SUPPORT.........................................14
2.0 Introduction................................................................................................14
2.1 Network Setup Structure............................................................................15
[4] Fig 2.0 Network Setup Structure.................................................................15
Internet and email server.................................................................................17
2.2 Termination Straight through Unshielded Twisted Pair (UTP) Category 5
(CAT 5) cable.................................................................................................... 18
2.2 Projects Undertaken...................................................................................19
2.2.1 Upgrade of Administration Block Network............................................19
2.2 Technologies Learnt...................................................................................19
2.3 Conclusion..................................................................................................20
CHAPTER 3: HARDWARE AND SOFTWARE MAINTENANCE AND SUPPORT............22
3.0 Introduction ...............................................................................................22
3.1 Hardware ...................................................................................................23
3.2 Computer Operating Systems ....................................................................23
 3.3Application Software ...................................................................................24
3.4 Debugging..................................................................................................24
3.3 Projects Undertaken...................................................................................25
3.3.1Commisioning of ESET NOD32 Antivirus................................................25
3.3.2 Commissioning of New Workstations....................................................26
3.4 Conclusion..................................................................................................26
CHAPTER 4: PLANT CONTROL SYSTEMS AND SOFTWARE DEVELOPMENT............26
4.0 Introduction ...............................................................................................27
4.1 Teleperm ME ..............................................................................................27
4.2 Teleperm XP...............................................................................................28
4.3 Technologies Learnt...................................................................................29
4.4 Software Development...............................................................................29
4.5 Conclusion..................................................................................................30
CHAPTER 5: PROBLEMS, RECOMMENDATIONS AND CONCLUSION.......................31
5.0 Problems.....................................................................................................31
5.1 Recommendations .....................................................................................32
5.2 Conclusion .................................................................................................33
[2] Fig 1.0 ZPC Organizational Structure:- Human Resources Department Wall
Chart, 2009....................................................................................................35
[4] Fig 2.0 Network Setup Structure:- produced by IT Software Technicians,
2009................................................................................................................. 35

2
CHAPTER 1: ATTACHMENT AT HWANGE POWER STATION

1.0 Introduction
I have been attached at Hwange Power Station from the 13th of September to date under the

Information Communication Technology department. During this period my manager and

supervisor had produced a detailed program which we followed and in this program we

covered the following areas of focus, computer hardware repairs and maintenance, computer

networking, systems administration, and software development which we started recently. I

learnt and gained a lot of technical knowledge both in terms of software packages and

hardware fault diagnosis and maintenance. I performed daily duties such as checking if all

the servers were up and actively involved in performing daily backups of AS/400, Inventory

3
Procurement Management System (IPMS) and Maintenance Management System (MMS)

application systems. Among other daily duties was checking if the Antivirus server was up to

date and that all the client machines were updating the ESET Nod 32 Antivirus. There were

other duties that were not definite such as end user support and these include network faults

in the Local Area network, hardware and software problems that would arise and were

reported to the ICT department via the MMS application system. I was also actively involved

in a number of projects that arose during my attachment period and these include upgrading

of old personal computers, commissioning of a Eset Node 32 Business edition antivirus,

commissioning of new personal computers and printers, upgrading a certain portion of

network from using UPT to fiber optic and software development of Asset register

management system. While in this department, I got the opportunity to participate,

experience and appreciate teamwork. I realized its importance, since it’s paramount to the

success of any organization; it really added distinctly to my scholastic knowledge and gave

me an understanding and expectations of the IT industry. Conclusively I have also made

recommendations concerning ICT at ZPC.

4
1.1 Zesa Holdings Organisational Structure

The Zimbabwe Electricity Supply Authority (ZESA) started major commercialization and

reform exercise in 1999, with the formation of Zimbabwe Power Company, ZPC under the

Electricity Act (Chapter 13:19) of 2002. ZESA was transformed from a vertically integrated

organization into separate specialized subsidiaries of a mother company, ZESA Holdings Ltd.

This comprised the following:

1. ZIMBABWE POWER COMPANY (ZPC): this controls all generation assets and

power station operations. It was established in October 1996, and ZPC directs all power

generation investments, locally and regionally.

2. ZIMBABWE ELECTRICITY TRANSMISSION COMPANY (ZETCO): this

handles all Grid assets and is responsible for managing, planning and operating the

system. It is involved in electricity trading.

3. ZIMBABWE ELECTRICITY DISTRIBUTION COMPANY (ZEDC): this is

responsible for the distribution assets and manages the supply and retailing of electricity

to customers.

4. ZESA ENTERPRISES (ZE): manages ZESA’s non-core business operations such as

transport, projects, production and services and the Technology Centre.

5. POWERTEL: provides landline infrastructure, fibre optics, mobile radios, and power

line networking and consultancy services for the telecommunications industry.

All the companies have their own board of directors who report to ZESA Holdings Limited,

but they determine their own management structures and appoint their own teams on a

competitive basis. To complete the unbundling of ZESA, the RURAL

ELECTRIFICATION BOARD AND FUND, accountable to the Ministry of Energy and

5
Power Development, was set up by rural Electrification Fund Act, giving ZESA Holdings

limited authority to transfer rural electrification business, staff, assets, liabilities, stores and

creditors to the rural electrification fund.

Ministry of Energy and Power

Board of ZESA Holdings Rural Electrification

Board

ZESA Holdings
Limited

ZPC ZETC ZEDC POWERTEL

[1] Figure 1.0: ZESA Holdings Limited Structure

Zimbabwe Power Company

VISION: To be the leading supplier of energy and related services.

MISSION: As a generator of electricity and supplier of energy-related services, which are

committed to delivering reliable energy to meet customer requirements, through:

• Use of environmentally friendly technologies.

• Development and retention of highly skilled, effective and motivated staff.

• Positive returns for our shareholders.

6
Safety, Health and Environment Policy.

We, the Hwange Thermal Power Station management and entire workforce, are committed to

working in a matter that meets international standards of Safety, Health and Environment

(SHE) protection. Our goal is to ensure that we meet our obligations of safety, health and

protection of the environment, stakeholders and the general public. To achieve this, the

Power station will:

• Strive to eliminate all injuries, prevent work environment and health impacts, and reduce

waste and emissions through full participation in hazard identification, risk assessment

and audits.

• Maintain the highest possible level of health among all employees including the

promotion of HIV/AIDS programs.

• Take appropriate measures to monitor and prevent pollution.

• Carry out environmental impact assessment for all new projects.

• Adhere to set levels of SHE protections as stipulated by local and international standards,

laws and regulations.

• Mobilise the necessary resources to ensure success of SHE programs.

• Put in place continued SHE awareness programs for all levels of the workforce.

• Monitor, evaluate and review SHE performance annually.

• A SHE report will be published annually and made available to all stakeholders.

Quality Policy Statement

7
Hwange Power Station is committed to operating, maintaining, and continuously improving

the business unit so that it delivers a service that meets world-class standards. To achieve

this, the Power Station works to a quality management system based on the international

standard ISO 9001:2000.

Through a systematic implementation of this quality management system from management

level down to the entire workforce, the Power Station is committed to achieve the following:

• To comply with the ever-demanding requirements by customers and other stakeholders,

as well as legislative authorities.

• To meet the requirements of the Power Purchase Agreement (PPA) with our external

customer, the Zimbabwe Electricity Transmission Company (ZETC)

• To meet applicable internal, national and international standards in our administrative,

commercial and technical operations.

• To ensure that the Station is insurable by the insurers at all times.

• To ensure the availability and efficient use of human, financial, and material resources.

• To inform and train the entire workforce on all aspects of the quality system.

The policy is supported by the objectives established by each and every function at various

organizational levels in the Power Station

1.2 History of Hwange Power Station

Hwange Power Station is situated in the North Western part of Zimbabwe. It is the largest

coal thermal power station in the country with a maximum output capacity of 920 Megawatts.

It consists of two stages with stage one having a total of four units each with a maximum

capacity of 120 Megawatts and stage two comprising of two units each with a maximum

generating capacity of 220 Megawatts. Hwange Power Station is capable of producing

8
approximately 45% of Zimbabwe`s total energy requirements. Hwange Power Station falls

under Zimbabwe Power Company which is a subsidiary of Zimbabwe Electricity Supply

Authority Holdings.

Construction of the power station started in 1973, and was suspended in 1975 due to the

liberation war and an Economic sanction imposed on the country and was resumed after

independence in 1980.

The thermal station uses coal as its major source of fuel and this fuel is obtained from the

nearby Hwange Colliery Open Cast mine via a 3.5 kilometer conveyor belt. A reliable source

of water lies further north, in Zambezi river through a 44 kilometer long pipeline. Water for

both Boilers and Cooling Towers is drawn by both high and low lift pumps to a storage

reservoir located adjacent to the station and is conveyed by gravity to the station.

1.3 Company’s Core Business

The core business at Hwange Power Station (HPS) is to generate electricity for consumption

in Zimbabwe and regionally. Electricity is produced using raw materials which are coal, coke

oven gas, water, propane, air and diesel. Coal and coke oven gas is supplied by Hwange

Colliery Company whilst diesel is supplied by National Oil Company of Zimbabwe

(NOCZIM) and Sakunda. Water is pumped from the Zambezi River through a 44km long

pipeline. The low-grade bituminous coal is used to heat the water in the boiler into high

pressure steam which then turns the generators to produce electrical energy. The generated

electrical power is fed into the national grid and from this point ZETDC takes over and has

the responsibility of transmitting and distribution the electrical power to its customers.

1.4 Major Customers

Zimbabwe Electricity Transmission Distribution Company (ZETDC) is the major customer

for Zimbabwe Power Company (ZPC). HPS operates and trades with ZETDC, its major

customer under a Power Purchase Agreement (PPA). ZETDC is the transmission business

9
 subsidiary of ZESA Holdings. ZETDC has both local and regional customers. The local

customers include households and industrial companies in Zimbabwe while some of the

regional customers are Namibia, Democratic Republic of Congo, Zambia and South Africa.

1.5 Profile of Management Team

The management team at HPS consists of the General Manager (GM) on top of the Hierarchy

and Section Heads just below the GM are Managers of different Departments. Section Heads

are under Departmental Managers and they also have their subordinates . The management

team comprises the following, General Manager , Maintenance Manager, Operations

Manager Production, Manager Engineering Manager, Finance Manager, Human

Resource Manager.

1.5.1Organisational Structure

General

Manager

Secretar
y

1.4
Enginee Maintenan Finance Operatio Productio Human
Purchasing
ring ce ns n Manager Resourc
Manage Manager e
r Manager Manager Manager
Manage

10
[2] Fig 1.0 ZPC Organizational Structure.

1.5.2 Zimbabwe Power Company Information Technology Structure

The Information Communication Technology department is responsible for all the

information and communication systems and activities which are available in the Power

station. Below is the organizational structure of the ICT section.

Head ICT

Engineer ICT (1)

Principal Technician (1)
(Plant Control Systems
) Principal Technician (1)

(Office Automation)
Systems

Telecoms
Hardware Software Hardware Software technicians
Technician Technician Technician Technician x2

[3] Fig 1.1: ICT Structure.

The basic activities that the department is involved in include:

11
• Installation and maintenance of computer systems

• User software administration

• Network administration and security on Local Area Network

• Hardware repairs

• User support

• Software and systems development

• Installation and maintenance of telecommunications systems

• System support and maintenance

• Plant control systems support

• Scheduling and report generation

1.6 Conclusion

ICT section falls under the Engineering Department, it is a small section but important in the

running of day to day activities in the company. There are many other sections which fall

under their respective departments and most of them work hand in hand with the ICT section

in order ensure smooth running of the power station. The top most goal for Hwange Power

Station is to generate electricity and thus all the departments work as a unit in order to

achieve this ultimate goal.

12
13
CHAPTER 2: COMPUTER NETWORKING AND SUPPORT

2.0 Introduction
The power station comprises of client base of 120 computers which are connected to a

centralized network server. These computers form a local area network (LAN) and after a

detailed study of the power station’s network I concluded that generally it employs an

extended star network topology. All client computers are required to logon to the zpc.hps

domain on the network server in order to gain access to the shared network resources. There

are four servers namely the Internet & Email server, Solaris server AS400 server and

domain server. The internet & email server is the one responsible for internet connection and

incoming and outgoing of emails. The Solaris server is responsible for two systems namely,

Inventory Procurement Management System (IPMS) and Maintenance Management System

(MMS), whilst the AS400 server is responsible for the functionality of the AS400 application

system. Lastly, the domain server is the one responsible for logging in users on to the Local

Area Network being the zpchps domain. If a user is not logged on to this domain then they

will not be able to access any LAN resources inclusive of imps/mms, as400, internet (for

those with access) and email. Hwange Power Station currently connects to the Internet using

a dial up modem and telephone line. MWEB Zimbabwe is the Internet service provider. The

internet server runs on a LINUX Red hat 9.0 platform. The server houses a POP3 mail server

that configures email users to the domain zpc.hps.co.zw through Outlook Express Below is a

simplified network diagram for HPS.

14
2.1 Network Setup Structure

Internet

MWEB

PSTN

e
Li n
one
Ph

Modem

Serial link

Email & Internet Server Sun Solaris Server

AS/400 Server

Cisco Switch for Users - LAN

` `
User Network Printer
User
[4] Fig 2.0 Network Setup Structure

The Hwange Power Station network works on a server-client basis. It has basically four

servers namely the Internet & Email server, Sun Solaris server (IPMS/MMS), AS400

server and the Domain server, and a client base of approximately 120 computers.

The internet & email server is the one responsible for internet connection and incoming and

outgoing of emails. The Solaris server is responsible for IPMS and MMS, whilst the AS400

15
server being responsible for the functionality of the AS400 application system. Lastly, the

domain server is the one responsible for logging in users on to the Local Area Network being

the zpchps domain. If a user is not logged on to this domain then they will not be able to

access any LAN resources inclusive of IPMS/MMS, AS400, internet (for those with access)

and email.

The Email/Internet server is directly connected to a modem and to a central Cisco Switch

which then distributes the network to other departments forming a Local Area Network

(LAN). There are 3 servers that are directly connected to the central Cisco switch and are

located in one room and these are Internet & Email , Sun Solaris server andAS400 server.

The domain server is located in the ICT workshop and thus is connected to a switch in the

ICT workshop.

The structure of the LAN at Hwange Power Station is an extended Star network topology

comprising of a dedicated Central Cisco switch which connects 14 departmental sections via

switches and hubs. Client computers may connect directly to the nearest switch or hub or may

connect to the switch through a patch panel. All the hubs have a data transfer rate of 10 Mbps

yet the switches transfer data at either 10 Mbps or 100 Mbps depending on the network

interface card (NIC). All client computers are required to logon to the zpc.hps domain on the

network server in order to gain access to the shared network resources. During my work

experience I carried out a number of tasks concerning computer networking and these

include:

• Installing and configuring Network interface cards.

• Configuring an outlook express account on user machine.

16
 • Resetting user password on outlook express.

• Terminating an RJ45 for Straight through and cross over cables.

• Installing switches.

• Setting up and installing a network printer and troubleshooting network printer

problems such as failure to print.

• Network configuration (Internet Protocol Address, Subnet Mask, DNS).

• Creating data points.

Internet and email server

Hwange power station currently connects to the internet through a dial up internet server

with MWEB Zimbabwe. The internet server runs on a LINUX Redhat 9.0 platform. The

server houses a POP3 mail server that configures email users to the domain

zpc.hps.co.zw through Outlook Express or Microsoft Outlook.

Below are the commands I used whilst working in LINUX:

• Creating email user accounts: - this was done within the root folder or mail folder

by the use of the command useradd <username> at the command prompt. For example in

order to add a user whose name is I Gavaza typing the command useradd igavaza would

result in the email address igavaza@zpc.hps.co.zw .

• Deleting email user accounts: In order to delete an email user account the

command userdel <username> is used, for example userdel igavaza will delete the email

account for I Gavaza.

17
• Managing user passwords: - at times an email user may require their email

passwords to be frequently changed for security reasons, or they may have forgotten their

password. The command used for resetting or renewing the password is passwd

<username>, for example passwd igavaza will prompt you to change the password for

igavaza and asks you to confirm the new password as well.

• Creating an internet user account: since there are users who are entitled to

internet access, user accounts are created for such and the command used after logging on

the internet server is htpasswd /etc/squid/squid_passwd <username>. Where htpasswd

/etc/squid/squid_passwd igavaza will create an internet user account for I Gavaza,

2.2 Termination Straight through Unshielded Twisted Pair (UTP) Category 5 (CAT 5)
cable

All client computers are connected to the network server using UTP CAT5 cables which are

normally enclosed in a protective trunking and run through the ceiling from the client

computer to the server room which houses all servers. I was actively involved in terminating

cables and the cables I constructed were straight through UTP cables and cross – over cables.

Straight through cables are normally used to connect a computer to a switch or hub or to

connect a computer from a data point which in turn is connected to a switch or hub. I used

and familiarized myself with the following basic resources:

• CAT5 cabling enough to connect one client computer to the nearest switch or hub or

to a data point.

• At least two RJ-45 connectors.

• RJ-45 crimping tools to attach the RJ-45 connectors to the cable.

• Ethernet continuity cabling tester.

18
 • Wire cutters.

2.2 Projects Undertaken

2.2.1 Upgrade of Administration Block Network

The Administration Block is a Building that is used by the General Manager, Management

and their respective secretaries. Initially this building was connected using Unshielded

Twisted Pair (UTP) cable from the Main Switch located in the main control room about 25

meters apart via a tunnel to the administration switch. Also pre-terminated optical fiber

supplied by Powertel was initially laid in the same tunnel from the main switch to the

administration block together with 3 more optical fiber cables which were for use in other

departments the UTP cable fails. In this small project I worked with two technicians and my

fellow student on attachment. The major fault was that the link between the Administration

block and main control switch was down. This was caused by water which sipped into the

tunnel. This tunnel also carried insulated electrical cables and these caused Electromagnetic

Induction effects in the CAT5 UTP cable thus causing interference in the electrical data

signals carried by the CAT5 UTP cable. Our task was to identify a free pair of fiber optical

cable that was running from the main switch to the administration block and use it to replace

the damaged UTP cable. In this project I learnt about a concept of looping in order to identify

a pair of cables amongst many cables.

2.2 Technologies Learnt

During my period of my attachment I acquired a lot of knowledge on computer networking

technologies and these includes creating data points and terminating UTP CAT5 cable which

we sometimes used as an uplink or fly-lead or to make a cross over UTP CAT5 cable. I used

19
various tools such as RJ-45 connectors, crimping tool, Continuity cable tester and cable cutter

to terminate UTP cables. I added nodes on the Local Area Network by adding switches and in

most cases these switches would be replacing a hub. I applied my theoretical knowledge I

learnt at college on client server architectures by learning how to physically set up client

server architecture between 2 workstations using a cross-over UTP cable.

2.3 Conclusion

Computer networking and support is an area that I learnt new technical tasks which include

terminating RJ-45, network troubleshooting techniques and email administration. The major

challenge that I faced during the course of studying computer networking were, lack of

resources such as RJ 45 terminators were scarce at a time we needed them most.

20
21
CHAPTER 3: HARDWARE AND SOFTWARE MAINTENANCE AND SUPPORT

3.0 Introduction
In order to effectively achieve Hwange power station’s goals and objectives, a number of

software application systems have been installed and these are administered and maintained

by the IT department. Throughout my attachment period I have been actively involved in the

day to day system administration, user support and data backup of these application systems.

This area that I managed to experience greater experience was on hardware and software

maintenance as well as user support or help desk. We carried out two projects which were

commissioning of a Licensed Antivirus system and commissioning of new desktop

computers and upgrading of old computers.

22
3.1 Hardware
Computer hardware equipment used in the Power station includes Visual display units,

printers, central processing units, hard disk drives, power supplies, computer motherboards,

Network interface cards (NIC), projector, keyboards and mice. In our day to day duties when

we were dealing with hardware we did more of corrective maintenance than preventive

maintenance due to a shortage of spare parts in the IT workshop. I installed and configured

new NIC on client computers and during this process I learned about a ping command “ping

127.0.0.1” that tests whether the NIC is working. I installed and loaded new hard disk drives

on computers with operating system. I recovered data from crushed hard drives and formatted

hard drives using Easy Recovery Software. I learnt how to use debug routines using a start

up floppy to debug a faulty hard drive. Debugging is a methodical process of finding and

reducing the number of bugs, or defects, in a computer program or a piece of electronic

hardware thus making it behave as expected. Debug is an MS-DOS command that can be

used to enter machine language into the computer either to create programs or test computer

peripherals by receiving back various computer machine code. The debug command is an

external command and is available in the below Microsoft operating systems. All

Versions of MS-DOS Windows 95, Windows 98, Windows ME, Windows NT Windows

2000, Windows XP However, some of these debug routines can also potentially damage

computer components or cause them not to work properly hence a thorough knowledge of

hardware and MS-DOS commands is needed. I never experienced many problems with

printers except paper jams and empty cartridges and these were simple to solve.

3.2 Computer Operating Systems

The majority of machines in the power station are running on Windows XP and Windows

2000 whilst a few run on Windows 98 and Windows Vista. The internet server uses Linux

Red hat 9.0 while the IPMS, MMS and plant control GET Machines use SCO-UNIX

operating system and the network server uses Server 2003. During my attachment period I

23
managed to work with all the operating systems mentioned above except for SCO-UNIX and

windows server 2003.

3.3Application Software
There are a number of application software’s used in the station and these include IPMS,

MMS, AS400, partition magic, easy recovery, ESET NOD 32 Antivirus, Microsoft Office

2000,Microsoft Office 2003, Microsoft Office 2007, AutoCAD. I managed to work with all

these and gained confidence in working with and troubleshooting software problems.

3.4 Debugging

Debugging is a methodical process of finding and reducing the number of bugs, or defects, in

a computer program or a piece of electronic hardware thus making it behave as expected.

Debug is an MS-DOS command that can be used to enter machine language into the

computer either to create programs or test computer peripherals by receiving back various

computer machine code. When carrying out debug routines on hard drives I used a start-up

floppy which entails the use of MS DOS debug commands. The debug command is an

external command and is available in the below Microsoft operating systems.

• All Versions of MS-DOS

• Windows 95

• Windows 98

• Windows ME

• Windows NT

• Windows 2000

• Windows XP

24
However, some of these debug routines can also potentially damage computer components or

cause them not to work properly hence a thorough knowledge of hardware and MS-DOS

commands is needed. I carried out these debug routines on a number of hard drives that were

malfunction due to viruses or defects in those hard drives.

3.3 Projects Undertaken

3.3.1Commisioning of ESET NOD32 Antivirus

Zimbabwe Power Company purchased licensed ESET NOD32 Business Edition Antivirus

software from ESET Zimbabwe for use and has a maximum of 300 users. In this project a

specialist from ESET came to commission the Antivirus and also to teach the ICT staff how

to basically set up the Antivirus software. As a student I was actively involved and learnt how

to set up and configure a Windows based Antivirus server and to set up and configure all the

computers in the station.

The major task in this project was to first make sure that all the computers were either

running on Windows XP Service pack 3 or Windows 2000 Service pack 4 thus all computers

that were not running on above mentioned Operating systems had to be loaded or upgraded

with Windows XP Service pack 3 or Windows 2000 Service pack 4 depending on the size of

Random Access memory (RAM), hard drive and processing speed on that individual

machine. With the help of other technicians we(students) did this exercise of upgrading the

operating systems on about 120 computers and installed ESET node antivirus on each and

every computer in the power station.

The setup incorporated was that all client computers were configured to update the Antivirus

from the Antivirus Server automatically after every 24 hours keeping the Antivirus up to date

and at a lower risk of attack from viruses, worms and spam’s.

25
3.3.2 Commissioning of New Workstations
New computers were bought and these were about 40. In this mini project I was actively

involved with loading them with Windows XP SP3 Operating system, installing and

configuring IPMS,MMS and AS400 application software’s., configuring user emails on

outlook express, configuring and installing network printers and also loading other

application software’s.

3.4 Conclusion
Most of the work I covered on a daily basis was to deal with hardware and software

maintenance and support. With a total of about 120 Computer users in the power station we

attended to all faults reported by these users. When a user submits a fault using MMS all

faults are logged into the MMS system and when it has been attended you indicate whether

you successfully completed it or not. At the end of the month the Principal technician would

compile all the job cards in MMS and compile a report showing how many faults were

reported and if there were successfully completed.

CHAPTER 4: PLANT CONTROL SYSTEMS AND SOFTWARE DEVELOPMENT

26
4.0 Introduction
Plant control systems are basically found and implemented in the Hwange Power Station

plant and there are used to control the machinery used to generate electrical power. There are

basically two Digital Distributed Control Systems (DDCS) used in the power station and both

were designed by Siemens, Stage 1 uses Siemens Teleperm ME, and stage 2 uses an

upgraded version Teleperm XP. Plant Control systems is a critical area in the generation of

electricity as it contains the automation systems which control, monitor and administer the

machinery used to generate electricity.

4.1 Teleperm ME

OT
OT1 OT2 3
Ethernet

Switc

Serve
r

Unit

GET
CS275 bus

FAE CS275 bus Switc

Struk

AS

[5] Fig 4.0 Teleperm ME

Key

27
 AS………Automation System

GET……..Graphical Engineering Tool

OT……….Operator Terminal

The FAE is a bus connector to the Automation system. The Operator Terminals in Teleperm

ME use a program known as Hummingbird that runs by showing the graphical user interface

(GUI) of a simulation of the physical plant operations. The operator terminal computers are

loaded with Windows XP operating system while the server units run on SCO-UNIX

operating system.

4.2 Teleperm XP

OT1 OT2 OT3 OT4 OT5

Terminalbus

PU1 PU2 SU ES
FBs: 1,2,3,
1,2,3 50 4,5,6
4,5,6
Anlagenbus

AS1 AS2 AS3 AS4

FBs: 1,2 2,3,4 1,4,5,6 6
6
[6] Fig 4.1 Teleperm XP

Key

AS………Automation System

SU………Server Unit

28
 PU……..Processor Unit

OT……..Operator Terminal

4.3 Technologies Learnt

I learnt how to check plant status, to start and stop processes and also to carry out backups on

server units and operator terminals. I was taught system administration using SCO – UNIX in

plant control systems and I had the opportunity to use basic commands for checking plant

status, starting and stopping a process.

I learnt about major devices that are used in the DDCS which are the star coupler and GET

and SRUCK machine. The GET and SRUCK machines are used to

• create simulation of the process variables,

• to backup data,

• to transfer and check plant data

• to generate code to modify parameters.

The star coupler is a device that takes in an input signal and splits it into several output

signals and serves the same function as a switch.

4.4 Software Development

I and my fellow student on attachment have been assigned to develop an Asset Register

management system and we are still in the early stages of system analysis. We began this

project on the on the 1st of May 2010. This system is meant to be used by the ICT personnel

at Hwange Power Station to manage all ICT assets in the power station. We are using Delphi

programming language to write the coding and to develop the interface. According to our

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schedule we must be implementing the system month end of August 2010. I was actively

involved in data gathering and the major data which we collected was the serial numbers for

the Computer equipment used by all the users in power station. This equipment includes

Computer box that embodies the Central Processing Unit (CPU), the Visual Display Unit

(VDU), the keyboard, mouse, printer, projector and scanner.

I have so far managed to design the interface forms for the Assert register system and also

made a database for user records and equipment records.

4.5 Conclusion
Since Plant Control systems is a critical area in the generation of electricity in the power

station I did not get the opportunity to physically study work in this area because the systems

are always running and in use by Plant Operators. Any mistakes when working on the system

can disrupt the generation of electricity. However I would get an opportunity when the units

were down thus could learn about backups on these machines which run on SCO UNIX

operating system. The Plant Control systems were designed by Siemens and hence when

there are major problems their specialists and consultants are called to solve these problems.

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CHAPTER 5: PROBLEMS, RECOMMENDATIONS AND CONCLUSION

5.0 Problems
Below are a number of problems the IT Department faced as whole during

my attachment.

• Network security was difficult to maintain as the Domain server is

misbehaving and hence anyone who could get a username and password could

basically access the internet at will and for as long as they wished. (The

principle previously employed had specific individuals who had internet access

and their access times set).

• Also the different operating systems in use make it difficult to introduce

a uniform network security measure as some operating systems are poor at

security.

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• The current network cables in use are susceptibly prone to natural

dangers like the rain and insects as well as rodents. This is proven as some of the

cables malfunction during the rainy season and some are at times bitten by

rodents.

• Most of the machines in use at the power station have since seen their

days this is mainly seen through the rate at which the same machines are always

in the workshop with one malfunction or the other. Also these machines have

since become very slow and have a small memory capacity which make sit

difficult to install certain operating systems ( like windows XP and Vista)and

application software (like Office 2003 & 2007, Acrobat 6-9) .

• Initially there was no Antivirus Server so there was a huge problem of

computers being frequently affected by viruses. The problem was solved when

the company purchased a licensed Antivirus software that had a dedicated server

which automatically updates user computer.

• Shortage of equipment for use by ICT personnel and examples of such

equipment are Digital multi meters, RJ 45 caps, and electronic component

spares.

5.1 Recommendations
To Hwange Power Station my recommendations for the ICT department are for them to add

on the ICT under-graduate attachment programme areas of focus such as working in different

departments within the station as could help in giving students a better appreciation of how

these departments work and their general contribution to the whole organization. I would also

recommend the upgrading of the current Network system from dial up which has a slow

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transmission rate to Very Small Terminal Aperture (VSAT) system which uses satellites and

provides faster and reliable network system. VSAT can also be easily used to form a Wide

Area Network which would incorporate all the ZPC social amenities within Hwange town.

Repair or reconfiguration of the Domain server and re-enforcement of the network security

through the introduction of user levels especially on internet access. Each user must be made

liable to their account i.e. if any network rule violations or breaches are experienced and

logged on the user’s account the user is to be found responsible and appropriate action taken

(e.g. downloads of pornography and infected materials).

5.2 Conclusion
The Industrial attachment at Hwange Power Station gave me a good picture of how a

company really operates and developed my imaginative and creative skills. My period of

attachment was an eye-opener as it also helped me to appreciate the operation of the working

environments versus the theoretical background I had gained from the college. My

communication skills greatly improved as I learnt to communicate with different users from

different departments within the company and I learnt to appreciate their different levels of

understanding of ICT technologies and equipment. Technically I gained considerable skills

and knowledge of troubleshooting software and hardware problems. I did get a lot of support

the ICT team I was working with, their patience and support really made me comfortable and

enjoyed working with them.

Working in all sections of the company provided me with more knowledge on business

know-how and management. The employees were also helpful and I got the assistance

required at all times and this contributed to my learning objectives.

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Appendix

ZESA – Zimbabwe Electricity Supply Authority

ZPC – Zimbabwe Power Company

ZETDC - Zimbabwe Electricity Transmission Distribution Company

ICT – Information Communication Technology

VSAT - Very Small Terminal Aperture

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References

[1] Figure 1.0: ZESA Holdings Limited Structure:- Human Resources Department Wall

Chart 2009

[2] Fig 1.0 ZPC Organizational Structure:- Human Resources Department Wall Chart, 2009

[3] Fig 1.1: ICT Structure:- ICT Engineer Wall chart, 2009

[4] Fig 2.0 Network Setup Structure:- produced by IT Software Technicians, 2009

[5] Fig 4.0 Teleperm ME:- Siemens Manual page 13 © Siemens AG 1997,

Prepared by Chris Waddicor

[6] Fig 4.1 Teleperm XP:- Siemens Manual page 7 © Siemens AG 1997,

Prepared by Chris Waddicor

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