STP052 13 C04 007 (A5 1303) .Rev.0

PROJECT: GPP5/6 PLC5 CONTROL SYSTEM UPGRADE PROJECT
ITEM: PLC
CONTRACT NO.:STP052
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CHAPTER 1 OVERVIEW
TABLE OF CONTENT
Paragraph Page
1. OVERVIEW ............................................................................................................ 3
1.1. DOCUMENT PURPOSE ................................................................................................................3
1.2. PROJECT DESCRIPTION .............................................................................................................3
1.3. PROJECT REQUIREMENT ...........................................................................................................3
1.4. VENDOR DESIGN DOCUMENTS ................................................................................................3
2. REFERENCE DOCUMENT .................................................................................... 5

2.1. CLIENT DESIGN DOCUMENT .....................................................................................................5
2.2. APPLICABLE CODES AND STANDARDS .................................................................................5
3. ABBREVIATIONS ................................................................................................... 6
4. SYSTEM HARDWARE ........................................................................................... 7

4.1. ControlLogix Enhanced Redundancy System .............................................................................7
4.1.1. General ..............................................................................................................................................7
4.1.2. Hardware Architecture ....................................................................................................................7
4.1.3. Controller Redundancy ...................................................................................................................7
4.1.4. Switchovers.......................................................................................................................................7
4.1.5. ControlNet Redundancy .................................................................................................................8
4.1.6. Online Modifications ........................................................................................................................8
4.1.7. Online Replacement ........................................................................................................................8
4.2. ENVIRONMENTAL CONDITIONS................................................................................................8
4.3. PHYSICAL DESCRIPTION ............................................................................................................8
4.4. SYSTEM ENCLOSURE CONSTRUCTION.................................................................................8
4.5. ENCLOSURE VENTILATION ........................................................................................................9
4.6. NAMEPLATES AND IDENTIFICATION .......................................................................................9
4.7. ELECTRICAL DESCRIPTION .......................................................................................................9
4.8. POWER DISTRIBUTION ................................................................................................................9
4.9. GROUNDING DESCRIPTION .......................................................................................................9
4.10. GROUNDING SYSTEMS ...............................................................................................................9
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4.11. CABLING / WIRING DESCRIPTION ............................................................................................9

4.12. WIRING COLORS shall be as described below: ........................................................................9
4.13. CORE MARKER NAMING ...........................................................................................................10
5. PROGRAMMABLE LOGIC CONTROLLER (PLC) ............................................... 11

5.1. SYSTEM HARDWARE SCOPE (MAJOR ITEMS) ...................................................................11
5.2. ControlLogix Chassis (1756-Axx) ................................................................................................12
5.3. ControlLogix Power Supply (1756-PA7x) ..................................................................................12
5.4. ControlLogix Controller (1756-L7x) .............................................................................................12
5.5. ControlLogix Redundancy Module (1756-RM2)........................................................................12
5.6. ControlLogix EtherNet/IP Module (1756-EN2T)........................................................................12
5.7. ControlLogix ControlNet Enhanced Module (1756-CN2R) .....................................................12
5.8. ControlLogix Digital Input Module (1756-IB16) .........................................................................13
5.9. ControlLogix Digital Output Module (1756-OB16E) .................................................................13
5.10. ControlLogix Analog Input Module (1756-IF16) ........................................................................13
6. SOFTWARE CONFIGURATION .......................................................................... 14

6.1. INTRODUCTION ...........................................................................................................................14
6.2. RSLOGIX 5000 FEATURE...........................................................................................................14
6.3. RSLOGIX 5000 VERSION ...........................................................................................................14
6.4. RSLOGIX 5000 MIGRATION.......................................................................................................15
6.5. RSLOGIX 5000 AND THIRD PARTY INTERFACING .............................................................20
7. SYSTEM VERIFICATION ..................................................................................... 21

7.1. Internal Acceptance Test ..............................................................................................................21
7.2. Factory Acceptance Test ..............................................................................................................21
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1. OVERVIEW
1.1. DOCUMENT PURPOSE
This Functional Design Specification (FDS) outlines the proposed design for B56-2305 AIR DRYER-
A5-1303 PLC5 Control System Upgrade Project. The FDS will cover the hardware and software
rd
design outlines as well as interface details to 3 party packages.
The guidelines are based upon sound engineering practices and standardized solutions that allow
consistent design of the configuration amongst all the PLC5 migration solution. The typical solutions
described in this document are based on standard functions and operations as described in the
Allen Bradley PLC5 Migration User Manual.
1.2. PROJECT DESCRIPTION

The system will provide a hot-backup redundancy ControlLogix PLC as direct replacement to the
obsolete PLC5 control system for above B56-2305 AIR DRYER-A5-1303 unit. The Control System
philosophy will be maintained accordingly to existing PLC program.
A complete new ControlLogix PLC and IO set will be provided to replace the existing redundant
PLC5 PLC and IO module. Migration kit of PLC5 to ControlLogix will be provided also to minimize
wiring works and shut-down time. Local Operator interface is maintained with the existing PanelView
Module with existing communication RIO network. Existing interface of PLC5 to centralized
DCS/SCADA will be replaced with redundant Modbus TCP/IP with the Prosoft Ethernet/IP to
Modbus TCP/IP Gateway.
The contract is between Sedia Teguh Sdn Bhd and Petronas Gas Bhd for the design, supply. Install
and commission of the above PLC5 migration. The main engineering contractor is Sedia Teguh Sdn
Bhd with the responsibility for the system specification and supply of design information.
The FDS provides information on how the System and associated equipment functions and the
methods by which it will be constructed and tested prior to delivery. Client documentation will be
used as the basis of the design requirements; a list of the client documentation is contained section
2.1 of this chapter.
1.3. PROJECT REQUIREMENT

The project requires hot-backup redundancy PLC system with easier maintenance and more
reliability in harsh working environment. To meet this requirement, the Allen Bradley ControlLogix
PLC will be utilized.
1.4. VENDOR DESIGN DOCUMENTS
A full list of design documents and drawings used to design the system can be found in the following
reference document:
Vendor Master Document List
Generic STP052-13-A01-001
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The following drawings& documents may be found as attachments to this FDS:
Project Execution and Quality Plan
Generic STP052-13-E01-001
Project Organization Chart
Project Schedule
Inspection Test Plan
Generic STP052-13-E02-001
Functional Design Specification
Generic STP052-13-C04
System Block Diagram
Generic STP052-13-B01
Equipment Data Sheet
Bill of Materials
Spare Parts and Interchangeability Record
Generic STP052-13-F02
Power Consumption
PLC I/O List
General Arrangement Drawings
Power Distribution Drawings
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2. REFERENCE DOCUMENT
2.1. CLIENT DESIGN DOCUMENT
DOCUMENT NUMBER TITLE
N/A Photo of the Existing Control Panel
th
N/A Existing PLC5 Logic Program Backup date 28 Jun 2013
563/5023/019-03 PLC SYSTEM ARCHITECTURE FOR DPCU
050/5023/019-03 PLC SYSTEM ARCHITECTURE FOR GPP5
060/5023/019-03 PLC SYSTEM ARCHITECTURE FOR GPP6
050/5023/002-03 OVERALL BLOCK DIAGRAM FOR PLC SYSTEM
N/A GPP-B PLC POPULATION LIST
Note Above Documentation in certain instances, may have been changed during the duration
of the project design. This will be reflected in the design drawing/documents but not updated in
this Functional Design Specification.
2.2. APPLICABLE CODES AND STANDARDS

System design will be in accordance with the Work Specification documents specified by the client.
Where applicable the equivalent European standard shall apply as listed in the International Safety
and Environmental Approvals (Doc No. 552517).
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3. ABBREVIATIONS
DMR Digital Microwave Radio
ENA Enable
EPS Early Production System
ESD Emergency Shutdown
EWS Engineering Workstation
FAT Factory Acceptance Test
FGS Fire & Gas System
FB Function Block
FPSO Floating Production Storage Offloading
HMI Human Machine Interface
I/O Input/ Output
IP Ingress Protection
IS Intrinsically Safe
LD Ladder Diagram
MOS Maintenance Override System
NIS Non-Intrinsically Safe
PLC Programmable Logic Controller
PSU Power Supply Unit
RTC Real Time Clock
SCADA Supervisory Control and Data Acquisition.
SIL Safety Integrity Level
UPS Uninteruptible Power Supply
WHP Wellhead Platform
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4. SYSTEM HARDWARE
4.1. ControlLogix Enhanced Redundancy System
4.1.1. General
Supervisory control is built around Rockwell Automations ControlLogix platform, delivering high-
performance processing and information management in an easy-to-use environment. ControlLogix
combines discrete and process control for drives, motion, safety and communications, with state-of-
the-art I/O, in a small, cost effective package.
ControlLogix Enhanced Redundancy System offers bumpless switchover and high availability.
ControlLogix supports online additions and modifications of I/O modules, while the process keeps
running. The system supports all IEC61131-3 programming languages. Plus every controller
features a tag-based, realtime database that integrates seamlessly with software applications.
4.1.2. Hardware Architecture
The ControlLogix Enhanced Redundancy System consists of a redundant chassis pair of two
synchronized ControlLogix chassis with identical components in each with matching chassis,
module type, slot placement, firmware revision and series level. The redundant chassis pair is
connected using fiber-optic cable via the 1756-RM2 Redundancy Module.
The ControlLogix I/O modules provided shall be simplex and reside in the remote I/O chassis. The
remote I/O chassis shall be connected to the controller chassis pair via dual redundant 5MBps
ControlNet I/O networks. The DHRIO modules shall also reside in the remote I/O chassis for
communication to existing DH/RIO network devices e.g. Panel View and DH+ peer to peer
communication.
4.1.3. Controller Redundancy
The 1756-RM2 Redundancy Modules, one in each chassis of the redundant chassis pair, jointly
supervise the control system operating states and transitions, establishing the framework for system
redundancy. This bridge between chassis facilitates the exchange of control data and
synchronization of operations.
Configuration of the redundant system is plug-and-play manner without any programming. Once the
redundant chassis pair contains all desired components are powered, no further tasks are required
to activate system redundancy. The 1756-RM2 modules automatically determine the operational
state of each of the chassis pair and are ready to accept commands and provide system monitoring.
The 1756-RM2 Redundancy Modules in both the primary and secondary chassis monitor events
that occur in each of the redundant chassis. If certain faults occur in the primary chassis, the
redundancy modules execute a switchover bumplessly to the healthy secondary chassis.
4.1.4. Switchovers
During redundant system operation, if certain conditions occur on the primary chassis, primary
control is switched to the secondary chassis. After a switchover occurs, the new primary controller
continues to execute programs beginning with the highest-priority task that had been executing on
the previous primary chassis.
These conditions below cause a switchover:

Loss of power
Major fault on the controller
Removal or insertion of any module
Failure of any module
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Damage to a ControlNet cable or tap - This event only causes a switchover if it results in
the ControlNet communication module transition to a lonely state, that is, the module
does not see any devices on the network.
Loss of an EtherNet/IP connection - This event only causes a switchover if it results in the
EtherNet/IP communication module transition to a lonely state, that is, the module does
not see any devices on the network.
A program prompted command to switchover
4.1.5. ControlNet Redundancy

Redundant ControlNet networks are used to connect redundant controller chassis to remote I/O
chassis. The use of redundant ControlNet media prevents a loss of communication if a trunk line or
tap is severed or disconnected.
4.1.6. Online Modifications
ControlLogix controllers and the RSLogix 5000 software provide the ability to perform runtime
modifications. This includes the creation of new data structures, tags, tasks, programs, and routines
and also the addition of select system I/O modules, all while the system is fully operational.
Additionally, application code can be modified, tested and downloaded while the system continues
to operate.
In addition to being able to modify a controllers contents while running, multiple users should have
simultaneously access to a running controller. Changes made by one user are to be automatically
propagated or uploaded to the other users project view so that each user has an up-to-date image.
4.1.7. Online Replacement
ControlLogix modules are capable of removal and insertion under power. This feature allows greater
availability of the overall control system because, while the module is being removed or inserted,
there is no additional disruption to the rest of the controlled process. For simplex I/O configuration,
MOS or force the affected I/O may require prior to module replacement.
4.2. ENVIRONMENTAL CONDITIONS

The System will be installed at indoor environment with shielded control panel with air conditional
condition.
The system will be able to operate without failure, without error and without incurring long or short
term damage if system is out of operation for a period up to 72 hours where temperature can be
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continually low or high (range 0 C to 60 C) humidity 5% to 95% (non-condensing).
4.3. PHYSICAL DESCRIPTION

Please refer to the general arrangement STP052-13-B02-007 of the ControlLogix Control System.
4.4. SYSTEM ENCLOSURE CONSTRUCTION

The redundant PLC set and IO module with migration kit will be installed at existing control panel
after the existing PLC5 Control System is dismantled during the shut-down. No new enclosure will
be constructing and supply in the project scope.
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4.5. ENCLOSURE VENTILATION

No changes to the existing system cabinet where enclosure IP rating, ventilation and facility utilities
remain unchanged.
4.6. NAMEPLATES AND IDENTIFICATION

No changes on the existing nameplate.
4.7. ELECTRICAL DESCRIPTION

The PLC and IO set will be powered by existing power source in the control panel. Minor wiring will
be carried out to the power distribution for the new PLC and IO set.
4.8. POWER DISTRIBUTION

Power Distribution to the PLC, IO, and any hardware in the control panel remained the similar; refer
to the Power Distribution Drawing STP052-13-B03-007 for more details.
4.9. GROUNDING DESCRIPTION

No grounding change is required. Grounding specification remained the same for the new PLC and
IO set.
4.10. GROUNDING SYSTEMS

Separate grounding systems will be provided for Equipment Safety Earth, Instrument Earth,
Electrical Earth and 0VDC Reference Ground. Dedicated Tinned Copper bus-bars will be provided
for each system. The Instrument Earth and 0VDC Reference Ground bus-bars will be fully isolated
from the cabinet metal works. The field power supplies are grounded, whilst the system power
supplies are directly connected to the UPS. The system -VE reference will be kept separate from the
field 0V reference grounds. All the earth and ground connections must be terminated at a suitable
location by others.
4.11. CABLING / WIRING DESCRIPTION

No new cabling and wiring will be supplied to the control panel, except minor touch up to the power
distribution to the PLC and IO module. System Cabling supplied shall be of flexible stranded copper
conductor type. Wiring shall be sized according to the load requirements and shall be a minimum of
2
0.5mm for signal and output controls. The wiring insulation shall be 600/1000V grade for power and
250/400V for other wiring.
4.12. WIRING COLORS shall be as described below:

Type of wire GPP Standard IEC Standard
AC Live Brown Brown
AC Neutral Blue Light Blue
Protective Earth Conductor Green and Yellow Green and Yellow
Control Voltage 120V DC White White
Control Voltage 24V DC Red Red
Control Voltage 0V DC Black Black
Non IS Signal Wiring Grey Grey
IS Signal Wiring Light Blue Blue
Instrument Earth Green and Yellow Green and Yellow
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4.13. CORE MARKER NAMING

No changes on the existing core marker naming where no installation works to the I/O cabling.
According to the migration kit, the existing PLC5 I/O swing arm will be maintained and mounted to
the assembly kit and cover beneath the new ControlLogix chassis (Existing IO core marker will be
covered with the assembly kit plate). New ControlLogix IO conversion cable is pre-molded and
connected between the new I/O card and existing PLC5 swing arm.
We will provide the label (as per existing I/O core marker) and place on the front of new
ControlLogix I/O card as per the I/O listing document STP052-13-C05-007.
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5. PROGRAMMABLE LOGIC CONTROLLER (PLC)

5.1. SYSTEM HARDWARE SCOPE (MAJOR ITEMS)
The Systems contains the following Materials:
No. Item Name Model Brand Quantity
CONTROLLER CHASSIS
1 1756-A4 Chassis 1756 4 slots Allen Bradley 2
2 1756-L71 Processor Logix5671 With 2 Mbytes Memory Allen Bradley 2
3 1756-RM2 Redundancy Module Allen Bradley 2
4 1756-RMC1 Redundancy Module Cable, 1M Allen Bradley 1
5 1756-PA72 VAC Power Supply 85-265 (5V @ 10 Amp) Allen Bradley 2
6 1756-CN2R ControlNet Interface Module Allen Bradley 2
7 1756-EN2T EtherNet 10-100M Bridge Module Allen Bradley 2
REMOTE I/O CHASSIS
1 1756-A7 Chassis 1756 7 slots Allen Bradley 1
2 1756-PA72 85-256 VAC Power Supply Assembly Allen Bradley 1
Mounting Assembly for 1771 to 1756 I/O Field
3 1492-MUA1B-A4-A7 Allen Bradley 1
Wiring Conversion System, 4 or 7 slot chassis
4 1756-CN2R ControlNet Redundant Interface Module Allen Bradley 1
5 1756-IB16 VDC Input 10-31 16 Pts (20 Pin) Allen Bradley 1
Conversion Module for 1771 to 1756 I/O Field Wiring
6 1492-CM1771-LD001
Conversion System
Allen Bradley 1
Conversion Cable for 1771 to 1756 I/O Field Wiring
7 1492-CONCAB005X
Conversion System, 0.5 meters
Allen Bradley 2
8 1756-IF16 Analog Input - Current/Voltage 16 Pts (36 Pin) Allen Bradley 1

9 1492-CM1771-LA001
Conversion System
Allen Bradley 1
Conversion Cable for 1771 to 1756 I/O Field Wiring
10 1492-CONACAB005B
Conversion System, 0.5 meters
Allen Bradley 1
11 1756-N2 Empty Slot Filler for 1756 Chassis Allen Bradley 2

12 1756-OB16E VDC 2 Amp Output 30-60 16 Pts (20 Pin) Allen Bradley 1
13 1492-CM1771-LD006
Conversion System
Allen Bradley 1
14 1786-TPS ControlNet T-Tap/Straight Allen Bradley 6

15 1786-XT ControlNet 75 OHM Terminator Plug Allen Bradley 4
16 1756-DHRIO Communication Module DH+ and RIO Allen Bradley 1
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5.2. ControlLogix Chassis (1756-Axx)

The same ControlLogix chassis is used for both controller and I/O modules and comes with various
slot numbers. The proposed controller chassis shall be 1756-A4 chassis with 4-slot, and the I/O
chassis shall consist of both 1756-A7 chassis with 7-slot. The chassis backplane provides a high-
speed communication path between modules and distributes power to each of the modules within
the chassis.
5.3. ControlLogix Power Supply (1756-PA7x)

ControlLogix power supplies are used with the 1756 chassis to provide 24V DC power directly to the
chassis backplane. The proposed 100-240VAC power supply 1756-PA72 shall be mounted directly
on the left end of the controller chassis, where it plugs directly into the backplane. Every chassis
shall be fitted with one power supply.
5.4. ControlLogix Controller (1756-L7x)

The ControlLogix controller provides a scalable controller solution that is capable of addressing a
large amount of I/O points. The proposed ControlLogix controller 1756-L71 is comes with 2MB user
memory. The controller shall be placed into the 2nd slot of the chassis.
The Logix CPU executes application code and messages. In the 1756-L71 controller, the Logix CPU
is a dual-core CPU. The backplane CPU communicates with I/O and sends/receives data from the
backplane. This CPU operates independently from the Logix CPU, so it sends and receives I/O
information asynchronous to program execution.
5.5. ControlLogix Redundancy Module (1756-RM2)

Two 1756-RM2 ControlLogix redundancy modules working together supervise the operating states
and state transitions, which establish the basic framework for redundancy operations. The
redundancy pairs provide a bridge between chassis pairs that allow other modules to exchange
control data and to synchronize their operations.
5.6. ControlLogix EtherNet/IP Module (1756-EN2T)

The Ethernet Industrial (EtherNet/IP) network protocol is an open industrial-networking standard that
supports both real-time I/O messaging and message exchange. The EtherNet/IP network uses off-
the-shelf Ethernet communication chips and physical media.
5.7. ControlLogix ControlNet Enhanced Module (1756-CN2R)

The ControlNet network is an open, control network for real-time, high-throughput applications. The
ControlNet network uses the Common Industrial Protocol (CIP) to combine the functionality of an I/O
network and a peer-to-peer network providing high-speed performance for both functions. The
ControlNet network supports deterministic, repeatable transfers of all mission-critical control data in
addition to supporting transfers of non-time-critical data. I/O updates and controller-to-controller
interlocking always take precedence over program uploads and downloads, and messaging.
The ControlLogix ControlNet Enhanced Module 1756-CN2R resides in the 1st slot of the
ControlLogix controller chassis and provides the interface to the I/O chassis. The connections are
via dual redundant co-axial ControlNet cables with 5MBps.
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5.8. ControlLogix Digital Input Module (1756-IB16)

The ControlLogix Digital Input module provides 16 input points arranged in 2 groups of 8 points. The
module operates in a wide voltage range of 10 - 31.2V DC with reverse polarity protection. The
module provides 250V continuous voltage isolation between outputs-to-backplane, and between
output group to group. The module supports software configurable electronic module keying.
The modules are installed in the I/O chassis. Configuration of the module is carried out using
RSLogix 5000. Once configured and loaded into the ControlLogix controller, replacement modules
can be replaced with chassis power applied without additional disruption to the rest of the controlled
process. For simplex I/O configuration, MOS or force the affected I/O may require prior to module
replacement.
5.9. ControlLogix Digital Output Module (1756-OB16E)

The ControlLogix 24Vdc Digital Output module provides 16 nos of electronic fused output points
arranged in 2 groups of 8 points. The module operates in a wide voltage range of 10 - 31.2V DC
with reverse polarity protection. Maximum current can be drawn per point is 0.5A, with total
maximum current module not exceeding 16A.
The module provides 250V continuous voltage isolation between outputs-to-backplane, and
between output group to group. The module supports software configurable electronic module
keying.
replacement.
5.10. ControlLogix Analog Input Module (1756-IF16)

The ControlLogix Analog Input module provides 16 nos of 2-wire current inputs. Input range is user
configurable for 0-20mA or 4-20mA with resolution 16 bits.
The module provides 250V continuous voltage isolation for basic insulation type and tested at
1350V AC for 60 seconds, for isolation between I/O to backplane. Each channel comes with
electronic voltage protection of +/- 30VDC. The module supports software configurable electronic
module keying.
replacement.
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6. SOFTWARE CONFIGURATION
6.1. INTRODUCTION
The ControlLogix PLC can be program and maintain with software RSLogix5000 which is one of the core
technologies of Rockwell Integrated Architecture, Logix offers a unique approach to automation a
single control platform with a common control engine and development environment expressly designed to
deliver world-class capabilities for any automation discipline.
6.2. RSLOGIX 5000 FEATURE
RSLogix 5000 software provides design, configuration to Control System involving

discrete, process, batch,motion, safety and drive-based applications, RSLogix 5000 offers an easy-to- use
IEC61131-3 compliant interface, symbolic programming with structures and arrays and a comprehensive
instruction set that serves many types of applications. It provides ladder logic, structured text, function block
diagram and sequential function chart editors for program development as well as support for
the S88 equipment phase state model for batch and machine control applications.
With RSLogix 5000 you can
use one intuitive design and configuration software package

simplify development of complex control solutions
have greater access to real-time information
develop localized applications in a single control platform
and achieve:
optimized productivity and the ability to react quickly to market and business needs
faster startups with reduced commissioning time
reduced maintenance and training costs
lower total cost of ownership
6.3. RSLOGIX 5000 VERSION
ControlLogix5000 system hardware will be flashed to version 20.054 Enhanced for redundancy.
This enhanced redundancy firmware bundle is comprised of series and firmware revisions for each of the
modules listed in Table 1.
IMPORTANT When designing, installing, and operating the redundant chassis pair for this enhanced
redundancy system revision, you can use only the modules specified in Table 1.
Also, keep in mind the series and firmware revision requirements listed apply only to
components used in the redundant chassis pair, not to components used with the
redundancy system outside the redundant chassis pair.
For example, you can use a 1756-CN2/B communication module, firmware revision 20.013,
in a redundant chassis pair, but you cannot use any 1756-CNB communication module in
the redundant chassis pair. However, you can use any enhanced or standard ControlNet
communication modules in a remote chassis.
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Table 1 - Required Series and Firmware Revisions for Components Used in an Enhanced
Redundancy System, Revision 20.054
Firmware
Cat. No. Module Description Series
Revision
1756-CN2 ControlLogix ControlNet bridge module B 20.020
1756-CN2R ControlLogix redundant media ControlNet bridge module
1756-CN2RXT ControlLogix-XT redundant media ControlNet bridge module
1756-EN2T ControlLogix EtherNet/IP bridge module Any 5.008(1)
1756-EN2TR ControlLogix EtherNet/IP communication module
1756-EN2F ControlLogix EtherNet/IP fiber communication module
1756-EN2TXT ControlLogix-XT EtherNet/IP bridge module Any 5.008(1)
1756-EN2TRXT ControlLogix-XT EtherNet/IP redundant bridge module Any 5.028
1756-L61 ControlLogix5561 controller 20.054
1756-L62 ControlLogix5562 controller
1756-L63XT ControlLogix-XT controller
1756-L73XT ControlLogix-XT controller
1756-RM2 ControlLogix redundancy module Any 20.004
1756-RM2XT ControlLogix redundancy module
1756-RM ControlLogix redundancy module Any 3.003
1756-RMXT ControlLogix-XT redundancy module
Note: Client to install the RSLogix5000 Software with Revision 20 to support the above controller.
6.4. RSLOGIX 5000 MIGRATION
PLC5 program will be migrated to ControlLogix by using the standard RSLogix5000 software. RSLogix 5000
programming software includes a translation tool that converts a PLC-5 import/export file (.PC5 extension)
into a complete import/export file (.L5K extension). The translation tool produces a syntactically correct
import/export file, but the exact intent of the original application could be lost. This loss could be due to
differences between rules of precedence, indexed addressing, I/O addressing, etc. The log file of the above
conversion process will define the error.
After running the conversion process, the resulting import/export file still requires further manipulation.
Additional work need to be carried out for the I/O mapping, language instruction that use BTD, MOV, or COP
instructions to place this mapped data into the structures created by the conversion process.
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System parameter is PLC5 will be migrated to ControlLogix. Each of the PLC has different format and it will
be checked to maintain the necessary setting i.e. serial port setting, date time.
Logic diagram will be maintained during the migration to make sure process is not affected with the upgrade
process.
Routine of PLC5 will be maintained in ControlLogix format as continuous, event or periodic task. Each
routine type will be set to the setting as per PLC5 i.e. scan time watchdog, scan interval and etc.
PLC variable in PLC5 (generic format i.e. B3:0/0, T4:0, N7:0, F8:0. Etc) will be migrated to ControlLogix
(Tag based i.e. B3[0], T4[0], N7[0], F8[0], etc). Description of the program will be maintained. (The program
description is depends on the completeness of description in original backup of PLC5 program).
Since the redundant ControlLogix System is deployed, the IO will be placed at the remote I/O chassis
with the ControlNet network and IO configuration mapping. An Example as below
16
ITEM: PLC
CONTRACT NO.:STP052
DOC. NO.: STP052-13-C04-007
REV. NO.: A
The Digital Input/Output, Analogue Input/Output will be mapped as following method.
At Controllogix, three subroutine Map_DI (Digital Input Mapping), Map_DO (Digital

Output Mapping) and Map_AI (Analog Input Mapping) and Map_AO (Analog Output Mapping)
to be created. Example as below
Digital Input in PLC5 will be remapped to ControlLogix ControlNet Remote I/O addressing.
(I:010 will be created to RIO_CN2R:1:I.Data and mapped to I[8])
Digital output in PLC5 will be remapped to ControlLogix ControlNet Remote I/O

addressing. (O:040 will be created to RIO_CN2R_01:1:O.Data and mapped to O[32])
17
ITEM: PLC
CONTRACT NO.:STP052
DOC. NO.: STP052-13-C04-007
REV. NO.: A
Note:
A MOV instruction moves one element at a time. A BTD instruction moves a group of bits,
which lets you account for the offset in the starting bit which occurs when you map an INT data
type to a DINT data type. If consecutive I/O groups map to consecutive elements in an array, a
COP instruction is more efficient.
For example, if I:000 through I:007 map to Remotel:1:I.Data[0] through Local:1:I.Data[7],use:

COP
Source Remote1:1:I.Data[0]
Destination I[0]
Length 8
Analogue Input in PLC5 will be remapped to ControlLogix ControlNet Remote I/O

addressing, and A/D conversion will be preserved. (O503TT0101 with N13:5 will be created in
RIO_CN2R:6:I.Ch0Data and mapped to N13[5] )
Note:
PLC5 AI & AO block transfer routine will be ignored. ControlLogix provides AI & AO with on
board scaling, and configuration need to carry out to each of the channel to the I/O module only
PLC5 instruction language will be maintained as possible from PLC5 to ControlLogix. Unsupported
PLC5 instruction language in ControlLogix will be migrated to available language in newer format. The
conversion process inserts a PCE (Possible Conversion Error) instruction to identify possible errors.
The PCE instruction follows this format (in the ASCII text file):
PCE(<Message>,<PCETag)
For example:
A rung in the converted import/export file would look like:
PCE( 3000, pce00001 ), OTE( B3[0].0 );
The translation tool only partially converts MSG instructions. Further RSLogix5000 programming software
to configure each MSG instruction by completing the information on the Communications tab as per
followed:
18
ITEM: PLC
CONTRACT NO.:STP052
DOC. NO.: STP052-13-C04-007
REV. NO.: A
Block transfer to PanelView Operator Interface will be implemented using the 1756-DHRIO module.
Standard PLC5 BTR/BTW instruction will be converted to ControlLogix MSG instruction to the Panel
View. Panel View RIO configuration (Rack No, Group No, Slot number will be entered to the MSG
command in ControlLogix. Program in Panel View remains unchanged.
BTR conversion BTW conversion
System fine tuning is subjected to the final program testing in ControlLogix to make sure the program is
running at optimized method where both of the PLC5 and ControlLogix is difference in architecture and
platform.
Other Considerations, the following are additional issues to keep in mind:

The time base for timer instructions is fixed at 1 msec for a Logix controller. The conversion process
scales PLC-5 timer presets and accumulators accordingly. For example, a PLC-5 timer with a time base
of 0.01 sec and a preset of 20 is converted to a time base of 1 msec and a preset of 200.
Instruction comments are not converted.
RSLogix 5000 programming software does not support programmable input interrupts (DIIs/PIIs). A
DII/PII program in converted as a program in the continuous task.
A Logix controller is a 32-bit based controller. This means that most of the Logix instructions use 32-bit
words, as opposed to the 16-bit words in PLC-5 processors. This might mean that instructions that use
masks might work differently after the conversion.
The conversion process creates alias tags for address comments. These aliases are then used in place
of the converted tags.Aliases take up memory in a Logix controller so you might want to delete those
aliases you do not plan to use. Use the RSLogix 5000 programming software to delete aliases after you
import the project.
19
ITEM: PLC
CONTRACT NO.:STP052
DOC. NO.: STP052-13-C04-007
REV. NO.: A
6.5. RSLOGIX 5000 AND THIRD PARTY INTERFACING
All signals interfacing with third party system for example DCS and Bently Naveda Vibration Monitoring
system at Modbus TCP will be mapped in the RSLogix5000 program via Prosoft EIP/Modbus IP Gateway.
Third Party system vendor to provide adequate information for the interfacing such as:-
-the interfacing signal listing (Modbus Address)
-Modbus TCP setting (IP, Speed, Port)
-Read / write attributes of signals
20
ITEM: PLC
CONTRACT NO.:STP052
DOC. NO.: STP052-13-C04-007
REV. NO.: A
7. System verification
The verification procedures to be implemented shall consist of 2 stages:-
Internal Acceptance Test
Factory Acceptance Test
7.1. Internal Acceptance Test
The system shall be fully tested and verified internally as according to the approved Factory Acceptance
Test (FAT) Procedure prior to the official FAT with Purchaser. The internal system validation records shall
be properly documented and to be presented for Purchaser review prior to FAT if required. The FAT
procedure shall be developed to include the following:
Visual Control System inspection for compliance to the specification.
QA Inspection, including all related documentation.
Hardware Tests.
Functional Tests, simulating system inputs and outputs.
Diagnostics Testing
7.2. Factory Acceptance Test
The official FAT shall be a repeat of the Internal Acceptance Test. 100% hardware and functional testing
shall be performed by Vendors Validation Engineers and shall be witnessed by the Purchasers
Inspector.
Test certification shall be provided within the FAT Procedure document. All tests successfully performed
shall be signed and dated by the Purchasers Inspector witnessing the tests and by Vendors Validation
Engineers, as testing progresses, to provide a record of the successful completion of tests performed.
Vendor shall provide a logbook for the recording of activities during the FAT phase of the project. This
logbook shall form a history of the operations performed and shall include details of any drawing/software
changes.
Upon completion of FAT, the Purchaser's Inspector shall provide Vendor with a Test Release Certificate
prior to releasing the tested system for rig-down and packing for shipment.
21

STP052 13 C04 007 (A5 1303) .Rev.0

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STP052 13 C04 007 (A5 1303) .Rev.0

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PROJECT: GPP5/6 PLC5 CONTROL SYSTEM UPGRADE PROJECT

2. REFERENCE DOCUMENT .................................................................................... 5

4. SYSTEM HARDWARE ........................................................................................... 7

4.11. CABLING / WIRING DESCRIPTION ............................................................................................9

5. PROGRAMMABLE LOGIC CONTROLLER (PLC) ............................................... 11

6. SOFTWARE CONFIGURATION .......................................................................... 14

7. SYSTEM VERIFICATION ..................................................................................... 21

1.2. PROJECT DESCRIPTION

1.3. PROJECT REQUIREMENT

1.4. VENDOR DESIGN DOCUMENTS

Vendor Master Document List

The following drawings& documents may be found as attachments to this FDS:

Project Execution and Quality Plan

Project Organization Chart

Inspection Test Plan

Functional Design Specification

System Block Diagram

Equipment Data Sheet

Spare Parts and Interchangeability Record

PLC I/O List

General Arrangement Drawings

Power Distribution Drawings

DOCUMENT NUMBER TITLE

N/A Photo of the Existing Control Panel

563/5023/019-03 PLC SYSTEM ARCHITECTURE FOR DPCU

050/5023/019-03 PLC SYSTEM ARCHITECTURE FOR GPP5

060/5023/019-03 PLC SYSTEM ARCHITECTURE FOR GPP6

050/5023/002-03 OVERALL BLOCK DIAGRAM FOR PLC SYSTEM

N/A GPP-B PLC POPULATION LIST

2.2. APPLICABLE CODES AND STANDARDS

These conditions below cause a switchover:

4.1.5. ControlNet Redundancy

4.2. ENVIRONMENTAL CONDITIONS

4.3. PHYSICAL DESCRIPTION

4.4. SYSTEM ENCLOSURE CONSTRUCTION

4.5. ENCLOSURE VENTILATION

4.6. NAMEPLATES AND IDENTIFICATION

4.7. ELECTRICAL DESCRIPTION

4.8. POWER DISTRIBUTION

4.9. GROUNDING DESCRIPTION

4.10. GROUNDING SYSTEMS

4.11. CABLING / WIRING DESCRIPTION

4.12. WIRING COLORS shall be as described below:

4.13. CORE MARKER NAMING

5. PROGRAMMABLE LOGIC CONTROLLER (PLC)

No. Item Name Model Brand Quantity

8 1756-IF16 Analog Input - Current/Voltage 16 Pts (36 Pin) Allen Bradley 1

11 1756-N2 Empty Slot Filler for 1756 Chassis Allen Bradley 2

14 1786-TPS ControlNet T-Tap/Straight Allen Bradley 6

5.2. ControlLogix Chassis (1756-Axx)

5.3. ControlLogix Power Supply (1756-PA7x)

5.4. ControlLogix Controller (1756-L7x)

5.5. ControlLogix Redundancy Module (1756-RM2)

5.6. ControlLogix EtherNet/IP Module (1756-EN2T)

5.7. ControlLogix ControlNet Enhanced Module (1756-CN2R)

5.8. ControlLogix Digital Input Module (1756-IB16)

5.9. ControlLogix Digital Output Module (1756-OB16E)

5.10. ControlLogix Analog Input Module (1756-IF16)

6.2. RSLOGIX 5000 FEATURE

RSLogix 5000 software provides design, configuration to Control System involving

With RSLogix 5000 you can

use one intuitive design and configuration software package

6.3. RSLOGIX 5000 VERSION