SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

Project Overview The existing Cart Transport System (CTS) was installed at SATS Catering Pte Ltd’s SICC2 site in 1995. The ‘low level’ controls for the system comprise 4 x Modicon 984 785E Central Processing Units (CPUs) and associated I/O and 1 x Modicon 984 145 CPU. Hanger information routing is aided using a Eureka Type 311 RFID Tag Reading System. Tag Readers are located at strategic decision points around the system, primarily before diverts and hoists. The PLC CPUs communicate to a higher level Cart Management Control System (CTMS) via the Modbus Plus protocol. The CTMS reads and writes information from/to unique PLC registers. The CTMS and its associated SCADA was previously upgraded by ASS in the year 2009. Both the Modicon 984 PLCs and the Eureka Tag Reading System have become obsolete and are no longer supported by their respective manufacturers and distributors. As a result of this situation, SATS decided to upgrade the overall system(s). To this end, ASS proposed to utilise the equipment described below to facilitate the upgrade and were awarded the upgrading project in April 2014. To mitigate system downtime, the overall upgrade was performed in stages.

• The Modicon 984 785E CPUs have been replaced with Modicon Quantum 534B CPUs

• The Modicon 984 145 CPU has been replaced with a Modicon Quantum BMXP CPU

• The Modicon MODSOFT Programs have been migrated to Modicon CONCEPT V2.6

• The Modicon 800 Series I/O has been replaced with Modicon Quantum 140 Series I/O

• The Eureka 311 Tag Reading System has been replaced with a Pepperl + Fuchs IDENT System

Phase 1 – Upgrade PLC CPUs and the Primary I/O Rack complete with modules. Migrate existing PLC Logic Programs from Modbus Plus to Modicon Concept. The primary rack houses the PLC CPU, Power Supply and several Digital I/O modules. The existing Modicon 800 Series I/O Rack was replaced with a new Quantum 16 Slot Rack which houses the Power Supply, Quantum CPU, RIO Module, Ethernet Module and Digital I/O Modules. The Quantum range of CPUs are able to support the existing 800 Series I/O located in the Sub-Racks. A special Swing Frame was used to replace the I/O Racks which eliminated the requirement for any cabling changes. The work was performed in 4 sub-phases (Phases 1A to 1D) to accommodate each of the 4 Main PLC Control Panels. Each Sub-Phase required System downtime for 1 Day (8 Hours).

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

This Phase enabled the PLC CPUs to be upgraded (complete with program migration) and ready to accept the installation of the new Modbus TCP/IP dependant Tag Reading System. Due to the dependence of the existing Eureka 311 Tag Reading System on the RS232 Ports (only available at the P892 Modules hosed in the PLC Sub-Racks), the remaining PLC Sub-Racks were upgraded in a later phase. With this phase complete, the new Tag Reading System could be implemented in parallel with the existing Eureka 311 Tag Reading System. SATS took this opportunity to also upgrade the Fault Displays located on each of the Main PLC Control Panel Doors. The existing Serial Alphanumeric Displays were replaced with Modbus TCP/IP enabled colour touch screen HMIs. In effect, as a serial connection would not be available later, this was a necessary requirement. The following Image 1 shows the installed Primary Modicon Quantum Rack complete with CPU and I/O Modules. Image 1 – Modicon Quantum Equipment

Phase 2 – Install Tag Reading System and Commissioning ASS proposed to use the Pepperl + Fuchs (P+F) IDENT RFID Tag Reading System. The system offers a reliable close proximity read utilising the Modbus TCP/IP protocol. Each IDENT Decoder Device is able to “multiplex” the signals from 4 x Read Heads. The IDENT Decoder Devices can be connected in series which minimises the cabling between the PLC and IDENT Decoder Devices. The IDENT Decoder Devices use a 24V DC Power source which was obtained from the existing CTS local Junction Boxes, again, minimising the cable installation. Apart from connectors and spacers for the equipment (Power, TCP/IP, Read Heads, spacers), the Pepperl + Fuchs IDENT System comprises 3 major components:

Modicon PLC and Tag Reading System Upgrade

• IDENT Controller Device

• Read Heads – Type: IQH1

• Passive RFID Tags – Type: The following are images 2 – Image 2 - IDENT Decoder

Image 3 - Read Head

Image 4 - Passive RFID Tag

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

IDENT Controller Devices – Type: IC-KP-B17-AIDA1

IQH1-FP-V1

Type: IQC21-50P

4 are of the P+F Equipment

Modicon PLC and Tag Reading System Upgrade

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

The following images 5 - 7 are of P+F Equipment installed Image 5 – IDENT Decoder Installed

Image 6 – Read Head Installed

Image 7 – Passive RFID Tag Installed

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

Please note that the new Passive RFID tag is initially installed in parallel with the existing Active Eureka 311 Tag. Tags can be easily Written to and Read from using a hand held device. Each CTS hanger/carrier was fitted with a new Passive RFID Tag together with the existing Eureka 311 Active RFID Tag. The configuration of the IDENT Decoder Devices is via a user friendly web browser interface. The remainder of the ‘system’ set-up (Read Head configuration) was ‘built’ into the PLC logic. The following Drawing 1 shows a typical topology for one PLC Control Panel Area. There are 4 PLC Control Panel Areas comprising a total of 27 IDENT Decoder Devices and 98 Read Heads. There are a total of 600 hangers in the CTS. Drawing 1 – PLC Control Panel Area Topology

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

The PLC Programs were updated to incorporate the changes required for the Tag Reading System. ASS implemented a simple key switch at each Main PLC Control Panel to enable the new Tag Reading System to be run in parallel to the existing Eureka 311 Tag Reading System. By activating the key switch, the new and existing Tag reading System would be running in parallel. With the key switch deactivated, only the existing 311 Tag reading System would be activated. The PLC programs were developed to incorporate the new Tag Reading System without making and fundamental changes to the existing Ladder Logic. The existing code for ‘No Read’ Alarms was not changed. The new PLC code interacted with the existing code seamlessly. The following diagram 1 shows the general ‘flow’ of the PLC logic. Diagram 1 – PLC Logic Flow

ASS developed some simple and basic SCADA pages to enable the visibility of both Tag Reading Systems running in parallel i.e. at the intermediate and existing logic blocks shown above.

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

As the installation potentially involved working on a live moving system and utilising existing Trunkings, SATS decided to implement a 3 week system shutdown to facilitate the installation and basic commissioning. The alternative would have been to use minimal daily system downtime (2 hours per day) which would have prolonged the overall project implementation. Once the installation and basic cable testing was completed, it was possible to ‘dry-run’ the CTS to ensure that no problems had occurred during the installation period. With the new P+F Tag Reading System installed, it was possible to use the temporary SCADA pages to monitor the performance of the new system and make necessary adjustments to Read Heads to optimise the read rate. Once confident of the system performance, the key switches were activated to utilise the system. The systems were run in parallel until the read rate of the new system was at an acceptable level. Once the system was acceptable, the existing 311 Tag Reading System was systematically dismantled (MUX Decoders, Antennae, Battery Tags, RS232 to 422 Converters removed). Phase 3 – Upgrade remaining PLC I/O Racks complete with modules With the new P+F Tag Reading System in place and the existing Eureka 311 System removed, it was possible to upgrade the remaining PLC Sub-Racks. This upgrade was carried out in 4 Sub-Phases (Phases 3A to 3D). Each Sub-Phase required system downtime for 1 day (8 hours). Utilising the special Swing Frame technology, the existing Modicon 800 Series Racks were replaced with Modicon Quantum 16 Slot Racks, complete with Power Supply Modules, RIO Modules and Digital I/O Modules. PLC Programs were modified (configuration changes) to accommodate the installation of the new Racks and Modules. Phase 4 – Migrate communications between PLCs and from PLCs to CTMS from Modbus Plus to Modbus TCP/IP With the PLC and Tag Reading System upgrade being completed and commissioned, it was possible to migrate the communications protocol between the PLCs and between the PLCs and the CTMS from Modbus Plus to Modbus TCP/IP. The PLCs were connected to the existing CTMS Ethernet Network via new cabling (laid during the Phase 2 shut down period) and local 8 Port Network Switches located in each Main PLC Control Panel. This upgrade has allowed for access to both the PLC CPUs and the IDENT Decoder Devices from anywhere on the CTMS Network. This is useful for the technical staff based in the Technical Duty Room. A router installed into this Network allows for remote access from outside of the facility. The following Drawing 2 shows the overall topology of the CTMS, PLCs and Tag Reading System after the upgrade was completed.

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

Drawing 2 – Topology of Completed System

Project Schedule Including for the design and the delivery lead time for some of the equipment (up to 12 weeks), the project was completed within an overall timeframe of 8 Months. During this time the system downtime was approx 30 days (all Phases). The actual new systems were fully available after approx. 6 Months. Summary The overall upgrade has been an overwhelming success . The effectiveness of the system has been proven with minimal ‘No Read’ Alarms. The Alarms that are generated (average: 3 per day), are generally associated with mechanical issues (Tag Brackets not aligned after collisions). The previous Eureka 311 System generated many faults (2500 per month) due to equipment/electronics failures and expired or low Tag batteries. The new P+F Tag Reading System is able to generate additional Alarms for ‘IDENT Decoder’ and ‘Read Head’ failures/malfunctions. The Modbus TCP/IP communications is faster and more reliable than the Modbus Plus protocol. The Modicon Quantum PLC equipment is reliable and easy to trouble shoot. The communications have also made maintenance easier (central point to access the equipment and remote access enabled).

SATS Catering SICC2 Modicon PLC and Tag Reading System Upgrade

Project Summary

The set-up required for replacement parts has been simplified and Tag Reading and Writing is made easy utilising a user friendly hand held device.