Case Studies | RCF Automation

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Replacement of Controllers for Gas Detection

One of RCF Automation’s integrated safety systems uses industrial networks to publish information from gas detectors from Life Safety Systems into Building Management Systems and IT infrastructure. This integration is a pivotal part of the operation for both managers who are responsible for the field devices and first responders who can enquire about the system when required.

Project Background

The existing controllers had an interface with the building Life Safety System via Modbus RTU, while the new controllers communicate in Modbus TCP. RCF Automation was engaged to decommission the Modbus RTU communication and establish communication with new controllers via Modbus TCP. All infrastructure to be used was supposed to be existing. Using RCF Automation’s approach to project management and technical development, we quickly identified technical issues with the initial solution requested by the customer. The following issues were found and addressed:

Issue

Solution

Modbus TCP network was supposed to be added to the existing automation network, creating traffic and workload that was not in the original design.

A well-known gateway has been added between both networks ensuring segregation and allowing user-defined access management.

Existing Network cables were not consistent and not properly documented. Part of the network was found to be incompatible with the protocol Modbus TCP.

The design of the infrastructure was added to the scope. Modified architecture included new cables and redeployment of existing network switches where required.

Differences in the Modbus mapping mean that a different programming approach was required and extra functionalities could be implemented.

The application was developed based on the guidance provided by the manufacturer of the new controllers, which conflicted with the initial assumptions made by the project.

The customer informed us that soon, other systems are supposed to read data from the new controllers and the expectation was to join multiple networks and have multiple clients acquiring data from the controllers.

The gateway selected was upgraded to a version that can operate in up to four different networks and manage traffic among them securely.

Most of these issues were addressed in the tender phase while we communicated with the customer via RFIs (requests for information). This approach allowed the customer to understand the costs generated by gaps in the scope before starting the project, which facilitated the project management and reduced costs with variations. The details of the infrastructure were only discovered in the first days of project development, thanks to RCF Automation’s approach to creating detailed design drawings in the early stage of the project.

As part of the network was supposed to use existing infrastructure, our engineers and technicians conducted a site inspection and found parts of the existing cabling to be non-compliant. As possible problems with the existing infrastructure had already been flagged by RCF Automation, this rework was conducted using resources allocated for this contingency. The timing when this discovery was made allowed the network rework to be performed before the installation started, so the impact on schedule was irrelevant.

Results

Using the RCF approach to project management and its quality management system, issues in the scope were found and addressed in the early stages of the project, either in the tender phase or soon after the project started. This allowed the project manager to implement a realistic schedule that minimised downtime and improved the coordination between all stakeholders.

Downtime in the communication reduced from 3 weeks to 1 day:
Early investigations of the proposed network topology found hidden issues. According to the original plan, these issues would not be discovered until commissioning, and the lead time to redesign the infrastructure and receive the materials needed could make communication impossible for several weeks after the new controllers were installed. The new controllers were fully integrated, with all communications, from the day they were commissioned.

Reduction in costs and lead time with future expansions:
The scope of work was adjusted early in the project and all new devices and programming implemented allow for the complete communication mapping to be acquired from the new controllers. This includes spare I/Os and possible future applications. Every part of the network was ready to operate when new sensors were added. Only minimal modifications to SCADA graphics and the usual commissioning work were required.

New standard deployment strategy created:
The approach to integration used by RCF Automation has been re-used across other buildings in the same site to integrate hundreds of similar sensors in the following years.