currently use control system from Allen Bradley, ControlLogix 1756 system family are installed with redundancy capability, the system need to be improved to increase the availability of the system, the existing system configuration are as shown in attached picture 1
The system has some of points which need to be improved to reduce downtime:
a-Network: Full redundant network is required, as shown above we have weak network with one switch hub which can cause system shutdown in case of fault, even communication between the CPUs and I/O modules are done through one hub and one Ethernet cable.
b-Workstation: Only one workstation can be a big issue in case shutdown because of fault in windows operating system or the computer itself.
c-Communication Module: The I/O modules can communicate with the CPUs through one Ethernet Module type 1756-EN2T, so any fault in this module will cause loosing the control and I/O monitoring between the CPUs and the I/O rack.
d-System Hardening: No system hardening is available now.
e-Galvanic Isolation: There are no Galvanic isolation between the control system and field I/O signals.
The suggested system will be shown in attached picture 2.
1st stage praper an technical offer &BOM 2nd stage programming and necessary configurations.