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2330002-DCS-0001, Rev 7 PDF
2330002-DCS-0001, Rev 7 PDF
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This document and any Honeywell documents, software, code and/or drawings
referenced herein, contain proprietary information and intellectual property of
Honeywell Limited. Information contained and referenced herein is to be used
solely for the purpose submitted, and no part of such information or its contents shall
be reproduced, published or disclosed to a third party without the express permission
of Honeywell Limited. The customer may copy and distribute the information
internally in a printed format on paper but in no other format with the sole exception
of electronic copies of software for archival purposes.
Notes:
Modifications after Rev 0 will be indicated by a revision change bar in the left
hand side margin and coloured text.
1. Introduction
1.1. Purpose of document
This set of procedures outlines the steps required to install and configure both the
stations and servers at the Onesteel Whyalla Blast Furnace. Specifically the
procedures cover the Microsoft Windows XP Operating System and Experion PKS
R101 Client software required for an operator or maintenance stations, and the
backup, restore and install procedures for the Microsoft Windows 2000 Server
Operating System and Experion PKS R101 Server Software on the Servers.
The following additional items are required in order to complete the installation of a
maintenance station:
Rockwell RSLogix5000 Install and Master Disk
The following install steps in the checklist can be ignored as they are not required or
licensed for this installation:
Add computer to domain (all PC‟s are in the EXPERIONPKS workgroup)
NOTE: Operator Entry Panels have been purchased for stations in the Control Room
(EXP_OPS1, EXP_OPS2 & EXP_MNT1). The installation instructions for these are
contained in a separate document as listed in the reference documents.
When the Experion PKS client components are selected the following items should be
installed:
HMIWeb Display Builder & Station
Quickbuilder
Display Builder
System Displays
Standard Displays
Note the required Installation file “EPKS R101.0 Post Release Patch 5.zip” and the
Software Change Notice can be found in the Program Files\Honeywell\Experion
PKS\Server\User\Patches directory on either server, which is a backed up directory.
Note the required Installation file “R101_Patch9.zip” and the Software Change Notice
can be found in the Program Files\Honeywell\Experion PKS\Server\User\Patches
directory on either server, which is a backed up directory.
Note the required Installation file “R101_Patch10.zip” and the Software Change
Notice can be found in the Program Files\Honeywell\Experion
PKS\Server\User\Patches directory on either server, which is a backed up directory.
When naming the Network Connections the following convention has been used on
each PC:
“FTE OWBF Yellow” for the Yellow connection
“FTE OWBF Green” for the Green connection
The table below outlines the FTE specific settings for each Station and/or Server.
xiv. Click “OK” then “OK” again and close Internet Explorer.
iii. From Control Panel go to System then the Automatic Updates Tab.
iv. Ensure that the “Keep my computer up to date” check box is unchecked.
OneSteel Whyalla Server & Station Installation & Backup Procedures
Blast Furnace Capital and Reline Projects Document: 2330002-DCS-0001
Project No: 2330002 Page 21 of 92 Rev 67, 25-Aug15-Dec-04
Honeywell
iv. To check the commands have worked, double click on the time on the taskbar.
Go to the Internet Time Tab and verify that the time was successfully
synchronized with EXP_SVRA.
2.9.9. Prevent the monitor from being switched off after idle time
This prevents the monitors being switched off automatically by the PC after 20mins
(default) idle time.
v. Open the Display Control Panel
vi. Click the “Power…” button to open the power settings
vii. Ensure all the Settings are set to “Never” for the „Home/Office Desk‟ power
scheme.
Knowledge
Install Order MS Fix Comments
Base Article
1 MS03-039 KB824146
2 MS03-041 KB823182
3 MS03-043 KB828035
4 MS04-003 KB832483
5 MS04-004 KB832894
6 MS04-007 KB828028
** Check Add/Remove programs as may have
been installed by prior installations ** (Win2K
Pre-SP4 Hotfix Q322913 Only)
** Check Add/Remove programs as may have
been installed by prior installations ** (Win2K
SP4 Hotfix Q815021 Only)
iii. Copy station.ini from the StationConfig folder to C:\WINDOWS on the Station
PC.
iv. Copy stn1_script.txt (and stn2_script.txt if configuring a station for a dual
operating screen) into the C:\Program Files\Honeywell\Experion
PKS\Client\Station directory on the Station PC. No longer required.
v. Copy default2.stb into the C:\Program Files\Honeywell\Experion
PKS\Client\System\R100 directory on the Station PC. This file defines the
toolbar, menus and keyboard configuration for station.
vi. Copy default.stn and backup.stn (and default2.stn and backup2.stn for
EXP_OPS1 &, EXP_OPS2, EXP_OPS3 and EXP_MNT4) to the C:\Program
Files\Honeywell\Experion PKS\Client\Station directory on the Station PC .
These files define the station connection, display directories and sound
configuration.
vii. Copy the “hosts” file into the WINDOWS\SYSTEM32\DRIVERS\ETC folder,
replacing the existing file.
viii. Open Station, if a dialog box comes up with all stations busy click ok. Go to
Station, Connect. Select Default, click edit Connection.
ix. Select either Static Station or rotary station and enter the appropriate station
number as per the table below for the station that is being installed.
x. Click save and repeat for the backup station (note: Use the same static station
number/rotary station selection).
ix. Under “Destination”, add the Computer name to the list of Specific PCs.
x. Click Save.
xi. If you wish the abstract to be copied across immediately then click “Replicate
Now”. After some time a report should be presented indicating which files
were copied from the server to each configured station PC,
xii. Delete the file sysdtldaca.dsp from the …client\system\R101 directory. (There
is a modified version of this file in the Non-Standard system display directory
in the Abstract directory.)
2.10.2. Create oper, elec and csc accounts and set group membership
i. Right Click “My Computer”, Select Manage.
ii. Select System Tools – Local Users and Groups – Users.
iii. Right Click and select “New User…”
iv. In the form enter Username = Oper, Full Name – Experion PKS Operator,
Password = oper.
v. Deselect “User must change password at next login”
vi. Select “Password never expires” and “User cannot change password”.
xiii. Click “Advanced..” then Find Now..” again and select “Engineering Repository
Users” then “OK”. Click ok.
vi. Restart computer to ensure the station is automatically logged in with the oper
account.
vii. Change the oper account settings to classic Windows settings: Right Click Start
– Properties, Select Classic Start Menu. Click Apply then ok.
viii. Right click on the desktop – click properties – on the themes tab, in the Theme
drop-down box select Windows Classic. Click Apply then ok.
NOTE: The configuration of the sounds used for each of the High and Urgent alarms
is contained within the .stn file (The properties for this are viewed from Station by
going to Station – Connect; then select a connection, click Edit Connection… and go
to the “Sounds Tab”.
The required .wav files are available on the C:\StationConfig directory on the A
server and should be placed in the indicated directories above on each station.
Also the properties for the audible alarms are configured on a Server Wide
basis. To view the details from Station go to Configure – System
Hardware – Server Wide Settings, then the Alarm/Event Options Tab. (For
the Audible Alarm to work the “Audible Active time” must be greater than
zero.
Note also that for Station STNOPS1_S2 that an Alarm/Event Printer should be
assigned to \\EXP_OPS1\ALMEVENT1 to print LOW, HIGH & URGENT Alarms,
and Operator Changes. This should be visible in the station configuration for
STN_OPS1_S2.
User Configuration > Administrative Templates > Start Menu and Taskbar
Setting State
Remove user's folders from the Start Menu Enabled
Remove links and access to Windows Update Enabled
Remove common program groups from Start Menu Enabled
Remove My Documents icon from Start Menu Enabled
Remove Documents menu from Start Menu Enabled
Remove programs on Settings menu Not Configured
Remove Network Connections from Start Menu Enabled
Remove Favorites menu from Start Menu Enabled
Remove Search menu from Start Menu Enabled
Remove Help menu from Start Menu NEnabled
Remove Run menu from Start Menu Enabled
Remove My Pictures icon from Start Menu Enabled
Remove My Music icon from Start Menu Enabled
Remove My Network Places icon from Start Menu Enabled
Add Logoff to the Start Menu Enabled
Remove Logoff on the Start Menu Not configured
Remove and prevent access to the Shut Down command Not configured
Remove Drag-and-drop context menus on the Start Menu Enabled
Prevent changes to Taskbar and Start Menu Settings Enabled
Remove access to the context menus for the taskbar Enabled
Do not keep history of recently opened documents Enabled
Clear history of recently opened documents on exit Enabled
Turn off personalized menus Enabled
Turn off user tracking Not configured
Add "Run in Separate Memory Space" check box to Run dialog box Not configured
Setting State
Hide and disable all items on the desktop Not configured
Remove My Documents icon on the desktop Enabled
Remove My Computer icon on the desktop Enabled
Remove Recycle Bin icon from desktop Enabled
Remove Properties from the My Documents context menu Not configured
Remove Properties from the My Computer context menu Not configured
Remove Properties from the Recycle Bin context menu Not configured
Hide My Network Places icon on desktop Enabled
Hide Internet Explorer icon on desktop Enabled
Do not add shares of recently opened documents to My Network Places Enabled
Prohibit user from changing My Documents path Enabled
Prevent adding, dragging, dropping and closing the Taskbar's toolbars Enabled
Prohibit adjusting desktop toolbars Enabled
Don't save settings at exit Enabled
Remove the Desktop Cleanup Wizard Enabled
Setting State
Don't display the Getting Started welcome screen at logon Not configured
Century interpretation for Year 2000 Not configured
Configure driver search locations Not configured
Code signing for device drivers Not configured
Custom user interface Not configured
Prevent access to the command prompt Enabled **
Prevent access to registry editing tools Enabled
Run only allowed Windows applications Not configured
Don't run specified Windows applications Not configured
Turn off Autoplay Enabled
Restrict these programs from being launched from Help Not configured
Download missing COM components Not configured
Windows Automatic Updates Disabled
Setting State
Removes the Folder Options menu item from the Tools menu Not Configured
Remove File menu from Windows Explorer Enabled
Remove "Map Network Drive" and "Disconnect Network Drive" Enabled
Remove Search button from Windows Explorer Enabled
Remove Windows Explorer's default context menu Enabled
Hides the Manage item on the Windows Explorer context menu Enabled
Allow only per user or approved shell extensions Not configured
Do not track Shell shortcuts during roaming Not configured
Hide these specified drives in My Computer Enabled **
Prevent access to drives from My Computer Enabled
Remove Hardware tab Not configured
Remove DFS tab Not configured
Remove Security tab Not configured
Setting State
Remove access to use all Windows Update featues Enabled
15. Minimise all items on the desktop (windows key + M) to show the properties
window for the GroupPolicy folder. Set the security for all accounts except
the oper account as below:
20. Logging back on as ps_user should provide the normal windows interface. If
this is not the case log on as the Administrator account, take ownership of the
Group Policy Folder and restore the backed up group policy folder.
3. Server Backup
3.1. Daily backup strategy
The daily backup is an automated backup run by CSC over the network (ie. through
the DSA routers) to backup the server data on their central backup server. This has
been tested to ensure there are no bandwidth problems which could affect the DSA
transfers. The "D:\ExperionBackup" directory on each of the A and B Experion PKS
Servers is copied to CSC's backup facilities. To ensure the contents of this directory
are kept up to date with sufficient data to restore any component of the configuration
(or the whole server if necessary) a batch file is scheduled to run each day on the
Experion PKS Servers which copies the following data into the "D:\ExperionBackup"
directory: (Note the "..." in the paths below indicates the "C:\Program
Files\Honeywell\Experion PKS\" directory on each Server)
ERDB Database
The engineering repository database (Control Builder database) is scheduled
to be automatically backed up daily to the “D:\ExperionBackup” directory using a
maintenance plan configured using the Microsoft SQL Server 2000 Enterprise
Manager.
* Note if the B Server is primary and not synchronised to the A server and database
changes are made on the Server (for example area, trend, group, history or point
configuration) these changes shall not be backed up by this backup regime. It is
recommended that the system be run with the A server as primary and synchronised
whenever possible.
6. Login to the Server using the ps_user password. You will then be presented with
the Server Desktop (Dell 'ripple' picture as Desktop background).
NOTE: Some keyboard shortcuts are not sent to the remote system (for example
Windows-E to call up Windows Explorer).
7. From the desktop double-click the "Shortcut to Eng Backup" shortcut to copy the
server configuration to the D:\ExperionBackup directory on the server. This takes
some minutes to complete. This batch file performs the following:
- Dumps of the following server database files are made to disk in the
server\user directory:
Areas
Acronyms
Messages
Trend configuration
Group configuration
- Point database backbuilds are then taken for all points of the following
types:
CDA – cdabkup.pnt (i.e. C200 resident points)
Redundancy Configuration:
Complete the configuration of the Server redundancy according to the
following instructions:
1. Ensure a copy of the existing “redun.hdw” file is obtained (and saved into the
same directory) from the …\server\user directory from a current backup of the
live system.
2. run the following command from a command prompt on the server being built:
hdwbld “\Program Files\Honeywell\Experion PKS\server\user\redun.hdw”
The qualified network card drivers for the Intel Pro/100S Desktop Network Adapters
are on the Common Components v141.3 CD. From the Device Manager the drivers
for each of the Intel Pro/100S Network adapter cards should be updated by:
- From the My Computer right click and select “Manage”
- Open the Device Manager
- Select the first network card,
- Right click and select “Properties”
- Select the Driver tab
- Click “Update Driver‟ and follow prompts to “Search for driver” and then
“Specify the location”, browsing to the following location for the driver on
the Common Components CD:
<CDROM>:\Drivers\Intel\pro100_v6.2
- The driver should then install and you can request to Reboot later.
- Repeat for the second network adapter.
- Re-boot the Server.
The Fault Tolerant Ethernet should now be installed as per the Fault Tolerant Ethernet
Planning, Installation and Service Guide. The FTE Software Installation instructions
begin in Section 4.3 of the document (page 63). Note „the CD‟ refers to the Common
Components Release 141.3 CD supplied with Experion PKS R101 media.
See the table in Section 2.6 for the required FTE Service Settings and names for the
LAN connections.
The following features of this system are also important:
- NetBIOS does need to be configured
- Each Server should have two single port Intel Pro 100S Desktop network
adapters installed
- Select all of the FTE Driver , FTE Auxiliary Status Display., HCI Runtime
& System Management Runtime components on the Server install.
- The Yellow(A) / Green (B) IP Addresses can be found in the Network
Design Spreadsheet.
If the mngr account password is not the same as the PlantScape mngr password it
must be changed according to the procedure in Knowledge Builder for changing the
MNGR account password as this password is used for a number of services and
DCOM components.
Prevent local logon of the mngr account from the local security policies.
From Administrative Tools control panel select Security Settings > Local
Policies > User Rights Assignment
Double click “Deny logon locally”
Add local “mngr” account to list.
Compress D drive
Select properties of D: drive in Windows Explorer
Check the “Compress drive to save disk space” box
Click “Apply”
Select “Apply changes to D:\, subfolders and files
Click “OK”
Share the abstract directory
Share the folder “C:\Program Files\Honeywell\Experion PKS\client\abstract” as
“abstract” with the following permissions:
1. Everyone – Read Only
2. Administrators – Full Control
3. Honeywell Administrators – Full Control
Create & share Databases directory
Create the folder “C:\Program Files\Honeywell\Experion
PKS\client\qckbld\Databases”
OneSteel Whyalla Server & Station Installation & Backup Procedures
Blast Furnace Capital and Reline Projects Document: 2330002-DCS-0001
Project No: 2330002 Page 67 of 92 Rev 67, 25-Aug15-Dec-04
Honeywell
Share the folder as “Databases” with the following permissions:
4. Everyone – Read Only
5. Administrators – Full Control
6. Honeywell Administrators – Full Control
Disable Automatic Updates
From the Automatic Updates Control Panel UNCHECK the “Keep my
computer up to date…” check box.
1. Run the displays_fix batch file from the Experion PKS R101 Reference Tools CD.
Stop the PlantScape Server and SQL Server Services before applying any of the
following patches:
Note the required Installation file “EPKS R101.0 Post Release Patch 5.zip”
and the Software Change Notice can be found in the C:\Program
Files\Honeywell\Experion PKS\Server\User\Patches directory on either server,
which is a backed up directory.
The Microsoft patches that are qualified for installation on Experion PKS systems are
listed on the following website:
http://www.ssol.acs.honeywell.com/SSOL/Rooms/DisplayPages/LayoutInitial?Container=com.
webridge.entity.Entity%5BOID%5B0E8FB4B95ECD4548A2A0466AA79469AE%5D%5D
All of the executables for the patch installers should be stored in a subdirectory of
“C:\Program Files\Honeywell\Experion PKS\server\user”.
Knowledge
Install Order MS Fix Comments
Base Article
1 MS03-026 KB823980 RPC Vulnerability
2 MS03-041 KB823182
3 MS03-042 KB826232
1. Make sure the server is stopped using the “Start-Stop Experion PKS Server”
application.
2. Insert the relevant backup tape (or other backup medium) into the appropriate
drive.
3. Open a Command Prompt window.
4. Type the following command to unload the current server database from
memory:
hscserver /unload
5. Use the Windows Backup program or Windows Explorer to restore the data
directory backup to the following folder (create the folder if necessary):
8. Delete the “points” file in the data directory and rename “points.bak” to
“points”
9. Start the server by typing the following at a command prompt:
hscserver /start
It is important that when restoring an ERDB and snapshot files that the latest backup
files are available to avoid „ghost‟ configurations in the controller. The procedures
for restoring and recovering the ERDB differ between a Server A or B replacement.
Consult the Backup/Restore section of the Administration Guide in Knowledge
Builder for further information about restoring the Engineering Database to a server in
redundant systems.
1. Stop the server and unload the databases by typing hscserver /unload at the
command prompt.
2. Check in
c:\Program Files\Honeywell\Experion PKS\server\evtarch\backup to
determine which Backup file you wish to restore. This is usually the file with
the most recent date and time, but it depends on your circumstances. Note the
name of this file.
3. Start Microsoft SQL Server Enterprise Manager (select Start > Programs >
SQL Server).
4. Expand the left tree down the path:
Microsoft SQL Servers > SQL Server Group > <PC Name> > Databases
> EMS Events
5. Right-click the EMS Events Database and select All Tasks > Restore
Database...
6. In the Restore Database dialog box, ensure that:
o Restore as database is set to EMS Events
o Restore is set to From Device
Press the Select Devices command button and add a new device
c:\Program Files\Honeywell\Experion PKS\server\evtarch\ba
ckup\EMSDailyBackup.dat
Click OK until you return to the Restore Database dialog box.
Backup number = 1
Restore backup = set
Database = Complete
NOTE that individual components backed up to the user directory may be restored to
the database in the event of some corruption or error in the configuration of these
components. See section 4.9.9 below for these specific components.
Configuration Filename
Area codes and descriptions areas.dmp
User acronym definitions useracronym.dmp
Operator Message definitions messages.dmp
Report definitions reports.dmp
History assignments for points fasthist.dmp (fast history assignment)
and parameters ** stdhist.dmp (standard history assignment)
exthist.dmp (extended history assignment)
Groups configuration (not groups.dmp
including custom group overview
displays) *
Trend configuration * trends.dmp
Reports configuration reports.dmp
(particularly WTP water usage,
and alarming reports)
Keyboard Configurations (server keyboard.dmp
side only, not the pushbutton
actions which are stored in the
Station‟s “.stb” file.
** The history assignments are also contained in the “.pnt” text files which are
generated and saved during the backup process. The “.pnt” files need to be filtered
for all lines starting in “HISTFAST”, “HISTSLOW” and “HISTEXTD” to extract the
fast history, standard history and extended history assignments respectively. Changes
to the assignment can then be made to the filtered file and built onto the Server using
the “pntbld” utility, provided ALL lines in the file ONLY start with one of the three
“HIST*” fields given above.
* The point assignments for the groups and trends are also contained in textual form
in the “.pnt” files which are generated during the backup process. The assignments
can be found by filtering these files for all lines which start with “GROUP” and/or
“TREND”. Although changes to the assignment can then be built using the “pntbld”
utility it is not recommended given the criticality of the group configuration to the
operation of the plant.
The following sections need to be considered (in order) when putting the spare Server
online after the failure of one of the „on-process‟ Servers. It is assumed that the
replacement Server has been prepared according to the Server Restore instructions
above. Unless indicated otherwise all activities are required for either a Server A or
Server B replacement.
Note:
Before starting the Time Service, ensure that the primary and backup Experion PKS
Servers, along with the Primary PlantScape Server, are configured to be in the same
time zone and Daylight Savings setting. The time zone setting can be checked by
opening Date/Time in the Windows Control Panel
To set up the time service as a time source on Server A (for Server B and all Stations):
1. Select Start > Run and run settimesource.vbs, which is located in the
server\run folder. This program is silent if successful.
2. Select Start > Settings > Control Panel > Administrative Tools > Services.
3. Select Windows Time service and set the startup type to Automatic.
4. If the Windows Time service is running, stop it.
5. Restart the Windows Time service.
5.4.2. VNC
Using a Maintenance or Operator Station use the VNC client
(\\exp_svra\vncviewer$\vncviewer.exe) to connect to the replacement server. Ensure
that a remote desktop session is presented after logging on to the Server.
5.4.3. RSLinx
Open Start > Program Files > Rockwell Software > RSLinx
Click on the RSWho toolbar icon.
Expand the AB-PCIC driver to show the online ControlNet nodes.
At least nodes 1 – 4 and one of 23 or 24 MUST be listed. For information the nodes
can be categorized as:
Nodes 1-4 are the C200 Controllers
Node 5 is the RNet Gateway PLC
Nodes 6 – 17 are ControlLogix PLC‟s
Nodes 18- 22 are Maintenance Stations.
Nodes 23 and 24 are the Servers (it is expected that only one of these will be
shown in RSLinx).
If no nodes are visible other than a Server node then check the ControlNet
connections and RSLinx Services.
5.5.1. DSA
When the replaced server is running as primary ensure that PlantScape is polling live
data from the Experion system by requesting the point detail on a PlantScape Station
for the F-BLAST2 point (from a PlantScape station type “F-BLAST2” and press
F12). Ensure that the PV parameter reading in the lower left corner updates (ie.
changes value) at least once every 20 seconds.
Check the DSA status page (pag119) on the PlantScape station by pressing F5 and
typing “119”, followed by [Enter]. Select the EXP_SVRA or EXP_SVRB link to
view the status of the DSA Connection to the Experion PKS Servers. There should at
least be an OK (green) link status to the current Primary Experion PKS Server..