Adapt Block Cloning Errors
There are two adapt block cloning errors, caused by failure to change S2 to match cloned logic. Two subsystems are not adapted, even though they look like they are.
TSTALM Cloning Errors
There are nine multiple TSTALM situations. Every one of these comes from S1 not being changed when logic was cloned. Fourteen actions can happen mysteriously when they should not, triggered by the prototype logic instead of the new logic. Even worse, fourteen actions do not happen when they should, because the cloned logic is not being tested.
Why fourteen? One instance was cloned badly six times.
TSTQ Block Inputs Without Quality to Test
There are 209 inputs to TSTQ blocks being tested that do not have quality to test. In addition, quality is being tested on 10 AO/L blocks that do not have quality on their input signal. Three of these flawed tests control the manual interlock of control loops, so the loop will not go into Manual when the quality is bad.
It is disconcerting that a number of the errors flagged look like OR and TSTALM block outputs are being handled incorrectly by being inputs to TSTQ blocks, instead of being OR'd with the outputs.
REDAI Blocks Used Without Being Tested for Quality
There are 46 instances where REDAI blocks can synthesize bad quality, but the value is then used whether or not it is bad. The first one I checked can be bad quality but still control a "FD AIR MASTER" control loop.
The one shown here is kind of cute, if you like scary productions. Good engineering was undone.
Function Block Errors
Among the function generator blocks, there are
- four that change from slope 1:3 to 1:1 instead of clamping
- four that change from slope 4:1 to 1:1 instead of clamping
- two that change from slope 7:1 to 1:1 instead of clamping
- three that with slope 1:1 that also do not clamp
Too Few Inputs
One 8 input Qualified OR block has four inputs, but needs seven to trigger it. It ain't gonna happen!
Rung Block Errors
Two rung blocks ignore an input without documentation. If a test is in progress, too bad!
One rung block tests vibration limits, but does not disable the result on bad quality, as designed.
There are 29 DAANG and AO/L blocks giving continuous exception reports.
There are 15 DAANG block tags that are designed to show some or all of 2nd and 3rd high and low alarms that will not do that.
One MA Station has type 5, not defined. Another has its initial mode after startup value set to 0, also not defined.
339 errors are outlined above. This is 339 errors more than the site knows about. What risks do these errors represent to the site? Why do these errors exist undetected? Should this system even be running?