THORPE PARK Scares Its Visitors but with Their Safety Always in Mind

Home , Colossus (Thorpe Park), Nemesis Inferno, Rush (Thorpe Park), Stealth (roller coaster)

THORPE PARK scares its visitors but with their safety always in mind GuardLogix PAC oversees the control and safety of 'SAW-The Ride' – all on a single network and using common hardware and software

Solutions A Rockwell Automation solution was installed, which included: • Allen-Bradley GuardLogix Programmable Automation Controller (PAC) • Allen-Bradley CompactBlock I/O • Allen-Bradley PanelView • EtherNet/IP and DeviceNet

Results • Simpler and quicker installation • Ease of use • Simpler fault finding • Three hundred thousand cycles without a single hardware fault Background • Health & Safety compliance Opened rather appropriately on Friday 13th March 2009, THORPE PARK's £13.5 million attraction 'SAW-The Ride' boasts a beyond-vertical drop of 100° from a staggering height of 100ft. Based on the popular blood-and- gore 'SAW' horror film franchise, the new ride also boasts a variety of macabre features that mimic the sinister trap-and-torture scenarios portrayed in the films. In addition to plummeting its riders from dizzying heights towards the head chopper, 'SAW-The Ride' hits between 4.0 and 4.7G a total of six times throughout the course of the 100-second ride; subjecting its passengers to a more extreme G-force experience than a space shuttle launch. Designed to provide the ultimate adrenalin rush, the ride has to adhere to rider safety, which is of paramount importance. For this reason it incorporates a state-of-the-art automation and safety infrastructure overseen by an Allen-Bradley GuardLogix PAC from Rockwell Automation. Challenge safety of 'SAW-The Ride' – all on a single network and using common hardware and software. Theme parks have their work cut out in their attempts to draw in the crowds. One of the most successful ways of doing this is to create high-profile themed rides and Solution attractions that pander to the needs of adrenalin junkies "All four of THORPE PARK's roller coasters – 'SAW-The Ride', looking for their next big thrill and. With this in mind, 'Stealth', 'Colossus' and 'Nemesis Inferno' – use Allen- 'SAW-The Ride' certainly delivers. Bradley hardware, so familiarity with RSLogix and its What many people do not see is what goes on behind modes of operation was never going to be an issue," the scenes. The modern thrill ride is often a superb explains Steve Wilson, Electrical Engineering Area example of automation and safety in harmony; with the Manager at THORPE PARK. "Although the controller control infrastructure often surpassing what one would program is rarely modified, we do have to undertake fault normally see in an industrial environment. finding and elicit statistical data; and for this we need an easy-to-understand solution." As well as employing state-of-the-art automation systems for its rides, THORPE PARK has the same The Allen-Bradley GuardLogix Programmable Automation responsibilities for its visitors that an industrial company Controller (PAC) replaces what would typically have been would have over its employees – namely their safety... a dual PLC solution. The single architecture not only day after day, ride after ride. makes it easier to build, maintain and integrate, but also, the software and programming for safety, maintenance In many instances, including other rides at THORPE PARK, and control is the same. It is also easier to access as there the on-ride automation and safety infrastructures are is no need for separate comms links between the two controlled by two separate control systems, each having PACs. discrete hardware and signal loops. These dual-system solutions certainly provide the necessary performance, Over DeviceNet, the PAC interacts with an Allen-Bradley but they add complexity and require greater design, CompactBlock I/O and third party drives over EtherNet/IP. installation, commissioning and running efforts. An overview of the solution is provided by an Allen- Bradley PanelView HMI, giving the engineers clear and It is for these reasons, in conjunction with its advanced unambiguous information about the current state of the capabilities, that THORPE PARK has employed an Allen- ride and its operating parameters during their regular Bradley GuardLogix PAC to oversee the control and checks. Wilson adds: "At THORPE PARK, we are driven by the guest experience coupled with ride availability, so reliability is paramount as is ease of fault finding. Every component on At THORPE PARK, we are driven by the the systems from simple sensors and switches up to the guest experience coupled with ride 500+ safety I/O is monitored and highlighted on the Allen- availability, so reliability is paramount Bradley PanelView display, giving us a clear and easy indication of how everything is working." as is ease of fault finding THORPE PARK is serviced by Rockwell Automation distributor Routeco. "The service we received from Jonathan Bye at Routeco is second to none," Wilson Results concludes. "Even when we ring at obscure times, he always goes out of his way to find the answer to our Mike Astles, Elelctrical Engineer at THORPE PARK, explains: questions. This may be the first Allen-Bradley single-PAC "By the end of 2010, the ride will have completed over installation, but I would like to think that it also won't be three hundred thousand cycles and we have not had a our last." single hardware fault in that time. I trained on site here at THORPE PARK, with engineers who have seen a wide Additional Information variety of control infrastructures, and many of them have commented on how easy the Rockwell Automation www.rockwellautomation.co.uk solution is to use. This is our first Allen Bradley single-PAC The results mentioned above are specific to THORPE PARK's use of Rockwell Automation products and services in installation – we all have respect for the system's potential conjunction with other products. Specific results may vary for other customers. and can't wait to see what other capabilities it will give us." Listen. Think. Solve., Allen-Bradley, GuardLogix, CompactBlock and PanelView are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.