replacement of legacy dcs - rockwell automation · pdf filecombined heat and power ......

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Replacement of Legacy DCS Thermo Systems / Rockwell Collaboration

Eric Silk, CEM Business Development Manager November 5, 2012

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

Q & A

Conclusions

Design and Implementation Strategies

Project Challenges

Project Introduction


Speaker Intro

Eric Silk, CEM

ME from Rutgers University, Graduating Class 2007

Thermo Systems LLC, since 2007 Engineering/Project Management

Business Development Manager

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Integrator Profile Thermo Systems LLC

Thermo Systems LLC Design Build Automation Engineering Firm RA Solution Partner/CSIA Level I Applications

Utilities (Combined Heat and Power (CHP), Chilled Water, Steam Systems, Power Generation, District Energy)

Process Controls (Pharma Manufacturing, Waste Water, Mining, other)

Critical HVAC

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Customer Profile Pepco Energy Services (PES)

PES Leading provider of energy-saving and sustainable energy

products and services headquartered in Arlington, VA. ESCO with Build, Own, Operate and Maintain capabilities

for CHP Parent company is Pepco Holdings Inc.

Delmarva Power PEPCO Atlantic City Electric Pepco Energy Services

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Site Profile PES In Atlantic City, NJ

Fourteen (14) Chillers – 16,000 ton capacity

Three (3) Saturated Steam Boilers – 210,000 Lb/hr capacity

Combined Heat and Power – 5.5MW w/ 50,000 Lb/hr waste

heat recovery (2011 Project)

Thirteen (13) Customers on District Energy Loop Energy Transfer Stations with dedicated metering PLCs

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Midtown Thermal Control Center (MTCC)


Profile - PES In Atlantic City, NJ

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Taj Mahal

Atlantic City Convention Center

Golden Nugget

Other PES Thermal Plants in Atlantic City


Project Profile MTCC DCS Replacement Project

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Yokogawa/JCI DCS Replacement

Rockwell Automation Solution Tools FT View SE SCADA

FT Historian SE

Allen Bradley PLCs

Life Cycle Replacement of a Legacy Yokogawa/JCI DCS and Viking Billing & Reporting System


Project Profile MTCC DCS Replacement Project

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Viking Billing & Reporting System Replacement Nexant Billing Software (by Nexant and PES IT)

Rockwell Automation Solution Tools RA Transaction Manager (bridge Plant with IT Billing) FT VantagePoint EMI (for reporting) Remote Building Integration via Firewalled PLCs

Life Cycle Replacement of a Legacy Yokogawa/JCI DCS and Viking Billing & Reporting System


Business Challenges

Proprietary DCS Billing

Many independent systems controlled by one DCS Processor Poor visibility of remote buildings Highly manual/inefficient billing and reporting software

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Now was the time to implement a reliable control system A global control room was a must that integrated all systems


Technical Challenges

Lacking expertise of proprietary DCS Lacking expertise of proprietary Billing System 24/7 Plant Operation – Contractually obligated to

produce chilled water and steam Inconsistent connectivity to remote Thermal Plants

Taj Mahal, Atlantic City Convention Center, Golden Nugget

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A non proprietary plant control system with billing integration was needed


Why Thermo Systems?

Initial involvement in CHP design

Design-Build / Turnkey capabilities

Experience in application: CHP, CHW & Steam Plants

Integrator with good quality control and documentation practices

Thermo Systems is a RA Solution Partner

Current PES Service Provider

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Why Rockwell Automation?

Customer experience with Rockwell products RA product offerings met customer requirements for PLCs,

historian, graphics, reporting and billing integration Non-proprietary and scalable Plant Standardization Common North American platform Local manufacturer; training and support with parts readily

available New FT View SE and Historian installed during CHP project

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DCS Replacement Project Approach

Leverage SCADA implemented during Cogeneration Project • FT View SE • FT Historian SE

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Phased Approach • Design – Drawings, Software Specification • Implementation

Up front coordination with Plant Operations • Minimize Downtime

Transition Plan – Engineering deliverable Client Support

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Transition Plan – Implementation in multiple phases o Dearator Tank and Boiler feedwater o Boiler CCS w/ PanelView (phased install qty. 3) o Data Concentrator – comms to 13 Customer ETS o Chilled Water Balance of Plant (BOP)

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Transition Plan – Implementation in multiple phases o Remote Terminal Units (RTUs) - Golden Nugget,

Taj Mahal, ACCC o Nexant billing integration via Transaction Manger o Steam metering upgrade and standardization

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DCS Replacement Sequence

Phased Implementation Necessary 24/7 operation Control of Steam Boilers Control of DA Tank and Feedwater

Boilers Heat Recovery Steam Generator (HRSG) Required use of rental DA Tank with temporary hookup

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DCS Replacement Solution (old)

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DCS Replacement Solution (new)

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Billing Replacement Solution -old data flow

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Billing Replacement Solution -new data flow

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Summary of Rockwell Equipment

Software Transaction Manager (billing) VantagePoint EMI (reporting) FT View SE FT Historian

Hardware ControlLogix PLC (qty 2) CompactLogix PLC (qty 6) Point IO (qty 1) PanelView HMI (qty 3) MicroLogix RTU panel (qty 4)

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Legend Plant Control Solution (Yokogawa DCS) Billing/Reporting Solution (Viking Billing)


Conclusions

Phased approach for complex retrofits

Understanding of plant operations

FATs help minimize troubleshooting

Deploying PLCs by system (distributed control)

PES teamed with Thermo Systems from start to finish (continuity)

Rockwell Automation provided the tools for success

Thermo Systems leveraged our experience in application

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Questions

Eric Silk, CEM Business Development Manager November 5, 2012

replacement of legacy dcs - rockwell automation · pdf filecombined heat and power ......

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