dcs migration - zero downtime upgrade

Eric V. Silk, CEM October 14, 2015

Agenda

Q & A

Conclusions

Design and Implementation Strategies

Project Challenges

Project Introduction

Pepco Energy Services (customer) partnered with Thermo Systems, a Rockwell Automation Solution Partner, to design, build, deploy and commission a turnkey replacement of its aging DCS system serving the district energy system in Midtown Atlantic City. The successful migration included zero customer downtime, ease of service, increased operational efficiency, billing accuracy, and expansion possibilities moving forward.

DCS Replacement in a 24/7 Critical District Energy Facility

Site ProfilePES 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 PACs

Midtown Thermal Control Center (MTCC)

Profile - PES In Atlantic City, NJ

• Remote Locations • Golden Nugget Plant• Convention Center Thermal Plant• Convention Center Solar System• Wilmington, DE Loop

MTCC

ACCC

2.4Mw PV

GN• MTCC Overview

• Cogen Plant• Boiler Plant• Chiller Plant• District Customers

Energy Distribution System• 4 miles of steam & chilled water piping • Fiber optic controls throughout system• Steam Header leaving the plant – 20”• Chilled water header leaving the plant – 42”

Energy Transfer Stations – ETS’s• Chilled water and steam heat exchangers located at various locations within customer sites• Transfer point of product for billing• Chilled water delivered at 42F

Steam Chilled Water• Caesars: 5 ETS’s 5 ETS’s• Bally’s : 2 ETS’s 2 ETS’s• Claridge: 1 ETS 1 ETS• Trump Plaza: 2 ETS’s 2 ETS’s• Boardwalk Hall: 2 ETS’s 2 ETS’s• Pier Shops: 1 ETS

Profile - MTCC In Atlantic City, NJ

Project ProfileMTCC DCS Replacement Project

• Yokogawa/JCI DCS Replacement

• Viking Billing & Reporting System Replacement

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

Project ProfileMTCC DCS Replacement Project

• Rockwell Automation Solution Tools• FT View SE SCADA• FT Historian SE• Allen Bradley PACs• RA Transaction Manager (bridge Plant with IT Billing)• FT VantagePoint EMI (for reporting/dashboarding)• Remote Building Integration via Firewalled PACs

• Nexant Utility Billing & Accounting System

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

PES’ Business Challenges

• Proprietary • DCS • Billing

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

Now was the time to implement a reliable control systemA 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

A non proprietary plant control system with billing integration was needed

Why Thermo Systems?

• Design-Build / Turnkey capabilities (Engaged as MAC)• Ability to take project from UR through commission and life cycle

support• Experience in application: CHP, CHW & Steam Plant• Integrator with good quality control and documentation practices• Thermo Systems is a RA Solution Partner• Current PES Service Provider

DCS Replacement Project Approach

• User Requirements – Thermo Systems knew what questions to ask..

• Phased Approach• Design – Drawings, Software Specification

• Implementation

• Up front coordination with Plant Operations• Transition Plan – Key to Success

– Minimize Downtime

• Client Support


• Transition Plan – Implementation in multiple phases• Dearator Tank and Boiler feedwater

• Boiler CCS w/ PanelView (phased install qty. 3)

• Data Concentrator – comms to 13 Customer ETS

• Chilled Water Balance of Plant (BOP)

• Remote Terminal Units (RTUs) - Golden Nugget, Taj Mahal, ACCC

• Nexant billing integration via Transaction Manger

• Steam metering upgrade and standardization


• Leverage SCADA implemented during a previous Cogeneration Project• FT View SE

• FT Historian SE

DCS Replacement Solution (old)

ETS ...

ETS 1

ETS 13

PLC5 DCS

BOILER 1 CCS

BOILER 2 CCS

BOILER 3 CCS

DA TANK BFW

CHW BOP

ETS 7A

ETS 7B

ETS 5

DCS Replacement Solution (new)

ETS ...

ETS 1

ETS 13

ControlLogix Data Concentrator

PLC

CompactLogixPLC w/PVSCADA

FT View SE w/Historian BOILER 2

CCS

BOILER 3CCS

DA TankBFW

CHWBOP

ETS 5

ETS 7A

ETS 7B

BOILER 1CCS

ControlLogixPLC

CompactLogixPLC

CompactLogixPLC w/PV

CompactLogixPLC w/PV

CompactLogixPLC

Point IO

CompactLogixPLC

DCS Replacement Sequence

Billing Replacement Solution - old data flow

Billing Replacement Solution - new data flow

ETS ...

ETS 1

ETS 13

ControlLogix PLCData Concentrator

ETS 5

ETS 7A

ETS 7B

Transaction Manager

Golden NuggetACCC

Nexant Billing Software

MicroLogixPLC

MicroLogixPLC

MicroLogixPLC

Taj Mahal CompactLogixPLC

MicrologixPLC

CompactLogixPLC

Dashboard

Summary of Rockwell Equipment

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

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

Conclusions

User Requirements & Transition Plan is key Phased approach for complex retrofits Understanding of plant operations FATs help minimize troubleshooting during startup Deploying PACs logically (separation of plants) PES teamed with Thermo Systems from start to finish (continuity) Rockwell Automation provided the tools for success Thermo Systems leveraged our experience in application

• Our engineers have depth and expertise in:

• Energy: Utilities / Facilities, CHP, critical HVAC, chilled water, boiler plants, power generation, data center critical HVAC

• Consumer: Life Sciences, Food & Beverage, Consumer Packaged Goods (CPG)

Thermo Systems – Industry Expertise

• Thermo Systems LLC is more than a systems integrator. We are a design-build control systems engineering and construction firm, managing and delivering turnkey (MAC) Main Automation Contractor projects

• Comprehensive Services (Greenfield or Brownfield) include:• Automation & Information Master Plan including Program/Project Management and Plant/OEM/Sub-

Contractor Coordination• Project Specifications, Documentation and Automation Architecture Standards • Automation & Information and I&C Design Services • Fabrication, Assembly and Testing• Systems Integration and Programming• Turn key I&C Electrical and Mechanical Installation• Start up, Commissioning and IQ/OQ• Staff augmentation through turnkey• 24/7/365 On-Site and Remote Support• Life-cycle Automation support including Assessments, Modernizations/Migrations

Thermo Systems – Overview

Thermo Systems – Across America

Questions

Eastern Region SupportEric V. Silk, [email protected]

Western Region SupportCory [email protected]

dcs migration - zero downtime upgrade

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