T66 Central Utility Building (CUB) Control System ... · • Burner Management and Combustion Control for Boilers, ... Heat Recovery Steam Generators ... System Costs Reduce Risks

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900C

T66 Central Utility Building (CUB) Control System Reliability, Optimization & Demand Management

Name – Doug Demian Title – Application Engineer Date – November 7 & 8, 2012

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

Agenda

Sample Graphics

Key Concepts

System Architecture

Why PlantPAx

Who we are

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

Electrical Control Solutions • Emergency Load Shedding • Electrical Distribution Monitoring and Control • Demand Management Solutions • Demand Response Solutions

Central Utility Building (CUB) Balance of Plant (BOP) Control Solutions for reliability & energy optimization of: • Chilled, Hot Water and Steam production & delivery • Co-Generation • Burner Management and Combustion Control for Boilers, HRSG’s / Steam Generation

Industrial HVAC Solutions • Monitoring & Control of Temperature, Pressure and Humidity • Environmental Monitoring in Critical Environments (Clean Room Manufacturing) • Air Handler Controls and Optimization • Building Automation Systems

3

Power & Energy Management Solutions (PEMS) – Focused Applications

Metering & Monitoring of Water, Air, Gas, Electricity, Steam & Production information to develop KPI’s to optimize resources!!


PEMS - Business Strategy

Focus on Repeatable Applications Have Subject Matter Experts as team leaders

10+ Years Industry Application Experience Maximize Re-Usable Code / Engineering – PlantPAx, GEMS to Reduce

Risk Leverage Local Engineering Resources

Local Support & Start-Up Assistance Help End User Establish And Deploy Standards

Corporate Deployment To Maximize Value Deliver to Facilities Around The World


• Chillers • VFD’s & MCC’s

• Cooling Water • Cooling Tower Fans • Chilled Water • Hot Water

• Electrical Switchgear • Back Up / Emergency Generation • Instrumentation & Metering • Boilers, Hot Water Generators • Cogeneration • Heat Recovery Steam Generators • Gas Compressor Skids • SCR Skids • Water Systems • Building Automation Systems

Why PlantPAx for CUB’s?

Premier Integration of Balance of Plant (BOP) Systems:


• Standard HMI Objects – Pumps, Valves

• Standard Control Modules • Scalable Controllers –

FactoryTalk Alarms & Events - Alarming, Monitoring and Controlling

• Networks – EtherNet IP, ControlNet

• Multiple Network Media & Protocols:

• Modbus • BACNet • N2 • Profibus • DNP 3.0

Premier Integration Utilizing

• Redundancy Options • HMI Servers • Controllers • Networks • Historians • Power Supplies

• Scalable • Open Architecture & Longevity

• Installed, Serviced and Supported by many

• Creates a biddable environment

• Secure Remote Access

Easy upgrades!!!


• Reduce Risk of deployment – repeatability & expandable • State of the Art - Yet Simple • Robust / Reliable (MTBF / MTTR) hardware • Built in Redundancy “As a Standard not an after thought” • Long Term Support & multiple sources • Longevity of hardware and software • A system that is “open” & User Friendly to quickly: Monitor, Predict,

Alarm, Diagnose and Repair Failures • A Solution that is Energy Efficient • Components are easily recognizable and maintainable by plant

personnel and multiple 3rd parties • Deployed and viewed from multiple locations • Partner with a knowledgeable and experienced solution provider

Benefits


• Ensure: • Safety Compliance • Environmental Compliance

• Optimize: • Central Utilities Building Operation

• Minimize: • Energy Usage in the Production of Thermal Water. • Production Costs by running in the most efficient manner possible • Downtime • Maintenance Costs

• Provide a high level of diagnostics • Longevity

Design Goals


CUB - Control System Architecture

Third Party interfaces via BACNet, Modbus, DNP 3.0 etc. to: VFD’s & MCC’s Electrical Systems Chillers Cogeneration Boilers ATS Generators HRSG / HWG Refrigerant Monitoring Metering & Monitoring Fire Alarm Leak Detection Battery Monitoring Load Banks

Server 1A – HMI Primary Server FactoryTalk View SE

Server 1B – HMI Secondary Server FactoryTalk View SE

Clients

3rd Party Interfaces: BACNet, Modbus

Thermal Plant Remote I/O Enclosure(S)

Redundant EtherNet HMI Network

Redundant EtherNet or ControlNet Control Network

Thermal Plant Controller Enclosure(s)

MCC’s VFD’s

Chilled Water Condenser

Water Cooling Towers AHU etc.


Cabinet Power Distribution / Layout

Redundant Processors

Power Distribution

Redundant Power Supplies: Processor I/O Racks

Redundant Power Supplies – I/O

Stratix Ethernet Switches

IFM Modules Terminal Boards

I/O Rack Redundant ControlNet


Cabinet Power Distribution

Redundant Power Supplies – I/O

Power Distribution

Redundant ControlNet On Fiber

Redundant Power Supplies – Processor / I/O Rack


Chiller Dispatch key concepts

To Add a Chiller (3) Conditions must be met

To Stop a Chiller (2) conditions must be met

Goal - Minimize Consumption & Maximize Output


Chiller Overview


Pumping Dispatch – Key Concepts

All Possible Pumping Combinations are calculated and the combination with the lowest electrical energy usage is dispatched


Hot Water System


Cogen - Balance of Plant Control

Interface with existing control systems Optimize the System Start / Warm Up / Synch / Load / Unload / Cool Down / Sequencing Direct control for diverter valves, High Temperature Water flow, heat

rejection, etc Supervisory Control of:

Heat Recovery Steam Generators Lube Oil Cooling Towers Water Treatment Fuel Gas Compressors


3rd Party Graphics Integration


3rd Party Skid Graphics Integration


3rd Party Graphics


3rd Party Graphics


3rd Party Graphics


Power Management Systems

Power Management Systems: Generator Supervisory Control Emergency Generation start up, synchronization & shut down Automatic Synchronization Breaker Control / Distribution Monitoring Load sharing Spinning reserve management Emergency Load Shedding Load Inhibiting Supervisory Black Start Recovery Balance of Plant Control.


Electrical Systems


3rd Party Integration

Third Party Systems: • Chillers – McQuay, York, Carrier • Boilers – Unilux, American • Chemical Feed Systems • 3rd party Unitary Controllers

• CRAH • AHU’s • VAV boxes

• Drives • Electrical Switchgear • Power Monitoring • Emergency Generation

Communication Interfaces: Modbus BACNet Lonworks Profibus

N2 HART OPC

Plus many more!! One Window to multiple systems


12:00

12:30 1:0

0

1:30

2:00

2:30

0

10

20

30

40

50

Baseline

with VFD

with Demand Mgmt

Cutting off this peak is Demand Management Solution: PEMS Demand Management Solution

Decreasing the area under the curve is Energy Conservation Solutions: Variable Frequency Drives, Energy Efficient Motors, Lighting, and Scheduling

Demand Management

kWd


Demand Management

Demand Management Load Limit Line

Shed Lowest Priority Load

Shed Next Lowest Priority Load

Dem

and

(kW

)

Demand Window (Time)


Track Demand Throughout the Interval


Easily Adjust Load Priorities


Automatic Set Point Adjustment


Why / Benefits - Snapshot

Redundancy Built-in redundancy of servers, networks, software, controllers, I/O and power supplies

Open Connectivity (risk)

Easy integration with numerous 3rd party devices – unparalleled in the industry

Robust (cost / risk)

Industrial Grade Control System – proven technology with industry leading high MTBF rates

Modular & Repeatable

Solution (cost / risk)

Re-use of our modular code and HMI templates to reduce risk of software defects – Thermal Plants, AHU’s, Electrical Systems, Generation

Support (cost)

Many sources for training, support & spare parts

Longevity (cost / risk)

Systems are supported and spare parts are available for many years


SUMMARY

Rockwell Automation is uniquely

qualified to be a global partner of choice

LowerStart Up

Costs

StartupOn time

LowerSystemCosts

ReduceRisks

LocalExpertise

ExtensiveFWT

ApplicationExperience

LeverageBest

Practices

CustomerValue

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900C

Q & A

Documents

T66 Central Utility Building (CUB) Control System ... · • Burner Management and Combustion Control for Boilers, ... Heat Recovery Steam Generators ... System Costs Reduce Risks