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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!!
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
• 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:
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
• 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!!!
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
• 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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
• 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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Cabinet Power Distribution
Redundant Power Supplies – I/O
Power Distribution
Redundant ControlNet On Fiber
Redundant Power Supplies – Processor / I/O Rack
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Pumping Dispatch – Key Concepts
All Possible Pumping Combinations are calculated and the combination with the lowest electrical energy usage is dispatched
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 16
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 22
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.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Demand Management
Demand Management Load Limit Line
Shed Lowest Priority Load
Shed Next Lowest Priority Load
Dem
and
(kW
)
Demand Window (Time)
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Track Demand Throughout the Interval
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
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