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

T66 Central Utility Building (CUB) Control System Reliability, Optimization & Demand Management Name Doug Demian Title Application Engineer Date November 7 & 8, 2012 Rev 5058-CO900C Copyright 2012 Rockwell Automation, Inc. All rights reserved.

2 Agenda Who we are Why PlantPAx System Architecture Key Concepts Sample Graphics

Power & Energy Management Solutions (PEMS) Focused Applications 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 Electrical Control Solutions Emergency Load Shedding Electrical Distribution Monitoring and Control Demand Management Solutions Demand Response Solutions 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 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. 3

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

Why PlantPAx for CUB s? Premier Integration of Balance of Plant (BOP) Systems: 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

Premier Integration Utilizing 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 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!!!

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

Design Goals 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

CUB - Control System Architecture Server 1A HMI Primary Server FactoryTalk View SE Clients Server 1B HMI Secondary Server FactoryTalk View SE Redundant EtherNet HMI Network Thermal Plant Controller Enclosure(s) 3 rd Party Interfaces: BACNet, Modbus Redundant EtherNet or ControlNet Control Network MCC s Chilled Water Condenser Water Cooling Towers AHU etc. VFD s Thermal Plant Remote I/O Enclosure(S) 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

Cabinet Power Distribution / Layout Power Distribution Redundant Power Supplies I/O Redundant Power Supplies: Processor I/O Racks Redundant ControlNet IFM Modules Terminal Boards Redundant Processors Stratix Ethernet Switches I/O Rack

Cabinet Power Distribution Power Distribution Redundant Power Supplies I/O Redundant Power Supplies Processor / I/O Rack Redundant ControlNet On Fiber

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

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

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

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.

3 rd Party Integration Third Party Systems: Chillers McQuay, York, Carrier Communication Interfaces: Boilers Unilux, American Modbus Chemical Feed Systems 3 rd party Unitary Controllers BACNet CRAH Lonworks AHU s Profibus VAV boxes N2 Drives Electrical Switchgear HART Power Monitoring OPC Emergency Generation Plus many more!! One Window to multiple systems

Demand Management kwd 50 40 30 20 10 0 Decreasing the area under the curve is Energy Conservation Solutions: Variable Frequency Drives, Energy Efficient Motors, Lighting, and Scheduling 12:00 12:30 1:00 1:30 2:00 2:30 Baseline with VFD with Demand Mgmt Cutting off this peak is Demand Management Solution: PEMS Demand Management Solution

Demand Management Demand Management Load Limit Line Demand (kw) Shed Lowest Priority Load Shed Next Lowest Priority Load Demand Window (Time)

Why / Benefits - Snapshot Redundancy Open Connectivity (risk) Robust (cost / risk) Modular & Repeatable Solution (cost / risk) Support (cost) Longevity (cost / risk) Built-in redundancy of servers, networks, software, controllers, I/O and power supplies Easy integration with numerous 3 rd party devices unparalleled in the industry Industrial Grade Control System proven technology with industry leading high MTBF rates Re-use of our modular code and HMI templates to reduce risk of software defects Thermal Plants, AHU s, Electrical Systems, Generation Many sources for training, support & spare parts Systems are supported and spare parts are available for many years

SUMMARY Lower Start Up Costs Leverage Best Practices Application Experience Startup On time Customer Value Extensive FWT Lower System Costs Reduce Risks Local Expertise Rockwell Automation is uniquely qualified to be a global partner of choice