University Of Vermont Central Plant Control Systems Upgrade

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University Of VermontCentral Plant Control
Systems Upgrade

• Sal Chiarelli
• Director of Physical Plant
• Michael Wells
• Central Plant Supervisor
• Ray Racine
• Senior Controls Engineer  Hallam-ICS

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Utilities Master Plan Main Schemes

• Document existing conditions
• Develop central chilled water plant
• Upgrade steam distribution system
• Minimize single point failure points
• Eliminate choke points on the distribution system
• Retire old inefficient equipment
• Upgrade Building Control Systems
• Co-generation possibilities
• Central chilled water plant
• Capacities/limitations
• Utility Corridors/ Plan the campus
• Reduce demand (all utilities)
• Spend now to save later/reduce excavation
• Upgrade Central Plant Control Systems

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Westinghouse to DeltaV

• From the old to the New
• From Charts that required Nightly changing
• Felt tip pens
• Ink cartridges

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The Amazing Conversion

• New Air Conditioning
• Upgraded Electrical Distribution
• New High Efficiency Lighting
• New Computer Terminals
• New Office Furniture
• Air Filtration System
• Increased Square Footage of Room
• Installed State-of-the-Art Delta-V Operating
  System

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The Beginning of New

• The installation of the new Delta-V Controllers
• New Air Conditioning to maintain constant
  temperature to assure life expectancy and
  computer function

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Each New Components Benefits

• New Air Conditioning
• Allows for higher quality air supply
• Computers have a safe environment
• Computers operate optimally
• Employees have a comfortable safer work
  environment which increases moral and
  productivity

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Each New Components Benefits

• Upgraded Electrical Distribution
• Allowed for more efficient VFDs to be installed
  thus decreasing electrical demands
• Decreased the possibility of single point
  failures
• Made maintenance of the system more user friendly
• Centralized three panels
• Afforded the opportunity for further expansion

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Each New Components Benefits

• Computerization of Control System
• Allowed for more efficient Reading to be Compiled
• Decreased the possibility of single point
  failures
• Made maintenance of the system more user friendly
• Centralized Control of the five Boilers
• Afforded the opportunity for further expansion

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Each New Components Benefits

• Computerization of Control System
• Allowing for custom Alarming on the new computer
  System
• A better view of Plant Systems

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Making way for the New

• First Panels To be removed were s 1 2
• Boiler Controls that were installed in 1970

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The Old BMS Control Panels

• Not only the Pneumatics were being removed but
  the old Burner Management System was going to be
  Computerized

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All of This Turned Into..
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THIS!!!!!!!!!!
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Halfway There
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Delta-V The Life Line of Campus
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Delta-V Hallam-ICS

• UVM selected the technicians of Hallam-ICS to
• Install Calibrate Instruments
• Work with Programmer to start-up boilers
• Initial Controls Vendor Programmer did not have
  DeltaV experience
• Code was not clean or consistent
• Start-up went poorly
• Operation of Boilers unreliable
• Trips not recorded
• UVM did not trust DeltaV system

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UVM forges a partnership

• Technicians told Mike about their programmer with
  boiler experience
• UVM contracted programmer for some simple fixes,
  which were successful built trust
• Programmer had boiler experience on several
  platforms, but had never touched DeltaV
• Hallam-ICS had already committed to learning this
  system now a real world chance
• UVM agreed to let programmer learn on-line for 1
  week (Hallam-ICS expense)
• Programmer attended custom 2-day training by
  Emerson (Hallam-ICS expense)

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DeltaV Gets a Facelift

• UVM contracts Hallam-ICS to convert Boiler 1
• New System New Rules
• Work with Operators to set color standards
• Work with burner vendor to customize (from
  scratch) BMS code to these burners - NFPA is only
  part of BMS
• Rewrite (from scratch) Combustion Controls to
  give reliable and efficient cross-limiting
  (understand burner efficiency Stoichiometry)
• Design Graphics for easy understanding and simple
  command entry
• Start / Stop Auto / Manual Setpoints
• Accurate First Out reporting
• Sensible Alarm strategies (color, sound,
  flashing)
• Custom Reports from Historical Trends Events

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Simple Graphics
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Simple Graphics
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Simple Graphics
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Simple Graphics
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Meaningful Help Always Available
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Meaningful Help Always Available
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DeltaV Redeemed

• Boiler 1 Started-Up on New Controls
• One Day Start-Up for Combustion BMS
• Next 3 Boilers in 2 days Boiler 5 / 2 days
• Boiler House Trusted the System
• Operators liked new interfaces
• Adopted Pop-Up for Controls Philosophy
• Screen Colors match piping colors in field
• Alarm and Warning set at sensible levels
• BMS Christmas Tree provides troubleshooting for
  light-off issues
• Standard Screen Navigation for all displays
• Overviews for system status

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Conversions are Never Finished

• Winter Loads show gradual changes
• Summer was not as forgiving
• Two Steam Absorption Chillers came on-line
• Wanted 20 KPPH Steam Right Now!!
• Plant Master could not respond without
  occasionally dumping a boiler
• Three days of work to re-tune Plant Master
• Re-Test for winter loads in December

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Just one More Thing

• Then came the Central Cooling Plant
• Two Steam Driven Chillers
• Four Towers and Fans
• Pumps Drives
• Comm. Interface to Chillers (Modbus Serial)
• Provide summer Load to Boiler House
• Used existing Control Philosophy
• Upgrade successfully integrated into DeltaV

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More Equipment
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Running Systems
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UVM Central Utilities Success Formula

• Consider current and Future Needs
• Develop Standards and stick with them
• Develop Equipment Vendor Relationships and
  Technical Support Relationships
• Keep it Simple
• Meet code requirements
• Make it as efficient as possible
• Dont make it any more complicated than
  absolutely necessary
• Train your whole Team to run the system