University Of Vermont Central Plant Control Systems Upgrade

1. 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

2. 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 *****

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

4. 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

5. 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

6. Each New Component’s 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

7. Each New Component’s Benefits • Upgraded Electrical Distribution • Allowed for more efficient VFD’s 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

8. Each New Component’s 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

9. Each New Component’s Benefits • Computerization of Control System • Allowing for custom Alarming on the new computer System • A better view of Plant Systems

10. Making way for the New • First Panels To be removed were #’s 1 & 2 • Boiler Controls that were installed in 1970 3&4 1&2

11. The Old BMS Control Panels • Not only the Pneumatics were being removed but the old Burner Management System was going to be Computerized

12. All of This Turned Into…..

13. THIS!!!!!!!!!!

14. Halfway There

15. Delta-V: The Life Line of Campus

16. 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

17. 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)

18. 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

19. Simple Graphics

20. Simple Graphics

21. Simple Graphics

22. Simple Graphics

23. Meaningful Help Always Available

24. Meaningful Help Always Available

25. 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

26. 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

27. 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

28. More Equipment

29. Running Systems

30. 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 • Don’t make it any more complicated than absolutely necessary • Train your whole Team to run the system