University Of Vermont Central Plant Control Systems Upgrade Sal Chiarelli Director of Physical Plant Director of Physical Plant Michael Wells Central Plant Supervisor Central Plant Supervisor Ray Racine Senior Controls Engineer Hallam-ICS Senior Controls Engineer Hallam-ICS

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 *****

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

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

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

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

Each New Component’s Benefits Upgraded Electrical Distribution Allowed for more efficient VFD’s to be installed thus decreasing electrical demands Allowed for more efficient VFD’s to be installed thus decreasing electrical demands Decreased the possibility of single point failures Decreased the possibility of single point failures Made maintenance of the system more user friendly Made maintenance of the system more user friendly Centralized three panels Centralized three panels Afforded the opportunity for further expansion Afforded the opportunity for further expansion

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

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

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

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

All of This Turned Into…..

THIS!!!!!!!!!!

Halfway There

Delta-V: The Life Line of Campus

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

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 UVM contracted programmer for some simple fixes, which were successful & built trust Programmer had boiler experience on several platforms, but had never touched DeltaV 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 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) 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) Programmer attended custom 2-day training by Emerson (Hallam-ICS expense)

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 Operators to set color standards Work with burner vendor to customize (from scratch) BMS code to these burners - NFPA is only part of BMS 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) 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 Design Graphics for easy understanding and simple command entry Start / Stop – Auto / Manual – Setpoints Accurate “First Out” reporting Accurate “First Out” reporting Sensible Alarm strategies (color, sound, flashing) Sensible Alarm strategies (color, sound, flashing) Custom Reports from Historical Trends & Events Custom Reports from Historical Trends & Events

Simple Graphics

Meaningful Help Always Available

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 Adopted Pop-Up for Controls Philosophy Screen Colors match piping colors in field Screen Colors match piping colors in field Alarm and Warning set at sensible levels Alarm and Warning set at sensible levels BMS “Christmas Tree” provides troubleshooting for light-off issues BMS “Christmas Tree” provides troubleshooting for light-off issues Standard Screen Navigation for all displays Standard Screen Navigation for all displays Overviews for system status Overviews for system status

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!! Wanted 20 KPPH Steam – Right Now!! Plant Master could not respond without occasionally dumping a boiler 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

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

More Equipment

Running Systems

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 Meet code requirements Make it as efficient as possible Make it as efficient as possible Don’t make it any more complicated than absolutely necessary Don’t make it any more complicated than absolutely necessary Train your whole Team to run the system