Power & Industrial Utilities Application Reference List

Applied Control Engineering, Inc. (ACE) has extensive experience with industrial utilities including combustion, cogeneration, combined-cycle, and Balance of Plant (BOP) controls.

Scope of Work

The scope of work for a typical industrial utility project includes:

  • A Functional Description including a narrative description, SAMA diagrams, logic diagrams, panel layout and termination diagrams, operator interface displays, as well as color and naming conventions.
  • Hardware/software systems integration linking OEM components and providing centralized coordinated control.
  • Customized reporting tools.
  • Web enabling and secure internet access.
  • Factory acceptance testing.
  • On-site startup assistance with comprehensive and documented testing.
  • Operator maintenance, training, and follow-up support.
Distinctive Features

An intuitive graphical user interface featuring:

  • Graphical access to monitoring and control functions using familiar Windows-type pop-ups, drop-down lists, and selector boxes.
  • Historical and real-time trending.
  • SQL database historian and reporting package.
  • Extensive diagnostics of both combustion control and burner management functions.
  • Security protected tuning of control and alarm functions.

State-of-the-art combustion control functions featuring:

  • Fully metered cross-limiting combustion controls.
  • Three-element drum level control.
  • Plant master with multiple output controller algorithms for fast response to load changes.
  • Independent, easily adjustable air/fuel curves for each fuel.
  • Fully coordinated sequencing with burner management system.
  • Full coordination and integration with other OEM systems such as CEMS, protective relay systems, and water treatment.
DSM Nutritional Products (formerly Roche Vitamins) - Belvidere, NJ
Utility Control System

4 7.5 MW Solar Gas Turbine Generator with Rentech Heat Recovery Steam Generator (HRSG) with duct burner, Siemens 2 MW steam turbine generator. The HRSG feeds the high-pressure header (1200 psig). The high-pressure header is let down through the backpressure steam turbine and parallel let-down stations to feed the 200 psig process steam header. Three back-up boilers also feed the 200 psig header. The control system balances the electrical and steam generation with the plant demands. The project includes Allen-Bradley ControlLogix and SLC-5/05s, Square D PowerLogic Circuit monitors, and multiple nodes of Wonderware InTouch HMI.

Controlled equipment includes:

  • Plant Master (1200 psig header)
  • Plant Master (200 psig header)
  • 100,000 PPH HRSG
  • Let down stations and steam turbine
  • One (1) Warm Standby 85,000 lbs/hr boiler
  • BOP including condensate return and deaerator

The combustion controls also interface to the Burner Management Systems (BMS) for the three (3) boilers and HRSG to allow remote start/stop and BMS alarm processing within the PC consoles. Data collected from the utility area is exported to a plant-wide historian system.

Taj Mahal Hotel and Casino / Conectiv - Atlantic City, NJ
Utility Control System Operated by Pepco Energy Services

Eight (8) low pressure package boilers, five (5) 1,500 ton chillers, two (2) 2,700 ton chillers, sixteen (16) cooling towers controlled by Allen-Bradley SLC and redundant Allen-Bradley PLC-5 with two (2) operator stations running Rockwell FactoryTalk View.

Controlled equipment includes:

  • Automatic start-up and staging of cooling towers based on chiller demand
  • Load balance control for chillers to preferentially load the more efficient chillers
  • Data acquisition and display for package boilers

Interfaced with the following OEM systems:

  • Trane chiller control panels via BACnet
  • Nextron Heat Trace control panel via Modbus TCP
  • tekWorx pump control panel via Modbus TCP
  • Nalco Chemical injection control panel via Modbus TCP

Also provided data logging to remote SQL server database.

University of Medicine and Dentistry - Newark, NJ
Gas Compressor Coordinated Control

Four (4) Howden Gas Compressors (providing high pressure gas to three (3) Solar 3.5 MW combustion turbines) were operating erratically and often tripped on large load changes. ACE redesigned, installed, and commissioned a revised piping arrangement and revised control scheme for the existing Allen-Bradley PLC-5 that optimally loaded each compressor and provided superior discharge pressure control. ACE also replaced the existing operator interface touch panels with new Wonderware InTouch units with enhanced alarming, historization, and diagnostics.

St. Paul’s School - Concord, NH
Utility Control System

One (1) 15 kPPH and two (2) 20 kPPH boilers and balance of plant controls using Allen-Bradley ControlLogix PLCs and Wonderware InTouch HMI.

Specified, designed, built and commissioned dual-fuel boiler control system plus an interface to Coen BMS to allow remote start/stop and alarm acknowledgement.

Daily and weekly reports include fuel usage, steam generation, and efficiency calculations.

DSM Nutritional Products (formerly Roche Vitamins) - Belvidere, NJ
Utility Control System

40 MW Gas Turbine Generator with HRSG, duct burner, three (3) boilers, Balance of Plant (BOP) controls, brine chiller controls, electric meter monitoring, interfaces to a CEMS system, condensate polishing system, demineralized water system, water treatment plant controls, waste treatment plant controls, control of three (3) substations and the switchyard (including synchronization with the utility). The project includes nineteen (19) Allen-Bradley SLC-5/05s, nine (9) Allen-Bradley PLC-5s, one (1) ControlLogix PLC, 150 Square D Powerlogic Circuit monitors, and multiple nodes of Wonderware InTouch HMI.

Controlled equipment includes:

  • Plant Master (200 psig header)
  • 350,000 PPH HRSG system
  • One (1) Hot Standby 95,000 lbs/hr boiler
  • One (1) Warm Standby 75,000 lbs/hr boiler
  • One (1) Warm Standby 85,000 lbs/hr boiler
  • BOP including condensate return, deaerator, brine chiller, chilled water, air compressors
  • River Water Treatment
  • Waste Water Treatment

The combustion controls also interface to the BMS for the three (3) boilers and HRSG to allow remote start/stop and BMS alarm processing within the PC consoles. Data collected from the utility area is exported to a plant-wide historian system.

The College of New Jersey - Ewing, NJ
Cogeneration Plant Control

Cogen plant including a 5 MW Gas Turbine Generator with HRSG; two (2) boilers, balance of plant controls; three (3) fuel-cell generating plants; monitoring of two (2) substations using Allen-Bradley PLC-5, SLC-5/04 and ControlLogix PLCs; oil-tank monitoring with Wonderware InTouch HMI, Wonderware InSQL Server, and Wonderware ActiveFactory.

Controlled/monitored equipment includes:

  • Gas Turbine and HRSG system
  • Two (2) boilers
  • Three (3) 200-kW Fuel Cells
  • BOP Systems

Daily and monthly reports include fuel usage, steam generation, and efficiency calculations.

National Institutes of Health / PEPCO Energy Services - Bethesda, MD
Cogeneration Control System

Designed, installed, and commissioned an electricity and steam generating utility control system using Allen-Bradley ControlLogix & Allen-Bradley SLC-5/04 PLCs, and Wonderware InTouch HMI.

The facility included the following systems:

  • A Combustion Turbine Generator (CTG) with HRSG that supplies steam to a 165 psig header
  • HRSG supplemental firing through a duct burner system that supplies steam to a 165 psig header
  • BOP auxiliaries including HRSG feedwater pumps, condensate booster pumps, deaerator, chilled water system and gas compressor

The completely integrated automation system is supervised from within a centralized control room featuring a modern and intuitive graphical operator interface. The control system provides coordinated control of the steam distribution system by either directly controlling (through the BOP control panel) or indirectly controlling/monitoring equipment supplied by others. The latter is made possible and accomplished by means of a system architecture providing communication links between all OEM system components.

The system provides daily and monthly reports include fuel usage, steam generation, efficiency calculations. Custom billing software was designed to conform to the complex contract between PEPCO and NIH.

BASF, Inc. (formerly CIBA Specialty Chemicals) - Newport, DE
Industrial Boiler Control System

Two (2) boilers and BOP controls using Modicon Quantum PLCs and Wonderware InTouch HMI for a specialty chemical/pigment manufacturer.

Specified, designed, built and commissioned dual-fuel boiler control system for local manufacturer of chemicals and pigments. The system consisted of low-NOx burners with FGR. Control system features include Modicon PLCs and Wonderware InTouch operator interface. Success with this and the following boiler project let to a partnership agreement with a leading E&C firm specializing in the industrial energy systems.

GE Aircraft Engines - Evendale, OH
Industrial Boiler Control System

Three (3) boilers and BOP controls using GE Fanuc 90-70 PLCs, Genius I/O, and Cimplicity HMI for an aircraft engine manufacturer.

Specified, designed, built, and commissioned a boiler control system for a leading manufacturer of aircraft engines. Control system features include GE PLCs with Genius I/O, Cimplicity operator interface, and MS Access for reporting.

Coatesville VA Medical Center - Coatesville, PA

Central heating plant for the hospital including two (2) dual fuel 20 kPPH boilers, two (2) dual fuel 40 kPPH boilers, deaerator, condensate tank, feedwater pumps, transfer pumps, plus monitoring of several pieces of BOP equipment.

Three (3) Siemens 353 controllers (fuel, air/O2, and feedwater) are used for the control and monitoring of each of the four boilers and for the BOP systems. A single Siemens 353 controller is used for the plant master and relief vent control. The controllers also provide coordination of purge and light-off sequences with their counterpart flame safety system over a dedicated, hardwired I/O interface.

Four (4)10” Wonderware Touch Panels mounted on the control enclosure comprise the local operator interface. One (1) Dell T3500 Workstation with a 42” Flat Panel Monitor and color laser printer is mounted in the office control room and serves as a remote monitor and reporting node. The operator interface displays are configured from Wonderware InTouch running under Windows XP Professional SP 3 operating system. Each Touch Panel Operator Interface and the Office Workstation has a complete view of all four boiler and BOP functions. Standard hardware diagnostics permit rapid failure detection and isolation.

The Fireye flame safety systems for each boiler support Modbus RS485 and are daisy-chained together. A Lantronix Modbus to Ethernet/TCP Bridge allows the Wonderware nodes to communicate with the flame safety systems.

The system components (operator workstations, controllers, computers, printers) are linked through a local Ethernet TCP/IP LAN.

Avantor Performance Materials (formerly Mallinckrodt Baker, Inc.) - Phillipsburg, NJ
Industrial Boiler Control System

Three (3) 40 kPPH boilers and BOP controls using Allen-Bradley ControlLogix PLCs and Wonderware InTouch HMI for a specialty chemical/pharmaceutical manufacturer.

Specified, designed, built and commissioned dual-fuel boiler control system. SQL database historian and reporting system provides daily and weekly reports including fuel usage, steam generation, and efficiency calculations. Adapted the control system to a burner upgrade and addition of FGR.

Bucknell University - Lewisburg, PA
Cogeneration Plant Control

Cogen plant including a 5 MW Gas Turbine Generator with HRSG, three (3) package boilers, and BOP controls using redundant Allen-Bradley PLC-5 PLCs and Citect HMI.

Controlled equipment includes:

  • Gas Turbine and HRSG System
  • Non-Condensing Steam Turbine
  • Three (3) Boilers
  • BOP

The control system includes three (3) redundant Allen-Bradley PLCs feeding three (3) redundant Citect SCADA nodes communicating over Ethernet. The Citect redundancy assures the integrity of I/O processing, trending, reporting, and alarming on each node.

Millennium Inorganic Chemicals - Ashtabula, OH
Cogeneration Plant Control

Cogen plant including five (5) MW Gas Turbine Generators, four (4) HRSGs, two (2) backpressure steam turbines, utility tie line control, switchyard monitoring, water treatment, and BOP controls at a chemical manufacturing site. The project was developed with Allen-Bradley ControlLogix processors and RSView32 HMI.

The system tied into:

  • The DH+ ports of five (5) PLC-5/40 C processors and two (2) SLC-5/04 processors through a ControlLogix Gateway (Ethernet TCP/IP to DH+ Bridge)
  • The Ethernet ports of four (4) SLC-5/05 processors through an Ethernet switch
  • The SNP port of a GE 90-30 PLC through a serial RS23/485 connection
  • The Modbus+ ports of two (2) Modicon Momentum controllers through an SA485 card

The system includes an algorithm for optimizing the flow of steam through a let-down system consisting of three (3) PRVs and two (2) backpressure steam turbines.

Ashland Chemical Co. - Cleveland, OH
Multi-Boiler/Multi-Fuel Control System

Control system for two boilers using Siemens 353 controllers for a specialty chemical manufacturer.

Consulted and developed boiler control strategy to allow burning of natural gas or natural gas and an organic byproduct from the chemical manufacturing process. In the dual-fuel mode, the control system lights off on gas up to 25% firing rate, then burns the distillate byproducts up to maximum firing rate. The system uses a fully metered, cross-limited algorithm with O2 trim for safe, efficient combustion. The system automatically adapts the air/fuel curves for selected fuel combination.

Lonza Chemical - Williamsport, PA
Multi-Boiler Control System

Turnkey control system for two (2) boiler feedwater systems using Allen-Bradley ProcessLogix DCS system.

Provided system engineering services to develop system architecture for a distributed control system for the boiler house and pilot plant facility. Provided control panels and system configuration for the boiler house and pilot plant systems.

Rohm & Haas Co. - Bristol, PA
Multi-Boiler Control and Data Management System

Two (2) boilers and BOP controls using Fisher PROVOX DCS for a specialty chemical manufacturer.

Consulted and developed boiler control strategy for a local chemical manufacturer under short time constraints to meet EPA data management requirements for the burning of hazardous waste as a supplemental fuel.

PEPCO Energy Services, Inc. - Whitemarsh, MD
Eastern Landfill Generating Station SCADA System

Control and supervisory system for three internal combustion engine/generators, two gas compressors, gas chiller, a flare system, and electrical switchgear using Allen-Bradley CompactLogix PLC and Wonderware InTouch HMI. Included interfaces to various OEM systems.

PEPCO Energy Services, Inc. - Bethlehem, PA
Renewable Energy/Landfill Generating Station

Control and supervisory system for a combustion turbine generator, two gas compressors, a flare system, and electrical switchgear using Allen-Bradley ControlLogix PLC and Wonderware InTouch HMI. Included interfaces to various OEM systems.

EXELON Generation, Inc. - Fairless Hills, PA
Land Fill Gas Generating Station

System engineering services and hardware for a system to provide continuous monitoring of fuel usage, including landfill gas and natural gas, electrical generation, and steam generation for two combustion turbine generators and three boilers. Control equipment included Allen-Bradley CompactLogix PLC, Wonderware Redundant Industrial Application Server, Wonderware InSQL Data Base Server, Wonderware Active Factory, and Wonderware InTouch HMI. Custom reports were generated in Excel for determining monthly payments to the land fill operator.

EXELON Generation, Inc. - Eddystone, PA
Desuperheater Controls Upgrade

System engineering services and hardware for a system to provide continuous control of Unit #3 and #4 desuperheater stations using Siemens controllers.

EXELON Generation, Inc. - Phoenixville, PA
Cromby 400 MW Coal Fired Generating Station

System engineering services and hardware for a system to provide continuous monitoring and reporting of condenser effluent flows and temperatures to verify compliance with PA DEP requirements. System equipment included Honeywell wireless transmitters, redundant Wonderware Industrial Application Server, Wonderware InSQL Database Server, Wonderware Active Factory, and Wonderware InTouch HMI. Custom reports were generated in Excel.

EXELON Generation, Inc. (formerly PECO Energy Services, Inc.) - Limerick, PA
RHR Heat Exchanger System

System engineering services, process and process control equipment including Moore Products single station digital controllers, a Genesis HMI workstation on an industrial PC, instrumentation, and Chromalox heaters for a pilot scale heat exchanger. Consulted and constructed heat transfer model of heat exchanger in the C programming language to aid in finding source of fouling. Recorded data from the actual heat exchanger; then replayed the dynamics in the pilot scale model of the exchanger by using the inverse of the process model to match inner tube wall temperature trajectories.

Ciba-Geigy - Toms River, NJ
Deep Well Pumping and Waste Treatment System

Created dynamic process model to evaluate deep well pumping strategies for two clean-up design strategies for a superfund site to prove viability to EPA. Developed control strategy and provided a portion of the configuration services.

Public and Industrial Utility Systems

In addition, our engineering staff has experience in public and industrial utility systems, including:

  • Monitoring and control of an SBR Waste Treatment facility at Woodloch Springs, PA.
  • Upgrade of a large industrial water and waste treatment facility at DSM, Inc. in Belvidere NJ. Supplied an Allen Bradley/Wonderware system to replace obsolete pneumatic and electronic panelboard equipment.
  • The DCS control system design, integration, and startup of a combined cycle cogeneration plant for the city of Kissimmee, FL.
  • Economic evaluation and systems design for pulp mill powerhouses, including recovery boilers.
  • Modeling and optimization of industrial utility systems.
  • Boiler tuning.