DCS replacement in a 24/7 Critical District Energy Facility. Pepco Energy Services (customer) partnered with Thermo Systems, a Rockwell Automation Solution Partner, to design, build, deploy and commission a turnkey replacement of its aging DCS system serving the district energy system in Midtown Atlantic City. The successful migration included zero customer downtime, ease of service, increased operational efficiency, billing accuracy, and expansion possibilities moving forward.

1. Eric V. Silk, CEM
October 14, 2015

2. Agenda
Q & A
Conclusions
Design and Implementation
Strategies
Project Challenges
Project Introduction

3. Pepco Energy Services (customer) partnered with Thermo Systems, a
Rockwell Automation Solution Partner, to design, build, deploy and
commission a turnkey replacement of its aging DCS system serving the
district energy system in Midtown Atlantic City. The successful migration
included zero customer downtime, ease of service, increased operational
efficiency, billing accuracy, and expansion possibilities moving forward.
DCS Replacement in a 24/7 Critical District
Energy Facility

4. Site Profile
PES In Atlantic City, NJ
• Fourteen (14) Chillers – 16,000 ton capacity
• Three (3) Saturated Steam Boilers – 210,000 Lb/hr capacity
• Combined Heat and Power – 5.5MW w/ 50,000 Lb/hr waste
heat recovery (2011 Project)
• Thirteen (13) Customers on District Energy Loop
• Energy Transfer Stations with dedicated metering PACs
Midtown Thermal Control Center (MTCC)

5. Profile - PES In Atlantic City, NJ
• Remote Locations
• Golden Nugget Plant
• Convention Center Thermal Plant
• Convention Center Solar System
• Wilmington, DE Loop
MTCC
ACCC
2.4Mw PV
GN
• MTCC Overview
• Cogen Plant
• Boiler Plant
• Chiller Plant
• District Customers

6. Energy Distribution System
• 4 miles of steam & chilled water piping
• Fiber optic controls throughout system
• Steam Header leaving the plant – 20”
• Chilled water header leaving the plant – 42”
Energy Transfer Stations – ETS’s
• Chilled water and steam heat exchangers located at various locations within customer sites
• Transfer point of product for billing
• Chilled water delivered at 42F
Steam Chilled Water
• Caesars: 5 ETS’s 5 ETS’s
• Bally’s : 2 ETS’s 2 ETS’s
• Claridge: 1 ETS 1 ETS
• Trump Plaza: 2 ETS’s 2 ETS’s
• Boardwalk Hall: 2 ETS’s 2 ETS’s
• Pier Shops: 1 ETS
Profile - MTCC In Atlantic City, NJ

7. Project Profile
MTCC DCS Replacement Project
• Yokogawa/JCI DCS Replacement
• Viking Billing & Reporting System Replacement
Life Cycle Replacement of a Legacy Yokogawa / JCI
DCS and Viking Billing & Reporting System

8. Project Profile
MTCC DCS Replacement Project
• Rockwell Automation Solution Tools
• FT View SE SCADA
• FT Historian SE
• Allen Bradley PACs
• RA Transaction Manager (bridge Plant with IT Billing)
• FT VantagePoint EMI (for reporting/dashboarding)
• Remote Building Integration via Firewalled PACs
• Nexant Utility Billing & Accounting System
Life Cycle Replacement of a Legacy Yokogawa/JCI DCS
and Viking Billing & Reporting System

9. PES’ Business Challenges
• Proprietary
• DCS
• Billing
• Many independent systems controlled by one DCS
• Poor visibility of remote buildings
• Highly manual/inefficient billing and reporting software
Now was the time to implement a reliable control system
A global control room was a must that integrated all systems

10. Technical Challenges
• Lacking expertise of proprietary DCS
• Lacking expertise of proprietary Billing System
• 24/7 Plant Operation – Contractually obligated to produce chilled
water and steam
• Inconsistent connectivity to remote Thermal Plants
• Taj Mahal, Atlantic City Convention Center, Golden Nugget
A non proprietary plant control system with billing
integration was needed

11. Why Thermo Systems?
• Design-Build / Turnkey capabilities (Engaged as MAC)
• Ability to take project from UR through commission and life cycle
support
• Experience in application: CHP, CHW & Steam Plant
• Integrator with good quality control and documentation practices
• Thermo Systems is a RA Solution Partner
• Current PES Service Provider

12. DCS Replacement Project Approach
• User Requirements
– Thermo Systems knew what questions to ask..
• Phased Approach
• Design – Drawings, Software Specification
• Implementation
• Up front coordination with Plant Operations
• Transition Plan – Key to Success
– Minimize Downtime
• Client Support

13. DCS Replacement Project Approach
• Transition Plan – Implementation in multiple phases
• Dearator Tank and Boiler feedwater
• Boiler CCS w/ PanelView (phased install qty. 3)
• Data Concentrator – comms to 13 Customer ETS
• Chilled Water Balance of Plant (BOP)
• Remote Terminal Units (RTUs) - Golden Nugget, Taj Mahal, ACCC
• Nexant billing integration via Transaction Manger
• Steam metering upgrade and standardization

14. DCS Replacement Project Approach
• Leverage SCADA implemented during a previous Cogeneration
Project
• FT View SE
• FT Historian SE

15. DCS Replacement Solution (old)
ETS
...
ETS
1
ETS
13
PLC5 DCS
BOILER 1 CCS
BOILER 2 CCS
BOILER 3 CCS
DA TANK BFW
CHW BOP
ETS 7A
ETS 7B
ETS 5

16. DCS Replacement Solution (new)
ETS
...
ETS
1
ETS
13
ControlLogix
Data Concentrator
PLC
CompactLogix
PLC w/PVSCADA
FT View SE
w/Historian BOILER 2
CCS
BOILER 3
CCS
DA Tank
BFW
CHW
BOP
ETS 5
ETS 7A
ETS 7B
BOILER 1
CCS
ControlLogix
PLC
CompactLogix
PLC
CompactLogix
PLC w/PV
CompactLogix
PLC w/PV
CompactLogix
PLC
Point IO
CompactLogix
PLC

17. DCS Replacement Sequence

18. DCS Replacement Sequence

19. DCS Replacement Sequence

20. Billing Replacement Solution
- old data flow

21. Billing Replacement Solution
- new data flow
ETS
...
ETS
1
ETS
13
ControlLogix PLC
Data Concentrator
ETS 5
ETS 7A
ETS 7B
Transaction
Manager
Golden
Nugget
ACCC
Nexant Billing Software
MicroLogix
PLC
MicroLogix
PLC
MicroLogix
PLC
Taj Mahal
CompactLogix
PLC
Micrologix
PLC
CompactLogix
PLC

22. Dashboard

23. Dashboard

24. Summary of Rockwell Equipment
• Software
• Transaction Manager (billing)
• VantagePoint EMI (reporting)
• FT View SE
• FT Historian
• Hardware
• ControlLogix PAC (qty 2)
• CompactLogix PAC (qty 6)
• Point IO (qty 1)
• PanelView HMI (qty 3)
• MicroLogix RTU panel (qty 4)

25. Conclusions
 User Requirements & Transition Plan is key
 Phased approach for complex retrofits
 Understanding of plant operations
 FATs help minimize troubleshooting during startup
 Deploying PACs logically (separation of plants)
 PES teamed with Thermo Systems from start to finish (continuity)
 Rockwell Automation provided the tools for success
 Thermo Systems leveraged our experience in application

26. • Our engineers have depth and expertise in:
• Energy: Utilities / Facilities, CHP, critical HVAC, chilled water, boiler plants, power
generation, data center critical HVAC
• Consumer: Life Sciences, Food & Beverage, Consumer Packaged Goods (CPG)
Thermo Systems – Industry Expertise

27. • Thermo Systems LLC is more than a systems integrator. We are a design-build
control systems engineering and construction firm, managing and delivering turnkey
(MAC) Main Automation Contractor projects
• Comprehensive Services (Greenfield or Brownfield) include:
• Automation & Information Master Plan including Program/Project Management and Plant/OEM/Sub-
Contractor Coordination
• Project Specifications, Documentation and Automation Architecture Standards
• Automation & Information and I&C Design Services
• Fabrication, Assembly and Testing
• Systems Integration and Programming
• Turn key I&C Electrical and Mechanical Installation
• Start up, Commissioning and IQ/OQ
• Staff augmentation through turnkey
• 24/7/365 On-Site and Remote Support
• Life-cycle Automation support including Assessments, Modernizations/Migrations
Thermo Systems – Overview

28. Thermo Systems – Across America

29. Questions
Eastern Region Support
Eric V. Silk, CEM
609-235-7653
eric.silk@thermosystems.com
Western Region Support
Cory Notaro
609-937-5818
cory.notaro@thermosystems.com