PROJECT SUCCESS STORIES & CLIENT TRIUMPHS

Siemens Energy, Inc. was chosen to provide two mobile power plants, each consisting of eight (8) turbine generators (TG) rated at 12.9 MW each for a country in South America. In addition to the TG units the plant consists of the necessary 13.8 kV switchgear (collection bus, intermediate bus, load bus) and the necessary balance of plant equipment (fuel compressors, air compressors, etc) for plant operation. Due to a declared national power emergency in the country the two mobile power plants were required to be delivered in less than 12 months.

Siemens Energy contracted with Control Infotech to provide the plant distributed control systems (DCS) for both plants. The DCS functions included coordination of the TG units (bringing them online, offline, operating mode), switchgear automation all the plant buses, power monitoring for the entire plant, and automatic control of all the remainder of the plant equipment.

Control Infotech's scope for this job included:

• Plant-wide DCS Integration
• Coordination of Eight 12.9 MW Turbine Generator Units
• Plant Switchgear Automation
• Plant-wide Power Monitoring
• 61850 Networking of Protection Relays into DCS
• BOP Network—Monitoring via Modbus TCP
• Plant-wide SCADA
• Plant WAN Gateway via DNP3

Control Infotech integrate the following networks for this project: 61850 – protective relaying (approximately 70 per plant), Modbus TCP/IP (balance of plant equipment); PROFIBUS (optical, for DCS I/O), TCP/IP (DCS terminal and plant bus) and DNP3 TCP (gateway to dispatch). Our total project scope includeds fiber optic communication design, DCS panel design, and interfacing to the 61850 protection relays (via a SICAM PAS data concentrator).

Siemens Industry, Inc. was engaged by a steel manufacturer in Ohio to provide complete switchgear, transformers, 138kV substation and facility wide power monitoring system for their new seamless pipe mill operation.

Siemens Industry contracted with Control Infotech to provide the power monitoring system for the seamless pipe mill.

Control Infotech's scope for this job included:

• Monitoring of 100 Protective Relays (main, feeder, transformer, etc.)
• Monitoring 88 Power Monitors
• Object oriented Client/Server SCADA, Power Monitoring and Event Recording

Integration of Discrete I/O Signals via PLC. The project integrated several networks / communication protocols to bring all the information together, including:

• Device to Data Concentrator Level: Serial RS232, RS485 multi-drop, Modbus RTU
• Data Concentrator to Server Level: Ethernet/IP, Modbus TCP
• Server / HMI level: Ethernet TCP/IP, OPC

This project was a medium voltage switchgear project for a city in Florida. Control Infotech worked with Siemens PT&D of Wendell, NC. Control Infotech's scope included software development, factory acceptance test, and site commissioning for medium voltage switchgear.

The switchgear panel has multiple incoming power sources consisting of main breakers and generator breakers. The switchgear also includes tie breakers and multiple feeder breakers. The PLC has to control two main (utility) breakers, three generator breakers and the associated tie breakers. In the event of power failure and / or power restoration the system can be selected for either closed transition or open transition schemes. During a closed transition, the control system coordinates the synchronization of the generator to the utility. Additionally, the system also utilizes a load management algorithm to open feeders to match the utilized power to the available power on the system. The PLC is a master and communicates to the protective relays over. The PLC also allows control and monitoring from existing SCADA.

The scope of the project included:

• Integration of Utility Power and Generator Power Sources
• Multiple Utility and Generator Power Sources
• Automatic Transfer Schemes - Open and Closed
• Control and Monitoring of All Electronic Devices
• Load Management System

The PLC is the central controller for the system. This PLC communicates to all the individual devices in the generator control system for control and status. All the major logic of the system resides in this PLC.

System integration: Flexible assembly system delivers in-sequence automotive cooling modules

A manufacturer in Charleston, SC produces automobile and truck engine cooling systems using programmable logic controllers (PLCs), radio frequency identification (RFID) tags, and machine-vision-guided robotics to check quality. The company found that manufacturing air conditioning and engine cooling systems for passenger and commercial vehicles accurately, in the proper sequence, is a priority for its customers.

One of the manufacturer's customers in the truck industry asked that assembled cooling modules be provided to its final assembly plant locations. The customer also requested that the company supply these completed cooling modules just-in-sequence (JIS), meaning that each module would be custom built in sequence for a particular truck, with the manufacturer's line operators pre-assembling the correct components on each module.

To satisfy customer requirements, a modular assembly line capable of building any cooling module with any set of components at any time was designed. The manufacturer chose Control Infotech for help designing and installing the PLC control system required to run the assembly line, and for ensuring that line operators could completely and accurately build, inspect, and load the cooling modules into shipping containers.

The flexibility of its new PLC-based assembly and work instruction system allows the manufacturer to build any model of cooling module in any order as specified by the customer. The material and information-handling chores all are coordinated by one PLC-based automation system responsible for all operations from order entry through shipping. A separate manufacturing execution system (MES) is not required. The manufacturer now provides its customers with just-in-sequence manufacturing services that would not otherwise be possible.

Reputable Switchgear OEM was chosen to provide low voltage switchgear. Siemens contracted with Control Infotech to provide software development and the Factory Acceptance Test for automatic changeover sequences and load control of the switchgear consisting of two sets of low voltage switchboards.

The switchboard panels have two sources of power. The panels have main breakers, tie breakers and feeder breakers. A PLC is used to control the two main breakers and the tie breaker in the event of power failure and power restoration. The PLC has a redundancy option with communication via PROFIBUS The system had its Factory Acceptance Test at the Siemens' facility in Grand Prairie, TX. Control Infotech also provided commissioning support at the end user site.

The system was automated with the following hardware and software:

• Siemens S7-300 PLC with redundancy
• Siemens software redundancy blocks
• Siemens Switchgear Products

Multinational EPC firm awarded a contract to Control Infotech for system integration for 42 Traction Power Substations

Dallas Area Rapid Transit (DART) is the local public transportation system in Dallas Texas. DART was expanding its transit network. A total of 42 new substations were installed in first phase of the project.

Control Infotech's scope consists of:

• Complete PLC programming for substation control
• Operator interface programming in each substation
• A-B PLC programming providing the gateway for communicating with the existing SCADA system in the Central Control Room via Ethernet TCP/IP

Each substation consists of following components:

• AC Main Circuit Breaker
• Rectifier Transformer
• Thyristor Controlled Rectifier
• DC Main Circuit Breakers
• Feeder Breaker

Each substation includes an AC protection relay (Siemens SIPROTEC 7SJ82) and four DC Feeder Protection relays (Sitras-PRO). A Siemens S7-PLC communicates with the protection relays through PROFIBUS.

Communication to an A-B SLC-500 PLC is through a ProSoft MVI-46 PDPS module (PROFIBUS Slave). A-B PLCs in adjacent substations are linked through Ethernet communication. Data packets are exchanged between adjacent substation for transfer trip functionality. Also, the A-B PLC is connected to the existing SCADA system through Ethernet for control and monitoring in remote operation mode.

Siemens S7-PLCs communicate to the Thyristor Control Rectifiers (TCR) PLC through PROFIBUS communication for monitoring status. An operator Interface (MP-377, 19" touch screen) in each substation displays the status of breakers and annunciations.