Greenfield building automation system case history

Building automation system case history greenfield manufacturing

RoviSys recently completed a comprehensive building automation system for a new high-technology manufacturing campus in Asia. Work for the more than a dozen buildings on the grounds included:

Fire alarm suppression and public address systems

Work included the two datacenters. Scope included specification, procurement, installation and testing of all smoke detectors, local building fire alarm panels, very early smoke detection alarm (VESDA), main fire alarm panel and passing of registered government inspection. We also performed conduit and cable schedule development for the isolated fire fiber network ring, setup of fire alarm system servers and workstations in the fire command center, graphics design and implementation on the workstations and linking of the fire server and all data to the overall plant SCADA system for historization.

Security access control

For all buildings and access points to the campus. Scope included specification, procurement and installation of all card scanners, door contacts, boom gates and turnstiles for access to all gates/pathways into the campus as well as the security access on all doors once inside. Also included were programming of the security levels on redundant servers, ID badge printing with associated security clearances, linking of the timesheet management system to the badge scanners and specification, procurement and installation of emergency rally point ID badge scanners.

Closed circuit television

For all buildings and access points to the overall site plus 65 ‘campus coverage’ pan-tilt-zoom cameras. Scope included specification, procurement and installation for all fixed and PTZ cameras, conduit and cable schedule development for networking via fiber all CCTV, networking bandwidth calculations, specification and installation of CCTV servers and quad-monitor workstations with workstation capability of accessing up to 16 cameras per monitor.

Building utilities automation

This included non-inline instrument installation for facility tower water, chilled water, process water, domestic water, fire water, diesel oil, compressed air and fuel gas systems. Scope included lead-lag control of Allen Bradley 6.6kV PowerFlex variable frequency drives for chilled water delivery, OPC interfacing for control and historization of various skid packages throughout the facility including waste water treatment, compressed air, process gas delivery, chillers and interface to the process plant buildings.

BMS/HVAC automation

This included instrument specification, procurement and non-inline instrument installation. Scope included controls configuration for the HVAC including variable volume air valves (VAVs) over BACnet, direct air handler unit (AHU) and makeup air unit (MAU) control, overall HVAC setback modes for nighttime energy savings and interface/control of 10 datacenter control room air conditioning (CRAC) units split between two datacenters.

Full Ethernet and fiber optic network design

For all above systems including network switch specification, procurement and installation, network bandwidth usage calculations, conduit and cable schedule development and fiber patching schedule development. Scope included physical patching and termination of the control system fiber network and physical patching and terminations for Siemens TerminalBus and PlantBus, ProfiBus, ModBus and Ethernet networks.

Power management and control system implementation

For 10 campus buildings. Scope included specification and installation of all switchgear monitoring equipment, stand-alone voltage and current transmitters, interface to Schneider servers, interface to two datacenter uninterrupted power supplies (UPSs), interface to ABB 66kV switchgear, interface to plant emergency generator and switchgear remote control mechanism design for site switchgear including 400V, 22kV, 6.6kV, and 66kV switchgear. Also included linking of all PQMS to the plant-wide SCADA system for control and historization.

Supervisory Control and Data Acquisition (SCADA) system

Specification, design and implementation. Scope included implantation of three sets of redundant 417H Siemens PLCs with redundant partners located in physically separate datacenters on the campus connected directly by fiber. The three sets of redundant PLCs controlled and monitored over 1,000 physical hardwire I/O brought into the system via 21 remote I/O (RIO) panels for plant utility systems, five RIO panels for plant BMS/HVAC systems and 10 RIO panels for plant power management I/O. This included specification, design, fabrication and installation of all PLC and RIO control panels, network design for connection of all RIO panels to redundant PLCs as well as network design and some physical installation of ModBus and ProfiBus networks spurring off from RIO panels. Scope also included specification, design and implementation of six redundant OS servers and two Open PCS7 servers to bring in more than 12,000 soft I/O from various systems around the facility, including the fire alarm and power management systems. Additional scope included specification, design and implementation for connecting ,ore than 18,000 SCADA system tags to an OSI soft plant historian complete with custom end-user-defined and RoviSys-configured reporting capability.