NPPD Gerald Gentleman Station DCS Upgrade

NPPD Gerald Gentleman Station DCS Upgrade Power Gen Center of Excellence: Paul Wiley, Alex Turner

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Nebraska Public Power District (NPPD) - Overview

• NPPD is Nebraska’s largest Electric Utility, HQ in Columbus, NE • Fleet is a diverse mix capable of producing > 3,000 MW:

• Cooper Nuclear Station - 810 MW • Gerald Gentleman Station - 2 coal fired units at 1,365MW * • Sheldon Station – 2 coal fired units at 225MW • Beatrice Station – 2 Gas fired CC units at 250MW * • Canaday Station – 1 Gas fired unit at 119MW * • 3 Peaking Plants (GT’s) totaling approximately 155 MW

capacity • 3 Hydro Plants totaling approximately 32MW capacity • NPPD owns, operates and purchases power from several wind

farms including NPPD’s Ainsworth with 36, 1.65MW turbines • NPPD also operates a network of irrigation canals, dams and

reservoirs along a 150 mile stretch of the Platte River

Honeywell DCS *


Overview of Projects Schedule

Overview of Projects Schedule: Unit 1 BCS – Spring 2011 Unit 2 BCS – Spring 2012 Unit 1 BMS – Spring 2013 Unit 2 BMS – Spring 2014 Unit 1 ILS – Spring 2015 Unit 2 ILS – Spring 2016 Units 1 & 2 Sootblowing Air Compressor upgrades 2013/14 NOTE: All DCS upgrades completed on schedule during Spring outages with no impact to NPPD Outage Schedules

Typical Results… Projects were completed on

Schedule Projects were completed on

Budget Unique FEED Process was Utilized:

• Drives out risk early in project execution cycle

• Minimizes Change Orders • Facilitates collaboration • Full range of Projects Services

and Support Good Customer Satisfaction


Design Basis

Configuration Design Basis: • Control Strategies are programmed into the redundant C300 controllers • Control Logic is developed and implemented using the existing Functional

Descriptions and P&ID’s • Updates added based on Honeywell’s latest design standards for C300

control Algorithms / functionality • Controls and graphics for operator interface developed by Honeywell and

reviewed jointly with NPPD • Extensive involvement by NPPD Ops with Graphics development

enhanced final versions. • Control strategies, logic and graphics were reviewed with NPPD during

two (2) Design Review Meetings – PDR and DDR • All strategies fully tested, reviewed with and approved by NPPD at FAT

prior to the installation on site


Honeywell Deliverables

Deliverables by Honeywell to NPPD: • Experion Documentation Set including System Design Manuals (SDM)

and Bill of Material • Project Plan, Schedule, bi-weekly Status minutes, Quarterly Status Report • Control Logic drawings generated from the Experion PKS Control Builder

software. • I/O database with the necessary details for terminating the wires to the

DCS • Hardware and system drawings - cabinets, architecture, power/grounding,

network drawings • HMI Web Displays per the Honeywell Proposal and agreements -

documented at project Design Review meetings and other correspondence including Graphics Standards Manual

• Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) Procedures

• Final project Functional Descriptions and As Built Drawings


Project Execution Process

All Honeywell projects follow our Global Project Methodology (GPM). GPM requires a project plan. The project plan for NPPD’s projects was provided to NPPD for review and comment. The project plan includes the following major sections: 1. Scope of Work Summary 2. Contractual Information 3. Experion System Controls 4. Project Deliverables 5. Honeywell Engineering Scope of Work 6. Risk and Opportunity Plan and Objectives 7. Health, Safety & Environment (HSE) Plan and Objectives


Project Execution Process

The project plan includes the following major sections (Cont.): 8. Quality Plan and Objectives 9. Project Acceptance Criteria 10. Project Schedule and major milestone events 11. Honeywell project team Organization 12. Communication plan, project reporting, details of bi-weekly status

review meetings, action log, etc. 13. Change Management plan 14. System Testing

Note: All project documentation is available on the Honeywell / NPPD

Extranet site


GGS Unit 1 BCS Upgrade Project – Spring 2011

Upgrade 12 existing HPM controllers to C300: • Unit Master • Mills ADEG; Mills BCFH • OFA/AR for ABEF and OFA/AR CDHG • Air Flow • Feedwater • Miscellaneous Control • DAS Digitals • DAS Analogs 1, DAS Analogs 2 • Annunciator Digitals

Upgrade Included 5 New C300 controllers (C Series IO): • Baghouse (requires 2 red C300 controllers) • Ash Handling • Soot Blowers • SOE C300


GGS Unit 1 BCS Upgrade Project – Spring 2011 Additional Equipment and Services:

• 5 Quad Icon Control Room Op Stations, 1 Op Station driving dual 42 in. monitors • 3 Eng Stations, 1 with 21 inch dual displays, 2 with dual 21 in. and 1 42 in. monitors • Experion Server included 1 redundant rack mounted set of servers with ESVT • 1 ACET • Experion Backup and Restore • AMCL to Control Modules • Advanced Alarm Management included 1 server and associated software • PHD Uniformance for PHD Collector • Network cabinet with 2 ea Cisco Switches and 2 ea 48 port patch panels



Upgrade 11 existing HPM controllers to C300: • Unit Master • Mills B&D; Mills AEF; Mills CGH • Air Flow • Feedwater • Miscellaneous Control • DAS Digitals • DAS Analogs 1, DAS Analogs 2 • Annunciator Digitals

Upgrade Included 7 New C300 controllers (C Series IO): • Baghouse (requires 2 red C300 controllers) • Ash Handling • Soot Blowers • OFA/AR for ABEF • OFA/AR for CDGH • SOE C300 (Included ATS CM’s/SCM’s)



Additional Equipment and Services: • 5 Quad Icon Control Room Op Stations, 1 Op Station driving dual 42 in. monitors • 3 Engineering Stations with 21 inch dual displays • Experion Server included 1 redundant rack mounted set of servers with ESVT • 1 ACET • Automatic Turbine Start-up CM’s/SCM’s • AMCL to Control Modules • Advanced Alarm Management included 1 server and associated software • Upgrade of the Cirrus CEMS system • PHD Uniformance for PHD Collector • Network cabinet with 2 ea Cisco Switches and 2 ea 48 port patch panels


GGS Unit 1 & 2 BMS Upgrade Projects – Spring 2013/2014

Upgrade of 2 existing FSC controllers to 2 C300 controllers: • Common BMS Functions, Mills were split between the 2 C300 controllers • Five (5) cabinets to house the C300 controllers and Series C IO • NFPA 85 Trip Testing • External Watchdog Timer Solid-state relays for C300 Controllers

Additional Equipment and Services :

• 3 Eng Stations with 21 inch dual displays configured as (2 ESC, 1 ESF) • Experion Server included 1 red. rack mounted set of servers with ESV • PHD Uniformance for PHD Collector and 1 ACE • Network cabinet with 2 ea Cisco Switches and 2 ea 48 port patch panels • On process migration of Unit 1 to Experion Release R410; Off process

migration to R410 for U2 in 2014 NOTES: • Honeywell also provided a review of the new BMS logic by a Nebraska certified PE. A white paper was provided certifying that the new BMS logic emulates the existing BMS logic.

• Honeywell and NPPD jointly developed a Front End Engineering Design (FEED) process which was used on this project.


GGS Unit 1 & 2 ILS Upgrade Projects – Spring 2015/2016

Upgrade of 2 existing FSC controllers to 2 C300’s for the ILS: • Common Interface Logic System (ILS) Functions • IO split between the 2 C300 controllers • Seven (7) cabinets to house the C300 controllers and Series C IO (Unit 1) • Twelve (12) cabinets to house the C300 controllers and Series C IO (Unit 2)

Additional Equipment and Services : • Removed LCN completely (Unit 1 in 2015, Unit 2 in 2016) • Also Hardware Refresh consisting of Op Stations, Servers, ACE, PHD • Planned migration of both units to Experion R431 in Spring 2016

NOTES: • Honeywell also provided a review of the new ILS logic by a Nebraska certified

PE. A white paper was provided certifying that the new ILS logic emulates the existing ILS logic.

• Honeywell and NPPD jointly developed a Front End Engineering Design (FEED) process which was used on this project.


Detailed FEED Overview

• NPPD and Honeywell have a long standing relationship and are in the midst of a major DCS modernization program to upgrade existing Honeywell TPS controls to Experion at Gerald Gentleman Station

• Detailed FEED includes all upfront HW engineering including: • Final “Issued for Construction” System Design Manual

• Final Bill of Materials ready for hardware order on factory

• Detailed analysis of Logics including a PE review if required


Detailed FEED Pros

• Drives risk out of project for customer and Honeywell • Fosters collaborative Honeywell/customer relationship • Fewer unexpected COs, lower administrative burden, greater

customer satisfaction • Better visibility to financial and resource needs, which allows the

customer and Honeywell to better plan for project work and modifications

• Reduced rework and ambiguity over scope responsibility. • Allows work to commence sooner by starting FEED under

Engineering Service Agreement (ESA)


Detailed FEED Cons

• ~ 5% increase in schedule duration due to transition from FEED to Project Phases and execution of HW design and Controls design in series.

• Note that schedule duration can be mitigated by booking Project as a CO to the FEED

• Additionally the increased duration can be mitigated by starting FEED under an Engineering Service Agreement (ESA)

• Typically shorter approval times for ESAs

• ESA will be a fraction of the overall project award amount

• Not appropriate for competitive bid situation


Example Schedule and Process 2015 Outage

Milestones Date • Award ESA (Paid FEED study) September 2013 • FEED KO and Site Walkdown October 2013 • Produce IFA Deliverables Oct – Dec 2013 • Midcourse Review Meeting January 2014 • Deliver Final IFC Deliverables February 2014 • Deliver Firm Fixed Proposal March 2014 • Contract Review Meeting March 2014 • Book Contract for Project as CO April 2014 • Order HW and Execute Project April 14 – May 15

Budgetary FEED + Project

Firm Proposal for FEED (ESA) – FEED

Phase

KO FEED and Site Walkdown

Midcourse Review Meeting

Issue Firm Fixed Price Proposal –

Project Phase

Contract Review Meeting

Book Project as CO to FEED

Commence Project Phase

+25/-10% Price for FEED is Approx 30% of Budgetary total

FEED Duration about 5-6 Mo.

All Issued for Approval (IFA) Deliverables are Reviewed in Person with Customer. Customer issues approval of design. Fully Approved System

Design (IFC) Low Risk

Contract Reviewed in Person with IFC Design Documents. All requirements are

fully understood by both parties.

Allows for quick booking and immediate commencement

of project.

SDM and BoM are complete and fully approved. Project team can order HW and

commence work immediately.

Start

Detailed FEED Study Execution Cycle

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NPPD Projects - Lesson's Learned

Flexibility is required to work around unforeseen events Continuity of Project team helped to address issues and

smooth the transitions from project to project The FEED process really works Excellent and frequent communication


Sample Graphics

Unit 1 Pulverizer Overview Unit 1 Turbine / Generator Unit 1 Unit Master C1 Pulverizer – Showing C1 Feeder Faceplate C1 Pulverizer – Showing C1 Feeder Faceplate with Permits C1 Pulverizer – Showing C1 Feeder Faceplate with Interlocks (and showing first out)

Unit 1 Electrical Distribution System Overview Unit 1 Sootblower System Overview


Sample Graphics

NPPD Gerald Gentleman Station DCS Upgrade

Technology

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