Overview

A major university sought to modernize its central power station, which generates steam, chilled water and electricity for campus buildings. The facility relied on multiple vendor‑supplied control systems that operated independently, making it difficult for operators to manage the plant holistically. A controls integrator was commissioned to replace aging hardware and unify disparate systems into a single platform.

Challenge

• Multiple vendor control systems with different protocols and interfaces
• Need to coordinate steam, chilled water and electrical generation from a central location
• Desire for a single operator interface with improved situational awareness
• Upgrade existing balance‑of‑plant controls without disrupting service
• Provide a flexible system that could accommodate future expansions

Solution

The integrator provided process control, direct digital control (DDC) and systems integration services for the power station. They selected and installed new PLCs to serve as the foundation for balance‑of‑plant controls and developed control strategies to unify the operations of steam, chilled water and electrical generation. Data and control functions from six different vendor systems were brought into a single SCADA platform, giving operators comprehensive visibility through new HMI stations. The integrator also furnished instruments, developed documentation and provided start‑up and commissioning services to ensure a seamless transition.

Technical Scope

• Deployment of new PLCs to replace and expand balance‑of‑plant control hardware
• Integration of six vendor‑supplied control systems into one SCADA platform
• HMI/SCADA development for operator stations and alarm management
• Instrumentation upgrades and I/O configuration
• Control strategy development and programming
• Full installation, commissioning and start‑up support

Results

The unified control architecture improved operator efficiency by presenting all plant processes on a single interface. Communication between previously isolated systems enabled coordinated operation of steam, chilled water and electrical generation, enhancing overall energy management. New PLC hardware and standardized instrumentation improved reliability and maintainability, while the flexible architecture allowed for future enhancements. Operators benefited from consistent alarms, trending and diagnostics, reducing downtime and improving campus utility service.

Key Advantages Delivered

• Consolidated control of multiple utility systems into one platform
• Simplified operator interface with unified alarms and trends
• Increased system reliability through new PLC hardware and instrumentation
• Improved coordination of steam, chilled water and electrical generation
• Foundation for future upgrades and expansions

Closing Summary

Through comprehensive integration and control system modernization, the university’s power station transitioned from isolated vendor systems to a cohesive platform. The project improved operational visibility, reliability and flexibility, enabling the facility to meet campus demands more efficiently and plan for future growth.

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