Ripon Cogeneration replaces aging, error-prone DCS with Rockwell Automation
MILWAUKEE, Dec. 8, 2014 — Ripon Cogeneration, which helps supply energy to homes and businesses throughout most of northern and central California, achieved unprecedented plant performance – including a 30 percent reduction in start-up time – by replacing its obsolete distributed control system (DCS) with the PlantPAx process automation system from Rockwell Automation.
“Besides significantly reducing costly shutdowns, the PlantPAx system has helped us comply better with state emissions and other regulations,” said Brett Weber, operations and maintenance manager, Ripon Cogeneration. “That’s because the controls are automated, and operators can easily monitor variables through the PlantPAx dashboards in real time.”With the addition of the new system, Ripon has reduced the number of nuisance trips nearly 90 percent. Multiple fail-safes were hard-coded into the previous DCS, so even small deviations in process variables would trip the entire system offline and force the 50-megawatt-capacity plant to shut down. Operators and technicians at the 25-year-old, gas-fired plant could only react to the safety trips, which occurred as often as three times each day.
The PlantPAx system, implemented by MAVERICK, a process recognized system integrator, includes an information-enabled, scalable, multidiscipline control platform that combines process and safety control with communication and state-of-the-art I/O. The plant’s old proprietary network was replaced with EtherNet/IP, allowing easy installation of the new system and smooth integration with the existing plant subsystems.
To eliminate the plant’s former error-prone, manual, data-collection process, the PlantPAx system includes data historian software, as well as a visualization, analysis and reporting portal that provides instant insight into production. The PlantPAx system leverages all historical data from the process system and automates daily production reports, allowing plant operators to focus more closely on system operations than on manual reporting.
“The PlantPAx system provides all the core capabilities expected in a world-class DCS – plus the multiple benefits of a single, cohesive, open communication protocol,” said Steve Pulsifer, director, Process Market Development, Rockwell Automation. “By implementing a modern DCS, Ripon Cogeneration now has the flexibility to respond to external pressures, such as regulatory compliance, while increasing efficiencies and productivity across its operation.”
To manage the system long-term, Ripon also implemented a support plan from Rockwell Automation that addresses parts replacement, ongoing technical support and an annual system check.
Weber will discuss his company’s migration from a legacy DCS system to the PlantPAx system from Rockwell Automation at the POWER-GEN International 2014 conference in Orlando, Florida. His presentation, “Cogeneration Legacy DCS Migration in Half the Time of Traditional Installations at a Fraction of the Cost” (Session 11A2), is scheduled for 1:30 p.m. PST on Tuesday, Dec. 9 at the Orange County Convention Center.
News Release Assets
Image available upon request or here at box.com.
About Rockwell Automation
Rockwell Automation Inc. (NYSE: ROK), the world’s largest company dedicated to industrial automation and information, makes its customers more productive and the world more sustainable. Headquartered in Milwaukee, Wis., Rockwell Automation employs about 22,500 people serving customers in more than 80 countries.
About MAVERICK®
Founded in 1999, MAVERICK is the largest independent systems integrator in North America, and is a global leader in industrial automation, enterprise integration and strategic manufacturing solutions for clients across a wide range of manufacturing and process industries. Leveraging its unique enterprise-wide perspective, MAVERICK identifies suboptimal operations and improves performance for greater safety, efficiency and overall profitability. The company’s people, processes and technical capabilities ensure delivery of the right solution for every project, using the most appropriate technology. Organizations around the world depend on MAVERICK’s responsiveness, results-driven approach and dedication to their success. Over the years, MAVERICK has completed more than 14,000 projects in 46 countries across six continents. To learn more about MAVERICK, please visit mavtechglobal.com.
Media Contacts
Stan Miller
Rockwell Automation
414.218.2185
samiller1@ra.rockwell.com
samiller1@ra.rockwell.com
Anne Neubauer
PadillaCRT
612.455.1917
anne.neubauer@padillacrt.com
Published December 7, 2014