Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Training Workstations
      • Training Calendar
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Smart Machine Workshops
      • VirtualConnect: Smart Manufacturing
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • Media Contacts
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Training Workstations
  • Training Calendar
  • View All
  • View All
  • Blogs
  • Automation Today
  • Podcasts
  • Media Contacts
  • View All
  • View Jobs
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Smart Machine Workshops
  • VirtualConnect: Smart Manufacturing
  • View All
  • Live
  • On-Demand
  • View All
  • Digital Transformation at Norbord
  • View All
  • Brighter, More Flexible Tower Light Now Available from Rockwell Automation
  • Delphi Award Received For Asset Management
  • Internal Bypass Expands Smart Motor Functionality
  • New IaaS Bundle Eases Industrial Networking
  • Rockwell Automation Names Sebastien Grau as Regional Sales Director for Middle East, Turkey and Sub Saharan Africa
  • Expanded Power Range for PowerFlex 6000 MV Drives
  • Studio 5000 Software Update Optimizes Productivity
  • FLEX 5000 I/O Modules Bring Greater Productivity and Flexibility to a Connected Enterprise
  • New Cable-Pull Switch Enhances Industrial Safety
  • Instant Industrial Device Analytics
  • Rockwell Automation to name Al Ghandi Electrical & Automation as Authorised Distributor in the UAE
  • Rockwell Automation to Broaden Connected Enterprise Consulting Expertise with Acquisition of Kalypso
  • Single-Control Multi-Well Pad Solution Cuts Costs
  • Advanced Light Curtain System Improves Flexibility and Safety
  • Automation University
  • Rockwell Automation to Showcase the ConnectedProduction Solutions and Premieres its ThinManager Software at ADIPEC 2018
  • Safe Torque Off Option Simplifies Machine Design
  • Machine Performance Analytics Bring OEM Expertise Into Producer’s Digital Environment
  • Software-Powered Connected Services
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Rockwell Automation Simplifies Analytics for Industrial Productivity
  • New Managing Director of Rockwell Automation for Sub-Saharan Africa announced
  • Securely Deploy Cloud and Mobile Technologies with New Network Guidance
  • Rockwell Automation drive system selected for Sumitomo Rubber’s rubber mixers
  • PlantPAx DCS Roadmap
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

Colorado Springs Utilities Improves Hydro Fleet System Availability

Four-service utility standardizes on Rockwell Automation PlantPAx Process Automation System

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Solutions

  • PlantPAx Process Automation System - Based on the success Colorado Springs Utilities (CSU) experienced at its Birdsall contingency power facility, it standardized on the PlantPAx system at its hydroelectric units
  • PACs - Allen-Bradley® ControlLogix® programmable automation controllers manage the process of reducing water pressure from 1,100 pounds psi to 35 psi
  • EtherNet/IP - EtherNet/IP network and microwave stations transfer data from remote hydro units to CSU’s main facility
  • Design - FactoryTalk® AssetCentre software consolidates human-machine interface data from each hydro unit for easy monitoring and change management

Results

  • System Availability - Increased system availability to nearly 100 percent, helping CSU save $50,000 annually
  • Improved Maintainability - New system allows operators to remotely troubleshoot, reducing the need for three monthly maintenance visits to the site. Standardization allows CSU to leverage a shared parts inventory

Background

Colorado Springs Utilities (CSU) provides electricity, natural gas, water and wastewater services to nearly 600,000 people in central Colorado. To help deliver these services, CSU operates and maintains four hydroelectric plants – one of which is in Manitou, Colo., a remote town nestled in the foothills of Pikes Peak. Surrounded by sweet-smelling pine trees, the plant is housed in a small brick building that is more than 100 years old. Despite its aging walls, the plant is essential to CSU and its customers. As water glides down the mountain, the plant's prime function is to break the head pressure of water from 1,100 pounds per square inch (psi) to 35 psi so it can be accommodated by the utility's water treatment plant.

As a byproduct of reducing water pressure, the Manitou plant's position at the base of the mountain is a premium location for producing electricity. This electricity is created when water from mountain reservoirs drops hundreds of feet through a pipe to the hydro plant. The high-pressure movement of the water through a turbine then turns a generator to make electricity. CSU currently generates up to 102,000 MW of renewable energy each year through its four hydro plants, fulfilling six percent of the city's need. CSU is gradually increasing this percentage to comply with a mandate on the state's large utilities that 10 percent of power be derived from renewable sources by 2015.

The shift towards renewable energy will help meet the state mandate, but also helps CSU address the rising cost of fuel. It currently costs $4 to generate one MW of electricity at its Manitou hydro plant. Generating the same amount of energy costs $12 at the city's two coal-fired plants and $90 at its natural gas-fired plant.

To take full advantage of hydroelectric power, CSU needed to address key issues with its hydro plants: system availability and maintainability.

Challenge

In addition to Manitou, CSU's unit in Ruxton also relied on old equipment that was failing at an alarming rate. CSU's maintenance engineers would journey up Pikes Peak using the Cog Railway an average of three times each month to address malfunctioning equipment. Although these treks were scenic, they were far from profitable. It took 20 minutes to reach Manitou and two and a half hours to reach Ruxton, its most remote hydro plant. After arriving at the facilities, engineers then needed to diagnose and secure parts to repair the problem. As this sometimes required multiple trips up and down the mountainside, downtime could extend for days.

“At our remote hydro plants, we maintained legacy DCS systems from two different vendors, both of which were aging and increasingly in need of hard-to-find replacement parts,” said Brent Richardson, plant manager, Colorado Springs Utilities. “The disparate control systems each required their own inventory of spare parts, along with engineers who were familiar with the ins and outs of maintaining them.”

For CSU to increase renewable energy production, it needed to increase system availability of its Manitou and Ruxton hydro units, which hovered at 50 percent. Making matters worse, 20 percent of the outages were unplanned, which were more costly for the utility. CSU's operators couldn't remotely access the hydro units from a central location, so it was always necessary to physically travel to the sites to assess the cause of each forced outage. At minimum, this resulted in several hours of downtime – but usually resulted in several days of lost production.

If for any reason CSU couldn't meet the power needs of residents, it had to purchase power on the open market. Because power is priced according to demand, and emergencies often occur at peak times, buying power is often very expensive. Even though its hydro plants only generated a small portion of the city's electricity, CSU wanted to secure every kW it could to avoid the open market.

Solution

With over 25 years in the power industry, Richardson was familiar with the legacy DCS systems used at CSU's hydro plants. But rather than simply replacing them with newer models, he saw the advantage of standardizing on a single control architecture for all of CSU's operations. CSU had recently upgraded its contingency-power generation facility in Birdsall to the Rockwell Automation® PlantPAx™ process automation system, and Richardson believed this platform would be ideal for the hydro plants as well.

“Rockwell Automation provided us with complete system specifications for Birdsall, mapping out every aspect of the architecture that would automate all key functions of the plant,” said Richardson. “It was one of the fastest and cleanest installations I've ever seen. Their knowledge of the issues facing our industry was impressive and helped us countless times over.”

Building off of the success of its Birdsall renovation, CSU decided to migrate its hydro units to the PlantPAx system. The company began this process with Ruxton – its most remote unit – and then migrated the control system at Manitou, its oldest unit.

To help understand the new PlantPAx system front to back – including how to operate, maintain and repair it – Richardson's staff performed the installation. “Traditional DCS suppliers don't provide us the option to install the control system – the custom code and configurations are just too complex,” said Richardson. “The modularity of the PlantPAx system enabled us to install it ourselves, which was critical to our decision to standardize on the platform.”

As part of the PlantPAx system, CSU installed an Allen-Bradley® ControlLogix® programmable automation controller on each of the plant's generators. The ControlLogix controller sends valuable diagnostics via EtherNet/IP to a microwave station and – at the base of the mountain – back to a ControlLogix controller at the Birdsall facility. FactoryTalk® AssetCentre software from Rockwell Automation consolidates human-machine interface data from the hydro units, allowing CSU's operators to centrally monitor and manage system parameters, such as water pressure, and adjust controller set points from the convenience of the Birdsall plant. By evaluating valuable diagnostics, such as I/O modules and field devices, operators can also remotely troubleshoot the system if necessary.

Results

Prior to the upgrade, it could take three or more days to recover the Manitou and Ruxton systems from a forced outage. After migrating to the PlantPAx system, CSU has experienced nearly 100 percent availability. CSU's operators remotely monitor each plant and diagnose issues as they arise, often well before the issues cause downtime.

“When maintenance is necessary, we can analyze the situation from the Birdsall location, gather all the necessary parts, and route water to one of CSU's other hydro stations during the repair to maintain power production,” said Richardson. “With a Rockwell Automation Parts Management Agreement and by standardizing on a single control architecture, we've further streamlined maintenance procedures. We have quick access to the spare parts we need and can share inventory across the organization.”

With downtime costing $100 dollars per hour, CSU estimates that the increase in availability is saving the company $50,000 annually from the operations and maintenance budget.

In addition, the company can now optimize renewable energy production by identifying the highest efficiency hydro units. As water pressure fluctuates based on where the hydro units are located on the mountain, the utility can select the best water route at any given time. Prior to the upgrade, CSU could produce three percent renewable energy – when the hydro units were functioning properly. Today, CSU can reliably produce six percent, and is well ahead of schedule for meeting the 2015 state mandate of 10 percent.

With a Rockwell Automation PlantPAx system, CSU now has the freedom to shift its focus from “maintenance mode” to generating more renewable energy. The increased availability and maintainability of the Manitou and Ruxton hydro plants will help CSU produce more renewable energy, benefiting the company's bottom-line and helping ensure safe, secure power for the residents of Colorado Springs, Colo. Next on CSU's agenda is upgrading its legacy DCS at its hydro plant in Tesla – an endeavor the utility anticipates will further improve its bottom line and the city's reliance on clean energy.

Published 04 April 2011

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left Home Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
  • Customer Experience Survey
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
South Africa/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
Home