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

Hospital Saves Energy with Integrated Architecture

Vital Efficienci replaces legacy energy control solution with a contemporary Allen-Bradley Integrated Architecture in order to make continuous energy savings over the next 15 years

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • York Hospital needed to both manage save energy and any investment it made in new technology had to be covered by the savings made – for the next 15 years.

Solutions

  • Allen-Bradley CompactLogix L33ER and L24ER PACs
  • Stratix 5700 managed Ethernet switches
  • Fibre EtherNet/IP network
  • Modbus and ASCII communication modules from ProSoft Technology
  • Vital Efficienci ECS SCADA solution based around Allen-Bradley architecture

Results

  • Open, scalable system deployed on robust, industry-proven COTS hardware
  • Significant savings already being forecast
  • “Outstanding support from Rockwell Automation”
  • Open solution will adapt and evolve much more easily over 25 year lifecycle
  • Secure and controllable remote access via browser or app

Background

York Teaching Hospital NHS Foundation Trust was designed in the 1960s and built in the 1970s and, as such, much of its energy infrastructure is now reaching end of life. This gave the Trust the opportunity to make significant improvements in the way the hospital generates and consumes heat and power.

With over 8,000 staff, the Trust treats over 700,000 people per year, giving it similar energy requirements to a small town. Indeed, in 2012/13, the Trust had a combined gas and electricity bill of £2.45 million and emitted 13,586 tonnes of CO2.

Following a competitive procurement process, the Vital Energi Group was selected to deliver a low-carbon energy solution, with guaranteed carbon and financial savings through its operating companies:

  • Vital Energi Utilities who design, build and operate low carbon based energy solutions for the localised generation, supply and distribution of heat, power and cooling
  • Vital Solutions, who develop and structure long term Energy Performance contracts for hospitals, universities and large commercial and industrial sites
  • Vital Efficienci, who design and deliver energy and carbon reduction solutions by measuring, managing, controlling and implementing solutions to reduce energy consumption

Vital Efficienci was tasked with reducing the hospital’s energy demand. A challenge made all the more difficult by the fact that the project would go from procurement stage to going live in just 20 months. The money saved by the new infrastructure could then be invested in front-line clinical care, improving services and offering real, tangible benefits to the people of Yorkshire.

Vital Efficienci worked with Rockwell Automation to develop a bespoke energy-management and control solution that would help the Trust to both measure and manage its energy consumption, while giving Vital Energi Group real-time remote access into the site for on-going management, balancing and monitoring.

Challenge

The project at York was procured and delivered in conjunction with the Carbon and Energy Fund, a procurement framework created to facilitate and manage complex energy infrastructure upgrades for the NHS and wider public sector. The money invested in CO2 reduction solutions is funded from the savings generated. The Vital Group has a 15-year operation and maintenance contract, which will ensure that savings are achieved every year. When possible it will try to exceed guaranteed savings, and these are then shared between the Trust and the Vital Energi Group.

Vital Energi Utilities was responsible for delivering the overall project and Vital Efficienci delivered the complete SCADA solution, alongside the operating principals and philosophies, and optimisation methodology developed for the plant. The control solution is split in two:

  • The BMS – supplied by a specialist supply partner – which manages and optimises the downstream energy assets
  • The SCADA system, supplied by Vital Efficienci, which manages and optimises the main energy centre (boiler house), with its two main plant rooms, and uses an Allen-Bradley architecture

According to Kenneth Kunz, Technical Director at Vital Efficienci: “This is a 15-year agreement, so we needed a robust industrial system that can work in a demanding environment and remain stable. It is for this reason that we decided to go with our own SCADA system and based it on proven, open industrial systems, with Rockwell Automation CompactLogix PACs at the heart.”

Solution

The existing energy system comprised gas-fired steam boilers controlled by an older and now unsupported control architecture. The Trust decided to proceed with the ECS (Energy Control Solution) typically known as SCADA from Vital Efficienci, based primarily on Allen-Bradley Integrated Architecture products.

The Trust was actually the first client of the new system, and required a complete upgrade and deployment of a new control infrastructure. “We developed different modules into our ECS system,” Kenneth explains, “which are unique to Vital Energi Group. Our solution is very open, unlike other typical BMS systems, which can often be a little more ‘black box' like and closed. They are satisfactory for alarming and monitoring, but they are often not optimized for energy centers. We developed new modules to make it unique and make it different to the market.”

Vital Efficienci did the coding in-house and worked together with Rockwell Automation on the design and writing of software for the MBus protocol (communications). Standard industry power meters use MBus communications and, at the time, it was not possible to integrate these meters into the CompactLogix PACs. So the Rockwell Automation Global OEM Technical Consultant (GOTC) and Kenneth wrote new software, which supported the implementation of certain power meters into the overall control system.“

MBus is not a standard,” Kenneth explains, “but I found a serial communications module from ProSoft Technology (a Rockwell Automation Encompass Partner) within the Logix family, so we were able to develop an ASCII driver that would communicate with the MBus protocol. MBus is only really used for heat meters, but these days, more and more heat meters are offering the ability to use Modbus. We used MBus in York, but going forwards we will use Modbus RTU/TCP-IP.”

The Vital Efficienci ECS system runs on Allen-Bradley® CompactLogix™ L33ER & L24ER programmable automation controllers running on a fibre EtherNet/IP™ network served by multiple I/O points and Stratix 5700™ managed Ethernet switches.

“We need these different interfaces because we have a lot of gas, steam, electrical and heat meters around the energy centre measuring set points,” Kenneth elaborates. “These data points allow us to populate a daily CSV file with raw data, which is sent out at midnight to our head office in Blackburn and then stored in the cloud. The data, collected every 30 minutes, is then entered into specialist software so we can see where savings are being made and compare figures against desired set points.”

Last year Kenneth changed Vital's meter standard in order to gather better quality, more uniform data. “Now it is all the same, it is much easier to work with on a day-to- day basis. The data collection is based on SQL, a flexible solution which also interfaces to a lot of other systems, and the system has been built based on good standards using products that will be on the market for many years.

“Above the CompactLogix PACs are a set of full servers that help ensure the whole system we design and deliver is robust, stable and future proof,” Kenneth explains. “The ECS Supervisor Server handles the Graphics and the SQL solution, while the ECS Report Server works beside it generating the data. Both are controlled with one screen, one keyboard and one mouse. The servers are also fail safe in case one stops working or we need to shut one down for maintenance."

Kenneth also believes that Vital Energi Group offer a unique solution compared to typical approaches. “We have two ways to remotely access the Trust's system, either back access or via a smartphone app. Back access is via a browser using a fixed IP. With this we are able to connect into the Trust's ECS supervisor. It's all encrypted and offers different levels of access and includes an operator interface where our own engineers can change different things such as set points or alarms. App access is more for our engineers, but we can open it to others and our open-source app is very popular and can be downloaded free for Apple or Android.”

Vital Efficienci also developed an alarm management and recording system that is monitored by personnel at Vital and used by its engineers to manage its on-call system. It uses an industrial mobile modem and SIM card (with antenna). Every time an alarm is generated in the Allen-Bradley PAC, it flashes on panel, appears on the ECS supervisor server and is sent to the engineer on duty via SMS, phone call and e-mail. Vital Energi or the Trust can then determine what sort of actions they want and can base the priorities on the severity of the issue.

“Now the ECS solution has been delivered, installed and proven we are fully prepared to handle a much wider range of projects and applications,” Kenneth enthuses, “and not just hospitals – any large establishment can benefit. We will soon be looking at industrial complexes; our system is flexible and can handle the variety.”

Results

Brian Golding, the Trust's Energy Manager explains: “We wanted Vital to look at our fundamental aims: reduce our carbon footprint, reduce our energy consumption, enhance our electricity resilience and take the project forward 15 years.”

“Brian is suitably impressed with our solution,” Kenneth elaborates, “it was delivered and installed within the agreed timescales and has not experienced any issues after one year of operation, and is delivering the level of control and energy savings envisaged in the original design. The system will continue to be developed and with the flexibility and scalability of the Allen-Bradley Integrated Architecture, can be easily deployed on existing systems, such as we have seen in York.

“Quality is a key driver and we need to have faith in the equipment we deploy” Kenneth explains. “We need robust solutions based on high-end materials. We insist on delivering quality on every project we work on, and must therefore use quality inputs to be able to deliver quality outcomes.

“The support from Rockwell Automation in the UK has been outstanding,” Kenneth concludes. “Without the right team around you and the right input from suppliers you cannot achieve goals and have success – Rockwell Automation is very much part of our team.”

The results mentioned above are specific to Vital Energi Group and York Teaching Hospital NHS Foundation Trust's use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.

Published 22 August 2016

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
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