Project Gallery | Utilities

Every project has a unique set of challenges and objectives, including scope, budget, time frame, regulatory requirements and more. MAVERICK addresses each concern in developing custom solutions that meet each client's needs. We offer extensive services and expertise for the power generation and utilities industry. Learn more …

Completed Projects

• Fast-Paced Modernization of Generator Control Systems Meets Increased Power Demand

  When Santee Cooper, a leading southeastern utility provider, inherited peaking generator with unreliable control systems, the company launched a modernization project to systems’ reliability and ease of operation. Unfortunately, the company lacked adequate monitoring capabilities and the documentation regarding system maintenance.
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• Industrial Power Plant Owner in Need of Process Control Programming — ASA

  An owner of a new power plant uncovered problems with their control system programming. Three months from startup, they required immediate assistance to resolve programming and control issues in order to meet operational requirements.
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• Advanced Automatic Generation Controls (AGC) in Power Plant

  An independent power producer needed advanced AGC in order to achieve competitive, market-based, remote dispatch control certification.
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• MAVERICK Technologies Wins Wind Farm Systems Construction Projects

  MAVERICK Technologies announced today that it will work as a subcontractor to manage utility substation construction projects involving new wind farm systems in two states.

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• MAVERICK Technologies Provides Startup Support for University Chilled Water Plant

  MAVERICK Technologies announced today that it will provide additional support for a chiller system installation project already underway at a major university.

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• Balance of Plant Controls on LM6000 Turbines

  An energy company, acting as the general contractor, awarded a contract to MAVERICK for the balance of plant (BOP) controls on four Frame 7 and six LM6000 turbines. MAVERICK installed one redundant 90-70 for the 7FA turbines and one redundant 90-70 for LM 6000 BOP. The serial interface to the GE Multilin power management system and the replication for GE S&S’s Wonderware HMI, using CIMPLICITY software, integrate to the Mark V HMI controls. There are a total of 1,900 I/Os and an extended 200 days of commissioning support. Both projects included installation of sequence of events recorders (SERs) for critical inputs utilizing Trimation software with fast input modules on the 90-30 for one millisecond event resolution reporting to the CIMPLICITY HMI.

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• Ongoing Control Consulting

  MAVERICK provides ongoing control consulting to the power operations group at a large packaging company. MAVERICK has been asked to review and enhance the recovery boiler GE 90-70 PLC BMS, as well as install a new GE 90-70 PLC BMS on the No. 3 power boiler (oil / bark). The project requires the addition of controls for the new pulp mill screens and paper machine cleaners. Controls were provided on a GE 90-70 PLC and Bailey Infi-90 platform with Wonderware HMI. MAVERICK also provided advanced Multi-Fuel Boiler and Plant PRV Optimization Schemes.

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• Major University Cogeneration Physical Plant

  MAVERICK Technologies provided engineering, configuration, control system cabinet integration services and startup services for a DeltaV control system for the expansion of a major university physical plant. The existing physical plant power generation facility included six coal-fired steam boiler/generator sets, and the plant was expanded with a pair of 13.2 MW Solar Titan combustion turbine generators (CTGs) with Heat Recovery Steam Generators (HRSGs) providing steam for an additional two Steam Turbine Generators and four new chilled water systems. The system included five pairs of MD controllers and over 800 analog and discrete input and output points. In addition to the process control of the DeltaV control system, MAVERICK provided a high-speed power management and load shedding system for the university. This system is capable of continuously calculating which loads are to be shed as a function of a variety of scenarios of generation capacity losses or losses of tie-lines to utility transmission lines, and shedding the required load within 200 milliseconds. This system was implemented in an Allen-Bradley ControlLogix redundant processor PLC, and interfaces with over 200 GE Multilin Universal Relay devices and over 200 breakers for data acquisition and load control. All of the power management and load shedding system is integrated into the DeltaV operator stations and application stations to provide the plant operators with one seamless window to the physical plant operations.

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• Bio-Gen Panel Manufacturing

  MAVERICK Technologies completed panel design and layout of DeltaV components in addition to power and control wiring diagrams for Fluor / Bio-Gen. These panels also included the required HMI Panels and Drive Panels to support this system. The DeltaV equipment was supplied by Bio-Gen, and MAVERICK supplied the remaining equipment, including the Allen-Bradley Drives. All panels were continuity tested followed by a complete power-up test by the client with manufacturing assistance. All of this equipment was for a new process facility in Research Triangle, NC.

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• Duke-Fluor Daniel Engineering

  Duke-Fluor Daniel Engineering designed, constructed and commissioned three Co-Gen plants over a period of four years in which MAVERICK participated in the panel design of DeltaV components in addition to control wiring diagrams. These cabinets were NEMA12 design in a continuous line-up containing all the required DeltaV. All Panels were continuity tested followed by a complete power-up test by the client with MAVERICK’s assistance.

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• New Compressor and Control Upgrades
  MAVERICK connected new and existing compressors to a facility’s Siemens Moore APACS control system. The project scope included DCS equipment specification; electrical, instrument and control system design; and installation and configuration of the new compressor. MAVERICK upgraded the controls of the existing compressors, replaced the instrumentation and connected it to a new APACS I/O panel. Engineering deliverables included detailed design drawings, specifications and schedules, the I/O list and DCS configuration (170 I/Os), HMI graphics utilizing Wonderware, customer acceptance testing, installation and documentation.
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• Control System Retrofit for Air Separation Unit
  One recent MAVERICK project included a control system retrofit to upgrade an air separation unit from an aging Bailey system to a Siemens Moore APACS platform, with design documentation to support FDA validation. Control system design and configuration consisted of approximately 650 field I/Os to be connected to the new DCS. The initial scope included the verification and correction of existing P&IDs and the development of a complete construction design package, including an I/O list, location plans, instrument specifications, wiring and connection diagrams, loop sheets and a construction specification.
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• Control System Retrofit for Air Separation Unit
  MAVERICK performed a control system retrofit to upgrade an air separation unit from pneumatic and relay-based controls to a Siemens Moore APACS platform with design documentation to support FDA validation. Control system design and configuration consisted of approximately 565 field I/Os to be connected to the new DCS. The initial scope included the verification and correction of existing P&IDs and the development of a complete construction design package, including an I/O list, location plans, instrument specifications, wiring and connection diagrams, loop sheets and a construction specification.
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• 500MW Power Plant Installation in Mexico
  MAVERICK served as the controls engineer for the startup and commissioning of the HRSG and BOP for two 7FA gas turbines and one D11 steam turbine. The project required working with the OEM to redesign the high-pressure steam bypass system control, tune the HRSG and BOP controls, and integrate the auxiliary standalone equipment — such as gas compressors, travelling screens, black water treatment and burner management system — into the control system. MAVERICK also provided support for engineering and control problems related to the plant operation and high-pressure steam drum level controls.
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• 100MW Power Plant Installation in Mexico
  MAVERICK served as the controls engineer for the startup and commissioning of the HRSG and BOP for four 7FA gas turbines and two D11 steam turbines. The project required working with the OEM to redesign the high-pressure steam bypass system control, tune the HRSG and BOP controls, and integrate the auxiliary standalone equipment — such as gas compressors, travelling screens, water treatment, seawater intakes and burner management system — into the control system. MAVERICK also provided follow-up support for engineering and control problems related to the plant operation and inlet pressure control for the steam turbines, high-pressure drum control and steam bypass controls.
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• 1135MW Power Plant Installation in Mexicoo
  MAVERICK served as the controls engineer for the startup and commissioning of the HRSG and BOP for four 7FA gas turbines and two D11 steam turbines. The project required working with the OEM to redesign the high-pressure steam bypass system control, tune the HRSG and BOP controls and integrate the auxiliary standalone equipment — such as gas compressors, travelling screens, water treatment, river water intakes and burn management systems — into the control system. MAVERICK also provided follow-up support for engineering and control problems related to the design and installation of 120V redundant source selector switches in the cabinets. MAVERICK continues to provide support, including tuning of controls, to maintain maximum plant efficiency, and technical services related to minor operational issues on an as-needed basis. Also, during the commissioning and startup of each plant, MAVERICK has provided informal on-site training of local client personnel.
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• Retrofit and Control Strategy Upgrades for City
  MAVERICK provided concept, systems engineering and startup for the retrofit of #3 and #4 utility boilers, including combustion control and burner management systems for both units. This was the first application of a GE Mark VI controller to conventional boiler BMS and CCS systems. MAVERICK was awarded a follow-on project to update the control strategy SAMA logic diagrams previously furnished by the AE firm to current as-built status to match the actual logic of the GE Mark VI control system, and to provide a written description of control mechanism (DCM) to accompany each control loop. This documentation was utilized to provide on-site training for the plant operating and maintenance staff in two separate three-day training sessions.
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• Boiler Control System Evaluation and Tuning
  MAVERICK is currently providing boiler control system evaluation and tuning services on boiler units #1-3 and unit #6. Included in these services will be a proposal for follow-on support work to re-characterize these units, and provide controls modification and tuning for improved unit efficiency and load following (travel rate) capability. These boiler-coordinated combustion controls are implemented with a Foxboro I/A DCS.
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• Steam Generator Controls Upgrade
  MAVERICK provided concept, systems engineering and startup services for controls upgrade of two HRSG steam generators, which were equipped with supplementary duct firing. MAVERICK also provided modification and tuning services for three boilers.
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• Control Systems Retrofit
  MAVERICK has completed a retrofit project for the combustion controls and BMS on the #4 and #5 power boilers, as well as the combo boiler. A follow-on project was awarded to MAVERICK to provide the same services for the recovery boiler combustion controls, BMS, black liquor and ESP systems. As part of this project, MAVERICK reviewed the current BMS, black liquor and ESP system logic to ensure compliance with NFPA and BLRBAC guidelines. To ensure compliance, MAVERICK supported the insurance agency with the control logic, supporting documentation and the functional testing during the boiler startup phase of the project. Power boilers #4 and # 5 were greenfield applications, and the combination boiler and recovery boiler were converted from single-loop controllers, pneumatic controls, vintage PLCs and relay logic. MAVERICK provided the plant master and individual boiler master control algorithms. Advanced algorithms were utilized to maintain the steam header pressure.
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• Design and Engineering, Construction, Training and Startup
  MAVERICK provided a turnkey project inclusive of E/I design and systems engineering, construction, training and startup services. The mill-wide project included 30,000 E/I design engineering effort-hours, 20,000 systems engineering effort-hours and 73,000 construction effort-hours.
  
  MAVERICK performed design and implementation to retrofit a mill-wide Honeywell TDC3000 network for the pulp mill, powerhouse and recovery areas. This project included 16 universal stations, three application modules and two history modules. The data highway elements consisted of 14 multifunction controllers, 20 basic controllers, 14 DHPs communicating one-to-one with Reliance Automate 30 PLCs. Total project I/O count was approximately 4000 points.
  
  MAVERICK assumed total responsibility for LCN NCF configuration, node assignment and area database partitioning. Efficient utilization of both applications and history modules was emphasized. File naming convention and standards were developed and used throughout.
  
  From a design and construction point of view, close adherence to recommended practices resulted in a "zero defects" installation meeting Honeywell's specifications. Master reference grounding and environmental monitoring was included in all cases.
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• Refinery Boilers B1, B1A and B1B
  MAVERICK was awarded and successfully executed a contract to provide a new coordinated combustion control implementation on the client's existing Honeywell TDC 3000 DCS for an 850 PSIG, 220 KPPH multi-burner, balanced draft boiler based on control strategies furnished by others. Included in this scope was review and comment on the proposed control strategies, implementation of the approved strategies, operator HMI screens, unit startup, characterization testing and tuning support, and as-built documentation. MAVERICK was awarded a follow-on contract for a scope similar to the one above for boiler units B1A and B1B.
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• Boiler Control System Conversion
  MAVERICK completed a fast-track project to convert the #2 power boiler to a Fisher Provox DCS. The #2 boiler is a B&W Stirling-D, three-tier, nine-burner, designed for gas, oil, coal and bark fuels. MAVERICK revised the SAMA diagrams and BMS logic diagrams to ensure that the BMS met NFPA guidelines. The BMS was completed in the Fisher DCS. DCS programming and operator interface screens were completed with customer acceptance testing done at MAVERICK's Pensacola facility. The I/O listing was more than 900. A simulation was completed using SIMVOX. MAVERICK provided an on-site construction coordinator to supervise the complicated installation phase of the project. The scrubber, sootblower and miscellaneous controls were included, as well as an architectural redesign of the power house central control room. The controls for two recovery boilers were moved to the new central control room as part of the project. For the recovery boiler, MAVERICK provided all I/E design engineering and black liquor divert / ESP hardwired logic.
  
  MAVERICK provided connections into the mill's plant header controls, provided the power boiler master and individual fuel master controls. Multi-boiler fuel algorithms were implemented to ensure that the least expensive fuel was optimized while at the same time allowing the boiler to handle the plant header changes with the most responsive fuel.
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• Concept, Systems Engineering and Startup for Retrofit
  MAVERICK provided concept, systems engineering and startup services for unit #1 and unit #2 oil and gas firing reburn retrofit. Major overfire air modifications were also performed, as well as standard burner / fuel / air control integration. Both units are rated at 800MWe.
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• Complete Design Engineering for Recovery Boiler Controls
  MAVERICK performed a complete design engineering package for all E/I work to install a Honeywell TDC3000 process manager system and Modicon 984 PLC on a new recovery boiler. MAVERICK completed all instrument specifications, wiring and connection diagrams for the project. All electrical power distribution and controls were also designed. MAVERICK completed systems programming of the Modicon PLC and performed complete functional testing and staging through the Honeywell PLC gateways. MAVERICK's lead engineers were completely trained in process manager implementation. MAVERICK provided 12,000 effort-hours of systems and design engineering.
  
  This project included three redundant process managers, two redundant PLC gateways, two universal stations, one LEPIU with 15 MUX boxes and one computing module. The approximate I/O for this project was 2,000 points.
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• Control System Design and Installation for Recovery Boiler
  MAVERICK completed a design and install contract for the #3 recovery boiler project. MAVERICK was responsible for electrical and instrument design, motor controls (including precipitator motors) and burner management system configuration in Allen-Bradley PLC 5/40s. MAVERICK received a contract to provide similar design services for the #1 and #2 recovery boilers.
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• Recovery Boiler Control System Upgrade
  MAVERICK completed an engineering project to upgrade the rapid drain and black liquor diversion control systems on three recovery boilers. A two-step ESP system was implemented as part of the design. The new control system employed Allen-Bradley PLC-5/25, Wonderware MMI, 8 graphics, 130 I/O points, and monitored operation of the recovery boilers during emergency shutdown procedure and rapid drain.
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• Recovery Boiler Recalibration
  MAVERICK completed a five-day annual recovery boiler maintenance shutdown to check and recalibrate more than 180 Asmart instrument devices. The project included a 10-person instrument / electrical technician crew with a supervisor.
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• Burner Management System Upgrade
  MAVERICK completed a contract to upgrade the existing Allen-Bradley packaged burner management system to include continuous hydrogen and natural gas pilot operation. The project objective was to increase turndown on the #3 and #4 gas / oil boilers. MAVERICK also provided the programming for the plant and boiler master algorithms and multi-boiler allocation. MAVERICK also provided complete DCS upgrade services for boilers #1, 2, 3 and 4.
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• New Boiler Procurement
  MAVERICK Technologies completed a turn-key design to furnish and install services for the replacement of a worn-out boiler with a new 150 KPPH, 600 PSIG, D-type package boiler. Services included writing the boiler procurement specification, assisting the client with bid evaluation and procurement of the new boiler, factory acceptance of the boiler, demolition planning, installation supervision, and new instrumentation design and procurement. Also included in the scope were the design, fabrication and installation of the BMS system in accordance with NFPA-85 requirements, design and implementation of the coordinated combustion control system on the client's Rosemount DeltaV hybrid control system, characterization and tuning of the unit, and delivery of as-built documentation.
  
  In addition, MAVERICK was awarded and successfully executed a contract to replace the burner management systems (BMS) on the #3 and #4 boilers to bring them into compliance with NFPA-85, including the addition of new block and bleed valves in each unit's fuel train.
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• Design and Systems Engineering to Control and Optimize Mill Power and Recovery Operations
  MAVERICK completed a major design and systems engineering project to implement a Bailey Net90 DCS system to control and optimize performance in the entire mill power and recovery operations. The work included four power boilers, two oil / coal, two oil / coal / bark, four turbine-generators, four evaporator sets, two recovery boilers and one new smith lime kiln. The total I/O for the project was over 5,000 points. The Bailey PC90 was used for motor and BMS systems on the boilers and the lime kiln. Advanced boiler algorithms were utilized for energy savings, PRV Control, mill header control, boiler optimization and turbine optimization. MAVERICK provided all I/E design engineering and DCS programming.
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• Recovery Boiler Retrofit
  MAVERICK completed a contract to retrofit the #4, #5 and #6 recovery boilers to a Bailey Infi-90 DCS. The project included converting the existing flame safety system and motor controls to an Allen-Bradley PLC system. Combined I/O for this project was approximately 1,300. A simulator written in Batch 90 was used to test the new control system.
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• Steam Generator Concept, Systems, and Design Engineering and Startup Services
  MAVERICK provided concept, systems, and design engineering and startup services for 14 HRSG steam generators (seven per site). HP and LP steam coordination, steam turbine loading and combustion turbine steam injection systems were also provided. HRSGs were equipped with supplementary duct firing. Complete plant automatic generation control (AGC) with integrated balancing authority dispatch coordination was installed after initial commissioning. Total plant output is 550MWe.
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• Steam Generator Concept, Systems Engineering and Startup Services
  MAVERICK provided concept, systems engineering and startup services for two HRSG steam generators. HP and LP steam coordination, steam turbine loading and combustion turbine steam injection systems were also provided. HRSGs were equipped with supplementary duct firing. Complete plant automatic generation control (AGC) was installed after initial commissioning. Total plant output is 105MWe.
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• Powerhouse Retrofit
  MAVERICK completed a retrofit of the existing powerhouse area with a Bailey Infi-90 / OIS system and Allen-Bradley PLCs. This project required development of all systems configuration, faceplates, graphics, trends and report logs. The project included burner management systems for all boilers. GE 9070 PLCs were utilized for gas-fired units. Burner management systems were designed for three oil / coal boilers, one oil / bark boiler and one oil / liquor recovery boiler. MAVERICK was responsible for revision of BMS logic to ensure that the BMS met NFPA and BLRBAC guidelines. MAVERICK worked with the insurance representative during the logic reviews and startup testing to ensure compliance and interpretations. MAVERICK provided optimization for the powerhouse control system. This included advanced algorithms for maintaining the mill header, boiler master controls, multi-fuel optimization and multi-boiler coordination controls. MAVERICK provided all I/E engineering, DCS/PLC programming and installation services.
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• Control System Design and Installation
  MAVERICK completed a major three-year design and install project to modernize the controls and install Bailey Infi 90 DCS and Allen-Bradley PLC equipment in all areas of the original mill from the wood yard to the paper machine. The work included system layout, design engineering, configuration and installation. This project required development of all installation design documentation and systems configuration, faceplates, graphics, trends, report logs, and all PLC digital and discrete logic. Allen-Bradley PLCs were used for the burner management systems for three bark / gas / oil boilers and one gas / oil boiler. MAVERICK was responsible for revisions to the BMS, black liquor and ESP logic to ensure that the BMS, black liquor and ESP systems met NFPA and BLRBAC guidelines. MAVERICK provided optimization for the powerhouse control system. This included advanced algorithms for maintaining the mill header, boiler master controls and multi-boiler coordination controls.
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• Pre-Engineering Scope Study for Recovery Boiler Controls Retrofit
  MAVERICK completed a pre-engineering scope study for a control retrofit in the recovery boiler, evaporator and precipitation areas of a mill. The study included several options for a new central control room.
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• Recovery and Power Area Controls Modernization
  MAVERICK completed modernization work on the recovery and power area controls. Phase 1 included the #3 recovery boiler, and the project design involved a split controls architecture using Honeywell DCS / Allen-Bradley PLC equipment. The burner management system and emergency shutdown procedure logic were verified against NFPA and BLRBAC specifications. The project size was approximately 650 I/O. MAVERICK's scope included instrument and electrical design, Honeywell DCS configuration, as well as checkout and startup of the new system. Several advanced control strategies were included as part of the change in control concept. Phase 2 included a similar scope for the #4 recovery boiler.
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• Advanced Boiler Control Algorithms
  MAVERICK provided advanced boiler control algorithms for two boilers to enable this facility to obtain efficiency improvements. The algorithms included boiler master controls, individual fuel master controls and selectable multi-fuel allocation schemes. MAVERICK also implemented a highly successful control algorithm on 12 pressure-reducing valves (PRVs). The mill continues to see the efficiency gains from these control changes. MAVERICK provided complete boiler control DCS conversion for the #3 and #4 bark boilers, as well as subsequent major updates to combustion air delivery controls for both units.
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• Combustion Control Implementation
  MAVERICK was awarded and successfully executed a contract to provide coordinated combustion control implementation for a new 190 KPPH single-burner D-Type boiler on the client's existing Honeywell TDC 3000 DCS. Included in this effort was the configuration of CCC logic in accordance with control strategy SAMA diagrams furnished by others, including modification of the control strategies for improved system performance, generation of operator HMI screens, unit startup, characterization testing and tuning, and furnishing of as-built SAMA diagram control strategies in AutoCAD.
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• Mill-Wide Controls Study
  MAVERICK has completed a mill-wide controls study for a 2,500-ton-per-day mill. The study involved a field survey of the four paper machines, continuous and batch digesters, recovery boiler, power boilers, wood yard, water treatment and all related process areas.
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• Power and Recovery Areas Controls Retrofit
  MAVERICK and ABB Bailey teamed together to complete a major controls retrofit project in the power and recovery areas of a client's mill. The project scope included an oil / coal-fired Riley power boiler, the #5 recovery boiler, four turbine-generators sets, steam and electrical distribution, two evaporator trains, lime kiln / causticizing / NCG, and design of a new centralized control room and rack room. The mill selected the Bailey Infi 90 DCS for the project including provision of the combustion controls. The burner management systems used Allen-Bradley PLC-5 PLCs for the control platform. MAVERICK was responsible for revision of the functional diagrams, BMS logic, black liquor logic and ESP logic to ensure that these systems met NFPA and BLRBAC guidelines.
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• Power Facility Multi-Unit Control System Modernization
  MAVERICK provided project design to support multi-unit control system modernization at a coal-fired commercial power facility, including the field instrument and device specification and preparation of procurement installation details as an integral part of the overall control system upgrade. Control of combustion control systems, including FD and ID fans, was included in this project scope.
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• Power Plant Controls Retrofit
  The project entailed a retrofit with Westinghouse WDPF controls for all major plant systems, totaling approximately 4,500 hard-wired inputs and outputs. MAVERICK performed all engineer / design aspects for this project from conceptual design through detailed design, construction and construction records completion. Documentation included input / output list development, maintenance, schematic and wiring diagram design and drafting conversion to AutoCAD, new WDPF wiring design, control board demolition, and cable relocation design and technical direction of the construction contractor. Field wiring diagrams to the distributed control system were developed using custom integration software that linked the input / output list and cable information to the DCS terminal block diagrams.
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• Power Plant Auxiliary System Control Retrofit
  This project entailed an auxiliary system control retrofit with Allen-Bradley PLCs for coal handling, baghouse, ash handling, lime handling, gas cleaning, sludge handling and water treatment subsystems totaling 3,000 I/O. MAVERICK performed all engineering, design, integration and construction manager aspects for this project from conceptual design through detailed design, construction, testing, startup and construction records completion. Wiring diagrams for replacement cabinet PLC racks, wiring of replacement prefabricated cable connectors and field wiring to the PLC subpanels were developed using custom integration software that linked the input / output list and cable information to the wiring drawings.
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• Power Plant Control System Retrofit
  This project entailed a retrofit with Bailey Infi-90 controls for all major plant systems, totaling approximately 5,400 hard-wired inputs and outputs. MAVERICK performed construction management and technical direction of startup for this project from the beginning of major retrofit construction through return to successful commercial operation.
  
  Tasks included:

  • Prioritization of contractor activities
  • Monitoring of progress as compared to schedule
  • Completion of construction tracking for hand-off to testing and startup teams
  • Testing methods and procedures
  • Prioritization of testing activities
  • Monitoring of testing progress
  • Investigation and reporting of configuration and HMI discrepancies
  • Tracking of problem resolution
  • Direction of startup teams through return to full load commercial operation.
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• Power Plant Control System Upgrade
  MAVERICK replaced a Siemens analog turbine control system (TCS) with WDPF DCS on a Kraftwerk Union / Allis-Chalmers turbine.
  
  Tasks included:

  • Interfacing to existing WDPF data highway
  • Performing electrical design
  • Supporting input / output (I/O) identification
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  • Upgrading a variety of field devices
  • Performing all drafting activities
  • Managing hardware I/O test and Factory Acceptance Test (FAT)
  • Directly supporting the DCS vendor (Westinghouse Process Control) with logic and graphics design, implementation, integration and testing
  • Supervising all construction activities, including power—up and checkout
  • Supporting plant startup activities
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• Power Plant – Phase I Prime Contractor Services
  MAVERICK provided prime contractor services to replace the following with a Westinghouse Ovation DCS:

  • Electromechanical, relay-based bottom ash controls
  • GE Mark II turbine controls and turbine auxiliary controls
  • GE generator and generator auxiliary controls
  • Station service control board
  • Electrical auxiliary power control board
  • WDPF Scrubber and baghouse control
  • WDPF plant Data Acquisition System (DAS), History Storage and Retrieval (HSR) and alarming features
  • WDPF DPUs replaced with Ovation processors and fiber—optic backbone
  • Upgraded and added operator interface consoles (WEStations)
  • Developed new operator interface graphics and analog and digital logic
  • Interfaced the Ovation data highway with an Allen-Bradley PLC network
  • Performed all engineering and design activities including drafting
  • Performed all I/O identification
  • Managed hardware I/O test and factory acceptance test (FAT)
  • Directly supported the DCS vendor (Westinghouse Process Control) with logic and graphics design, implementation, integration and testing
  • Supervised all construction activities, including power—up and checkout
  • Supported plant startup activities
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• Power Plant – Phase II Prime Contractor Services
  MAVERICK provided prime contractor services to replace the following with a Westinghouse Ovation DCS:

  • C-E FSSS burner management system (BMS)
  • Bailey 820 combustion control system (CCS)
  • Boiler turbine generator (BTG) bench-board controls
  • Modicon 484 PLC demineralizer controls
  • Upgraded and added operator interface consoles (WEStations)
  • Developed new operator interface graphics and analog and digital logic
  • Interfaced the Ovation data highway with an Allen-Bradley PLC system
  • Performed all engineering and design activities including drafting
  • Performed all I/O identification
  • Managed hardware I/O test and factory acceptance test (FAT)
  • Directly supported the DCS vendor (Westinghouse Process Control) with logic and graphics design, implementation, integration and testing
  • Supervised all construction activities, including power—up and checkout
  • Supported plant startup activities
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• BOP Controls for Six Turbines
  This client awarded MAVERICK the BOP controls for six GE 7 FA turbines from GE Power Systems. The client acted as the general contractor with utilities engineering assigned to the design and engineering. MAVERICK was given this contract because of its previous experience and ability to understand the GE Power Systems turbine controls. One redundant GE Fanuc 90-70 PLC and one GE Fanuc 90-30 PLC are being used as the BOP controls. The total I/O count is 900.
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• BOP Controls for Four Turbines
  One client, acting as the general contractor, awarded a contract to MAVERICK for the BOP controls on four (Frame 7 and 6) LM6000 turbines. MAVERICK installed one redundant 90-70 for the 7FA turbines and one redundant 90-70 for LM 6000 BOP. There is a serial interface to the multilink power management system and a replication for GE S&Ss Wonderware HMI using CIMPLICITY software integrated to the Mark V HMI controls. There are a total of 1,900 I/Os and an extended commissioning support.
  
  NOTE: Both projects included installation of sequence of events recorders (SERs) for critical inputs utilizing Trimation software with fast input modules on the 90-30 for one-millisecond event resolution reporting to the CIMPLICITY HMI.
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• Integrated Control System
  In conjunction with the installation of two GE Frame 7 FA simple cycle gas turbines, MAVERICK and GE Turbine Controls provided a control system using the GE Mark V Turbine Control System and GE Fanuc PLCs with a shared GE Cimplicity Operator Interface. The integrated control system allows operators to control and monitor the gas turbine generators (GTGs) and plant auxiliaries or balance of plant (BOP) equipment with the same operator interface. Also included was a continuous emissions monitoring and sampling system for two-stack monitoring that provided the control room with display and reporting functions.
  
  Complete documentation included interconnection drawings, control system drawings, installation drawings, location drawings, system specifications and documentation. Many of the documentation tasks were performed utilizing INtools. By using this package system, design and record maintenance will be simplified, as the database-driven tools include instrument index, integrated instrument specification sheets, wiring connection reports, wiring connection drawings and loop drawings.
  
  The BOP control system included functionality for the unified operator interface, analog and digital loop control, alarm indication and first-out printing. The BOP controls included equipment associated with raw water, fire protection, fuel systems, water and waste treatment facilities, safety systems and air compression systems.
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• BOP Design and Configuration
  An independent power producer hired another company to provide construction and project management and utilities engineering for the engineering contractor. Two service providers operated jointly from a commercial standpoint. The client selected a GE Frame 7FA turbine with a Mark V controller as the turbine of choice.
  
  MAVERICK's engineering project team provided services to design and configure the balance of plant controls using a GE Fanuc 90-30 PLC and CIMPLICITY HMI. The system was integrated with the GE-supplied Mark V combustion turbine control system using the local and remote operator interfaces and printers. The total I/O count included 25 analog inputs, four analog outputs, 90 digital inputs and 24 digital outputs.
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• BOP Control System Design and Implementation
  MAVERICK engineers provided services to design and implement a BOP control system for a simple cycle facility. The controls were configured using a GE Fanuc 90/30 series PLC and the operator interface used was the CIMPLICITY HMI, which also acted as the unified operator interface for the turbine controller. The BOP controls maintain field equipment associated with raw water, fire protection, fuel systems, water and waste treatment facilities, safety systems and air compression systems.
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• Steam Generator Control System Concept, Design Engineering and Startup Services
  MAVERICK provided concept, systems, and design engineering and startup services for 14 HRSG steam generators (seven per site). HP and LP steam coordination, steam turbine loading and combustion turbine steam injection systems were also provided. HRSGs were equipped with supplementary duct firing. Complete plant automatic generator control (AGC) with integrated balancing authority dispatch coordination was installed after initial commissioning. Total plant output is 550MWe.
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• Steam Generator Control System Concept, Engineering and Startup Services
  MAVERICK provided concept, systems engineering and startup services for two HRSG steam generators. HP and LP steam coordination, steam turbine loading and combustion turbine steam injection systems were also provided. HRSGs were equipped with supplementary duct firing. Complete plant automatic generator control (AGC) was installed after initial commissioning. Total plant output is 105MWe.
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