Dual Fuel Power Generation Facility
Modernized a municipal power generation facility with 8 dual fuel generators, replacing outdated mechanical controls with comprehensive digital monitoring.
The Challenge
A municipal power generation facility with 8 dual fuel generators (natural gas / diesel) needed to modernize their outdated mechanical control systems and implement comprehensive monitoring across their generators and electrical distribution infrastructure.
How We Solved It
- 01Replaced outdated mechanical air & hydraulic controls with electric sensors for improved accuracy and reliability
- 02Implemented FactoryTalk SE Distributed as the primary HMI platform for operator interface and control
- 03Deployed Ignition for advanced reporting, historian functionality, and data trending capabilities
- 04Designed custom PLC control panels featuring Allen-Bradley 1756 I/O modules with integrated Kinetix Motion Control systems
- 05Integrated Basler DECS-250 (1407-CGCM) generator monitoring and control systems for comprehensive engine management
- 06Extended monitoring capabilities to include substations and capacitor banks throughout the municipal electrical grid
- 07Successfully completed modernization of 6 out of 8 generators, with the remaining 2 units scheduled for completion
The Result
Six of eight generators were successfully modernized with digital controls and real-time monitoring, with the remaining two units scheduled for completion. The facility gained live visibility into generator performance, substation status, and capacitor bank operation across the entire municipal electrical grid — replacing a system that had relied on manual, mechanical instrumentation.