Biomass Energy Plant Control Systems Upgrade: Enhancing Efficiency and Reliability with Rockwell PlantPAx DCS Integration
Wunderlich-Malec Engineering (WM) specializes in advanced control system solutions for biomass energy generation. As renewable energy demand continues to grow, biomass plants require innovative automation to enhance reliability, efficiency, and operational performance.
At a leading Biomass Energy Generation plant WM successfully replaced outdated control systems with the advanced Rockwell PlantPAx Distributed Control System (DCS). The new control system is significantly improving plant efficiency, minimizing downtime, and providing reliable future operations.
Background & Customer Needs/Requirements
A leading 25+ MW wood biomass energy generation plant was operating on an aging system infrastructure, including:
- A Bailey INFI90 powerhouse Balance of Plant (BOP) control system.
- A GE Mark III Turbine Control System (TCS).
- Three traveling grate stoker steam boilers and two GE steam turbine generators.
- Disconnected systems, limiting operational visibility and efficiency.
The customer required a modern, integrated DCS to enhance:
- Reliability – Reduce system failures and unplanned downtime.
- Efficiency – Improve boiler and turbine performance.
- Scalability – Ensure seamless future plant expansions.
- Usability – Standardize operator controls in a single-seat HMI.
- Minimized Downtime – Achieve the upgrade with minimal disruption.
WM ’s Approach & Solutions
- Front-End Engineering Design (FEED) & Site Assessment:
- Conducted a site survey and operational review to develop a comprehensive upgrade plan.
- Utilized Ground Penetrating Radar (GPR) to map underground utilities and optimize fiber routing.
- Created detailed AutoCAD IFC drawings for below-grade carrier system installation.
- Technology Selection & Design:
- Replaced legacy INFI90 & Mark III with a Rockwell PlantPAx DCS for complete system integration.
- Developed and tested SAMA-based control logic to enhance boiler reliability and efficiency.
- Designed for future scalability, allowing seamless I/O expansions.
- Execution & Downtime Minimization:
- Developed a coordinated pre-outage and post-outage schedule in collaboration with plant personnel.
- Implemented detailed control logic testing pre-outage to reduce on-site commissioning time.
- Limited total plant outage to three weeks, ensuring uninterrupted energy production.
- Cost Optimization & Sustainability:
- Identified and repurposed existing field equipment and wiring to minimize costs.
- Standardized control room interfaces, replacing multiple systems with a unified PlantPAx HMI.
- Trained operators on new control system functionalities, improving efficiency and adaptability.
Why Choose Wunderlich-Malec Engineering?
WME’s industry-leading automation and controls team has a proven record of delivering high-impact control system upgrades with minimal disruption. Our ability to integrate advanced DCS solutions, leverage innovative engineering design methodologies, and provide unparalleled customer support ensures long-term reliability and operational excellence.
📞 Contact us today to learn how WME can optimize your energy plant’s automation!
Customer Benefits
Challenge: Separate outdated Infi90 & Mark III Systems
WME Solution: Upgraded into single PlantPAx DCS
Customer Benefit: Unified control, reduced complexity
Challenge: Legacy hardware & software
WME Solution: New state-of-the-art system
Customer Benefit: Improved efficiency, reliability
Challenge: Operator limitations
WME Solution: Single-seat HMI control room
Customer Benefit: Enhance operation visibility
Challenge: Risk of high downtime
WME Solution: Pre-outage planning & coordination
Customer Benefit: Minimal plant outage
Challenge: High maintenance costs
WME Solution: Standardized, modernized system
Customer Benefit: Lower maintenance costs
✓ Significantly Improved Operational Reliability
✓ Reduced Maintenance Costs & Increased Efficiency
✓ Minimal Downtime & Seamless Transition to Modern Controls
✓ Future-Proof Design for Expansion & Enhanced System Visibility