MSE-Tetragenics
SCADA Experience and Qualifications
STATEMENT OF QUALIFICATIONS
Automation Controls Monitoring
Office Locations Visit us online at www.mse-ta.com or http://www.tetragenics.com/
Headquarters: Western Regional Office West Virginia Office Tennessee Office
200 Technology Way 1845 Terminal Drive, Ste. 120 3592 Collins Ferry Road 679 Emory Valley Road Suite A
Butte, Montana 59701 Richland, WA 99354 Suite 160 Oak Ridge, TN 37830
406.494.7100 509-371-0827 Morgantown, WV 26505 865-220-8551
MSE-Tetragenics -i- 304-598-1126 Qualifications
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MSE-Tetragenics
SCADA Experience and Qualifications
MSE‐Tetragenics
SCADA
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MSE-Tetragenics
SCADA Experience and Qualifications
Table of Contents
MSE-Tetragenics Offers You More............................................................................................. iv
MSE-Tetragenics ............................................................................................................................ 1
Installation Site Map .................................................................................................................. 3
Products and Services .................................................................................................................. 5
Homeland Security..................................................................................................................... 6
Specific Products and Services ............................................................................................... 7
Supervisory Control and Data Acquisition (SCADA) ............................................................... 7
Power Plant Automation and Control....................................................................................... 7
Substation Automation and Control ......................................................................................... 7
Communications Monitoring and Control System (CMS) ........................................................ 7
Remote Terminal Units ............................................................................................................ 8
Master Platforms ...................................................................................................................... 8
Programmable Logic Controller (PLC)................................................................................... 10
Graphical User Interfaces ...................................................................................................... 10
Engineering Services/System Integration .............................................................................. 10
Factory Acceptance Testing (FAT) ........................................................................................ 10
Additional Qualifications......................................................................................................... 11
Project Organization and Experience ........................................................................................ 12
Example Projects ..................................................................................................................... 12
Army Corps of Engineers – Nashville District – Dale Hollow Project .................................... 13
Army Corps of Engineers – Nashville District- Cordell Hull Lake .......................................... 16
Army Corps of Engineers – Nashville District- Old-Hickory ................................................... 19
Army Corps of Engineers – Nashville District- Wolf Creek .................................................... 22
Army Corps of Engineers – JEM Meter Replacement ........................................................... 25
PPL Montana Hydroelectric SCADA...................................................................................... 26
Rochester Gas and Electric Hydroelectric System ................................................................ 31
Rochester Gas and Electric Hydroelectric System Court Street............................................ 34
Lewis County Public Utility District (PUD).............................................................................. 37
Louisiana Hydroelectric.......................................................................................................... 39
City of New Martinsville.......................................................................................................... 41
California Department of Water Resouces System ............................................................... 44
Communications Monitoring and Control System – NorthWestern Energy* ......................... 47
Substation Monitoring and Control System – NorthWestern Energy Company*................... 49
SCADA/Telemetry Improvements on Water System – Town of Superior ............................. 49
Water System Improvements – Butte Silver Bow Water Department ................................... 50
Water System Improvements – City of Hamilton ................................................................... 51
Water System Improvements – Emerald Bio ......................................................................... 51
Water System Improvements – City of Havre........................................................................ 51
Water System Improvements – City of Culbertson................................................................ 52
Water System Improvements – East Glacier ......................................................................... 52
Water System – Town of Philipsburg..................................................................................... 52
Water and Wastewater System – Galen Campus ................................................................. 53
Industrial Wastewater Treatment – Atlantic Richfield Company............................................ 53
Wastewater/Air Emissions System – Fort Bragg Military Reservation .................................. 53
Industrial Waste Minimization and Prevention – Watervliet Arsenal ..................................... 54
Industrial Wastewater Treatment Control System Upgrade – Watervliet .............................. 54
Underground Storage Tank Monitoring System – Fort Lewis Storage Tanks ....................... 55
Water Treatment Plant – Emeryville ...................................................................................... 55
Critical Aircraft Parts QA Monitoring System – Corpus Christie Army Depot ........................ 55
Water Treatment Plant Control System Upgrade – Hawthorne Army Depot......................... 56
Mine Internet Monitoring System – Calliopi Mine .................................................................. 56
PLC Panel Fabrication – ASiMI ............................................................................................. 56
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SCADA Experience and Qualifications
MSE-TETRAGENICS
OFFERS YOU MORE
More than 31 years of Supervisory Control and Data Acquisition (SCADA) and
project management experience, and more than 29 years of engineering, construction
management, and turnkey experience.
Complete SCADA, Plant Control, Substation, and Communications monitoring
systems.
Advanced system integration services using high tech, state-of-the-art equipment and
technology in a variety of diverse systems and situations.
Mechanical, software, electrical, instrumentation and control (I&C), and programming
engineering services.
Secure software systems, dependable hardware components, and advanced
surveillance equipment.
Construction, civil/structural, process/chemical, biological, aerospace, environmental,
remediation, geophysical, environmental, and mineral processing engineering services.
Economic cost analysis services.
Advanced laboratory for factory testing, and a 45-acre test facility site that meets all
applicable environmental laws and regulations, which includes a UL – Industrial
Control Panel Shop.
Complete documentation and help systems control department.
Dedicated engineers and staff – more than 125 qualified engineers, craftsman,
scientists, drafters, and staff ready to provide exceptional service and new technology.
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SCADA Experience and Qualifications
MSE-TETRAGENICS
M
SE-Tetragenics, a division of MSE Technology Applications Inc. (MSE), delivers complete
SCADA solutions for Automation, Controls, and Monitoring. We develop hardware and
software for Plant Control Systems (PCS) used in the utility industry for hydroelectric and
substation automation, and Communications Monitoring Systems (CMS) for the telecommunications
industry. Turn-key industrial solutions are provided, from challenging hydroelectric generation projects
to water/wastewater projects of any size.
We have years of system integration experience with commercially available PLCs and software, such as
Modicon®, Allen Bradley®, GE®, and Wonderware® to name a few. We manufacture UL508A certified
panels and RTU/PLC controls for water and wastewater systems and treatment facilities.
We have delivered our solutions to communications companies and electric, water, and wastewater
utilities throughout North America.
History: Although formally incorporated in 1982, Tetragenics’ history began in 1972. In the early
seventies, the automation department of a Montana utility company successfully synchronized and started
hydroelectric generators remotely. These pioneering engineering efforts in hardware and software design
became the basis of Tetragenics. Since then, we have advanced the product lines and continued to provide
innovative monitoring and control systems. In 2002, MSE purchased Tetragenics to add to an expanding
Overview
products and services line. MSE is a diversified research and engineering company with more than 29
years of demonstrated, corporate environmental experience. Headquartered in Butte, Montana, MSE is
one of the larger engineering services and technology applications firms in the Rocky Mountain region
offering comprehensive, state-of-the-art engineering services from initial studies and site visits to final
design and construction oversight. Formed in 1974, MSE has completed more than $450 million dollars
of work - $100 million directly related to engineering services.
Today: MSE (now offering the expanded services of Tetragenics) possess a unique ability to offer
virtually all engineering, fabrication, installation, and start-up services to our clients. Specific capabilities
include engineering for infrastructure development and improvements, facility upgrades and alteration,
system design and construction, construction management, geotechnical services, and structural design
for commercial and industrial sites. Because of our large, multidisciplinary staff of engineering
professionals, combined with work control, project management, and budgeting systems, we can respond
rapidly and appropriately to customer requirements. Licensed professional engineers (P.E.) lead all the
major engineering disciplines, including mechanical, electrical, and structural. Also, we maintain our own
internal support services including drafting, surveying, laboratory, and document production to ensure
high quality products.
Currently, we have more than 200 employees, comprised largely of scientists, engineers, skilled crafts
people, and technicians, including the following:
Instrumentation & Control engineers Process engineers Quality Control professionals
Electrical engineers Technology developers Risk analysts
Mechanical engineers Waste management specialists Structural engineers
Plant/facility managers Environmental scientists Biologists
Chemical / process engineers Environmental engineers Geotechnical engineers
Chemists Environmental S&H specialists Hydrogeologists
Civil engineers Geological engineers Industrial hygienists
Economists
MSE-Tetragenics -1- Qualifications
MSE-Tetragenics
SCADA Experience and Qualifications
Total Systems: MSE’s technology experience and background compliment the Tetragenics systems.
And Tetragenics’ SCADA experience compliments MSE’s existing instrumentation and control
department. Combined, we have more than 52 years of experience working with SCADA systems and
innovative technologies. And it all goes together to give you a system that is extremely powerful, with
built in flexibility to allow you to modify or override the system (with the right security clearances) all
within a secure system infrastructure.
We provide substation control and
monitoring from single substation
systems to large 200+ substation systems.
Our RTUs are ruggedized to withstand
temperature, vibration, and voltage
extremes, enhancing reliability.
Our systems are especially suited to
hydroelectric generator operations Taiwan
Scotland
because they incorporate modules for Japan
generator synchronization; shaft speed Poland
Canada
sending; load, reactive power, pond level,
and downstream flow control; and
automatic reporting capabilities. For Corporate Headquarters
areas that require unattended plant Office Locations
operation, our systems provide a security Color denotes project locations
verification feature that not only helps Figure 1. MSE Office Locations and Combined Project Locations.
keep your site safe from intruders, but can
also help troubleshoot site problems, monitor access, monitor water quality, detect chemical oddities,
monitor air quality, etc.
Support: With a solid grounding in the utility industry, experience in telecommunications, and diverse
engineering experience, we can provide support on just about any system you have or buy and provide
support for any situation you encounter, be it electrical, mechanical, chemical, biological, environmental,
or system specific. And we offer 24 hour -7 days a week customer support. Our professional resources
support the company’s main office and additional offices across the United States. (See Figure 1).
UL® Industrial Control Panel Shop: MSE is a UL 508A Industrial Control Panel Shop,
manufacturing custom control panels used in a variety of applications. MSE is certified with an
Underwriters Laboratories UL508A certification in the United States, and a Canadian Underwriters
Laboratory CUL for Industrial Control panels in Canada, as shown at www.ul.com (file: E229857
INDUSTRIAL CONTROL PANELS - NITW, NITW7).
MSE’s Industrial Control Panel Shop provides design, fabrication, wiring, implementation, and system
commissioning. Panel applications include SCADA, pump/motor/process control, and security/remote
monitoring.
MSE’s staff is composed of UL-trained and Instrument Society of America (ISA) Certified Technicians
and Engineers, skilled in providing customized solutions for industrial panels, engineered to meet specific
needs and often include remote telemetry transmission. ISA drawings including Piping & Instrument
Diagrams, Process Flow Diagrams, Instrumentation Loop Diagrams, and Control Elementaries are
professionally provided.
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Installation Site Map
Most facilities can benefit from automation technology. We partner with utilities, wastewater treatment
customers, communication providers, government facilities, and large industrial customers to develop
systems that allow more efficient management of resources. Our modular design architecture allows easy
expansion and maintenance. We have successfully installed equipment or integrated systems for diverse
projects across most of the United States (refer to the map following).
MSE-Tetragenics -3- Qualifications
Automation, Control, and Monitoring Sites
, , , g
Town of Superior, Philipsburg, Galen, Butte (Silver Bow Water) MT
Mission Valley Power SCADA
Hamilton Booster Pump Milltown United States Only
Verizon Wireless (VW) Hamilton Mycotech Industrial Automation
Tacoma Northwestern Energy (NWE)
Northern Telephone
Ft Lewis Cowlitz Shelby Water Plant Control / Lift Station Control
Storage 360 WA
Havre Water Plant
MSE-Tetragenics
Tank IA PPL Montana
Lewis County Culbertson
Mayfield
MT Traverse City Central Vermont
Avista PT
ND MN Green Mountain
than 25 years.
PPL ME
PCS Power
OR ID Beaverton
Midstate IA Yellowstone Valley 360
VW Niagra Mohawk VT.
PT SCADA CMS SCADA Model 2F
VW 360
360 VW WI N.H.
Snedigar
SD RG&E
VW Ranch 360
WY IA MA
Idaho Power & 360 PT
CA Light (VR-2)
Grand Electric SCADA NY
RI Watervliet Arsenal
VW Industrial Waste
NV 360 IA MI PA Minimization
Sherwin UT CT
Williams NE
R IL
Plant Wells REA SCADA VW 360 IN OH NJ
IA VW Commonwealth DE
Hawthorne CO MD
360 MO
CDWR Allwest CMS
R
VW KS New Martinsville
VW WV
-4-
R City of Hurricane VA
KY Duke Energy
Altamont (Nantahala Pwr&Lt )
R
AZ NC
R
NM TN
OK
R VW TX AR
SC Fort Bragg Army Depot
VW AL GA
VW PT MS
ACOE
VW Georgia Army Corp of Engineers (ACOE)
Power
LA
PT
Protocol Translator
Remote Terminal Units (RTUs) PT
FL
Communications Monitoring
and Control (CMS)
CMS RTUs
Louisiana Hydroelectric
Water and Wastewater
Sterling Chemicals
Plant Control System (PCS) Corpus Christi Army Depot Monitoring System
R PCS/RTU (Controlling RTU)
SCADA MSE-Tetragenics
Note:
Symbols may represent more than one site. http://www.tetragenics.com
Other (VR-2, Model products)
companies, rural electric companies, water and wastewater facilities, and communications
IA - California Department of Water Resources: Over 300 Controlling PCS/RTUs and 45 TG332-based RTUs
Industrial Automation Ph: (406) 533-6800
Qualifications
companies. Some of our customers have worked with our equipment and our team for more
- Verizon Wireless: 4 Dual CMS Masters and over 1,400 RTU sites throughout the western regions.
- City of Tacoma: 3 PCSs, 3 RTUs throughout regions.
Our customers include utility and electric companies, government facilities, alternative energy
- PPL Montana: PCSs and RTUs throughout Montana dams msetg-scada_map_all_r9a 5/2005
- 360 Networks (360): 80 CMS RTUs and dual CMS Master throughout U.S.
MSE-Tetragenics
SCADA Experience and Qualifications
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SCADA Experience and Qualifications
PRODUCTS AND SERVICES
The first system we designed and installed was created to automate a hydroelectric plant with six, 10 MW
generators (the first such automation in this country) as well as provide the SCADA functionality with the
substations. Since then, we have extended our business to include system integration and consulting
services, and expanded our range to the power transmission/distribution and substation industry,
telecommunications industry, water and wastewater co-operatives, the mining industry, and government
projects. As security issues become paramount, we also use our years of experience working with
SCADA systems to modify software and hardware to provide additional security at remote sites and
dams.
Our systems contain multiple layers of products. This modular design makes it easier to change hardware,
is cost-effective, and provides additional security. The layered products seamlessly combine into
advanced systems with versatile features such as the following:
Products and Services
Site security Tetragenics
Putting You in Control
Site monitoring
Remote control and monitoring - monitoring and controlling local and
remote units from a central NOC (Network Operations Center) A high-tech
process controller used to
Web-enabled interfaces control communications
Protocol integration – allowing customers to use new and existing monitoring, SCADA, or
equipment hydro control systems using
a variety of configurations.
Energy management services (includes networking and
Internet features).
Our systems feature the proven hardware and software necessary for
unattended, reliable, and safe operation. The system provides process control
Translate up
functions for plant automation, sequence-of-events recording, SCADA, and to 18 different protocols to a
remote monitoring and control from one integrated system. Our SCADA single output protocol for
systems are used in electric power generation stations, industrial building connection to a host system.
security systems, fresh water management and wastewater management system,
and substations. In the communications industry, our systems provide Remote Terminal
monitoring and control for various businesses. Units (RTUs) intelligent
enough to control processes
without intervention from a
As a rule, we find cost-effective ways to provide SCADA systems for our master or controller.
customers or integrate new features into existing systems. We provide easy-to-
use, yet sophisticated equipment and application software for system
automation including load control, synchronization, and spill control used in
Hydroelectric Power Plant applications. Using our experience and innovative I-Spy Serial
Communications Analyzer
thinking, we are redefining the way companies use SCADA applications. Not allows you to troubleshoot
only for monitoring and control, but also for site access, border security, video communications between
surveillance, chemical monitoring, power management, water treatment, two devices.
injection surveillance … as the automation industry advances, so does the list of
how we can use SCADA systems.
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SCADA Experience and Qualifications
Homeland Security
Using software and hardware components in single or multiple systems, we can provide additional
security features, or integrate them into an existing system.
Security / Surveillance
● Property Facility Site security ● Video surveillance
● Building access security ● Chemical monitoring (i.e., in water)
● Site access ● Access logs
Security Verification
Information can be relayed to one master computer at a central location. Security verification modules
deny system access to unauthorized personnel and provide access information to the master computer
such as the following:
● Trigger sensors (doors, audio, video, lights)
● Time sensitive entry (security codes must be entered within a specified time frame)
● User identification based on entry code (relayed to the Master)
● Timed alarms (access allowed only during specific times)
● Entry and exit identification and validation (users identified on entry and exit at site)
Building Security
Also, our SCADA system can be used in industrial building security systems to monitor and control
building elements:
● Alarms ● Heating systems
● Area accesses ● Power management
● Temperatures (boilers, environment, rooms)
Water Management
One of the most important issues today is water — fresh water and wastewater. Our systems can be
beneficial to those involved in water management and help to monitor and control the following:
Fresh Water Management
● Water Levels and Storage ● Water temperatures
● Flow Control/Monitoring ● Metering
● Water Treatment
Wastewater Management
● Fluid levels ● Fluid temperatures
● Chemical treatment injection ● Bacteria levels
● Pump controls
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Specific Products and Services
Supervisory Control and Data Acquisition (SCADA)
Tetragenics SCADA systems provide unsurpassed reliability and security for clients. System
highlights include time-stamped sequence of events recording to one millisecond, analog data
processing at the RTU, and reporting by exception. Our SCADA systems are extremely popular for
use in generating stations and in industrial load control and energy management applications. They
monitor and control electric power generation stations, substations, and transmission lines; provide
security in industrial buildings; and help manage fresh water and wastewater systems.
Designed with the user in mind, our systems are sophisticated but easy to use and learn. Advanced
editing software gives operators control, while color graphic, user-specified screens show the system
status at a glance. Operating in an open, real-time environment, our SCADA systems provide features
essential for companies working in today’s data intensive, automated environments:
Accurate time tagging
System enhancing hysteresis and filtering
Self-checking mechanism (watchdog timers)
Interval processing
Analog averaging
Special alarm functions
Point overrides
Control tags
Fast processing: program code resides in Erasable Programmable Read-Only Memory (EPROM)
Proportional Integral Derivative (PID) closed loop control
Sequential control features
Versatile software modules that allow you to add special features to support unique
characteristics
The ability to communicate with other intelligent electronic devices (IEDs)
Power Plant Automation and Control
For plant operation that is both reliable and cost-effective, our fully integrated plant automation and
control system, with a selection of operations modules, will meet your requirements. It is suited to
large, unattended facilities such as hydroelectric generating facilities. Tighter controls and cost savings
are only some of the benefits that our plant automation technology will bring to your operation.
Substation Automation and Control
The same products used in the power plant applications also monitor and control substations.
Millisecond “time-stamping” of alarms is a very important feature to help in trouble-shooting system
interruptions. Communication with other intelligent devices such as meters and relays not only cut
down on construction costs, but also provide all the information available from these devices.
Communications Monitoring and Control System (CMS)
Our line of advanced products and software allows you to monitor and control virtually every type of
communication medium, such as microwave, cellular, fiber optic, hardwire, satellite, and radio.
Communications are critical to your business. Tetragenics equipment will keep your communications
network up and running.
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SCADA Experience and Qualifications
Remote Terminal Units
One of our continually growing products is the intelligent RTU that is smart and fast. An inventive
design enables the RTU to process information at the remote site and transmit only the information
required for routine system operation (reporting by exception). This feature frees up the master
terminal to perform vital tasks while eliminating the transfer of useless data. If communication is
interrupted, the RTUs keep working, storing valuable data for automatic recall once communication is
restored. Nothing is lost. We also provide RTUs that can dial out to the master to establish
communications. No other product provides a superior package of speed, versatility, accuracy,
reliability, and value. To meet industry demands, we offer a family of RTUs including small RTUs
(one rack unit size called MiniMotes) that perform the functions but take up less space. Each RTU in a
family gives you intelligent monitoring and controlling capabilities, and then builds on that base to
offer advanced features. For more information, visit the RTU site at
http://www.tetragenics.com/rtus.htm.
SCADA and CMS RTUs: Both the SCADA and CMS RTUs are modular in design — this allows for
convenient maintenance and cost-effective expandability. Plus, we can customize each configuration
based on customer needs and site requirements. Within the SCADA family of RTUs, we offer a choice
of two powerful processing units: the TG332 RTU or VME RTU. Each unit gives you intelligent
monitoring and controlling capabilities, and then builds on that base to offer advanced features.
Master Platforms
We offer single or dual master systems and Graphical User Interfaces (GUIs) that can accommodate
hundreds of RTUs and other interfaces with thousands of input/output points. We provide a host of
options and software platforms to ensure you get the system you want.
Tetragenics’ MC3000 SCADA Master contains features that place Ethernet, Intranet/Internet, and dial
up capabilities at your fingertips, at the speed you need. Able to run on multiple platforms, the
MC3000 is ideally suited for monitoring and control systems that require performance and scalability
offered by today’s powerful computers. Using DNP3 Host protocol, the MC3000 achieves standard,
open-based interconnectivity between substation computers, RTUs, intelligent electronic devices
(IEDs), and other master stations. The MC3000 combines advanced Tetragenics software with 32-bit
protected mode processing, built-in diagnostics, critical alarm upgrading, security, Ethernet support,
multi-region/number callout, network data logging, and multiple downloading options. And you can
view the system status locally or remotely via an Intranet/Internet and a web browser.
The MC3000 can run on multiple platforms and is ideally suited for small to large monitoring and
control projects that demand performance, security, and connectivity.
MC3000 SCADA Master System Highlights
Plant Control System (PCS) – provides load, spill, pond, VAR, volt, power factor, VAR
Balancing functions
CMS - monitors and controls equipment from a remote location
Millisecond Time Stamping - records events to millisecond accuracy
Protocols- communicates data and control commands between devices with DNP3, Modbus,
JEM2, Schweitzer, and Tetragenics protocols
Industrial Flexibility - monitors and controls a wide variety of industrial applications, such as
hydro power plants, utility substations, communications towers, water and wastewater plants, and
energy management systems
Communications Devices - provides real-time data acquisition, remote control, and intelligent
alarm notification from multiple communication devices
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SCADA Experience and Qualifications
Security - requires a case-sensitive user name and password with 255 access levels available
Scalability - supports up to 128 polling ports, and 236 RTUs per polling port, for a maximum of
30,208 RTUs - typical system with 10 polling ports can poll 2,360 RTUs
Control System - provides connectivity and sophisticated logic execution capabilities for handling
complex scripting, discrete, and process applications
HMI - enables view/control functionality with the WinTetraVision 32 bit (WTV32) GUI
Command Center - capabilities of 24/7 network monitoring turn any PC into a communications
command center
Water Optimization - accepts the desired water flow request and determines a generator loading
scheme to maximize the MW production for the allocated flow
Internet/Intranet Ready - provides viewing of system with a Web browser, with a customizable
homepage provided
User-Defined Logic/Control Sequences - executes time/event-activated sequences and controls
Reporting by Exception - opens up communications channels by only reporting values that have
changed since the last polling cycle
Input/Output Points - views and controls I/O points instantly, anywhere on the network
Auto Generated Text Screens - generates text screens automatically at run time, displaying the
status of each input and output in the system
User Defined Graphics - configures high definition graphic screens for visualization and industrial
process control
Ethernet Polling - communicates with remote units over the network
System Editors - uses Windows-based System Database Editors (SDE), containing user-friendly
tables with scrolling parameters for easy editing
Trending - creates graphical trends of real-time and historical data
I/O Sources - connects to virtually any industrial automation control device
Email Alarm Notification - emails notification of alarms automatically (used in addition to audible
and call out alarm features)
Ping Alarming - provides automatic pinging features for selected devices on the network
Alarm Levels - contains user-defined alarm levels with 128 available configurations
Custom Modules - allows custom system expansion by system administrator or Tetragenics
Engineer
Historical Data Archive - stores data for later viewing, or import into other programs for analysis
Support - provides user documentation, as well as a one year warranty and 24/7 technical support
System Integration – customize the system to your hardware/system specifications
Other Standard Features include the following:
HMI/SCADA software Screen blanking
Ethernet functionality Event-driven processing
Full network capability over TCP/IP [Master- Multiple input/output systems Help screens
to-Master/RTU/GUI] Pop-up windows
RTU communications: dial up, Ethernet, Online file utilities
radio, satellite, and RS-232, 422, 485 Communications and alarm status
Real-time data/information collection Alarm annunciation, paging, and messaging
Customized reports tools
Multiple download capabilities Communications tracking and stats
Dial-up RTU support Online parameter changes
Critical alarm upgrading Auto-generated and customizable web pages
Security with 255 access levels of password Custom graphical views of processes
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SCADA Experience and Qualifications
protection Distributed alarms and data logging
Integrated, real-time statistical process control Animated graphics
Global daily log file PID (proportional integral derivative) control
Automatic reports Audible alarms
Multi-region/number callout Ping capabilities
Scalable to hundreds of nodes in a distributed Electronic CRT printing (Eprinter)
network Fast booting
Support for standard protocols Event notification
Web control and monitoring High input/output count
Windows-based system database editors Modular design
TBOS RTU support (CMS versions) Object-based architecture
Sequential control Online configuration
Real-time data monitoring and historical Http server functionality
trending Runs on windows® platforms (XP, 2000, NT,
Easy alarm recognition 98)
Diagnostics XML ready
History files
Programmable Logic Controller (PLC)
Tetragenics provides a variety of PLC devices and engineering services to meet all your automation
requirements. While specializing in turnkey applications, we also provide engineering services for the
expansion of existing installations.
Graphical User Interfaces
WinTetraVision (WTV-32) is a program that turns your personal computer into a friendly, graphical
user interface. It lets you view and control your MC3000 Master system using the advanced functions
of today’s computer software technology. With WTV you can use multitasking and multi-session
capabilities while interfacing to your Tetragenics system. Using the WTV advanced GUI interface
software, you can view your system on multiple monitors from a single PC (Win 98, ME, 2000, and
XP); run multiple configurations and multiple sessions of WTV connected to the same or different
RTUs/Masters simultaneously; and view your system from any computer with access to a browser and
the MC3000 Master (direct access, dial-up access, Ethernet, LAN/WAN).
Engineering Services/System Integration
Software, hardware, and project engineering services. Tetragenics provides system integration and
engineering services for hydro automation, SCADA, and communications monitoring and control
systems. If you are looking to move to a new technology but want to use your existing equipment or
protocols, we provide integration services and can support a growing list of protocols. Our integration
service people provide real-time solutions to integrate existing and new systems, saving you money
and time. Basically, we can build a bridge between your existing products and new products or
between existing (old) functionalities and new technologies, or replace an obsolete system. Flexible
integration services allow us to tie multiple vendor systems together using off-the-shelf products,
Tetragenics products, or other products. We can integrate components from different vendors at
cost-effective prices so you get the best system. And, based on our experience, we can perform
feasibility studies to help you decide what you need.
Factory Acceptance Testing (FAT)
All our equipment is factory tested at our in-house facilities. Each component (for example, digital or
analog circuit board) is tested as a single unit and then again when it goes into a system. FATs are
conducted in a controlled environment by project engineers and technicians, and then the system is
tested again during customer FATs.
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SCADA Experience and Qualifications
Additional Qualifications
System Engineering
Design, installation, start-up, and operation training for control and operation of the following:
contaminated water and soil process treatment systems.
industrial waste treatment systems.
solid waste thermal treatment systems.
Electrical Engineering
Design, studies, cost estimates, and installation for the following:
plant electrical upgrades and code compliance.
low to medium power switchgear and motor control centers for process plants.
control panel and switch panel design and layout.
Instrumentation and Control Engineering
Designs, studies, and estimates for the following
automate and modernize plant control systems.
install instrument control and diagnostic systems for new or modified plant systems.
fabricate control panels and consoles and equipment racks.
implement integrated and distributed control systems using various field-bus configurations.
implement PLC ladder logic control programs.
program and integrate Human-Machine Interface (HMI) and touch-screen panels for viewing.
Construction Administration
Provide experienced personnel to provide the following:
support design professionals from pre-bid quality control reviews through project start-up.
construction administration services for lump sum, unit price, or time and materials construction
contracts.
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PROJECT ORGANIZATION AND EXPERIENCE
MSE-Tetragenics organizes personnel in a modified matrix system. A Project Engineer (PE)/Project
Manager (PM) is assigned to each project. Core personnel are also assigned to larger projects if
warranted. The PE/PM is responsible for all aspects of project implementation, including client interface,
budget and schedule, skill base allocation, as well as all technical and quality requirements. The PE/PM is
the customer’s single point of contact for all aspects of the project.
A baseline schedule, clearly defining milestones of interest to the customer, is developed at the beginning
of each project. In the case of cost reimbursement projects, budgets are also attached to scheduled
activities. This baseline forms the basis for project tracking and reporting for the life of the project. As the
project evolves, any situation that impacts completion of critical milestones is negotiated with the
customer prior to changing the baseline.
The PE/PM is responsible for keeping both the customer and management apprised of the status of the
project. Project status is reported to senior management on a monthly basis. This internal status review
allows us to redirect company resources to ensure that all projects are completed in a timely, cost-
effective manner.
We believe that cooperation and communication between the customer and PE/PM is essential to the
success of any project. As such, our project organizational approach encourages open communications
with the customer. We also believe that communication with construction contractors during the design
Project Management
phase provides valuable insights that will ultimately benefit all parties.
Our staff includes engineers experienced in construction administration and we provide these services on
many of our engineering projects. For each project, we define owner, contractor, and engineer
relationships and performance expectations as outlined by the Engineer’s Joint Contract Documents
Committee (EJCDC) unless directed otherwise. We use EJCDC documents whenever possible; however,
the concepts and principals of these documents are generally applicable to work using other standard
documents.
We have gathered real life project management knowledge and experience. Our PEs/PMs work with the
customer from start to finish, and beyond. As our front line for customer service, our PEs/PMs provide
top-of-the-line services, including the following:
Working with system designers to capture customer requirements
Setting clear objectives and project definitions
Defining the scope of the project
Organizing all project planning, schedules, and resource forecasting
Providing progress tracking and reporting
Managing Customer’s expectations
Example Projects
The following projects provide relevant examples of our experience and work.
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Army Corps of Engineers – Nashville District – Dale Hollow Project
The Dale Hollow Dam is a
US Army Corps of Engineers
(USACE) operated
hydroelectric power
generating plant that is
located two miles northeast of
Celina, Tennessee. The intent
of this Dale Hollow project is
to upgrade the dam from its
current control configuration
to a digital control
configuration that can be
operated remotely from
Cordell Hull Dam located
north of Carthage, Tennessee.
A “one-button” startup at Dale Hollow from Cordell Hull Dam is the objective of this project. The Center
Hill Dam is currently controlled via the existing MSE-Tetragenics SCADA system at Cordell Hull. The
Dale Hollow Project consists of providing new equipment to automate Dale Hollow and upgrading the
existing SCADA systems at Cordell Hull and Center Hill Plants. Refer to project 2 describing previous
Cordell Hull/Center Hill projects. USACE awarded MSE-Tetragenics the contract (via Tinaa Services,
Inc.) for the Dale Hollow Project in October, 2008, with completion scheduled in 2009. We also had
previously provided engineering and technical assistance for the Dale Hollow Plant generator
synchronization scheme.
Cordell Hull / Dale Hollow and Center Hill Plant Control Systems. All three plants provide
hydroelectric power and are managed by the USACE.
3. Start/
4.Project/
1. Work Performed for: Completion 5. References
Tech Mgr:
dates:
Army Corps of Engineers– Oct 08 –2009 Steve Ostenburg Mr. Richard Rieger
Nashville District 406-533-6801 Army Corps of Engineers,
15 Overlook Circle steve.ostenburg@mse- Nashville District
Hendersonville, TN 37075- ta.com 615-824-1052
3469 richard.r.rieger@usace.army.mil
2. General Scope of Work – Contract Value:
Initial Contract (2008): $336,970
Task: Automate the Dale Hollow hydroelectric plant to allow remote monitoring and control from the
Cordell Hull Hydroelectric Plant. Upgrade the MC3000 Master SCADA system at Cordell Hull and the
Plant Control system at Center Hill. Obtain JEMStar meter data from all three plants at the Cordell Hull
master. Obtain temperature data at the Dale Hollow and Center Hill plants.
History: The Cordell Hull, Dale Hollow, and Center Hill projects were designed by the U. S. Army Corps
of Engineers and built by private contractors under the supervision of the Corps. The dams, power
plants, and reservoirs are operated by the Nashville District of the Corps of Engineers. The projects
were designed to develop hydroelectric power and control water resources in the Cumberland River
basin.
System: The Cordell Hull MC3000 SCADA System is a Hydroelectric Plant Control System. It consists
of an MSE-Tetragenics MC3000 Master processor located at the Cordell Hull Hydroelectric Plant
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(Carthage, TN) and dedicated, intelligent RTUs located at the Center Hill Hydroelectric Plant (Lancaster,
TN) and the Dale Hollow Hydroelectric Plant (Celina, TN).
There are three generators located in the Dale Hollow plant, each with a rated capacity of 18 MW. Dale
Hollow also contains a smaller generator to provide station service power. Power is transmitted from the
plant using transmission lines, interconnected to each other and the plant via power transformers and
switchyard equipment.
There are three identical generators located in the Center Hill plant, each with a rated capacity of 45
MW. Center Hill also contains a smaller generator to provide station service power. Power is transmitted
from the plant using a combination of 161 KV and 46KV transmission lines, interconnected to each other
and the plant via power transformers and switchyard equipment.
All Center Hill and Dale Hollow Plant equipment is monitored and controlled by one VME based RTU at
each plant. This RTU can start and stop the generators, control the MW output, control the exciter to
adjust the generator voltage and MVARs, perform corrective actions in response to alarm conditions,
and monitor various quantities associated with the plant. It can also operate independently of the Master
processor to provide safe control of the Plant if communication with the Master is lost. Another small
RTU located in the Cordell Hull Power Plant provides several analog output signals and controls the
Cordell Hull Plant annunciator horn.
MSE-Tetragenics is providing the SR4000 Speed Relay for shaft speed detection and control at Dale
Hollow. In addition, both Dale Hollow and Center Hill RTUs communicate via Modbus protocol with three
temperature recorders to monitor critical temperatures in each plant.
The Master processor is the MSE-Tetragenics MC3000 Master. The Master communicates with the
RTUs via Ethernet TCP/IP satellite/T1 links. The Master is responsible for presenting information to the
Plant operators, accepting commands from the operators, logging alarm and status changes, and
coordinating actions between the RTUs.
The Master interacts with the plant operators via operator workstations. A workstation is based on a
personal computer (PC) platform and operates with the MSE-Tetragenics WTV (WinTetraVision) Human
Machine Interface (HMI) software package. From a workstation, an operator can display information in a
logical manner and issue commands to perform various actions. The workstations communicate with the
Master using an Ethernet network. Also, the Master itself contains the WTV software and can be used
as a workstation. You can also configure the Master as a node on a local Ethernet network. Doing so
allows any PC on the network that contains the WTV software to act as an operator workstation.
The Master logs information to daily log files as well as two printers. One printer logs all alarm and status
changes. The other prints various reports produced by the Master. Either printer will take over the
function of the other if the other printer fails. Both printers communicate with the Master using dedicated
serial communications lines, and both are continuous feed impact printers so that any messages and
reports are printed immediately. A virtual desktop printer is also available from any PC on the LAN.
The Master logs alarm and status changes, operator commands, and other information to disk files for
archival purposes. Also, the Master obtains MWHr information from multiple JEMStar meters via DNP
Protocol communication to intelligent devices located at the Cordell Hull, Dale Hollow and the Center Hill
Plants.
A block diagram of the SCADA system follows.
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Project Title Dale Hollow Automation Project
Contract Number / Type MSE-09-2008-003 / Fixed
Acted as Prime No. The prime contractor is Tinaa Services, Inc 108 Cooperative Way
Kalispell, MT 59901 Phone 406.755.2404
Functional Areas Involved Generator unit controls, excitation controls, governor controls
Plant Name Cordell Hull, Dale Hollow, Center Hill
Plant Location Carthage, Celina, and Lancaster, TN
Hydro-Generating Unit Number Center Hill: Units 1-3 @ 45 MW. Dale Hollow Units 1-3 @ 18MW
Combined Unit Output (MW) Center Hill: 135 MW, Dale Hollow: 54 MW
USACE – Nashville District
USACE Dale Hollow/ Cordell Hull/ Center Hill System
LAN
LAN
MC3000 Master/ TG332 RTU Master
WTV32 HMI Support Unit
Center
Satellite Upgrade
Cordell Hull Hill
Serial G-Series Plant Control Unit 1
Power Plant Siemens Temperature
Converter
RTU System Recorder
DNP Center Hill
3.0 Unit 2
Power Plant Units 1-3
Cordell DNP 3.0 Temperature
Siemens Digital Input Section Recorder
512 Digital Inputs
RTU
}
Unit 3
Cordell JEMStar Optional
}
Digital Output Section Temperature
Hull JEMStar Meters Meters Local
128 Digital Output Points Recorder
WTV32
HMI
ESS PC Analog Input Section
Satellite *M Hendersonville, TN Center 96 analog input points
Hill
LAN
Unit 1
DNP 3.0 G-Series Plant Control
Optional Local System
Temperature DNP
Dale Hollow Recorder
3.0
WTV32 HMI Dale Hollow
Siemens Unit 2
Power Plant Units 1-3
RTU Temperature
Digital Input Section Recorder
...
}
416 digital inputs SEL 2030
JEMStar Meters Serial
Unit 3
Digital Output Section Temperature
Converter Recorder SEL devices
192 Digital Output Points
TG332 Top of
Dam RTU Analog Input Section
Dale 8 Analog Inputs 160 analog input points
Hollow
Provided by USACE/existing
All communications provided by others * Telephone Dial AnywhereMWhr
Reports via PC
JEMStar RTU: Remote Terminal Unit
HMI: Human Machine Interface
Figure 1. Block diagram showing USACE Dale Hollow SCADA System
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Army Corps of Engineers – Nashville District- Cordell Hull Lake
Cordell Hull / Center Hill Plant
Control System. Cordell Hull Dam, just
north of Carthage, TN, forms Cordell Hull
Lake. The dam and lake provide
hydroelectric power. The lake is managed by
the USACE. MSE was the prime contractor.
3. Start/Completion 4.Project/
1. Work Performed for: 5. References
dates: Tech Mgr:
Army Corps of Engineers– Nov 2000 – Sept 02 June Tangaro Mr. Richard Rieger
Nashville District Upgrade 2009 406-533-6806 Army Corps of Engineers,
15 Overlook Circle june.tangaro@mse- Nashville District
Hendersonville, TN 37075-3469 ta.com 615-824-1052
richard.r.rieger@usace.army.mil
2. General Scope of Work – Contract Value:
Initial Contract (2000): $245,400 To Date: $255,906
Task: Automate the Center Hill hydroelectric plant to allow remote monitoring and control from the
Cordell Hull Hydroelectric Plant and obtain MWHR data from JEM-2 Meters at both plants.
History: The Cordell Hull and Center Hill projects were designed by the U. S. Army Corps of Engineers
and built by private contractors under the supervision of the Corps. The dams, power plants, and
reservoirs are operated by the Nashville District of the Corps of Engineers. Both projects were designed
to develop hydroelectric power and control water resources in the Cumberland River basin.
System: The Cordell Hull MC3000 SCADA System is a Hydroelectric Plant Control System. It consists of
an MSE-Tetragenics MC3000 Master processor located at the Cordell Hull Hydroelectric Plant
(Carthage, TN) and a dedicated, intelligent RTU located at the Center Hill Hydroelectric Plant
(Lancaster, TN).
There are three identical generators located in the Center Hill plant, each with a rated capacity of 45
MW. Center Hill also contains a smaller generator to provide station service power. Power is transmitted
from the plant using a combination of 161 KV and 46KV transmission lines, interconnected to each other
and the plant via power transformers and switchyard equipment.
All Center Hill Plant equipment is monitored and controlled by the one RTU. This RTU can start and stop
the generators, control the MW output, control the exciter to adjust the generator voltage and MVARs,
perform corrective actions in response to alarm conditions, and monitor various quantities associated
with the plant. It can also operate independently of the Master processor to provide safe control of the
Plant if communication with the Master is lost. Another small RTU located in the Cordell Hull Power
Plant provides several analog output signals and controls the Cordell Hull Plant annunciator horn.
The Master processor is the MSE-Tetragenics MC3000 Master. The Master communicates with the
RTUs via dedicated serial communications lines. The Master is responsible for presenting information to
the Cordell Hull Plant operators, accepting commands from the operators, logging alarm and status
changes, and coordinating actions between the RTUs.
The Master interacts with the plant operators via operator workstations. A workstation is based on a
personal computer (PC) platform and operates with the MSE-Tetragenics WTV (WinTetraVision) Human
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Machine Interface (HMI) software package. From a workstation, an operator can display information in a
logical manner and issue commands to perform various actions. The workstations communicate with the
Master using an Ethernet network. Also, the Master itself contains the WTV software and can be used
as a workstation. You can also configure the Master as a node on a local Ethernet network. Doing so
allows any PC on the network that contains the WTV software to act as an operator workstation.
The Master logs information to two printers. One printer logs all alarm and status changes. The other
prints various reports produced by the Master. Either printer will take over the function of the other if the
other printer fails. Both printers communicate with the Master using dedicated serial communications
lines, and both are continuous feed impact printers so that any messages and reports are printed
immediately.
The Master logs alarm and status changes, operator commands, and other information to disk files for
archival purposes. Also, the Master obtains MWHr information from several JEMSTAR meters located at
both the Cordell Hull Plant and the Center Hill Plant.
When the USACE replaced their JEM-2 meters, MSE-Tetragenics provided an upgrade to the MC3000
Master System in 2004-2005 to allow polling of the new JEMSTAR meters using DNP 3.0 protocol via a
Siemens RTU.
2009: MSE-Tetragenics is providing a 2009 upgrade to the Cordell Hull/Center Hill Control System in
conjunction with the Dale Hollow Project (see previous section). We are providing a new Cordell Hull
MC3000 Master and a VME CPU and Chassis upgrade at the Center Hill plant. The existing RTU I/O
equipment will remain in place. Temperature data will be acquired via Modbus protocol. Master
communications with the RTUs will be via TCP/IP T1/Satellite with automatic switch over by the Master if
the primary system fails. A block diagram of the pre 2009 SCADA system follows.
Project Title Cordell Hull / Center Hill Plant Control System
Contract Number / Type DACW62-01-P-0018* / Fixed
Upgrade: 2004-05
* This original contract also covered the Old Hickory Project
Acted as Prime Yes
Functional Areas Involved Generator unit controls, excitation controls, governor controls
Plant Name Cordell Hull, Center Hill
Plant Location Carthage and Lancaster, TN
Hydro-Generating Unit Number Center Hill: Units 1-3 @ 45 MW
Combined Unit Output (MW) 135 MW
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Figure 2. Block diagram showing USACE Cordell Hull SCADA System
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Army Corps of Engineers – Nashville District- Old-Hickory
Old Hickory / J. Percy Priest / Cheatham Plant
Control System. The Tennessee River system dams,
locks, and reservoirs were designed specifically to operate as
one system that meets many needs. Every day, the Tennessee
Valley Authority (TVA) balances these needs for water in
order to deliver the greatest value for the 8.5 million people
of the Tennessee Valley. Old Hickory Lock and Dam is
located in central Tennessee, approximately 25 miles
upstream from Nashville. The reservoir behind the dam is
Old Hickory Lake. The power plant is operated so as to use
as much of the water flow as possible for power production. J. Percy Priest Dam is in north central
Tennessee about 10 miles east of downtown Nashville. The reservoir behind the dam is Percy Priest Lake.
The dam has contributed significantly in reducing the frequency and severity of flooding in the
Cumberland Valley. Cheatham Reservoir Dam is located at mile marker 148.7 on the Cumberland River
in Dickson and Cheatham Counties. The USACE constructed and maintains Cheatham Lake Reservoir
and Dam.
3. Start/Completion 4.Project/ Tech
1. Work Performed for: 5. References
dates: Mgr:
Army Corps of Engineers– Nov 2000 – Sept 02 June Tangaro Mr. Richard Rieger
Nashville District Upgrade 2009 406-533-6806 Army Corps of Engineers,
15 Overlook Circle june.tangaro@mse- Nashville District
Hendersonville, TN 37075-3469 ta.com 615-824-1052
richard.r.rieger@usace.army.mil
2. General Scope of Work – Contract Value:
Initial Contract (2000): $245,400 To Date: $267,645
Task: Automate the J. Percy Priest and Cheatham hydroelectric plants to allow remote monitoring and
control from the Old Hickory Hydroelectric Plant and obtain MWHR data from JEM-2 Meters at all three
plants.
History: The Old Hickory, J. Percy Priest, and Cheatham Dams are key projects in the development of
the Cumberland River Basin. All three projects were designed by the U.S. Army Corps of Engineers and
built by private contractors under the Corp's supervision. Each dam has contributed significantly in
reducing the frequency and severity of flooding in the Cumberland Valley. In addition to the far reaching
effects of flood control, each project contributes to the available electric power supply of this area.
System: The Old Hickory MC3000 SCADA system is an MSE-Tetragenics Hydroelectric PCS. It
consists of an MSE-Tetragenics MC3000 Master processor (dual configuration) located at the Old
Hickory Hydroelectric Plant (Hendersonville, TN) and dedicated, intelligent RTUs located at the J. Percy
Priest and Cheatham Hydroelectric Plants (located at Nashville, TN, and Charlotte, TN, respectively).
There are three identical generators located in the Cheatham plant, each with a rated capacity of 14
MW. Power is transmitted from the plant using a combination of three 69-KV transmission lines,
interconnected to each other and the plant via power transformers and switchyard equipment. One
generator located at the J. Percy Priest plant has a rated capacity of 33 MW. Power is transmitted from
the plant using a single 69 KV transmission line.
For both power plants, all plant equipment is monitored and controlled by the RTU at the respective
plant. This RTU can start and stop the generators, control the MW output, control the exciter to adjust
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SCADA Experience and Qualifications
the generator voltage and MVARs, perform corrective actions in response to alarm conditions, and
monitor various quantities associated with the plant. It can also operate independently of the Master
processor to provide safe control of the plant if communication with the Master is lost. Another small
RTU located in the Old Hickory power plant provides analog output signals and controls the Old Hickory
Plant annunciator horn.
The MC3000 operates on a standard PC running Windows operating system The Master communicates
with the RTUs via dedicated serial communications lines. The Master is responsible for presenting
information to the Old Hickory Plant operators, accepting commands from the operators, logging alarm
and status changes, and coordinating actions between the RTUs.
We configured the Old Hickory MC3000 Master as a dual Master system consisting of two MC3000
Masters and an MSE-Tetragenics ISM. This configuration allows either of the MC3000s to be designated
as the Primary, with the other being a "hot standby" (backup) unit ready to take over in case the Primary
Master ceases operation for any reason.
Operators interact with the MC3000 via operator workstations. Each operator workstation is based on a
PC platform running Windows® and operates with the WTV HMI software package. From a workstation,
operators can display information in a logical manner and issue commands to perform various actions.
The Master writes information to two printers. One printer is used for all alarm and status change
messages; the other printer is used for the various reports produced by the Master. Either printer will
take over the function of the other if the other printer fails. Both printers are continuous feed impact
printers so that any messages and reports are printed immediately rather than having to wait for a
complete page to be printed.
The MC3000 logs alarm and status changes, operator commands, and other information to disk files for
archival purposes. The MC3000 obtains MWHR information from several JEMSTAR meters located at
the Old Hickory, Cheatham, and J. Percy Priest plants. The JEM meter information is used to create
various reports.
When the USACE replaced their JEM II meters, MSE-Tetragenics provided an upgrade to the MC3000
Master System in 2004-2005 to allow polling of the new JEMSTAR meters using DNP 3.0 protocol via a
Siemens RTU.
2009: In the 2009 upgrade to the Old Hickory, J. Percy Priest, Cheatham Plant Control System, MSE-
Tetragenics is providing new Old Hickory dual MC3000 Masters and a VME CPU and Chassis upgrade
at the J. Percy Priest and Cheatham plants. The existing RTU I/O equipment will remain in place.
Temperature data will be acquired via Modbus protocol. Master communications with both RTUs will be
via TCP/IP T1/Satellite with automatic switch over by the Master if the primary system fails.
A block diagram of the pre-2009 SCADA system follows.
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SCADA Experience and Qualifications
Project Title Old Hickory / J. Percy Priest / Cheatham Plant Control System
Contract Number / Type DACW62-01-P-0018* / Fixed
Upgrade: 2004-05
* This original contract also covered the Cordell Hull Project
Acted as Prime Yes
Functional Areas Involved Generator unit controls, excitation controls, governor controls
Plant Names Old Hickory, J. Percy Priest, Cheatham
Plant Locations Hendersonville, Nashville and Charlotte, TN
Hydro-Generating Unit Number J. Percy Priest: Unit 1 @ 38 MW; Cheatham: Units 1-3 @ 14 MW
Combined Unit Output (MW) 80 MW
Figure 3. Block Diagram of USACE Old Hickory SCADA System
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Army Corps of Engineers – Nashville District- Wolf Creek
Wolf Creek / Laurel River Plant Control System.
The Wolf Creek Dam is on the Cumberland River in the
Western part of Russell County, Kentucky. It was
constructed to generate hydroelectricity and prevent flooding
but is better known for creating Lake Cumberland, which has
become a popular tourist attraction and is also the largest
man-made lake east of the Mississippi River.
3. Start/Completion 4.Project/ Tech
1. Work Performed for: 5. References
dates: Mgr:
Army Corps of Engineers– June 1999 – Apr 2000 June Tangaro Mr. Richard Rieger
Nashville District Upgrade: 2007 406-533-6806 Army Corps of Engineers,
15 Overlook Circle june.tangaro@mse- Nashville District
Hendersonville, TN 37075-3469 ta.com 615-824-1052
richard.r.rieger@usace.army.mil
2. General Scope of Work – Contract Value:
Initial Contract (1999): $57,520 To Date: $149,269
Task: Automate the Laurel River hydroelectric plant to allow remote monitoring and control from the
Wolf Creek Hydroelectric Plant and obtain MWHR data from JEM-2 Meters at both plants.
History: The Laurel River and Wolf Creek Dams are projects in the development of the Cumberland
River Basin. Both projects were designed by the U.S. Army Corps of Engineers and built by private
contractors under the Corp's supervision. Each project was designed to control water resources in the
Cumberland River basin and develop hydroelectric power.
System: The Wolf Creek MC3000 SCADA system is a Hydroelectric PCS consisting of an MSE-
Tetragenics MC3000 Master processor located at the Wolf Creek Hydroelectric Plant (Jamestown, KY)
and a dedicated, intelligent RTU located at the Laurel River Hydroelectric Plant (Laurel County, KY).
There is one generator located in the Laurel Power Plant and Dam, with a rated capacity of 68 MVA.
The generator feeds through a 13.8 KV ACB to a single 78 MVA, 13.8/161 KV transformer bank.
All Laurel River plant equipment is monitored and controlled by the one RTU. This RTU can start and
stop the generators, control the MW output, control the exciter to adjust the generator voltage and
MVARs, perform corrective actions in response to alarm conditions, and monitor various quantities
associated with the plant. It can also operate independently of the Master processor to provide safe
control of the Plant if communication with the Master is lost. Another small RTU located in the Wolf
Creek power plant provides several analog output signals and controls the Wolf Creek plant annunciator
horn. The Master communicates with the RTU via dedicated serial communications lines. The Master is
responsible for presenting information to the Wolf Creek Operators, accepting commands from the
operators, logging alarm and status changes.
In January 2007, MSE-Tetragenics completed an upgrade of the plant control system for the Laurel
River hydroelectric plant and the MC3000 Master Control System at the Wolf Creek Plant. To enable
faster Ethernet satellite communications between the Master and the RTU at Laurel River, we upgraded
the RTU to our VME-based G-Series system. For this cost-saving upgrade, we replaced only the RTU’s
chassis and central processing unit, allowing all input/output cards and wiring to remain in place.
The Master interacts with the plant operators via operator workstations based on a PC platform running
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SCADA Experience and Qualifications
our WTV HMI software package. From a workstation, an operator can display information in a logical
manner and issue commands to perform various actions. The workstations communicate with the
Master using an Ethernet network. Also, the Master itself contains the WTV software and can be used
as a workstation. Operators can also configure the Master as a node on a local Ethernet network. Doing
so allows any PC on the network that contains the WTV software to act as an operator workstation.
The Master logs information to two printers. One printer logs all alarm and status changes. The other
prints various reports produced by the Master. Either printer will take over the function of the other if the
other printer fails. Both printers communicate with the Master using dedicated serial communications
lines, and both are continuous feed impact printers so that any messages and reports are printed
immediately. The Master logs alarm and status changes, operator commands, and other information to
disk files for archival purposes. Also, the Master obtains MWHr information from several JEMSTAR
meters located at both the Wolf Creek Plant and the Laurel Plant. When the USACE replaced their JEM
II meters, MSE-Tetragenics provided an upgrade to the MC3000 Master System in 2004-2005 to allow
polling of the new JEMSTAR meters using DNP 3.0 protocol via a Siemens RTU.
2007: MSE-Tetragenics provided an upgrade to this system in 2007. The new MC3000 Master
communicates with the Laurel River Plant via satellite using the new efficient TCP/IP Block Protocol. The
Laurel River RTU was upgraded to a VME-based CPU and chassis, allowing existing I/O equipment and
wiring to remain in place. Using the MC3000-created daily log files and electronic virtual desktop printer
allowed the elimination of the two serial printers.
A block diagram of the SCADA system follows.
Project Title Wolf Creek / Laurel River Plant Control System
Contract Number / Date / Type DACW62-99-M-0192 / Fixed
Upgrade: 2007
Acted as Prime Yes
Functional Areas Involved Generator unit controls, excitation controls, governor controls
Plant Name Laurel River Hydroelectric Plant
Plant Location Laurel County, KY
Hydro-Generating Unit Number Laurel River Plant: Unit 1 @ 68 MW
Unit Output (MW) 68 MW
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Figure 4. Block Diagram for USACE Wolf Creek SCADA System
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SCADA Experience and Qualifications
Army Corps of Engineers – JEM Meter Replacement
3. Start/Completion 4.Project/ Tech
1. Work Performed for: 5. References
dates: Mgr:
Army Corps of Engineers– Jan 04 – Sept 05 June Tangaro Mr. Richard Rieger
Nashville District 406-533-6806 Army Corps of Engineers,
15 Overlook Circle june.tangaro@mse- Nashville District
Hendersonville, TN 37075-3469 ta.com 615-824-1052
richard.r.rieger@usace.army.mil
2. General Scope of Work – Contract Value:
Initial Contract (2004): $59,920 To Date: $81,000
Task: Upgrade three existing MC3000 SCADA PC-based Master databases and provide two new
Masters to monitor and report Kilowatt-hour data gathered via DNP 3.0 protocol from Tennessee Valley
Authority Telegyr RTUs communicating with the new JEMSTAR Meters (replacing original JEM-2
meters).
System: MSE-Tetragenics installed all the Masters in hydroelectric plants operated by the USACE in
Tennessee and Kentucky. The three existing Masters were originally installed in 1999-2001 and
communicated with JEM-2 meters. They monitor and control one to three hydroelectric plants each via
our remote TG332-based PCS. One Master system is a dual hot-standby system using the ISM. The
others are single Masters.
Number of I/O points: Existing MC3000 Masters: Cordell Hull: 2698, Old Hickory: 1791, Wolf Creek: 977.
New MC3000 Masters: Dale Hollow: 454, Barkley: 696
Summary of Control System software: The software includes MSE-Tetragenics MC3000 Master, DNP
3.0 Host protocol, PCS Software, and Symantec PCAnywhere for sending report files to a remote
computer. Major data acquisition and control function is to monitor and report kilowatt-hour data and
monitor and control remote hydroelectric plants.
Project Title Nashville JEM Meter Replacement
Contract Number / Type W912P5-04-P-0024 / T&M
Acted as Prime Yes
Functional Areas Involved JEM Meter Replacement
Plant Names Cordell Hull, Old Hickory, Wolf Creek, Dale Hollow, and Barkley
Plant Locations Tennessee and Kentucky
Hydro-Generating Unit Number N/A
Unit Output (MW) N/A
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PPL Montana Hydroelectric SCADA
Hydroelectric SCADA System. PPL Montana provides energy to
Montana and open market sales throughout the NW and owns and
operates 11 hydroelectric projects that have a total generating capacity
of 602 megawatts, as well as one reservoir. The facilities are located on
the Clark Fork, Flathead, Madison, and Missouri rivers and on West
Rosebud Creek. We have provided and continue to provide a variety of
equipment and systems to PPL Montana, a utility company based in
Allentown, PA, with offices in Montana. PPL Montana owns major
dams along the Missouri River and provides energy to Montana. The
sections below describe the complete system and shows information on
the various dams for which we provide equipment, systems, and
support. We have equipment in most PPL Montana dams. The Holter
Plant also incorporates OPC technology to communicate with proprietary third-part devices. The Ryan
plant was one of the first hydroelectric plants in the United States to use automation. The operators were
very skeptical about allowing computers to start/stop/synch generators. They were also worried that they
would lose their jobs due to automation. We solved this challenge with regular communication between
management, operators, and MSE-Tetragenics staff; extensive training and support for the operators; and
by the reliability of the system.
1. Work Performed for: 3. Start/Completion dates: 4.Project/ 5. References
Tech Mgr:
PPL Montana 1983 to 2008 Steve Ostenburg Mr. Gus Wilkins,
45 Basin Creek Road Various projects for each 406-533-6801 PPL Montana
Butte, MT 59702 dam are listed below steve.ostenburg@mse- (406) 533-3457
ta.com AJWilkins@pplmt.com
2. General Scope of Work – Contract Value:
Please see individual tables following the system description.
Task: Monitor and control the 9 hydroelectric plants along the Missouri River, the Flathead River, and
the Clark Fork River.
History: From The Montana Power Company's (MPC) “Timely responses from
first hydro dam system on the Missouri River in the Technical Support have
1890s, to another five dams in a 16-mile section below cial
been crucial for our up-time.”
the city of Great Falls, Montana, to its last hydroelectric Lee Waananen: PPL Montana, LLC
project completed in 1958, MPC helped begin the
development of organized hydro power. Hydro
generating facilities produced all MPC’s electricity from
the time the company was formed in 1912 until 1951, when the first thermal generating plant was built in
Billings, Montana. Now owned by PPL Montana LLC, the hydro facilities continue to generate power.
The System: In 1972, the Automation Department of the Montana Power Company (later known as
MSE-Tetragenics), provided its first hydro-automation PCS for the Ryan Plant by automating six, 10 MW
generators. The system provided unattended, reliable, and cost-effective power plant operation. Since
then, MSE-Tetragenics has provided, installed, and maintained plant control systems in their
hydroelectric plants. There are five plants on the Missouri river near Great Falls Montana, each with a
VME-based PCS that is monitored and controlled from the dispatch center located at the Rainbow Plant
by an MSE-Tetragenics MC3000W Master. This is a dual “hot” standby configuration with workstations
connected via TCP/IP (refer to the block diagram on page 14). From the Master, operators monitor and
control the generators, spill gates, and other major equipment located at the five power plants. The
system provides complete control, since these plants are not staffed 24 hours a day. The system can
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start, synchronize, and stop generators as well as provide plant load and voltage control, VAR balance,
and alarm control. All status changes, keyboard entry, and automatic messages are time-stamped to
one millisecond for “sequence-of-events” recording. At the Morony and Cochrane plants, the system
also controls the spill gates to manage the water during periods of high runoff. Within each plant, a color
graphics HMI workstation and data logger directly communicate with the local PCS.
The original Ryan and Morony automation systems date back to 1972 and 1973 when the first computer-
based automation systems were installed. In 1989, these plants were upgraded with MSE-Tetragenics
hardware and software. Beginning in 1989, major upgrades to each of the PPL plants took place, with
upgrades to CPU hardware and software. In 2006, PPL began the next major upgrade to each of the 9
plants with upgrades to CPU hardware and software – that upgrade is in process now. In addition, as the
demand for more data and security increases, software enhancements are delivered to PPL as needed.
The MSE-Tetragenics MC3000W Master at the Rainbow Plant generates customized automatic reports,
emails reports (based on alarms), and logs every event, whether operator keyed, status change, or
alarm activated, to a daily log file. Thompson Falls has two PCSs (one for each power plant) and an
MC3000W Master. The Master is connected to PPL Montana's Wide Area Network (WAN) for remote
access. This plant is controlled based on a pond level set point. The generators are a priority over the
spill gates. This plant has all the functionality described previously.
Kerr has one PCS, a downstream RTU, a Top-of-Dam RTU, and an MC3000W Master. Again, the
Master is connected to the WAN for remote access. This plant is controlled primarily based on the river
flow. The generators in this plant have very large vibration zones and the plant control module takes
these zones into account as it determines the set points for each generator. This plant has all the
functionality described previously. Hauser has a TG332-based RTU and an MC3000W Master. The
Master connects to the WAN for remote access. Most of the data is collected via protective relays and
meters using Modbus protocol. Critical data (such as breaker status) is brought through the RTU for one
millisecond time stamping.
The Holter Plant VME-based PCS can start, synchronize, and stop generators as well as provide plant
load and voltage control, VAR balance, and alarm control. MSE-Tetragenics is currently in the process
of upgrading this plant to our latest PCS. New features include Internet/Intranet viewing of the data,
Ethernet polling of intelligent electronic devices (IEDs) using Modbus and DNP 3.0 protocols, on-line
trending, and animated graphics support. The chart below shows the entire system point counts by
plant, and plant information. This is followed by a diagram of the entire system and information on the
individual plants.
Input and output point count for each power plant: Power Plant Information
Black Eagle PCS Ryan PCS Black Eagle Ryan
Digital Inputs 176 points Digital Inputs 288 points Constructed in 1926 (18,000 kW) Constructed in 1915 (60,000 kW)
Analog Inputs 96 points Analog Inputs 96 points 3 generators @ 6 MW each 6 generators @ 10 MW each
Digital Outputs 64 points Digital Outputs 128 points Head is 54 feet Head is 60 feet
Counter Inputs 8 points Counter Inputs 16 points There are no spillgates
Cochrane
Rainbow RTU Cochrane PCS Rainbow Constructed in 1958
Digital Inputs 32 points Digital Inputs 128 points Constructed in 1910 (35,000 kW) 2 generators @ 25 MW each
Analog Inputs 64 points Analog Inputs 32 points 6 generators @ 3.9 MW each Head is 80 feet
Digital Outputs 32 points Digital Outputs 32 points 2 generators @ 6.0 MW each 1 Controllable Spillgate
Head is 114 feet
Kerr PCS Morony PCS There are no spillgates Morony
Digital Inputs 192 points Digital Inputs 128 points There are no spillgates Constructed in 1930 (47,000 kW)
Analog Inputs 64 points Analog Inputs 64 points 2 generators @ 24 MW each
Digital Outputs 64 points Digital Outputs 96 points Head is 80 feet
Counter Inputs 8 points Counter Inputs 8 points 2 Controllable Spillgates
Thompson Falls PCS
Digital Inputs 544 points
Analog Inputs 192 points
Digital Outputs 192 points
Counter Inputs 24 points
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Figure 5. PPL Montana Complete SCADA System Diagram
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The information in the first table is the same for all PPL projects. Specific plant information follows.
All PPL Projects PPL Plant Control Systems – General Information for all Plants
Acted as Prime Yes
Functional Areas Involved unit controls, excitation controls, governor controls, protective relaying
Customer PPL Montana, 45 Basin Creek Road, Butte, MT 59702
Customer Contact Mr. Gus Wilkins, PPL Montana, (406) 533-3457, AJWilkins@pplweb.com
Project Title Holter Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1989): $65,000 To Date: $228,060
Contract Number / Date / Type MSE: C0382* / 1989-1990 / Fixed
Upgrade: 2006 … * Original contract not available
Plant Location Missouri River, 43 miles NE of Helena, MT
Hydro-Generating Unit Number Units 1-4 @ 12 MW
Combined Unit Output (MW) 48 MW
Project Title Thompson Falls Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1988): $71,000 To Date: $280,000
Contract Number / Date / Type MSE: C0342* / 1988-1990 / Fixed
Upgrade: 2006 … * Original contract not available
Plant Location Clark Fork River, Thompson Falls, MT
Hydro-Generating Unit Number Units 1-6 @ 6.2 MW; Unit 7 @ 55 MW
Combined Unit Output (MW) 95 MW
Project Title Hauser Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (2003): $36,700 To Date: $47,808
Contract Number / Date / Type #246181-C /June 03 – July 04 / Fixed
Plant Location Missouri River, 14 miles NE of Helena, MT
Hydro-Generating Unit Number Units 1-6 @ 3 MW
Combined Unit Output (MW) 17 MW
Project Title Rainbow Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1998): $61,000 To Date: $133,900
Contract Number / Date / Type MSE: C0156* / 1998-1999 / Fixed
Upgrade: 2001, 2003 … * Original contract not available
Plant Location Missouri River, 6 miles NE of Great Falls, MT
Hydro-Generating Unit Number Units 1-8 @ 4.5 MW
Combined Unit Output (MW) 36 MW
Project Title Black Eagle Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1999): $62,000 To Date: $140,000
Contract Number / Date / Type MSE: C0083* / 1999-1999 / Fixed
Upgrade: 2006 … * Original contract not available
Plant Location Missouri River, 2 miles NE of Great Falls, MT
Hydro-Generating Unit Number Units 1-3 @ 7 MW
Combined Unit Output (MW) 19 MW
Project Title Kerr Hydroelectric Project - Plant Control System
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Dollar Amount Initial Contract: (1990) $68,000 To Date: $234,186
Contract Number / Date / Type MSE: C0208* / 1990-90 / Fixed * Original contract not available
Plant Location Flathead River, 5 miles SW of Polson, MT
Hydro-Generating Unit Number Units 1-3 @ 59 MW
Combined Unit Output (MW) 177 MW
Project Title Ryan Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1985): $72,000 To Date: $175,360
Contract Number / Date / Type MSE: C0083* / 1985-1986 / Fixed * Original contract not available
Plant Location Missouri River, 10 miles NE of Great Falls, MT
Hydro-Generating Unit Number Units 1-6 @ 10 MW
Combined Unit Output (MW) 60 MW
Project Title Cochrane Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1984): $60,000 To Date: $120,000
Contract Number / Date / Type MSE: C0083* / 1984-1984 / Fixed * Original contract not available
Plant Location Missouri River, 8 miles NE of Great Falls, MT
Hydro-Generating Unit Number Units 1 & 2 @ 30 MW
Combined Unit Output (MW) 60 MW
Project Title Morony Hydroelectric Project - Plant Control System
Dollar Amount Initial Contract (1983): $62,000 To Date: $216,000
Contract Number / Date / Type MSE: C0083* / 1983-1983 / Fixed * Original contract not available
Plant Location Missouri River, 12 miles NE of Great Falls, MT
Hydro-Generating Unit Number Units 1 & 2 @ 24 MW
Combined Unit Output (MW) 48 MW
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Rochester Gas and Electric Hydroelectric System
Station 5 Plant Control System. RG&E is a subsidiary of
Energy East Corporation, a super-regional energy services and
delivery company in the Northeast. RG&E provides electricity and
natural gas energy and related services to approximately 650,000
residents and businesses in a nine-county region centered on the City
(http://www.rge.com).
of Rochester in Upstate New York. (http://www.rge.com The
RG&E system monitors and controls five hydroelectric power plants
remotely from the dispatch located in a separate facility. Station five
is the main focus as this dam and powerhouse control the Genesee
River through Rochester, New York.
1. Work Performed for: 3. Start/Completion 4.Project/ 5. References
dates: Tech Mgr:
Rochester Gas & 1994 – 1994 Steve Ostenburg Mr. Hugh Ives
Electric 406-533-6801 Rochester Gas & Electric
89 East Avenue steve.ostenburg@mse- 585-724-8209
Rochester, NY 14649 ta.com Hugh_Ives@rge.com
2. General Scope of Work – Contract Value:
Initial Contract (1994): $82,360 To Date: $744,473
Task: Monitor and Control Station 2, Station 5 headgates and generators, Station 13, Station 26, and
Central Avenue dam.
History: RG&E originally installed an MSE-Tetragenics “We have never had a
SCADA system to control three generators at their Station hardware failure with
5 generation plant. The SCADA system consisted of one Tetragenics hardware.”
VME-based PCS at the Station 5 powerhouse and an - Michael Haas: FPL Energy…
MC260 PC-based Master at the Beebee Station. The
MSE-Tetragenics system monitored both analog and “Product
digital statuses and alarms, and operators adjusted the durability/reliability++
load by entering generator set points from the Beebee Equipment quality++
Station Master (approximately three miles away). The Ability to customize to
PCS maintained the set points, adjusting both the customer's needs++”
governors for load and exciters for voltage. RG&E wanted le
Hugh Ives: Rochester Gas & Electric
to automate the Station 5 headgates as well to implement
a pond level control scheme. The headgates, however,
were unique in that they had internal water chambers and the gate elevation was based on the internal
water level. Based on joint effort between RG&E and MSE-Tetragenics, we designed algorithms to
control the weir tube, inlet, and outlet valves to maintain a given gate elevation. Once the gates were
controllable, we implemented our standard Pond Level Control using both the generators and
headgates. The priority is to load generators first and unload them once the headgates are closed. With
this success, we added more plants to the system.
The System: The RG&E system consists of dual-redundant MC3000 Master servers, one VME-based
PCS, six TG332-based RTUs, one local human-machine interface (HMI) mounted in the Master cabinet,
HMI workstations via the local area network (LAN) connection and remote dial-in, and log/report printers.
In 2008, we upgraded the dual MC3000 to the latest revision of software and replaced the Station 5
head-gate CPU with the G Series VME processor and software.
Figure 6 on page 33 shows the complete system.
The dual-redundant MC3000 Masters are two rack-mount PC-based servers connected to our Intelligent
Switching Module (ISM). Both Masters communicate with the ISM via serial RS232 channels. The ISM
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provides primary/backup status, MC3000 run status, and ISM position. The ISM also provides electrical
continuity for all the serial RS232 ports between the primary Master and the Polling channels. If the
primary Master fails, the ISM automatically switches to the backup Master to continue operation. The
MC3000 Masters have a network connection back to the LAN providing many purposes such as HMI,
disk sharing, email, file manipulation, web access (view only), and sharing data between the primary
Master and backup Master. The primary Master polls the plants using RS232 channels at various baud
rates depending on the channel’s capability.
The Crest Gate RTU is the most recent RTU added to the system. It supports all the hydraulic pump
logic needed for 4 new crest-type gates. This logic includes gate drift, pump alternation, leak detection,
and pump pressure monitoring.
We established a communication link between the Station 26 RTU and the Court Street PCS. The link
transfers data between both systems. The data needed in the Court Street PCS is used in the Pond
Level Control module for total water calculations and allocation. The data needed in the RG&E system is
spill gate information used in their load allocation.
Our programmers wrote the control algorithms specifically for each gate and generator as well as
various plant functions such as downstream siren control. Under normal operations, the system controls
the gates and generators based on a Pond Level set point. Operators can also enter set points directly
to generators and various gates. The sector gate is a floating gate requiring control of inlet and outlet
valves to achieve a specified level. These valves can also be given individual setpoints in the semi-
automatic mode. Originally it was thought that this gate could never be automated, however it works so
well that a similar dam with the same type of gates have also been automated.
Automatic Pond Level Control: With the ability to enter set points for both the generators and the
headgates in place, implementing our standard Pond Control was the next step. The Pond Control
module automatically calculates and implements set points to both the generators and headgates based
on a specified pond level set point and changes in the pond level. To maximize generation, Pond Control
automatically starts and stops the generators using our standard sequential and control software.
Flexible Control: The SCADA system gives RG&E different ways to control their plants: operators can
enter set points either to the generators and spill gates individually in a semi-automatic mode, or in the
fully automatic Pond Level Control mode.
Project Title Station 5 Plant Control System
MSE: C0218* / Fixed
Contract Number / Type Upgrades: 1998, 1999, 2005, 2008
* Original contract not available
Acted as Prime Yes
Functional Areas Involved Unit controls, excitation controls, governor controls, protective relaying
Gate Control: floating type sector gates and crestgate control
Plant Names Station 5, Station 2, Station 13, Station 26, & Central Ave.
Plant Locations Rochester, NY
Station 5: Units 1 & 2 @ 13 MW; Unit 3 @ 18 MW
Hydro-Generating Unit Number Station 2: Units 1 & 2 @ 16 MW; Unit 3 @ 30 MW
Station 26: Unit 1 @ 10 MW
Combined Unit Output (MW) 116 MW
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Figure 6. Block Diagram of RG&E SCADA System
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Rochester Gas and Electric Hydroelectric System Court Street
Court Street Plant Control System.
1. Work Performed for: 3. Start/Completion 4.Project/ 5. References
dates: Tech Mgr:
Rochester Gas & Electric Nov 04 – Nov 05 Steve Ostenburg Mr. Hugh Ives
89 East Avenue 406-533-6801 Rochester Gas & Electric
Rochester, NY 14649 steve.ostenburg@mse- 585-724-8209
ta.com Hugh_Ives@rge.com
2. General Scope of Work – Contract Value:
Initial Contract (2004): $111,371 To Date: $120,887
Task: Automate floating sector gates at the Court Street Dam with a SCADA PCS.
History: The Court Street Dam is located in the City of Rochester just south of the Court Street Bridge.
The dam, which is owned and operated by the New York State Canal Corporation, provides level control
at the Genesee River and Erie Canal crossing approximately 3 miles up stream, and headwater for
RG&E’s Station 26 hydroelectric generator.
The Court Street Dam was built in the early 1900s. Though the dam has been refurbished in the past,
the operation had never been upgraded to automatic controls or electronic implementation. The Dam
consisted of four (4) floating sector gates that were manually repositioned using hand cranks on gate
control and regulating devices (valves, props, and weir tubes). The one exception was that gates 3 & 4
weir tubes had been motorized, but were still repositioned by local start-up controls. The water level and
gate position indicating equipment consisted of cables that moved pointers on staff gauges located in
the control houses. By referring to the position and level indicators and using the various valve hand
cranks, operators raised and lowered the gates as necessary to maintain the river pond within a
prescribed range.
System: RG&E and New York State Canal Corporation (NYSCC) entered into an agreement to
automate the Court Street Dam facility, referred collectively to as Owner. RG&E, serving as Project
Manager, managed the automatic control system design and construction for all related modifications to
the dam. RG&E selected MSE-Tetragenics as the SCADA contractor and Sear-Brown Group as the
Project Engineer to design a system that was acceptable to NYSCC and to oversee construction.
NYSCC was actively involved through completion of the project. This included system design, control
system development, operations & management (O&M) personnel training, and system testing and
acceptance. NYSCC personnel continue to operate and maintain the facility after installation of the
automatic control system project.
The Court Street Dam Automation Project (the Project) was divided into three Prime Contracts: 1)
SCADA; 2) Motor Actuators; 3) General Construction. The SCADA portion is described below under
Work Covered Under Contract Documents. The General Contractor (GenC) was responsible for
installing and/or coordinating the installation of the SCADA system and motor actuators. The GenC
supplied and installed the balance of the materials, equipment, and services not covered by the SCADA
system and Motor Actuator contracts.
This project automated the operation of the dam and made it possible to monitor and control the facility
from onsite and remote control workstations (PCs). The supply and installation of permanent remote
workstation and related work is not included as part of this project. An overview of the new equipment
that was installed is as follows:
Controls: A SCADA control system provided by MSE-Tetragenics operates, monitors, and collects data.
This system communicates with the existing MSE-Tetragenics system located at Station 26 for data
transfer. The data received through the Station 26 RTU is generator information needed for the Pond
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Level module. Also the data sent to Station 26 is spill gate information needed in the RG&E Station 5
PCS.
The SCADA system has two (2) central operator control stations (HMI workstations), one located in each
of the control buildings. The SCADA system also has two (2) laptop computers fully configured with
remote control capability via dial-in telephone lines. The system has the capacity to add a permanent
remote control workstation in the future. The control system provides four (4) methods for operating the
spill gates: 1) Manual (via manual hand-crank operation; 2) Local (via hardwired controls at each
actuator) 3) Station (via on-site workstations); 4) Remote (via off-site workstations/laptops). The SCADA
system workstations provide three (3) basic modes of control: 1) Discrete (starting/stopping of individual
devices); 2) Semi-automatic (gate set point control); 3) Automatic (operate gates to maintain a river level
set point). Spill warning sirens and alarm control routines are incorporated into the system.
The control system operates the dam by modulating the valves and props through the new actuators to
regulate individual gate internal water chambers. This controls the “floating” level of the gate(s). SCADA
control and monitoring of the actuators is performed through serial communication connections via
RS485 between the SCADA microprocessor and the actuators. New electronic level and position
detection transducers are incorporated into the control system for status, alarm, control, and feedback
information.
Electrical: The electrical service to the dam was upgraded to accommodate simultaneous operation of all
spill gates and the new control equipment. A second power feed or equal rating and automatic throw-
over switch was added to increase reliability of the control system. In addition, a new Uninterruptible
Power Supply (UPS) system was added to maintain the power requirements of the new control system
for a period of 120 minutes.
Miscellaneous Subsystems: New systems installed for site protection and enhanced operation include a
security and fire detection system, spill warning siren system, facility enunciator/alarm system, level
display panels, automatic electric service transfer switch, and a UPS. These subsystems interface to the
control system.
Work Covered by Contract Documents: SCADA System: Supply of a complete SCADA including:
hardware, software, system design and design documentation, system assembly, algorithm
development, and system configuration, factory acceptance testing, O&M manuals, O&M personnel
training, equipment delivery, and field testing and startup services. The SCADA system monitors and
controls (both automatic and discrete/set point modes) the operation of four (4) spill gates and
appurtenant equipment and systems.
The control system design requires that the motor actuators communicate with the SCADA system via
serial communications (Modbus). Therefore, as part of their respective work scopes, it was required that
MSE-Tetragenics and the Motor Actuator Supplier work directly to ensure protocol compatibility so that
the control system supplied was fully functional as specified. As part of that working relationship, the
Motor Actuator Supplier provided three (3) actuators to MSE-Tetragenics to configure and test.
The GenC contracted with an I&C company to supply all specified instruments, instrument calibrations,
system checkout, system startup, debugging and SCADA commissioning test, installation oversight
(GenC installation support) and training of NYSCC personnel on the instrumentation system. This
included ensuring that instrument model numbers specified in the Instrument and Controls I/O and
Device list performed the intended function. The I&C company also worked directly with MSE-
Tetragenics during configuration of the system to develop analog scaling, elevation offsets, normal and
alarm status of digital inputs, and review/provide comments to the I/O list. The Master I/O list was
developed and maintained by the MSE-Tetragenics.
Execution: SCADA Control System: One (1) complete SCADA System was provided by MSE-
Tetragenics. The list below shows the hardware comprising the SCADA control system. The GenC’s
proposal included the labor, equipment, and materials necessary to receive, unload, transport, install (as
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required) and protect the SCADA control system equipment. Note: The GenC installed (set in position,
level and anchor, etc.) the SCADA system cabinet. The control system components, PCs, and printer
were assembled and commissioned by MSE-Tetragenics.
One (1) control cabinet with dual bay 19” rack, terminal decks, wiring harness, termination panels,
control relays, power switching panel, convenience receptacle, lighting, and cooling packages.
Estimate weight and dimensions: 300 lbs; 81”H x 24”W x 32”D.
One (1) MC3000 SCADA Master installed on industrial grade 19” rack mount PC with pullout
keyboard and flat screen monitor.
One (1) TG332 based RTU to include I/O boards, power supplies, cords, modems, etc.
Two (2) Desktop PCs with 19” monitors, keyboards, and mouse.
Printer
Interconnect/Cabinet Layout/Power drawings
O&M Manual(s)
Field Operational Checkout (FOC)
Site Acceptance Test (SAT)
Project Title Court Street Plant Control System
Contract Number / Type 5000008466 / Fixed
Acted as Prime Yes
Functional Areas Involved Gate Control: floating type sector gates
Plant Names Court Street Dam
Plant Locations Rochester, NY
Hydro-Generating Unit Number N/A
Combined Unit Output (MW) N/A
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Lewis County Public Utility District (PUD)
Cowlitz Falls Plant Control System. The Cowlitz Falls Project is a 70-megawatt hydroelectric
dam constructed in the early 1990s. The dam and power generation facility were completed in 1994. The
dam is 140 feet high and spans approximately 700 feet across the Cowlitz River. The reservoir behind the
dam has a surface area of approximately 610 acres. The Cowlitz Falls Project is built in a narrow
constricted portion of the Cowlitz River immediately upstream from Tacoma Power’s Riffe Reservoir in
eastern Lewis County. Situated a short distance below the confluence with the Cispus River, the dam
operates in a "run-of-the-river" mode, using water from the Cowlitz and Cispus Rivers. The Cowlitz Falls
Project produces on average 260,000 megawatt hours (Mwhrs) annually or approximately one-third (1/3)
of the annual needs of Lewis County PUD. The Lewis County PUD is owner of the Project, while the
Bonneville Power Administration (BPA) has purchased the annual output of the Project under a long-term
contract.
1. Work Performed for: 3. Start/Completion 4.Project/ 5. References
dates: Tech Mgr:
Lewis County Public 1992 – 1993 Steve Steve Ostenburg Mr. Joe First
Utility District #1 Upgrade 2004 406-533-6801 Lewis County Public Utility
PO Box 580 steve.ostenburg@ District #1
Morton, WA 98356 mse-ta.com 360-497-5351
joe.first@lewiscounty.com
2. General Scope of Work – Contract Value:
Initial Contract (1992): $239,104 To Date: $505,910
Task: Monitor and control the hydroelectric plant at Cowlitz
Falls, verify data, and respond to data according to complex
algorithms “The hardware has
performed flawlessly in 12
History: In 1992, the Lewis County PUD needed a fully years of operation. There has
automatic SCADA system for its new Cowlitz Falls never been a failure that
hydroelectric plant. The plant would supply up to 40% of required manning the project
Lewis County’s electrical needs. MSE-Tetragenics provided a
beyond the normal work
full SCADA system to operate the plant and maintain pond
levels. The system used complex algorithms and protocols to day. MSE-Tetragenics also
maintain control and communicate with other units along the excels in support. Employees
line. The project was completed and throughout the years go the extra mile to correct
MSE-Tetragenics has provided enhancements and
modifications.
any problems.
”
Jim Byrd: Public Utility District #1
The system was upgraded in 2004 with an MC3000 SCADA of Lewis County, Cowlitz Falls Dam
Master and the Plant Control System (PCS) was converted to
our newest G-Series PCS.
The System: The SCADA system consists of an MC3000 SCADA Master, G Series PCS, and TG 2000
Series RTUs. The SCADA Master operates the plant, maintains the pond within its operating range, and
draws down the reservoir in the event of a flood upstream at the town of Randle, WA. We developed
complex algorithms to verify data and respond accordingly to that data. To obtain and verify data, several
protocols are used to communicate with other intelligent devices. One protocol communicates with a flow
sensing unit near the town of Randle. This direct line informs the Master if a flood is occurring. The flow
data obtained from the Randle flow gauge must be verified, so another link accesses the United States
Geological Survey (USGS). The data obtained from the USGS includes the Randle reading, as well as
readings further upstream. The Master controls the generators and spillways, and maximizes generation
in order to maintain the pond level. Once generation is at capacity, the Master opens spillways in a priority
order to pass any additional water. The plant has two 35 MW generators, for a total capacity of 70 MW,
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with a normal operating head of 91 feet. (Refer to the diagram below.)
Project Title: Cowlitz Falls Plant Control System
Dollar Amount: Initial Contract (1992): $239,104 To Date: $505,910
Contract Number / Type C0403* / Fixed
Upgrades: 1996, 1999, 2004
* Original contract not available
Acted as Prime Yes
Functional Areas Involved: Unit controls, excitation controls, governor controls, protective relaying
Plant Name Cowlitz Falls
Plant Location Randle, WA
Hydro-Generating Unit Number Units 1 & 2 @ 35 MW
Unit Output (MW) 70 MW
Figure 7. Cowlitz Falls Plant Control System Block Diagram
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Louisiana Hydroelectric
Vidalia Plant Control System. The largest
prefabricated power plant in the world, the Sidney A
Murray, Jr. Hydroelectric Station was completed 40
miles south of Vidalia in 1990. It was designed to
harness the power of the Mississippi River and to
stabilize energy rates for the citizens of the Town of
Vidalia.
1. Work Performed 3. Start/Completion 4.Project/ 5. References
for: dates: Tech Mgr:
Louisiana 1987 – 1990 June Tangaro Mr. Dale Methvin
Hydroelectric 406-533-6806 Louisiana Hydroelectric
5707 Highway 15 june.tangaro@mse- (225) 492-2153 x208
Vidalia, LA 71373 ta.com dmethvin@lahydro.com
2. General Scope of Work – Contract Value:
Initial Contract (1987): $466,822 To Date: $775,500
Task: Monitor and control Sidney A. Murray Jr. Hydroelectric Plant and handle large volumes of input
and output controls, sense water levels, monitor and control flow, and monitor essential parameters.
History: Built to service the electrical power needs of Vidalia, Louisiana, the Sidney A. Murray Jr.
Hydroelectric Plant is the largest low-head generating plant in the United States. The plant contains
eight 24 megawatt (MW) generators producing a total of 192 MW. Aware of plant and operator needs,
MSE-Tetragenics provided a distributed control system comprised of powerful PCSs and Masters to
automate the plant. The system encompasses over 4000 combined input/output points.
The System: In 1990, MSE-Tetragenics linked nine, 3-bay PCSs in a star configuration to an MC300
Series Master. One PCS monitors plant common functions and the other eight individually monitor each
generator.
Upgraded in 1999/2000, each PCS now links to an MC3000 Master. An RTU at the inter-tie substation in
Vidalia monitors power flow information for that location. Each generator PCS can operate
independently without the MC3000 Master to maintain current setpoints and take action to protect the
generator if an alarm condition occurs.
Operators monitor and control the plant from graphic workstations connected to the MC3000 Master via
an Ethernet LAN. From the workstations, operators can stop and start generators with a single
command, and specify setpoints to control MW and MVar loading. They can also operate individual
devices from the workstations.
The plant receives a daily water flow allocation from the U.S. Army Corps of Engineers (USACE). The
MC3000 Master performs water optimization computations to maximize MW production for the current
available head water and tail water, and maintains the assigned water flow. It also calculates the
optimum selection of generators, starts and/or stops generators as necessary, and assigns MW
allocations to the running generators.
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Project Title Vidalia Plant Control System
Contract Number / Type C0201* / T&M - Upgrade: 1999-2000 *Original contract not available.
Acted as Prime Yes
Functional Areas Involved: Unit controls, excitation controls, governor controls, protective relaying
Plant Name Sidney A. Murray Jr. Hydroelectric Plant
Plant Location Vidalia, LA
Hydro-Generating Unit Number Units 1-8 @ 24 MW
Combined Unit Output (MW) 192 MW
Figure 8. Louisiana Hydroelectric Plant Control System
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City of New Martinsville
New Martinsville Hannibal Hydroelectric Plant
Control System. The New Martinsville Hannibal
Hydroelectric Plant is located on the Ohio River in New
Martinsville, West Virginia. It is adjacent to the Army Corps
of Engineers Hannibal Lock and Dam facility. It operates in
a “run-of-the-river” mode and has two Fuji generators and
horizontal bulb turbines with Kaplan adjustable blades (three
blades per unit). The governors are from Woodward. The
plant was built in1988 with the generators coming on line in
July and August of that year.
1. Work Performed for: 3. Start/ Completion 4.Project/ Tech 5. References
dates: Mgr:
City of New Martinsville 1987 – 1988 June Tangaro Mr. Charles Stora
One Howard T. Jeffers Drive Upgrade 2002 406-533-6806 New Martinsville Hannibal
P.O. Box 682 june.tangaro@mse- Hydroelectric Plant
New Martinsville, WV 26115 ta.com 304-455-5200
nmhydro@ovis.net
2. General Scope of Work – Contract Value:
Initial Contract (1987): $58,300 To Date $156,100
Task: Monitor and control the hydroelectric plant at New Martinsville, West Virginia; verify data, and
respond to data according to complex algorithms.
History: In 2002, MSE-Tetragenics upgraded the PCS at the New Martinsville Hannibal Hydroelectric
Plant. We provided the original PCS in 1988 when the plant was built. This PCS included three cabinets
and three chassis’s in Cabinet No. 2 to hold the CPU and I/O cards. We provided an efficient, cost
effective software and hardware upgrade that used most of the original equipment. New Martinsville has
been our customer since 1987.
System: The new system is a TG332-based PCS with no RTUs; we upgraded the existing MSE-
Tetragenics VME-based system in 2002. The system uses WTV16s and DOS-based editors. Our scope
of work involved removing the entire Model 2112 chassis, which occupied the top portion of Cabinet No.
2. Included in the removal were the outdated VME-based Force 1-D CPU, the Serial Input/Output (SIO)
expansion card, all memory boards, the bus buffer board/cable chassis connections, and all the existing
power supplies serving the three MSE-Tetragenics chassis’s located in this cabinet. The two existing
Model 2121 Chassis’s remained in the cabinet. To provide a connection between them, we mounted a
new bus buffer board and cable assembly on the backplanes of the two chassis. We upgraded the PCS
from a VME Force Central Processing Unit (CPU) to our TG332 CPU board featuring the Motorola
MC68332 microcontroller. This CPU and companion daughter memory board replaced the Force CPU
and was mounted in the existing lower (second) Model 2121 chassis. The TG332 CPU, which has a 20
MHz, 32 bit processor, was designed to interface into our 2000 Series bus; therefore, it simply plugged
into this chassis. The daughter board provided an additional 1MB of memory and filled the slot next to
the CPU. The CPU has five RS-232 communications ports, eliminating the need for an SIO expansion
board. The communication port configuration is now:
Port Description
A Local Display (WTV)
1 Alarm Printer (Serial), Debug/Download
2 Local Display (WTV) and Edit Station with Reports Printer (Parallel)
3 Army Corps Display (VT100 Terminal)
4 Army Corps Display (VT100 Terminal)
Also mounted in the lower Model 2121 chassis was the existing analog input board and a new MSE-
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Tetragenics 2000 series Analog-to-Digital (A/D) converter board that ties the analog points into the
TG332 CPU. This new A/D board coordinated the database and system features to provide better
resolution in converting the analog signals to digital engineering values. For example, over a possible
resolution of +/-10 volts, a 4-20 mA input signal resolution increased to approximately -6 to +10 volts
from the previous resolution of about +1 to +5 volts. This assumes an option C (0-20 mA) analog input
board.
The five existing separate power supplies were replaced by one 129 Vdc power supply to provide +5 Vdc
to each remaining Model 2121 chassis and +/- 15 Vdc to the lower chassis containing the Analog A/D
Converter and Analog Input cards. The new equipment no longer required the +/- 12 Vdc output provided
for the existing Model 2112 Chassis VME bus, although the new power supply had that output available.
Part of the space in the cabinet left by removing the existing Model 2112 VME / TG Bus chassis was
occupied by an MSE-Tetragenics Model 2807 seven-slot, modem mounting panel. The existing PCS
short-haul modems, used for communications to the display devices and printers, were mounted on this
panel to help “clean up” the hardware installation inside the cabinet. Once the above changes were
made, there were four remaining slots in the top Model 2121 Chassis and five remaining slots in the
bottom Model 2121 chassis for future expansion of the system.
Since the original installation in 1987/1988, we have standardized, numbered, and documented our
interconnection hoods. As a part of this upgrade, we provided new standard modular hoods and RJ-45
terminated CAT-5 cable to connect the PCS to the short-haul modems that communicate with peripheral
devices (WTVs, VT-100s, and printers). We also upgraded connection hoods and cables between the
peripheral devices and their short-haul modems. The existing short-haul modems and wiring between
them remained in place.
Project Title New Martinsville Hannibal Hydroelectric Plant Control System
Contract Number / Type C0086* / Fixed
Upgrade: 2002
*Original contract not available
Acted as Prime Yes
Functional Areas Involved Unit controls, excitation controls, governor controls, protective relaying
The Plant Name New Martinsville Hannibal Hydroelectric Plant
Plant Location New Martinsville, West Virginia
Hydro-Generating Unit Number Units 1 & 2 @ 18.8 MW each
Unit Output (MW) 37.6 MW
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Figure 9. New Martinsville Hydroelectric System
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California Department of Water Resouces System
Water System Improvements and Support. California
Aqueduct: Our systems help monitor and control water storage
and transport along the California State Aqueduct. Linking the
two parts of the state, the California Department of Water
Resources (DWR) Project redistributes water from places of
abundance to areas in need.
1. Work Performed for: 3. Start/ Completion 4.Project/ Tech 5. References
dates: Mgr:
California Department of Water June 90 – Dec 93 Chad Carpenter Mr. Hans Pettersen
Resources California Department of
1416 9th Street, Room 640 Water Resources
Sacramento, CA 95814 (916) 653-9630
hansp@water.ca.gov
2. General Scope of Work – Contract Value:
Initial Contract: $6,124,597 To Date: $8,535,393
Task: Our contract with the California Department of Water Resources was a multimillion-dollar project to
supply more than 300 RTUs to help control one of the world's largest agricultural and municipal water
transportation systems.
History: The California State Water Project is the nation’s largest state-built water and power
development and distribution system with 32 major storage facilities (including 20 primary lakes and
reservoirs), 17 pumping plants, 5 hydroelectric power plants, 3 pump-generating plants, and more than
660 miles of canals, tunnels and siphons.
System: The California Aqueduct transports most of the California State Water Project’s water. Our
RTUs (also referred to as PLCs) remotely control and monitor pumping stations and aqueduct control
structures throughout the state of California, improving the efficiency of the water system's operations.
From the control center, operators can access data from any RTU, and the information is displayed in
easy-to-read charts and graphs.
The 300+ remote terminal units (RTUs) that were assembled, tested, and shipped accounted for the
majority of equipment. The total input/output supported exceeds 30,000 points. Along with the RTUs,
over 10 graphical operator interface workstation platforms were configured and shipped to communicate
with plant RTUs. Operators can view data and operate the plant from a single location.
Control System software was developed for each RTU platform depending on site requirements and
operational parameters. Every RTU program was developed to support the following advanced
monitoring and control features:
Real-Time I/O processing with alarms and events time stamped to the millisecond
Sequence of Events processing to store point transitions in a memory queue until the data is
requested.
Report by exception data exchange
Secure protocol communications with check-before-execute messages to prevent un-commanded
controls
Unique specialized sequential control strategies
Local operator interface terminal port
System wide time synchronization
Protocol support to retrieve data via a communications port from power meters, flow meters, and
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other intelligent electronic devices.
Specialized control strategies were developed in the RTU databases to perform plant functions as
required at the different locations. Some of the control functions are listed below:
Bring a generation unit online
Regulate a reservoir level
Control aqueduct water flow
Startup a pumping plant
Plant monitoring
Event based alarm control
The original contract mandated an aggressive delivery schedule of material and system installation
deadlines beginning in June 1990 and continuing through late 1993. We were able to keep pace and
meet the scheduled requirements. We performed major updates and additions to the project in 1994, and
in 2004 we developed and implemented RTU system enhancements.
Since 2003 we have renewed two 3-year maintenance contracts with DWR. These provide hardware
support, system troubleshooting, and new development.
In 2007, MSE-Tetragenics and DWR completed a two week site acceptance test on our new VME RTU
platform. Following an extensive test plan, we proved the functionality of the new VME G-Series Central
Processing Unit (CPU) and software platform. Once completed, the tests showed that our equipment and
software can provide a long-term cost savings solution to meet both DWR’s immediate and evolving
control operation needs for new and existing Remote Terminal Unit (RTU) installations. The RTU
performance test is best summarized by a single comment from a tester: “It would take three separate
devices to get the same functionality provided by the MSE-Tetragenics G-Series RTU.” The MSE-
Tetragenics system provides a protocol translator/data concentrator, sequence-of-events recorder, and a
plant logic controller in one unit — a PLC-based system would require three devices.
To further validate the new G-Series RTU platform, DWR personnel upgraded an existing RTU and have
been field testing the new system. The system went live on October 18, 2007, and no major difficulties
have been reported.
Water System Improvements and Support – California State Water
Project Title:
Project
Dollar Amount Initial Contract: $6,124,597 To Date: $8,535,393
Contract Number / Type DWR-8020 / Fixed
Upgrades 1993, 1994, 2004, 2006, 2007
Acted as Prime Yes
Functional Areas Involved Large Scale Water System Improvements
Plant Names California Aqueduct
Plant Locations California
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Figure 10. California Department of Water Resources Project Information
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Communications Monitoring and Control System – NorthWestern Energy*
Project: MC3000 Master Control System * The Montana Power Company
Customer: NorthWestern Energy (formerly Montana Power sold its utility business to PPL
Company) Montana LLC and NorthWestern
Energy. Tetragenics currently
Contact: Kirt Mayson, NorthWestern Energy, Butte, MT, 406- performs work for both new
497-3845, Kirt.Mayson@northwestern.com companies.
Task: Monitor and control microwave stations at remote sites,
often subject to extreme climate changes.
History: In the 1980s, Tetragenics provided a Communications Monitoring and Control System
for MPC (now Northwestern Energy) that consisted of MC3000 Series Masters and
RTUs. The system monitored and controlled the company’s analog and digital remote
microwave sites, 2-way radio systems, and emergency generators at the sites. In 1998, we
upgraded the system to include MC3000 Series Masters and RTUs linked over a
LAN/WAN.
System: The system contains two MC3000 separate Masters on a WAN/LAN (Wide Area
Network/Local Area Network). One Master is on the Analog (microwave) system and the
other is on the Digital system. (Refer to the diagram on the next page.) The Analog
Master communicates with over 75 remote sites and functions with analog (voltage
inputs), digital (status points), and control features. The Digital Master communications
with over 40 sites performing similar functions as those listed for the Analog Master, but
also carries transmission line protective relaying using digital channel banks. The
Tetragenics RTUs at each site monitor and report on the station's situation, functions, and
conditions. The RTU reports on the following:
• More than 11 different types of microwave radios (analog and digital) and 2 way
radio signals
• Generator status
• Fuel levels
• Environmental conditions at the site (inside and outside)
• Station power (AC or DC)
• Tower lights.
The RTUs transmit the information to the appropriate Master. The Master relays it to
operators at a main operation center and to various terminals connected to the system.
From the main center, operators see site and generator conditions at a glance. If
necessary, they can send someone to a site (or not if the climate conditions are extreme).
In some cases, operators can correct problems themselves using the Masters link to the
RTU.
Each RTU is an intelligent device with a built in microprocessor that allows stand-alone
(out of touch with the Master) control and monitoring. The RTUs continue to store site
information when communication is lost. When communication is restored, the RTUs
forward the information to the Master.
A Model 31 Alarm Annunciator augments the security of the system by providing surge
protection, communications switching, and alarm annunciation capabilities.
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NorthWestern Energy System Diagram
-- At a Glance --
Started/Ended: 1980 – Upgrade 1998 – ongoing upgrades
System: 2 Masters: MC360 Masters upgraded to MC3000
Masters, one Analog and one Digital.
RTUs: 75 Analog Microwave RTUs and 40 Digital Microwave
RTUs and Fiber RTUs
Interfaces with: Model 31 Alarm Annunciator, Microwave, Telephone,
Fiber, and 2-way Radio Equipment
Access: Workstations and ECC via microwave
Editing/GUIs: File transfers via LAN connections over TCP/IP
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Substation Monitoring and Control System – NorthWestern Energy Company*
Project: Dual MC3000 Master Front End Processor and Substation RTUs
Customer: Montana Power Company, now Northwestern Energy
Contact: Laura Cook, NorthWestern Energy, Butte, MT, 406-497-4145,
Laura.Cook@Northwestern.com
Task: Provide Front End Processor (FEP) for ESCA EMS Management system with over 200
RTUs for substation monitor and control.
History: In the 1980s, Tetragenics provided a Substation Monitoring and Control System for MPC
(now Northwestern Energy) that consisted of Dual MC3000 Series FEP and RTUs. The
system monitored and controlled the company’s spread throughout the state of Montana.
Upgrades have been provided over the years, as new technologies were available as well
as the Customer needs changed. This includes for example, RTUs polled over a
LAN/WAN.
System: The system contains a dual “hot-standby” MC3000 FEP on a WAN/LAN (Wide Area
Network/Local Area Network). The MC3000 FEP polls the RTUs via several mediums
of communications and relays the data to an ESCA Energy Management System.
Each RTU is an intelligent microprocessor based device that allows stand-alone (out of
touch with the Master) control and monitoring. The RTUs continue to store site
information when communication is lost. When communication is restored, the RTUs
forward the information to the Master.
SCADA/Telemetry Improvements on Water System – Town of Superior
Project: SCADA/Telemetry Improvements
Customer: Town of Superior-Superior, MT
Contact: Roger Wasley, Phone: (406) 822-4672, supertwn@bigsky.net
System: The Telemetry System Improvements project was to modernize the Town of Superior’s
water system controls and monitoring. MSE designed, installed, and started the telemetry
system improvements. The Town of Superior received the Montana Rural Water
"Outstanding System of the Year Award" – the telemetry system improvements were a
key part of this award. The following outlines the major components of the system
improvements
Designed, installed, and programmed RTU panels for three well house control
stations.
Designed, installed, and programmed the Tetragenics RTU for the town’s main
storage reservoir. This RTU reports back to the wells with level and alarm conditions.
Control at the wells is executed based on parameters such as tank level, pump cycles,
and last starts as well as pump failures.
Applied for, procured, and delivered a VHF FCC radio license for the telemetry
system, There was a very short construction schedule for this project and we were
able to deliver the license, start the system on time, and turn it over to the owner. We
used high quality digital radios with built-in remote diagnostic reporting features for
this project.
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Installed an operator interface LCD panel at the main well pump house. The display
allows an operator to view system parameters and control the whole water system
from this location. This feature has saved the town money and other resources by
freeing up the operator for other valuable duties.
Provided start up and system training for the Town of Superior personnel.
Water System Improvements – Butte Silver Bow Water Department
Project: Butte Silver Bow Water System Improvements
Customer: Butte, MT, Butte-Silver Bow County
Contact: Jean Pentecost Phone: (406) 497-6530, jpentecost@co.silverbow.mt.us
System: Butte Silver Bow’s existing SCADA system, controlling both the municipal and
industrial water systems, was covered by a maintenance agreement. Under this
agreement, MSE was to service any failures, logic changes, or HMI changes. MSE
supported design, construction oversight, and start up of water utility improvements for
the city-county of Butte Silver Bow. These system improvements helped bring the
county’s municipal water system to within (and exceeding) required state and federal
compliance requirements. MSE designs also referenced all safe drinking water
recommended standards and practices.
The upgrade included design, development, and implementation of a SCADA system that
included over a dozen remote sites communicating back to the central water treatment
facility control room. We provided various pump lift station electrical designs, including
start up, training, and documentation. To achieve this, we performed the following I&C
and electrical related tasks:
(1) An FMT® HMI upgrade included a windows-based software package that could
control the Bighole and Moulton water treatment plants. All the points were converted to
the new system and new operator screens created; the operator computers were
networked together providing additional interfaces; the existing communications link
between plants was revamped; and Modicon® PLCs were installed at each location
creating a dial up configuration to exchange data continuously (this method proved to be
faster and more reliable than the previous radio polling).
(2) A new Modicon® PLC control system was incorporated into the Ramsay pump
station. This system controlled the supply of industrial water from Silver Lake to ASiMi
(Silicon Plant) and Montana Resources. This system was tied to the Bighole water
treatment plant via a new radio link and allowed operators to enter flow set points from
their FMT® HMI console. The logic for this site included flow control, constant and
variable speed pump control, and various alarm condition reporting.
(3) New Modicon® PLC controllers were programmed and installed at Silver Lake and
Myers Dam. Both these sites had new radio links back to the Bighole water treatment
plant. Operators could view alarms and set parameters for flow and level control via the
FMT® HMI screens created for these sites.
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Water System Improvements – City of Hamilton
Project: Water System Improvements
Customer: City of Hamilton, Montana
Contact: Lorin Lowry Phone : (406) 363-2101
System: Tetragenics programmed a new Opto-22® PLC and installed it at the Weber booster
station. This new controller was programmed to start and stop pumps based on the
current flow and discharge water pressure provided to a residential area. The logic
incorporated several inputs and timing parameters to properly control and sequence the
starting of the pumps. Local visual alarms and a discharge pressure chart recorder were
outputs from the controller.
Water System Improvements – Emerald Bio
Project: Water System Improvements
Customer: Emerald Bio (Formerly Mycotech - providing hazardous waste treatments)
Contact: Gary Chatriand Phone: (406) 782-2386
System: For Mycotech, Tetragenics integrated an Opto-22 PLC and Opto Display® HMI into an
existing control system for process control. The manufacturing process produced a
patented product that was very sensitive to the environmental conditions being controlled
during the different process stages. Because different stages in the process require
different set points for humidity, air velocity, and pressure, the original system did not
provide the necessary level of integration. The basis for the project was to provide one
central workstation that could be used to monitor and control the environmental
parameters of each stage. The new PLC and HMI allowed value trending, data archiving,
and set point changes to be made by operators on one device. A protocol driver in the
PLC was written to read and write data between separate 3rd party integrated PID
controllers and the new HMI.
Water System Improvements – City of Havre
Project: Water System Improvements
Customer: City of Havre, Montana
Contact: Jeff Jensen Phone : (406) 265-5215 havrewtp@mtintouch.net
System: For the City of Havre, Tetragenics incorporated an Opto-22 PC-based controller and
Opto Display® HMI for pump and tank level control at the treatment plant. The new
automatic system had to maintain adequate water pressure for residential and fire use. We
installed remote I/O modules at three remote storage sites and two pump sites. The data
from each site is polled over radio links provided with the control system and reported
back to the treatment plant. From the HMI at the treatment plant, operators can change
set points, view current data, and control the remote pumps.
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Water System Improvements – City of Culbertson
Project: Water System Improvements
Customer: City of Culbertson, Montana
Contact: Steve Moore Phone : (406) 787-5271
System: The Tetragenics project with the City of Culbertson was to replace the existing PLC
control system at the water treatment plant. The scope of the project involved
implementing a Modicon® PLC, a WonderWare® HMI, and an auto-dialer at the plant.
We created control logic to control the filtering process on two existing filter units while
maintaining a tank level set point. The control logic included several key processes and
filtering sequences to deliver treated water to the city. We added an HMI for operator
control, value trending, and data archiving. The plant was programmed to run
automatically and used an auto-dialer to alert personnel if there was a problem.
Water System Improvements – East Glacier
Project: Water System Improvements
Customer: East Glacier, Montana
System: Tetragenics installed Modicon® PLCs at a pumping facility in East Glacier to control the
water level in the Rising Sun remote tank. A new radio link for communications between
the pump station and the tank was also installed. Because there was no power at the tank,
a solar power system at the tank to power the control system equipment was
implemented. Control logic to automatically cycles the pumps based on the tank level.
Water System – Town of Philipsburg
Project: SCADA Water System
Customer: Town of Philipsburg, Montana
Contact: Dick Hoehne Phone: (406) 859-3455 pworks@blackfoot.net
System: MSE upgraded the existing SCADA system for the town of Philipsburg. The new system
consists of five PLCs: four slaves and one master. The new system consists of the
following features.
A master Modicon® PLC and radio located at the town shop. This unit polls the remote
sites and posts the data locally to a new RSView® HMI. The HMI allows operators to
monitor system parameters, archive and trend data, and acts as a call out dialer for
failures or alarms within the water system. An Allen-Bradley PanelView® Operator
Interface Terminal (OIT) was installed at local sites.
One slave located at the Fred Burr water storage tank and chlorinator controls tank
levels and monitors key water system parameters such as turbidity, pH, temp, chlorine
residuals, and overflow alarms.
One slave located at the metal water tank monitors tank water level.
One slave located at the pressure reducing valve location monitors and controls water
system distribution pressure. The slave also provides a time schedule program to make
sure that both water tanks get equal usage during the winter months.
One slave at the Montana Silver Springs (MSS) Booster Pump Station controls
pumping the water from the MSS to the Fred Burr tank. The MSS water is used to
augment the surface water being input into the Fred Burr tank. This system also
controls and monitors chlorine residuals and pump station flows.
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Water and Wastewater System – Galen Campus
Project: Water and Wastewater SCADA System
Customer: Galen Montana Campus, Montana
Contact: Tom Piercy Phone: (406) 533-6827
System: MSE installed a SCADA system for the Galen Montana campus. The new system
monitors and controls the level of drinking water stored in a new elevated storage tank.
The tank reports its level to two well houses, and the Rugid Computer® RTUs at the well
houses start and stop automatically depending on operator start and stop set points. The
SCADA system communicates using licensed free spread spectrum radios. There is one
master radio and three slave sites on this system. The new system also monitors plant
statuses for the upgraded wastewater treatment plant. All water and wastewater system
parameters are posted to this site from the master RTU and current data is archived and
viewed with an NI Lookout® HMI personal computer. With this configuration, an
operator can dial into the system remotely from home or any other location and view the
water and wastewater system parameters. The treatment plant also has an automatic
telephone dialer to call out operators in case of failures or alarms.
Industrial Wastewater Treatment – Atlantic Richfield Company
Project: Wastewater Treatment Control System – Lower Area One
Customer: Atlantic Richfield Company – Butte, MT
Contact: Cody Carpenter Phone: (406) 782-5177
System: The project consisted of the collection and treatment of settling ponds as an effective,
long-term solution for cleaning groundwater contaminated with heavy metals as a result
of mining. MSE was asked to monitor critical data, automate pump controls,
display/archive data, and initiate alarm callouts. To achieve this, the Tetragenics
MC3000 SCADA Master® with the WTV32® HMI was used to interface to the Modicon®
PLCs.
Wastewater/Air Emissions System – Fort Bragg Military Reservation
Project: Wastewater/Air Emissions SCADA System
Customer: Fort Bragg Military Reservation – Fort Bragg, North Carolina
System: MSE assists Fort Bragg in executing projects to reduce environmental stewardship costs
through the use of innovative technologies and techniques. Projects conducted for Fort
Bragg include automation of environmental data collection, transmission, and analysis,
evaluation of processes to reduce contaminants in drinking water, reuse of wastewater for
landscape area irrigation and modeling to reduce the costs of sedimentation control.
MSE provided design, installation, construction oversight, and start-up services for a
large, industrial SCADA system for the Public Works Business Center (PWBC) and
Environmental Compliance Office located on the Fort Bragg Military Reservation. The
system consisted of Modicon® PLCs, NI Lookout® HMI, and a Cutler-Hammer OIT.
These system improvements helped bring Fort Bragg into compliance with state and
federal requirements for both their air quality permit as well as their wastewater
collection permit requirements. Installation of the new system has prevented raw sewage
spills and releases, which has saved thousands of dollars in fines and other costly
compliance issues. Key projects include:
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Installation of the SCADA system on the wastewater collection and treatment
system. The SCADA system allows the Fort Bragg DPW to monitor potential
problems in the wastewater collection and transportation system. The information
collected is automatically updated to workstations at Fort Bragg PWBC, the
Water Treatment Plant, the Wastewater Treatment Plant and Pope Air Force
Base. Potential problems are identified by alarms, allowing timely response and
avoidance of overflow conditions. Fort Bragg has been able to avoid regulatory
violations that had been common before the MSE SCADA system was installed;
Addition of SCADA capabilities to monitor fuel usage rates and air emissions
from various incinerators, boilers, and generators located across Fort Bragg.
The Air Emissions Data System assists Fort Bragg in maintaining compliance
with their Title V Air Permit;
Design, installation, and test of a pressure monitoring system on the Ft. Bragg
drinking water treatment plant distribution network. The network is tied to the
SCADA system and allows more efficient use of potable water at Fort Bragg;
Design, installation, and test water quality monitoring on the Ft. Bragg drinking
water treatment plant distribution network, which is tied to the SCADA and gives
the Department of Defense information on water quality and corrosion rates.
Industrial Waste Minimization and Prevention – Watervliet Arsenal
Project: Industrial Waste Minimization and Prevention
Customer: Watervliet Arsenal, New York
Contact: John Hockenbury, Phone: (518) 266-5736, hockenbury@wva.army.mil
System: The goal of the Industrial Pollution Minimization project, a multi-year project being
conducted at the Watervliet Arsenal in Watervliet, New York, is to minimize or eliminate
waste from industrial processes through modernization of process control and data
collection systems. As part of this project, MSE performed numerous installations and
updated process control and data collection systems at the Arsenal. The system consisted
of Allen-Bradley® PLCs and a WonderWare® HMI. We also provided design services;
layout, fabrication, and installation services (panel and rack mounted instrumentation and
control equipment); and industrial networking systems services.
Industrial Wastewater Treatment Control System Upgrade – Watervliet
Project: Industrial Wastewater Treatment Plant Control System Upgrades and Studies
Customer: Watervliet Arsenal, Watervliet, New York
Contact: Tom Herold, Phone: (518) 266-5020
System: MSE was responsible for the upgrade, design, installation, and troubleshooting of the
I&C systems at the industrial wastewater treatment plant. We completely redesigned the
control system to include Allen-Bradley® PLCs, WonderWare® HMIs, single loop digital
controllers, and multiple instrumentation equipment to measure flow, temperature,
pressure, pH, oxidation-reduction potential (ORP), conductivity, level, and density. We
documented the new and existing instrumentation using ISA standards, and wrote
operation and maintenance manuals for the new systems.
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Underground Storage Tank Monitoring System – Fort Lewis Storage Tanks
Project: Fort Lewis Remote Underground Storage Tank Monitoring
Customer: Fort Lewis, Washington
Contact: James Lee, Phone: (253) 967-3268 Fax: (253) 967-4786, leejf@lewis.army.mil
System: At Fort Lewis, Washington, MSE provided a system to continuously monitor remote
underground oil storage tanks for leaks and overfills. The tank status is sent to a central
gathering computer in the environmental office, where a graphics display map shows the
location and detailed status of each tank. The alarms are logged into a database to provide
historical information and trending.
Water Treatment Plant – Emeryville
Project: Water Treatment Plant
Customer: Emeryville, California
Contact: Larry Mencin Phone: (216) 566-1768 Fax: (216) 566-1768
System: This project included the design, construction, and commissioning of a ground water
treatment plant to remove arsenic from a subsurface aquifer. The Allen-Bradley® PLC-
based control system manages 10 ground wells, several pumps, and tank level controls.
We designed the system software to provide a fully automated plant with only minimal
operator interface required, using an Allen-Bradley PanelView® OIT. As part of the
project, we provided full system documentation including drawings, operation
procedures, maintenance procedures, and the necessary equipment lists.
Critical Aircraft Parts QA Monitoring System – Corpus Christie Army Depot
Project: Critical Aircraft Parts Quality Assurance (QA) Monitoring System
Customer: Corpus Christie Army Depot
Contact: Jim Holiday, Phone: (461) 961-3243
System: As part of a team with National Chemical Corp., we installed instrumentation equipment
and networked computers to provide detailed current and historical data on process
parameters during the critical plating and heat treating processes. Sampled data was sent
to the database server and stored in a format that could be viewed on web browsers for
quality assurance and quality control review. We installed numerous monitoring
instruments, a computer network, Modicon® PLCs, and a main central control station
with a Citect® HMI. For this project, we conducted rigorous process evaluations and
obtained buy-off by operations personnel. We provided extensive formal training for the
operators and provided full engineering support for the start-up phase.
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Water Treatment Plant Control System Upgrade – Hawthorne Army Depot
Project: Water Treatment Plant Control System Upgrade
Customer: Hawthorne Army Depot, Hawthorne, Nevada
Contact: Dave Mussleman, Phone: (755) 945-1211
System: The Hawthorne Water Treatment Plant Control upgrade project was specified to
modernize the existing manual operations of Hawthorn’s existing water treatment plant
facility. The goals were to automate the plant operations, double the water treatment
throughput capacity, and reduce the risk of environmental spills. For this project, MSE
installed a modern fieldbus network of instruments and mechanical equipment, and tied
the network into an Allen-Bradley® PLC with a WonderWare® HMI as a front end. This
project also included Visual Basic programming to provide a user interface with the
chemical feed pumps and the HMI software. We provided the engineering design,
programming, construction, commissioning, training, and documentation for this project.
Mine Internet Monitoring System – Calliopi Mine
Project: Calliopi Mine Internet Monitoring System
Customer: Calliopi Mine (Montana)
Contact: Roger Wilmoth (513) 569-7509
System: This project was designed to poll and warehouse remote sampling data from the Calliopi
Mine site automatically and send it to one location. We linked the remote monitoring
sites to a PC at the MSE testing facility in Butte, Montana, via a cellular modem
connection. The dedicated PC polls data from the remote sites. We also included the
technology to demonstrate remote site monitoring using two web cameras. The cameras
download images to the PC at MSE. The images and data can be viewed via the Internet
from the dedicated PC.
PLC Panel Fabrication – ASiMI
Project: Silane Loading Facility Expansion Project
Customer: Advanced Silicon Materials, LLC (ASiMI) – Butte, MT
Contact: Brian Sullivan, Phone: (406) 496-9844, sullivan@asimimt.com
System: This project required the fabrication, testing, and delivery of twenty UL 508A certified
programmable logic controller (PLC) cabinets for the Silane Loading Facility Expansion
Project at the Advanced Silicon Materials, LLC (ASiMI) plant in Butte, Montana.
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