Energy University: Intro to Energy Intelligence
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Transcript of Energy University: Intro to Energy Intelligence
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Energy UniversityIntro to Energy Intelligence
What’s the idea?
Make more with less!
Energy cost 30% of
operational cost
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How much Energy do we spend
per machine, area, product, …?
Where to save Energy
without impact on performance?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The classical approach
External consultancy or experts implementing energy monitoring
Disconnected from other existing systems and data
Existing information can/will not be used
Local production is not involved in the whole approach
Non integrated approach has limited success
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Energy Intelligence approach
Energy monitoring as an integrated approach
Existing systems, data and information will be used
Experts support implementation and use of system
Local production is involved in the whole approach
System can be extended or combined with other performance management initiatives
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
What is my equipment utilization?
What are the energy intensive processes?
How do we avoid costly energy demand charges?
How do I create a more energy efficient machine?How much energy is
consumed to make this product?
How to ensure uptime and reduce energy cost?
How do I increase throughputwhile reducing energy usage?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:- Right Sources
- Right Granularity- Right Measurements
Predict:- Baseline
- Production Output- Energy and Carbon cost
Calculate:- Production vs. Non-Production
WAGES and Emissions- Actual cost of WAGES and GHG
Analyze + Report:- Baselines, Production,
Output, Targets, and Regulatory limits
- KPIs and Benchmarks
Visualize : - Energy usage against production
output- Compare performance across multiple facilities
Ener
gy M
onito
ring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:- Right Sources
- Right Granularity- Right Measurements
Predict:- Baseline
- Production Output- Energy and Carbon cost
Calculate:- Production vs. Non-Production
WAGES and Emissions- Actual cost of WAGES and GHG
Analyze + Report:- Baselines, Production,
Output, Targets, and Regulatory limits
- KPIs and Benchmarks
Visualize : - Energy usage against production
output- Compare performance across multiple facilities
Ener
gy M
onito
ring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
What is already available? Data in different data sources
Historian PLC Energy solution Intelligent Motor Control
Where to start? Define and document areas, machines, products
with highest energy demand What’s needed to get a clear picture?
Can we get more data from PLC’s? Where do we need new power monitors?Mon
itor +
Mea
sure
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
SQL Server
Control System
Energy
Physical model
Datapoints
Organized Information
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:- Right Sources
- Right Granularity- Right Measurements
Predict:- Baseline
- Production Output- Energy and Carbon cost
Calculate:- Production vs. Non-Production
WAGES and Emissions- Actual cost of WAGES and GHG
Analyze + Report:- Baselines, Production,
Output, Targets, and Regulatory limits
- KPIs and Benchmarks
Visualize : - Energy usage against production
output- Compare performance across multiple facilities
Ener
gy M
onito
ring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy consumption Baseline per area, line, machine, product, … Listing of energy efficiency of lines and machines
Production Output per area, line, machine, product, …
Energy and Carbon cost W.A.G.E.S – detailed cost prediction Carbon cost
Def
ine
the
base
-line
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Data must be plotted on a graph in order to define the general consumption base-line
Consumption rates are plotted in a scatter plot against production or any other variable previously identified, and the best fit line is identified.
This graph is the image of the business average energy performance
Def
ine
the
base
-line
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:- Right Sources
- Right Granularity- Right Measurements
Predict:- Baseline
- Production Output- Energy and Carbon cost
Calculate:- Production vs. Non-Production
WAGES and Emissions- Actual cost of WAGES and GHG
Analyze + Report:- Baselines, Production,
Output, Targets, and Regulatory limits
- KPIs and Benchmarks
Visualize : - Energy usage against production
output- Compare performance across multiple facilities
Ener
gy M
onito
ring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Moulding Area Packaging Area
Plant
Calculated energy information
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Equi
pmen
t Ene
rgy
Effic
ienc
y
BoilerFuel input 100% + Air
Ste
am o
utpu
t
Flue
Gas
Wat
er
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:- Right Sources
- Right Granularity- Right Measurements
Predict:- Baseline
- Production Output- Energy and Carbon cost
Calculate:- Production vs. Non-Production
WAGES and Emissions- Actual cost of WAGES and GHG
Analyze + Report:- Baselines, Production,
Output, Targets, and Regulatory limits
- KPIs and Benchmarks
Visualize : - Energy usage against production
output- Compare performance across multiple facilities
Ener
gy M
onito
ring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Provide energy managers with feedback on operating practices, results of energy management projects
Guidance on the level of energy use that is expected in a certain period
Give early warning of unexpected excess consumption caused by malfunctions, operator error, unwanted user behaviors and maintenance errors
“you cannot manage what you cannot measure”
Mon
itorin
g &
Tar
getin
g
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 21
Primarily a management technique that uses energy information as a basis to Eliminate waste Reduce current levels of energy use Improve existing operating procedures
Combines the principles of energy use and statistics Monitoring is aimed at establishing a pattern of consumption Targeting is the identification of desirable energy levels
Allows users understand what drives energy consumption Production? Weather? Hours of Operation?M
onito
ring
& T
arge
ting
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 22
Mon
itorin
g &
Tar
getin
g
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Alig
n En
ergy
Dat
a w
ith P
rodu
ctio
n D
ata
Energy and Production data
Production
Context Information
Software
IMPROVEDDecision Making
Decision
People
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:- Right Sources
- Right Granularity- Right Measurements
Predict:- Baseline
- Production Output- Energy and Carbon cost
Calculate:- Production vs. Non-Production
WAGES and Emissions- Actual cost of WAGES and GHG
Analyze + Report:- Baselines, Production,
Output, Targets, and Regulatory limits
- KPIs and Benchmarks
Visualize : - Energy usage against production
output- Compare performance across multiple facilities
Ener
gy M
onito
ring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Visualize: Key Performance Indicators
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Visualize: Real-time Dashboards
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 27
Fast and cost effective resolution Unexpected overspend Quick notice through email notification Remote adjustments Cloud based solutions possible
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Plant Floor Operator
Equipment / Line
Production Management
Plant
Enterprise
Executive
Rol
e-ba
sed
spec
ific
Info
rmat
ion
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy Management
activities
Fix Air Leaks
VFD’s on Pumps, Fans,
Dampers
Fix Steam Leaks
Influence behaviors
Energy Efficient Motors
Energy Efficient Lighting
Power Factor
Correction
Change production schedule
Stra
tegi
es im
plem
ente
d
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
Performance
Control System
Energy
Information Portal
Electrical power consumption was 15% above plan – solved! Utilized compressor built in timer to
shutoff during non production periods
Reduced operating distribution pressure from 7.4 bar to 6.8 bar. No impact on OEE!
Consumption reduced and stays within base line!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
Maintenance
Control System
Energy
Information Portal
Spike in Energy Consumption over a number of days – solved! Maintenance changed replacement
procedure of parts - increasing time between part maintenance.
After alignment of Maintenance schedule with Energy usage consumption went down again
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
Maintenance
Control System
Energy
Information Portal
Current energy bill much higher than expected – solved! The discrepancy was caused by the Utility
provider billing the customer of an incorrect meter where EnergyMetrix was creating the "Shadow Bill" from the correct meter.
Customer received a substantial refund from Utility Supplier in the region of €300,000
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy Intelligence
33
Customized examples
Trend
Excel Reports
Dashboard
Demand charts
Demand vs. consumption charts
48hr dashboard
Tabular reports
Real time access to Power Meters Demand and
consumption reporting
Advanced billing capabilities
Power Quality reporting and analyses
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
One central Information Portal
Rich template and report library
RSEnergyMetrix® connector now corecomponent of VantagePoint
All RSEnergyMetrix reports can be attached to the physical model of the plant
Ener
gy In
tellig
ence
Impact on performance can immediately be measured
Role based specific information
Mobile ready
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 35
PM 1000PowerFlex® Drives
Power Control Components
PM 5000
IntelliCENTERIntelligent
Motor Control
EtherNet/IP
Logix Controller
Dire
ct co
nnec
tion
with
Roc
kwell
dev
ices
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Global food manufacturer Building the department and line structure as model in
FactoryTalk® Vantage Point®
Using Vantage Point to connect to data sources with the built-in connectors
Generating KPIs and reports to summarize the relevant data on a weekly or monthly basis with the built-in Excel Add-In
Publishing the reports in the FactoryTalk VantagePoint Portal to make them available to the relevant user groups
Set-up and generation by the local customer staff supported by Rockwell Automation – very low budget for the project with a direct return on investment!
Easy to extend - include additional data sources and contextVant
ageP
oint
for U
tiliti
es R
epor
ting
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Reports of the department PH KPI Energy Report Consumptions last week Weekly Report accessible
Departments (Consumers) The types have an additional sub group
plant/lineMonthly Consumptions Report is generated automatically at the end
of the month and published in the portal
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Weekly Report Steam Generation
Weekly Report Purified Water Generation
Specific Energy Consumptions (e.g. Pressurized air
in the department PH)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Total Energy Consumption in department PH in the last 7 days
Via a link in the report, trend based analysis can
be conducted
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Summary Customer uses mainly existing energy data from two 3rd party
Historians
Data organization/structuring in VantagePoint model
Cryptic lists of data points turned into mean full and structured information
Data points with mean full names and comments
Data points attached to the physical plant model
Energy manager is able to create reports, trends and dashboards on his own
First improvements directly after implementationVant
ageP
oint
for U
tiliti
es R
epor
ting
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Accurate visibility of energy consumption of your assets
Compare energy efficiency across plants and assets with normalized data
Analyze energy usage trends compared to historical patterns and forecasts
Trigger alerts from unexpected deviations
Prioritize actions and investments based on financial and operational parameters
Make more with less!
Increasing Energy Efficiency is Team Work!We deliver the information, which enable
your team to be successful!Ove
rcom
e th
e C
halle
nge
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
TechED Labs
Related RSTechED 2014 sessions
Energy University: Energy Intelligence with FactoryTalk EnergyMetrix Hands on Lab
Introduction to FactoryTalk VantagePoint and Enterprise Manufacturing Intelligence
FactoryTalk VantagePoint EMI: 50 Minutes to Value
FactoryTalk VantagePoint EMI Basic Lab: Building an Information System
Mobility and Portability with Today's Rockwell Software
Introduction to FactoryTalk Historian: Overview Strategies for Collecting and Analyzing Data
FactoryTalk VantagePoint EMI: 50 Minutes to Value
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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