2014 Software Global Client Conference

Energy Performance

Solutions for Plants.

Solutions for each step in

your journey.

WW INFO-03

Michael Munro

Strategic Marketing - Power Software

and Systems

Christian-Marc Pouyez

Product Manager – Intelligence & CEM


The Schneider Electric approach to Energy Management

How do we deliver Energy Efficiency projects?

Step 3: Look for improvements.

Discover the root cause of energy over-consumption in order to improve energy efficiency.

Energy Improvement &

Optimization

Step 4: Plan for sustainability.

Track opportunities and identify projects for continuous improvement.

Ste

p 1

: S

ite E

nerg

y A

ssessm

ent

Continuous Improvement

& Sustainability Strategies

Energy Awareness

Energy Improvement

Energy Performance

Step 2: Become energy aware.

Get a detailed view of the energy used in the process using energy aware infrastructures.

Energy Control &

Monitoring

What is happening? Why is that happening? How can we sustain it?

External analysts agree: energy management is a journey

Energy Awareness

Energy Improvement

Energy Performance


Scenario 1: Energy Awareness


Brian

Energy Manager

Wonderbrew Inc.


Current Situation:

• Already completed some

efficiency projects – where next?

• Energy data scattered, multiple

tools, incomplete picture

• Manual reporting – time

consuming

Objectives:

• Better visibility with standardized

tools across all utilities

• Save time reporting to corporate

• Baseline current energy usage

• Satisfy a limited audience:

engineering & management

Corporate Goal

Reduce energy consumption by 10% in a year

2014 Software Global Client Conference 9

How to start - establish a plan and commit

http://www.energystar.gov/buildings/about-us/how-can-

we-help-you/build-energy-program/guidelines

Energy Management is a journey!


Site Energy Assessment

●Baseline energy use and cost history from utility

bills

● Identify and prioritize the energy types

(WAGES)

● Identify key areas of high energy consumption

● Understand your energy flows in relation to

industrial processes

● Survey existing metering available and identify

requirements for additional metering

● Identify key stakeholders


●Metering: the foundation

● Close the key data gaps

● Additional metering can be added in future

●Software & communications

● Data network – bring it all together

● Automatic data collection and storage

● Time-interval logging aligned with utility

● All utilities stored in central repository

● Use a common data model across all data sources

● Consider data quality

Energy Control & Monitoring “You can only manage what you can measure”


●Use, understand, and share the data

● Begin to see patterns and trends

● Sometimes unexpected…energy use is often hidden

●Basic reporting:

● Energy consumption trends – when am I using energy?

● Energy consumption by hierarchy – where am I using energy?

● Energy comparisons – by process, equipment, time

● Custom reports

Energy Control & Monitoring Reporting and visualization


Solution functional overview

Production

and Energy I/Os

Visualization

and Analysis

Reports

Configuration

and Management

Meter Config.

Hierarchies

Data Storage

Data Acquisition

Energy

Database

Direct Meter

Acquisition

Real Time Data

Acquisition


Sample Reports


Benefits:

Key areas of the plant are measured

for energy consumption

Easy access to data with automated

reporting from a central location

Ability to justify and prioritize specific

energy conservation measures

Objectives:

Better visibility with standardized tools

across utilities

Limited audience: engineering &

management

Provide reports to corporate

Baseline current energy usage

Solution benefits


Case Study

European consumer goods

manufacturing plant

Situation:

• Corporate mandate to reduce energy use in

the plant

• Multiple systems

• Many existing meters not being read

Solution:

• 81 Schneider Electric power meters

• Schneider Electric PLCs to record energy

pulses from water, gas, electrical meters

• Power Monitoring Expert software to collect

and visualize data

Results:

• Centralized tool to collect and manage all energy data

• Ability to support and justify energy efficiency projects

• Ability to allocate the energy costs to production


Scenario 2: Energy Intensity


Brian

Energy Manager

Wonderbrew Inc.


Current Situation:

• Metering and reporting are active

• Single Tool

• Lots of data, spending lots of time to

understand data

• Good days, bad days, not able to

explain why

Objectives:

• Understand what is driving the

energy consumption

• Identify opportunities for systematic

improvements

• Define realistic targets per process

area

• Raising awareness in the facility:

broader audience

Corporate Goal

Reduce energy intensity by 10% in a year


●Central repository extended to capture:

● Production events (batch start/stop, etc)

● Production output – how much

● Other context: Product type, Order number, Shift

●Combine energy with production context:

● Energy use per unit of output – efficiency

● “Typical” use can now be understood in context of production

● Energy usage more predictable

Energy Control & Monitoring Add production context to energy data


● Identify the main drivers for energy consumption

● Production volume, production type, weather influences, etc

●Using historical data, define targets for key areas

● Targets can be at process level or down to specific metering points

●Provide visibility of actuals and targets to the right people (actionable)

● Real-time dashboards

● Daily reports

Energy Control & Monitoring Set baselines and targets



Production

and Energy I/Os

Visualization

and Analysis

Reports HMI Displays Dashboards

Configuration

and Management

(web based)

Meter Config.

Hierarchies

Targets Definition

Data Storage

Data Acquisition

Energy

Database

Direct Meter

Acquisition

Real Time Data

Acquisition


Sample Visualizations


Benefits:

Start managing energy as a variable

cost (not a fixed cost)

Sustain energy use reductions using

targets

Drive accountability on energy use

with broader visibility on energy KPIs

and targets

Solution benefits

Objectives:

Understand what is driving the energy

consumption

Identify opportunities for systematic

improvements

Define realistic targets per process

area

Raising awareness in the facility:

broader audience


Case Study Coca-Cola

Swaziland

Conco Ltd

Situation:

• Goal to reduce energy consumption by 20%

in one year

• Emphasis on reducing consumption

holistically (no accountability)

• Energy users not empowered enough to take

control of situations

Solution:

• Wonderware System Platform with CEM and

SmartGlance

• Monitoring of Water, Air, Electricity and

Steam.

• Implementation of smarter energy usage/cost

control protocols

Results:

• Improved visibility into energy usage and cost by area of the plant,

• Ability to control high-energy operations to take place during low-cost periods

• Personnel awareness of their immediate impact on energy cost

Above all resulted in reduction of energy consumption


Scenario 3: Power Quality


Cathy

Facility Maintenance Engineer

Wonderbrew Inc.


Current Situation:

• Variable speed drives going offline

• Motors overheating

• Breakers tripping randomly

Objectives:

• Maximize reliability of electrical

supply to the process

• Optimize electrical equipment

performance & utilization

• Reduce maintenance costs

Corporate Goal

Reduce electrical downtime in production by 10%


● Install power quality metering at main and critical loads

● Advanced meters capture harmonics, voltage dips, surges

● Blink of an eye: tenths of a second

● Magnitude, duration, signature are all important

●Analyze root cause

● Harmonic loads, internal vs external

● Implement mitigation solutions

● Power conditioning equipment, utility remedies

● Continuous monitoring to track over time

Energy Improvement & Optimization Improve Power Quality


Solution functional overview Visualization

and Analysis

Reports Dashboards

Energy & Power Analytics and Business Logic

Configuration

and Management

(web based)

Meter Config.

Hierarchies

Data Storage

Data Acquisition

Energy

Database

Smart Meter Log

Acquisition


Benefits:

Reduce production downtime due to

electrical failures and motor faults

Reduce MTBF of equipment

Increase Overall Equipment

Effectiveness (OEE)

Reduce energy waste

Solution benefits

Objectives:

Maximize availability of electrical

supply to the process

Optimize electrical equipment

performance & utilization

Reduce maintenance costs


Case Study

Leading Manufacturer of

Consumer Packaged Goods

Situation:

• Production line stoppages due to unknown

reasons

• 3 – 8 hours of downtime to restart process

• Loss of $20k per hour of lost production

Solution:

• Initial assessment by Schneider expert

• Advanced PQ meter installed on main incomer

• 25 power meters with harmonics measurement

installed on distribution panels

• Schneider Electric power monitoring software

Results:

• Identified electrical transients from upstream (utility) source

• Proof captured by system provided leverage to compel response from utility operator

• Same system was able to be used to collect energy baseline for the facility and allocate costs

to production units


Scenario 4: Energy Cost


Robert

Facility Manager

Wonderbrew Inc.


Current Situation:

• Monthly utility bill, paid by

accounting, fixed cost

• Not full understanding of what is

driving utility cost beyond

consumption

Objectives:

• Better understanding of utility bill

(electricity)

• Reduce penalties

• Allocate costs to departments to

drive accountability

Corporate Goal

Reduce plant electrical bill by 10% this year


●Review and understand utility rates and impact on your bill

● Most are complicated and include several different types of charges

● Time of use charges, demand charges, power factor

● Ensure your metering infrastructure can provide this data

● Implement demand management

● Can be 30% of electrical bill

● Strategies range from minor process change to utility demand response

●Validate your bills and allocate costs

● Reconcile your data with utility data – sometimes there can be errors

● Allocate costs to drive accountability – not only about conservation

Energy Improvement & Optimization Optimize electrical costs



Production

and Energy I/Os

Visualization

and Analysis


Configuration

and Management

(web based)

Meter Config.

Hierarchies Rates Definition

Data Storage

Data Acquisition

Energy

Database

Smart Meter Log

Acquisition

Real Time Data

Acquisition



Benefits:

Reduce energy costs by avoiding

unnecessary demand peaks and

higher ratchet levels

Reduce penalties due to proper

identification of power factor issues

Drive accountability of departments

by a fact-based allocation of costs

Solution benefits

Objectives:

Better understanding of utility bill

(electricity)

Reduce penalties

Allocate costs to departments to drive

accountability


Case Study

Corporate campus

Building products manufacturer

Situation:

• 150 acre campus with mix of office, lab,

and pilot manufacturing facilities

• New utility Demand Response (DR)

programs

• Desire to use existing emergency backup

capacity to exploit DR opportunities

Solution:

• Schneider Electric power monitoring

system

• Schneider Electric revenue-accurate

metering to prove compliance with utility

programs

• Real-time reporting to track actual load

curtailment to verify performance

Results:

• Campus able to interrupt 80% of peak summer electrical load within 2 hours, without impact to

business operations

• 12% annual reduction in electrical costs sustained over 3 years


Energy Performance is a journey!

Corporate

Meet standards, goals, compliance

Regional Management

Integration of energy and sustainability information for decision making

Individual Plants Monitor KPIs, Optimize Energy Usage

Enterprises need to consider top to bottom….

Plant-level

Energy Efficiency

Enterprise Level

Digital Energy Services Platform

Corporate


Regional Management



Plants need an individual journey with a standardized

approach

Plant-level

Energy Efficiency


Plant Energy Performance – a modular approach

Production

and Energy I/Os

Visualization

and Analysis


Configuration

and Management

(web based)

Meter Config.

Hierarchies Rates Definition

Targets Definition Data Editing

Data Upload

Data Storage

Data Acquisition

Energy

Database

Smart Meter Log

Acquisition

Real Time Data

Acquisition


Goals: • Optimize

Consumption

• Maximize availability

& utilization of energy.

Collaborative architecture bridging silos to yield

optimized plants & processes.

Goals: • Optimize Production

• Maximize availability

& utilization of assets.

We are building on our shared experiences in energy

management

Devices & I/Os

Energy Monitoring

Process Control

Energy Control

Process SCADA

Energy SCADA

Process MES

Energy Analytics

Plant Energy Performance: Reduced energy consumption per unit of production and improved plant efficiency

Broad portfolio of energy management products and solutions, with deep energy

management expertise

Energy Control & Monitoring

Process Control & Automation


Next Steps for Plant Energy Performance

●Research phase – customer value and technical feasibility

●Voice of Customer – your chance to influence the product roadmap

●Validation – beta customers to pilot the solution – could it be you??


An update on Wonderware CEM


CEM 2014 R2 To be released in Fall 2014

• Full support of Application Server Redundancy

• New Demand Attribute in Meter object

• Easier installation and configuration

• Documentation improvements and addition of offline documentation

• The most robust version ever!

• Technology Update:

•System Platform 2014 and possibly 2014 R2

•Windows and SQL Server support, in line with System Platform 2014 R2


To learn more…

Corporate


Regional Management



Enterprises need to consider top to bottom….

Plant-level

Energy Efficiency

Enterprise Level

Digital Energy Services Platform For more information…

For more information, come and see us at Expo

Christian-Marc Pouyez

Michael MacKenzie

Peter

Hogg

Kim Custeau

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