Energy University: Intro to Energy Intelligence

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Energy UniversityIntro to Energy Intelligence

What’s the idea?

Make more with less!

Energy cost 30% of

operational cost


How much Energy do we spend

per machine, area, product, …?

Where to save Energy

without impact on performance?


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


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


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?


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


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


Historian

SQL Server

Control System

Energy

Physical model

Datapoints

Organized Information




Predict:- Baseline









Ener

gy M

onito

ring


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


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




Predict:- Baseline









Ener

gy M

onito

ring


Moulding Area Packaging Area

Plant

Calculated energy information


Equi

pmen

t Ene

rgy

Effic

ienc

y

BoilerFuel input 100% + Air

Ste

am o

utpu

t

Flue

Gas

Wat

er




Predict:- Baseline









Ener

gy M

onito

ring


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


Mon

itorin

g &

Tar

getin

g


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




Predict:- Baseline









Ener

gy M

onito

ring


Visualize: Key Performance Indicators


Visualize: Real-time Dashboards


Fast and cost effective resolution Unexpected overspend Quick notice through email notification Remote adjustments Cloud based solutions possible


Plant Floor Operator

Equipment / Line

Production Management

Plant

Enterprise

Executive

Rol

e-ba

sed

spec

ific

Info

rmat

ion


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


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!


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


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


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


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


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


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


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


Weekly Report Steam Generation

Weekly Report Purified Water Generation

Specific Energy Consumptions (e.g. Pressurized air

in the department PH)


Total Energy Consumption in department PH in the last 7 days

Via a link in the report, trend based analysis can

be conducted


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


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


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


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Energy University: Intro to Energy Intelligence

Technology

Transcript of Energy University: Intro to Energy Intelligence