information is the key to unlocking energy savings · unlocking energy savings presenter: rosanne...

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Information is the key to unlocking Energy SavingsPresenter: Rosanne Sabiston, Power Control Business Manager

2017 WEA AUSTRALIAN CONFERENCE – Production & Applied Technology


Defining Energy : W.A.G.E.S

� Energy Components :

� Water / Wastewater

� Air

� Gas

� Electricity

� Steam

� Energy costs can be 20 percent of Cost of Goods Sold for food & beverage plants

� Energy should be thought of as an INGREDIENT

� Information can tell you how much of that ingredient is required for products you make (effectively becomes an input into a recipe)

� Sustainability is a part of your BRAND: H&M Clothing example


World-wide energy consumption will increase over

70% 2035by

Why Energy Management?

3


Why Manage Industrial Energy?

Source: US Energy Information Agency:

Energy management can result in significant savings

�Over 60% of Fortune 100 companies have made public commitments to reduce energy

� 195 countries participated in the 2015 UN Climate Change Conference

� Less than 5% use software to track and analyze energy data

Global Energy Usage by Sector


The key to reducing energy-relatedexpenses is understanding

where, when and how much is being consumed.


Impactful results BEGIN WITH A PLAN

6


Leadership

• Establish goals & objectives – get everyone involved in wanting to do this (so you can celebrate success!)• Select collaborating companies – who can help you get there?

Education

• Equip personnel on how to assess opportunities & make improvements levering new technology• They must know where, when and how much is being consumed today.

Projects

• Effective project scoping of energy solutions• Successful execution and adoption of energy saving projects

Visibility

• Establish an energy information system and base line – relate energy to activities/processes• Understand and set metrics (so you can celebrate success!)

Control

• Coordinate activities and control processes to proactively reduce energy consumption

Your Energy Management Strategy

Continuous analysis &

Improvement

Foundation:Information


Electric Motors

� An easy target for energy cost savings!


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Building an Informative Platform

� Here are some cost effective and starting points for building up intelligence on what your motor electricity costs are:

� Power Monitors

� PowerMonitor 5000

� Intelligent Motor Control Devices

� E300 Intelligent Overload Relays

� PowerFlex® Variable Speed Drives

� Linking process control to Intelligent Electrical Devices

� Prosoft 61850 gateway modules


PowerMonitor 5000

� Monitors 4 voltage and 4 current channels for every electrical cycle

� 1024 data points across 8 channels every 12-17 milliseconds

� Calculates over 6,000 parameters every cycle

� Why do you need one?

� Provides an extensive array of power quality information to help you understand issues coming into and throughout your facility.

� You can only do something about your Power Quality issues if you know what they are. How do you size generators today?

� How much will it cost?

� ~$2-5k, depending on the model you choose

� http://ab.rockwellautomation.com/Energy-Monitoring/1426-PowerMonitor-5000#documentation


Power Monitoring Architecture

� PowerMonitor™ 5000

- Main Input Meter- Point of Use Metering

FACTORY FLOOR


- Sub Metering- Point of Use Metering


- Point of Use Metering- Sub Metering


PowerFlex® Variable Speed Drives

� http://ab.rockwellautomation.com/Drives

1


VSD Energy Savings Calculator for Pumps & Fans

� http://www.rockwellenergycalc.com/


E300 Intelligent Overload Relay

� It does more than protect your motor!� Real-time diagnostics are transformed into actionable information which maximizes your up-time and protects your assets.

� It will save you on energy costs� Provide power values (kW, kVAR, kVA, and PF), energy values (kWh, kVARh, and kVAh), and demand values (kW, kVAR, and kVA). This data should be collected at a minimum of 15 minute intervals.

� http://www.rockwellautomation.com/global/news/blog/detail.page?docid=834992cd408b3d1f186a135ce240d673&G11N/Locale=en&geography=global&content_type=blog&pagetitle=Electronic-Relay-|-Blog

� Using this detailed load profile information, a facility can better understand what is causing the base energy consumption for a facility and identify areas where to reduce it , for example:

� turning off exhaust fans during non-working hours,� lowering thermostats to prevent chillers from operating during non-working hours,

� identifying air leaks in compressed air systems, etc…� At less than $1k each, this is a very cost effective starting point!


ProSoft TechnologyEtherNet/IP to IEC 61850 Gateway

� Enables communication between the Intelligent Electronic Devices (IEDs) on an IEC- 61850 network and Programmable Automation Controllers (PACs) on an EtherNet/IP network.

� Bridges the gap between Process and Electrical systems

� Enables automatic coordination of Power Supply and Process Operations

http://www.ab.com/db/encompass/bps_dir_update.show_page?x_directory_id=10533&x_region=ASIA


Typical Process & Electrical Automation

Process Control System

VISUALIZATION

ARCHIVING

REPORTINGElectrical SCADA System

Industrial ComputerDCS/PAC

ARCHIVING

REPORTING

VISUALIZATION

INTELLIGENT MOTOR CONTROL INTELLIGENT ELECTRICAL DEVICES


� Motor Status

� Application Voltage and Current

� Motor Speed

� Motor Temperatures

� Process Set Points

� Process Alarms and Events

� Power Factor

� Voltage & Current at various locations in distribution system

� Harmonics at Point of Common Coupling

� Switch and Transformer Status

� Local Generation Control and Status

� Power Quality

� % Loading

� Power System Alarms and Events

Typical Process & Electrical Automation

Process Control System Electrical SCADA System

Bi directional data sharing between

Intelligent Devices canincrease productivity


Unified Power and Automation

OPTIMIZESRESOURCE MANAGEMENT

IMPROVESSYSTEM RESILIENCY

ENHANCESSAFETY & EMISSIONS MONITORING

� Use single time-synchronized communication infrastructure� Utilize Object Based Logix Capabilities (UDTs, EDS, AOPs/AOIs, Faceplates)

� Realize better load management� Accurately allocate energy cost to process with advanced energy metering

� Monitor insulation breakdown & thermal limit violation� Achieve dynamic load shedding� Measure energy vs. planned equipment life

� Limit exposure with remote control & monitoring� Anticipate air gap breakdown / arc flash� Proactively respond to weather conditions� Reduce emissions

UNIFIESAUTOMATION PLATFORM


In Summary : Why does all this matter?

� Energy cost is rising. Energy reliability is poor.

� The future:

� You may be told when you can and cannot run.

� We will all need to be more coordinated in how and when we consume energy

� Energy storage is available today – can you use it? How much do you need?

� Use information from smart devices to understand how you operate today

� The future of consumers

� They will want to know you are helping our planet! It’s your brand at stake

� You will need this data to help your consumers buy your product

� E.g. My wine is better than X wine because my carbon footprint per bottle is better!


Additional resources to help you start

� “How a Well-Planned Strategy Can Help the Food & Beverage Industry More Effectively Manage Its Energy-Related Costs” : https://lnkd.in/ghshMTt

� Energy Savings Calculator: http://www.rockwellenergycalc.com/

� Rockwell Automation – Building Blocks for Energy Savings

� Smart Devices: Powerflex Drives, Power Monitors – PM5000; Intelligent overload relays – E300; Centerline 2500 MCC; Prosoft gateway 61850

� Information Software: FactoryTalk (FT) Historian, FT EnergyMetrics, FT Analytics,

� Control: CompactLogix, Logix, Pavilion8 Advanced Process Control,

� Integration: Connect Power information with Process information: use Prosoftgateway into Logix AOPs and faceplates.

� Contact: Alan Ford, Rockwell Automation – Adelaide Office: [email protected]

information is the key to unlocking energy savings · unlocking energy savings presenter: rosanne...

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