5 secrets to a successful energy intelligence strategy · these strategies can potentially reduce...

$: 5 Secrets to a Successful Energy Intelligence Strategy · These strategies can potentially reduce en\rgy usage by up to 30%.\爀屮\爀屮On the plant floor, about 50% of the energy$
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

5 Secrets to a Successful Energy Intelligence StrategyWebinar

Jan PingelProduct Manager, Energy IntelligenceOctober 16, 2013

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

50%World-wide energy consumption will increase over

BY 2035SOURCE: LNS RESEARCH

Reduce speed 20%,save 50% energy

On plant floor

50%of the energy

consumed is by electric motors.

Presenter

Presentation Notes

SUSTAINABLE An important aspect of Sustainability in a Connected Enterprise is the reduction of energy consumption and becoming more sustainable. A recent LNS Research study cites that world-wide energy consumption will increase over 50% by 2035. This is driving the industrial sector to develop strategies around Energy Intelligence. These strategies can potentially reduce energy usage by up to 30%. On the plant floor, about 50% of the energy consumed by electric motors. We need to start looking at energy as we do Safety; it’s a more sustainable way of doing business. Our Intelligent Motor Control offerings, including digital drives and motor control centers, can help provide a more sustainable plant floor environment. Variable Speed Drives, can help to reduce energy consumption over more traditional full voltage solutions. through adoption of variable speed control. For example, just reducing the speed of a variable torque application by 20% can save up to 50% in energy consumption Another example, our IntelliCENTER Motor Control Center offering comes preconfigured with our FactoryTalk EnergyMetrix software. This allows for real-time monitoring of energy down to the device level, and the ability to manage energy consumption at the point of use. Looking forward, Rockwell Automation is actively engaged with ODVA to drive a standard for representing power & energy in a wide range of industrial devices. These activities will enable a consistent methodology to design, monitor and control energy applications. <CLICK>


Leading global provider of industrial power, control and information solutions

Leading global provider of industrial power, control and information solutions

Rockwell Automation At A Glance

3

Fiscal 2012 Sales$6.26 Billion> 50% outside the U.S.22% in emerging markets

Two Segments – One BusinessArchitecture & SoftwareControl Products & Solutions

Global Reach22,000 employeesPartnerNetwork™80+ countries

Serving Customers for 100+ YearsCulture of integrity & corporate responsibilityDomain expertiseTechnology innovation

Presenter

Presentation Notes

Our value-driven approach has helped Rockwell Automation become a leading global provider of industrial power, control and information solutions.� And our $6.26 billion business continues to grow our worldwide presence. More than fifty percent of our sales are from outside the United States – about twenty-two percent of which come from emerging markets. Our company is comprised of two segments – Architecture & Software and Control Products & Solutions – which operate as one business. To deliver solutions in more than eighty countries, our 22,000 employees team with our global PartnerNetwork, which includes distributors, system integrators and OEMs.� At Rockwell Automation, we remain keenly focused on these tenants, which have fueled our history of success: Integrity and corporate responsibility Domain expertise And technology innovation


Global Leadership & Recognition

Top 100 Innovative Companies

4

Top 100 Global Innovators

World’s Most Ethical Companies

Better Business Bureau International Torch Award

Top 100 Company Sustainable Performance Leader

Company Index Corporate Responsibility

Most Sustainable Companies

Innovation Ethics & Integrity

Corporate Responsibility & Sustainability

Presenter

Presentation Notes

Our team’s pursuit of excellence and commitment to doing the right thing have been recognized by a range of organizations. Rockwell Automation is credited with a number of achievements.� For example, our company was cited as a leading innovator by both Forbes and Thomson Reuters.� And for the fifth time, Rockwell Automation was named one of the world’s most ethical companies by Ethisphere. In addition, the Council of Better Business Bureaus (BBB) presented Rockwell Automation with the International Torch Award for Marketplace Excellence. � Our global commitment to building a more sustainable future was also recognized by our selection to a number of well-respected indices, including the Justmeans Global 1000, the FTSE4 Good Index and the Dow Jones Sustainability North America Index. �

http://images.google.com/imgres?imgurl=http://www.sumitomotrust.co.jp/IR/company/jp/images/index/FTSE4Good.jpg&imgrefurl=http://www.sumitomotrust.co.jp/IR/company/index_en.html&usg=__--p3J-xHJKDhHnVCTTvL2mqrJ4U=&h=3823&w=4724&sz=976&hl=en&start=3&tbnid=4NWOTvrEh2USOM:&tbnh=121&tbnw=150&prev=/images?q=FTSE4+Good&gbv=2&hl=en


5 Secrets to a Successful Energy Intelligence Strategy

5


Market Drivers

Cost Volatility• Reduce costs• Maintain Competitive

Advantage• Predictability of prices

Government Regulations• Compliance to current and

future regulations

Supply Scarcity• Resource constraints• Energy reliability and

availability

Sustainability• Corporate initiatives• Brand protection

Presenter

Presentation Notes

Innovation is critical to helping meet key global imperatives like Energy, Globalization, Agility, and Economic challenges At Rockwell Automation, these challenges and needs for innovation are a part of how we do business To address these challenges RA has and continues to innovate with: Multi-Disciplined control platforms such as Logix Products built on open systems & Standards Productivity tools to shorten the time to value World class Support, Maintenance and Migration tools

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 7

Business Drivers

LNS Research Industrial Energy Management Research, 2013

Improved economics is the primary driver for energy management

Presenter

Presentation Notes

In a recent LNS study it was found that Manufacturers are starting to look at Energy Management as a means to save cost and increase efficiency …. Energy is no longer considered overhead … it is a manageable resource!


Top Energy Management Challenges

LNS Research Industrial Energy Management Research, 2013

Your Automation vendor can help address these

challenges

Technology related


Energy Management Maturity Curve

Energy Awareness

Energy Awareness

Energy Efficiency Energy

Efficiency

Energy Optimization

Energy Optimization

9

Three Stages Most Companies Experience

• Energy no longer just “cost of doing business”

• Energy Monitoring in place

• Energy cost allocated across all departments • Energy Awareness

program in place• Initiatives to reduce energy

usage in place• Energy usage associated

with production is understood and monitored

• Continuous Improvement for energy is ongoing

• Energy is viewed as Cost of goods sold (COGS)

• Energy cost savings programs - Demand Response and Load Shedding are in place

Presenter

Presentation Notes

Energy Awareness – understand there is a problem/opportunity. Might have some metering in place Energy Efficiency – taken step to implement: shadow billing, base load analysis,


The Pressure to Improve Productivity How your control system can help

10 10

v

MANUFACTURINGASSETS

Data

Waste

Product

Raw Materials

TimePeople

Energy

To improve Productivity, you need actionable information. Your control system contains a hidden wealth of information.

Presenter

Presentation Notes

As we know, any manufacturing process has inputs and outputs. Inputs would not only be the raw materials used to produce the finished product, but also Human Resources, Time, and becoming very important lately, the Energy used in the manufacturing process itself. We’re also familiar that the outputs will be good product and unfortunately some scrap or waste. However, a tremendous side benefit of an Information-Enabled control platform such as Logix & Integrated Architecture is the data that is generated. This data can be utilized to learn more about the process itself for the purpose of improving productivity Manufacturing Intelligence is the term we use when we turn data into real knowledge (information), and drive business results based on that knowledge.


Energy and Production data

Production

Context Information

Software

IMPROVEDDecision Making

Decision

People

Energy IntelligenceAligning Energy Usage with Production Data

Presenter

Presentation Notes

Software which brings production data from many sources for reporting, analysis, and visualization Data combined from multiple sources provides context will help users find what they need Turn data into real knowledge (information), and drive business results based on that knowledge Maps energy data from multiple energy meters into logical units Combines relevant energy data with manufacturing data from multiple sources to present the entire picture References energy and production data directly at its source�“Single Version of the Truth”


Connect to the Right Data


What Impacts Energy Usage?

13

61FMonday Milwaukee

66F 30 in 49F 0.00 in

Production

Operation Execution Equipment Efficiency

Presenter

Presentation Notes

Some other factors as well: Pricing, specific process based variables, etc. Note: Doesn’t mean you reduce your energy by produce less – Operations: Changing behaviors …


Identifying Energy Related Sources

14

Energy Consumption Data

Equipment Process Data

kWh / day

Production Data

Maintenance Data

Environmental Data

Production Schedule

Presenter

Presentation Notes

Energy Consumption and demand data Production data: Output, Schedule, Quality, etc. Environment data: NOAA, local weather station, facility weather station User data, Shift data, set point data, process data etc. OEE data Maintenance data Equipment process data Production data


Plant Management

Maintenance

Control Engineering

Quality

Machine Builder

Scheduling

Information Technology

Planning and Logistics

Operator

Knowledge Worker

How will you use Energy information? Understand what data is needed and where

How much energy is consumed to make

this product?

What are the energy intensive

processes?

How do we avoid costly energy demand charges?

How do I increase throughput while

reducing energy usage?

How to ensure uptime and reduce

energy cost?

How do I create a more energy

efficient machine?

Presenter

Presentation Notes

In a typical manufacturing plant there are numerous daily questions that needs to be answered in order to fully understand and manage energy usage and looking at potential for savings and optimization. You might recognize some of these questions from your own experience …


More Than Just Electricity

16

Water

Mega Liters consumed, Discharged

Gallons of Water per unit of Product Produced

Air

Air Flow,

Pressure,

kWh’s consumed

Gas

Gas Consumption

Electricity

Demand Management

Load Profiling

Power Factor Control

Steam

Mass, Energy, Net Steam,

Heat Differential,

Presenter

Presentation Notes

When we talk about EM – it is not just electricity, but all your wages …


Correlate Energy to Production


Energy Information at the Site/Area level

Metered energy at the main and switchgear will only provide energy usage at the site / area level

Presenter

Presentation Notes

With VantagePoint energy the ultimate goal is to have the energy information organized and available at the production asset levels. This way the energy information can be truly correlated to the production and operations information for relevant and actionable decision support. Because we are not necessarily advocating placing physical power meters at every asset level in the organization, which would typically be very cost prohibited, we are adding the capability with VantagePoint Energy Add-on to combine actual metered energy information with virtualized energy information, derived energy information and aggregated energy information. The goal is to drive energy information down as low as you can into your asset model, by virtualizing energy information where you and estimate the energy consumption based on other process variables in equipment, deriving energy information by combining the available information in the plant, and lastly aggregating energy information up in the asset model to have a full picture of the energy usage at every level in the asset model allowing you to correlate the information with available production information at those levels.


Energy Information at the Asset Level

ENTERPRISE

SITE

AREA

PROCESS CELL PRODUCTION UNIT

PRODUCTION LINE

UNIT WORK CELL

Metered energy allocated across all assets allows for correlation of energy usage to production

Presenter

Presentation Notes

With VantagePoint energy the ultimate goal is to have the energy information organized and available at the production asset levels. This way the energy information can be truly correlated to the production and operations information for relevant and actionable decision support. Because we are not necessarily advocating placing physical power meters at every asset level in the organization, which would typically be very cost prohibited, we are adding the capability with VantagePoint Energy Add-on to combine actual metered energy information with virtualized energy information, derived energy information and aggregated energy information. The goal is to drive energy information down as low as you can into your asset model, by virtualizing energy information where you and estimate the energy consumption based on other process variables in equipment, deriving energy information by combining the available information in the plant, and lastly aggregating energy information up in the asset model to have a full picture of the energy usage at every level in the asset model allowing you to correlate the information with available production information at those levels.


Correlating Energy and Production Data

20

Gain new insight to improving operations and reduce energy use

Correlate energy consumption to key production and/or process variables

Correlate energy demand events with production and/or process variables

Correlate production and/or process events with energy consumption


Some Examples

21

Correlate Energy with OEE

Correlate Energy with Weather

Equipment #2

kWh / day

Equipment #1

kWh / day

Gas consumption correlated todegree days

Energy Usage correlated with equipment OEE


Beyond Energy Consumption – Looking at Energy Cost

22

Energy Use Management vs. Energy Procurement Strategies

Energy Management system focused on reducing overall energy use

Assign cost to energy use data to gain a better understanding of cost

Energy Procurement strategies focused on reducing energy cost.

Strategies for looking at energy cost:

Manage your energy use

Alter Production Schedule

Enabling smarter purchase decisions

Make vs. Buy decisions

Load shedding

Participate in Demand Response

Managing cost is typically part of the more Mature manufacturers !!

Presenter

Presentation Notes

Know and optimize your energy use Will then enable you to make smarter purchasing decision Also enables you to plan production, and be smarter about how you .. Advanced Cost Analysis Make vs. Buy, Load shedding Maturity curve: Optimization: Make/Buy decisions, Demand Response,


Identify Critical KPI’s to Target


Baseline vs. Benchmark

24

Establish Baseline of Energy Use

Can’t just compare annual energy use !!

Other factors come into play (e.g. weather, production output, etc.)

Use this baseline to track performance going forward

Equipment Benchmarking

Use accepted performance standards

Chiller, Compressor, Cooling Tower, Boiler

2012

2013


What are the right KPI’s?

25

SimpleSimple ComplexComplex Normalized Statistical

Model

Normalized Statistical

ModelBase Load/Peak Load

compared to standard

Month vs. same month last year

Actual vs. budget

Annualized trend

Energy useper unit output

(Energy Intensity)

Cooling energy per degree day

Specific Energy Consumption (SEC)

Equipment Coefficientof Performance (COP)

Example:

Energy Use =(3.679 x

Production) +(129.504 x

Temperature) +63.581


Simple Energy KPI’s

26

Understand and track your base load and peak load

Provides an early indication that something has changed

May need to be addressed

Base load

Peak load


Examples of Relevant Variables

27

Production Output

61FMonday Milwaukee

66F 30 in 49F 0.00 in

Raw Material Conditions

Square Footage / Occupancy

Presenter

Presentation Notes

Energy Consumption can vary due to: Production throughput Weather and other environmental variables Raw material variances: moisture content storage temperature Etc. Occupancy / Square Footage Other Relevant Variables


Statistical Analysis Plays Key Role

28


Establishing Baseline and Targets

29

Baseline based on regression of relevant variables from prior year(s)

Will enable targeting for energy use and energy savings tracking

Tracking actuals against baseline can lead to predicting future cost

Presenter

Presentation Notes

Compare energy use with baselines/ targets (historic) But also be able to predict energy use based on production schedule and weather predictions etc. Become more proactive ..


Asset Energy Efficiency - Benchmarking

30

Use generally accepted efficiency calculations for benchmarking

Air compressor Specific Energy Consumption

Boiler Efficiency Calculation

Chiller and Refrigeration Coefficient of Performance

Allows for comparison of equipment to industry standard

Resources available on DOE: Advanced Manufacturing Office

http://www.eere.energy.gov/manufacturing/

http://www.eere.energy.gov/manufacturing/


Equipment Efficiency References

31

DOE: Improving Compressed Air System Performance

http://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/compressed_air_sourceb ook.pdfA sourcebook for industry

DOE: Improve Your Boiler's Combustion Efficiency - Steam Tip Sheet #4

http://www1.eere.energy.gov/library/asset_handler.aspx?src=http://www1.eere.energy.gov/ manufacturing/tech_deployment/pdfs/steam4_boiler_efficiency.pdf&id=5600This revised AMO tip sheet helps plants establish a program for the regular inspection, testing and repair of stream traps.

Other sites:

http://www.energystar.govhttp://www.stanford.edu/class/cee115http://www.mntap.umn.edu/greenbusiness/energy.htmhttps://www.progress-energy.com

http://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/compressed_air_sourcebook.pdf



http://www1.eere.energy.gov/library/asset_handler.aspx?src=http://www1.eere.energy.gov/manufacturing/tech_deployment/pdfs/steam4_boiler_efficiency.pdf&id=5600



http://www.stanford.edu/

http://www.stanford.edu/class/cee115

http://www.mntap.umn.edu/greenbusiness/energy.htm

http://www.mntap.umn.edu/greenbusiness/energy.htm

https://www.progress-energy.com/


Use Dashboards / Role Based Reports


Mac

hine

Are

aPr

oduc

tion

Plan

t

Quality & Operations Maintenance

Plant Manager

Document effects of improvement activities

Production

FinanceSales / Customers

Employees

Balanced Scorecard

Engineer Operator

Production Manager

Different Users, Different NeedsLi

ne

Define Corporate objectives & observe actively Costs, production output, overall efficiency Financial indicators, capacity

Production output, achieving targets Efficiency of production

Ways to improve production and yield Minimize scrap & rework Monitor process, ensure compliance

Reducing downtime Preventive Maintenance

Monitoring process to keep production running Identifying problems in real time Improvement activities

Keeping plant running Predictive maintenance Optimize asset availability

Presenter

Presentation Notes

Different Users (Job Roles) in the enterprise have different information needs Plant Managers Define Corporate objectives & observe actively Costs, production output, overall efficiency Financial indicators, capacity Quality & Operations Ways to improve production and yield Minimize scrap & rework Monitor process, ensure compliance Engineering Keeping plant running Predictive maintenance Optimize asset availability Operators Monitoring process to keep production running Identifying problems in real time Improvement activities Document effects of improvement activities Production Manager Production output, achieving targets Efficiency of production Maintenance Reducing downtime Preventive Maintenance


Dashboards and Reports

34


Key Capabilities to Look for in a System

35

Correlate disparate data sources

Any data could be relevant – example maintenance can correlate to equipment efficiency

Ad-hoc reporting / trending

Easy way to look for root-cause by correlating relevant data in either trends or excel reports for easy analysis

Dashboards and Reports – should be accessible to all where relevant

Role-based access – with configurable portals

Key elements:

Single version of the truth

Information on the go

Notifications

Presenter

Presentation Notes

Single version of the truth – single portal access to all data, leave the data where it is Information on the go – mobile, collaborative Notifications/eventing: Make critical data available to you in realtime


Ensure investments reach full potential


Not One and Done !!

37

Need to be part of continuous process

Presenter

Presentation Notes

Not a one and done – need to be part of continuous process Fairly Common Process for Improving Energy Performance Energy Assessment Identify opportunities and significant energy uses Define critical and other variables affecting energy use Define EnPI’s (Energy KPI’s) Establish baseline(s), targets and action plans Implement Action Plans, Data Collection Monitor and check progress, Analyze Re-asses Action Plans, Opportunities, and start over ……


Make Sure You Prioritize and Integrate Relevant and visible energy information

38

Rule of thumb: 20% of equipment uses 80% of energy

Make sure the focus is on the highest consumption or highest potential

Make the energy information available

Real-time data for decision making at the plant floor

Empower plant floor personnel, allow them to take action

Ultimately make energy an integral part of the product

Energy on the BOM – results in complete visibility

$0.0012/SKU

0.23 BTU/UNIT

$0.03/GAL


Energy Trends in the Industrial Space

$0.0012/SKU

0.23 BTU/UNIT

$7.23/sqft

$0.03/GAL

Presenter

Presentation Notes

Producers can use less energy through scheduling production intelligently (e.g. reducing clean in place operations or equipment changeovers) , taking advantage of more efficient equipment, or design improvements, such as reuse of waste heat into their processes. By leveraging variable frequency drives and power control, energy-efficient components and advanced motion control solutions such as servo motors and direct drive technology from Rockwell Automation, manufacturers can significantly reduce the amount of energy required to power their processes. Manufacturers can use more cost-effective energy by managing where, how, and when energy is used in order to harness it when it is least expensive, such as during off-peak times, or balance it with their own abilities to produce energy onsite. Rockwell Automation can help provide manufacturers with visibility into energy pricing and identify opportunities for demand management solutions to lower the cost of the energy being consumed in the facility. Manufacturers can optimize energy use so as to achieve production goals in the least expensive, most profitable way while balancing the many variables inherent to manufacturing. Rockwell Automation’s methodology for industrial energy management empowers manufacturers to strategically invest energy into their production processes to gain higher returns on their energy expenses by actively managing energy as an input to production.


CHALLENGE SOLUTION

Case Study: Real-time Energy Reporting Global Pet food manufacturer

Reduce energy consumption by 3%, cutting annual energy costs by $845,000

Harmonize manufacturing data within and among different plants

Foundation for long term 100% sustainable production

• Visualize the most important energy flows in real time

• Identify zones running unnormally vs. production

• Allow energy consumtion analysesImprove energy efficiencyReduce primary energy consumption

Customer turned to Rockwell Automation to help them reduce energy usage

• Monitoring of electricity, gas, steam, compressed air and water at a line-level

• integrates and leverages multiple existing sources of energy data at all plant sites, and provides a powerful reporting layer on top of existing automation infrastructures by using FactoryTalk VantagePoint

• Web based reporting

RE

SU

LTS


CHALLENGE SOLUTION

Case Study – Steel Case Office Furniture supplier optimizes energy consumption

• Outdated boiler control system

• Comply with ISO 140001 Environmental Management System Standard

• Manual collection of WAGES dataI

Reduce energy consumption

Reduce overall Carbon Footprint

Energy Monitoring justifies investments in new more energy efficient technologies

• Implemented a real-time tracking and monitoring system for WAGES usage using Allen-Bradley FactoryTalk EnergyMetrix software and PowerMonitors

• Replaced boiler control system with Rockwell Automation PlantPAx process automation system

RE

SU

LTS

Reduce energy consumption by 15%, providing significant energy costs savings across the organization

Reduce the overall Carbon Footprint by 25%

Improved Insight now easily allows for justification for new and more energy efficient technologies.


For more information:

http://discover.rockwellautomation.com/energy

43

Jan PingelProduct Manager, Energy Intelligence

[email protected]

Jan PingelProduct Manager, Energy Intelligence

[email protected]


www.rockwellautomation.com

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