integrated power and automation

29
Reducing Cost through Integrated Power and Automation Reducing Cost through Integrated Power and Automation Larry O’Brien Research Director ARC Advisory Group [email protected]

Upload: arc-advisory-group

Post on 29-Nov-2014

418 views

Category:

Technology


4 download

DESCRIPTION

 

TRANSCRIPT

Page 1: Integrated Power and Automation

Reducing Cost through Integrated Power and Automation

Reducing Cost through Integrated Power and Automation

Larry O’BrienResearch Director

ARC Advisory [email protected]

Page 2: Integrated Power and Automation

OutlineOutline

The Cost of PowerHow Well is Power Managed in Today’s Plants?How Well is Power Managed in Today s Plants?The Business Value of Integrated Power & AutomationEnabling TechnologiesKnowledge/Cognitive ManagementWh t D th F t H ld?What Does the Future Hold?

2© ARC Advisory Group

Page 3: Integrated Power and Automation

The Cost of PowerThe Cost of Power

Oil Prices Have Declined, BUT…Power Prices Have Increased and Will Continue To Do SoMY Electricity Bill Hasn’t Gone Down, Has Yours?

3© ARC Advisory Group

Page 4: Integrated Power and Automation

Industry and Its Role in Power ConsumptionIndustry and Its Role in Power Consumption

Industry is Number One Consumer of Total EnergyIndustry is Number Two Consumer of Power Behind B ildingsBehind BuildingsIndustry Generates a Significant Amount of its Own Power

4© ARC Advisory Group

Page 5: Integrated Power and Automation

Manufacturers and Processors Have The Most To Gain By Saving Energyy g gy

• Produces approximately 30% of U.S greenhouse gas emissions

• Accounts for more than 35% of U.S.natural gas demand

• Energy is key to economic growth in domestic manufacturing I d t

Transportation

Energy Use

manufacturing

• Many companies have been unable to pass higher energy costs on to their customers, which has impacted their profit margins negatively

Industry33.4%

p27.2%

negatively

• Having an Efficient Energy Management Strategy is Part of the “Triple Bottom Line”: Social, Economic, and Environmental

Commercial17.9%Residential

21.5%• As an Environmental Compliance Strategy,

Improved Energy Management is More Cost Effective Than an “End of Pipe” Solution

• It’s Sound Business Practice

21.5%Source: US Department of Energy

5© ARC Advisory Group

Page 6: Integrated Power and Automation

How Well is Power Managed in Today’s Plants?How Well is Power Managed in Today’s Plants?

Energy Ranks High on the List for Concerns to Manufacturers (Even Some of the Raw MaterialsManufacturers (Even Some of the Raw Materials Cost is Related to Power Generation).

6© ARC Advisory Group

Page 7: Integrated Power and Automation

Major Energy-Intensive IndustriesSustainability impacts ALL!Major Energy-Intensive IndustriesSustainability impacts ALL!

1000

Industrial Energy Intensity vs. Energy Consumption

Petroleum

1000

ty GD

P) Energy-Intensive

Industries

Chemicals

PaperPrimaryMetals

Nonmetallic Mi lWoodTextiles/Apparel

100

Inte

nsi

td

Btu

/$

Mining

Food Processing

Minerals

Tobacco/Beverages

Furniture

Leather Machinery and Computers

Wood

TransportationFabricated Metals

Textiles/Apparel

Plastics/Rubber

Printing

10

En

erg

y

ho

usa

nd

Energy Consumption (Trillion Btu)

Leather Machinery and ComputersElectrical

PrintingMiscellaneous

1

10 100 1000 10000

(Th

7© ARC Advisory Group

Energy Consumption (Trillion Btu)

Source: US Department of Energy

Page 8: Integrated Power and Automation

Where Does the Power Go?Where Does the Power Go?

Process Heating is Number One Energy ConsumerMachine Drive is Number TwoMachine Drive is Number Two

8© ARC Advisory Group

Source: EIA

Page 9: Integrated Power and Automation

Power Management Philosophy Behind Many of Today’s Plants is……Power Management Philosophy Behind Many of Today’s Plants is……

Energy Management Initiative Status

Leaders Program in place

Competitors

Plan to implement

Investigating

Followers

No plans underway

Don't know

0% 25% 50% 75% 100%

9© ARC Advisory Group

Page 10: Integrated Power and Automation

Energy Efficiency GainsEnergy Efficiency Gains

Leaders25% or more

20% to 25%

15% to 20%

Followers

Competitors 10% to 15%

5% to 10%

None

Don't know

0% 25% 50% 75% 100%

Don't know

Leaders make more consistent gains

10© ARC Advisory Group

Page 11: Integrated Power and Automation

Integration of Power and Automation: Basic PremiseIntegration of Power and Automation: Basic Premise

Automation and Electrification are Still Separate Islands of FunctionalityIslands of FunctionalityMotor Control Centers are Also Largely SeparateOperators Have No View Into Power Side, Cannot Identify or Take Advantage of Savings OpportunitiesFew Suppliers Offer True Capability to IntegrateFew Suppliers Offer True Capability to Integrate the Worlds of Power, Motor Controls/Drives, and Automation Systems in a Single Environment That Allows End User to Make Intelligent DecisionsAllows End User to Make Intelligent Decisions About Energy Management

11© ARC Advisory Group

Page 12: Integrated Power and Automation

ARC Definition of Integrated Automation and Power ManagementARC Definition of Integrated Automation and Power Managementgg

Integration of various power related systems, devices, equipment, and power related data withdevices, equipment, and power related data with the process automation systemDriven not just by functionality, but an overall strategy to implement a collaborativestrategy to implement a collaborative manufacturing environment with a holistic approach to power and energy managementEMS, Intelligent Motor Control Centers, Switchgear and Electrical Equipment, Intelligent Field Devices, Optimization, Asset Management, p , gInformation is Provided According to ARC Concept of Information in Context, Right People, Right Time with the Most Effective Visual

12© ARC Advisory Group

Time, with the Most Effective Visual Representation

Page 13: Integrated Power and Automation

Automation & Electrical SystemsAutomation & Electrical Systems

Long tradition of separate roles, separate domains in the plant, separate requirements. Many commonalities in system requirements: high reliability and availability, safety, etc. When you look at most people’s depictions of a DCS/PAS, the don’t take power management into accountdon’t take power management into account.

Business Planning & Supply Chain Management

Business Process

Transactions

Business Work

ProcessesC a a age e tTransactions Processes

Collaborative Automation System

S95.01 Definition

Production DefinitionProduction Definition

Production Capability

Production Plan

Production Information

Manufacturing Work

PProduction

Real-time Control &

Events

ProcessesManagement Transactions Production Management

BatchContinuous Logic

S8

8 S

tru

ctu

res

Sensors, Actuators, and Logical Devices

13© ARC Advisory Group

TTP

F

F

F

L

F

L

L

F

L

L

L

TTP

F

F

F

L

F

L

L

F

L

L

L

TTP

F

F

F

L

F

L

L

F

L

L

L

TTP

F

F

F

L

F

L

L

F

L

L

L

TTP

F

F

F

L

F

L

L

F

L

L

LLogical Devices

Page 14: Integrated Power and Automation

Power & Electrical are Part of Production Resources in CPS Power & Electrical are Part of Production Resources in CPS

Enterprise/BusinessOperations

Inbound Supply Chain& Logistics

CRM

Operations Management

Shipping, Outbound

R&D, Product/Plant

Collaborative Production

Environment

a age e

Supply Chain& Logistics

Design and Engineering Production

Resources

14© ARC Advisory Group

Process Automation Power & Electrical

Page 15: Integrated Power and Automation

Collaborative Power And Control SolutionsCollaborative Power And Control Solutions

♦ C-PACS articulate the convergence of multiple disciplines on a common platformdisciplines on a common platform

♦ C-PACS specify functions under a single environmentenvironment

♦ C-PACS promote the value of the common communications infrastructure

♦ C-PACS recognize the value of standards in automation

♦ C-PACS demonstrate the importance of a single power, and control platform

15© ARC Advisory Group

Page 16: Integrated Power and Automation

C-PACS – The Foundation for CMM

E t i BusinessBusiness Process ComponentsS l Ch i M

Business Process ComponentsS l Ch i MEnterprise

SystemsBusiness Processes

Service-Based S i B d I f t t ISA 95

Supply Chain ManagementProduct Lifecycle Management

Supply Chain ManagementProduct Lifecycle Management

W k Fl

Operations ManagementOperations Management

Architecture Service-Based Infrastructure

ProductionFactory O ti

Mfg Ops &Mfg Ops &ProductionProduction

Factory Factory

ISA 95 Models

Work Flow

Production ProcessesOperations

Systems & Services

Production Production ProcessesProcesses

Product Product DefinitionDefinition

Production Production ManagementManagement

AutomationAutomation

POWER: Power Meters, Circuit Breakers, Transfer Switches, Intelligent Motor Control Centers,…

OPC-UA

PA

CS

Control & Device Networks: Real-Time

16© ARC Advisory Group

Automation: Motor Drives, Logic, Motion, HMI, Sensors, Actuators,…

C-P

Page 17: Integrated Power and Automation

C-PACS Model

Device ControlNetwork Network

Logic HMI

Logic HMI

Process Control

Common Tagging & Single Database

Common Development Pl tf & C fi ti

Motion

Control

Power

MotionNetworks

Single DatabasePlatform & Configuration Tools

Process Control

PowerM i

i ifi l i i

Motion

17© ARC Advisory Group

Domain Specific Solutions Are Converging to Improve Performance

Page 18: Integrated Power and Automation

Business Value of Integrated Power Management and Automation SystemsBusiness Value of Integrated Power Management and Automation Systems

In many cases the potential savings can equal 10 percent of total power consumptionThis can equal the entire amount of power a plant purchases from outside electricity generating sourcesYou could be selling power back to the grid!Again, value goes beyond cost of energy – integrated power and automation gives improved visibility into entire scope of plant operations that leads to improved early event detection, increased reliabilityincreased reliabilityProcess Industries are particularly heavy power users (see heating applications in total industrial power consumption) so the opportunity is quite largeoppo y q gIn many cases this is unexplored territory and there are a lot of opportunities that immediately present themselvesLarge investments are not required to realize benefits

18© ARC Advisory Group

g q

Page 19: Integrated Power and Automation

Integrated Power and Automation is Enabled by IEC 61850Integrated Power and Automation is Enabled by IEC 61850

IEC 61850 is an Ethernet based solution that has the capability to provide tight integration betweenthe capability to provide tight integration between Automation and Power systems.IEC 61850 does for protection and process measurement in a substation what fieldbus ismeasurement in a substation, what fieldbus is doing for process control and multivendor device standardization. Enhanced diagnostics.

19© ARC Advisory Group

Page 20: Integrated Power and Automation

IEC 61850 Brings Power of Digital Networking to Power ManagementIEC 61850 Brings Power of Digital Networking to Power Management

20© ARC Advisory Group

Page 21: Integrated Power and Automation

IEC 61850 Benefits, ChallengesIEC 61850 Benefits, Challenges

Benefits: Challenges:Reduced implementation time• Application Development• Integration

IEC61850 is relatively new• Will continue to evolve

Product AvailabilityGrowing but remains somewhat

Reduced Wiring Costs

Easier equipment upgrade

• Growing, but remains somewhat limited

IEC61850 compliance does not yet guarantee interoperability• Different interpretations of standards

by developersEasier application migration to new technology

Less vendor lock-in

by developers• Standard and product improvements

and updates are ongoingLearning curve – new techniques and terminology• BUT long term training reduced due

Better, more uniform engineering and tools• Standardized naming semantics• e.g. Failure analysis, maintenance,

system simulations

• BUT, long-term training reduced due to common data models and communication techniques

Network design is critical• Ensure networking expertise is

included on project teams

21© ARC Advisory Group

system simulations included on project teams

Page 22: Integrated Power and Automation

Intelligent Motor Control Centers and Variable Speed DrivesIntelligent Motor Control Centers and Variable Speed Drives

Motors consume 64% of all energy consumed in industry.industry.Most industries can significantly reduce their energy costs just by addressing inefficiencies that reside in their motor loadsreside in their motor loads.Rule of thumb: In a single year, motors can consume up to 10 times their initial cost.

Source: Schneider

22© ARC Advisory Group

Page 23: Integrated Power and Automation

Intelligent Motor Control Centers and Variable Speed DrivesIntelligent Motor Control Centers and Variable Speed Drives

Source: Schneider Electric

23© ARC Advisory Group

Source: Schneider Electric

Page 24: Integrated Power and Automation

Intelligent Motor Controls Example: AC Drives & Energy Savings in Pipeline ApplicationsIntelligent Motor Controls Example: AC Drives & Energy Savings in Pipeline Applications

In oil and gas pipeline applications it is very common to control the output of variable torque loads such as those found in pumps fans and blowers by throttling their input orfound in pumps, fans, and blowers by throttling their input or output. This method, however, is inefficient The application of AC drives to large fans and pumps to control flow by modulating their speed can produce y g p psignificant energy savingsThe higher the level of motor operating time and the larger the variation in load duty cycles, the greater the savings One pipeline customer expects to save $5 million annually in transportation expenses and achieve reduced pipeline shutdowns that can cost up to $750,000 per shutdown when the pipeline is running at full capacitythe pipeline is running at full capacity

24© ARC Advisory Group

Page 25: Integrated Power and Automation

Intelligent Field Devices and Plant Asset ManagementIntelligent Field Devices and Plant Asset Management

Use of intelligent Coriolis Meters to improve fuel gas measurement (see Emerson Example)Integrating electrical and motor control centers into PAM systemscenters into PAM systemsIntegrating machinery health managementAre you making the right measurements? AreAre you making the right measurements? Are they visible?

25© ARC Advisory Group

Page 26: Integrated Power and Automation

Optimization, Simulation, Process ModelingOptimization, Simulation, Process Modeling

Coordinated control between assets (boilers, turbines and other equipment)Allocate loading of boilers and turbines for optimum

tig p

operationsDevelop process models• So that the control strategies “know” each asset, what they’re

capable of, and how they interact with each otherFeed steam and electricity use information to the plant energy system for predictive controlEstablish automated, real-time connections with electricity providersy p• To include electricity buy and sell factors into the energy

management modelsAdjust process setpoints to least, but safe, costImplement Tie-Line ControlImplement Tie Line Control• For prioritized load shedding and purchased power optimization• Real-time price schedules

26© ARC Advisory Group

Source: Emerson Process Management

Page 27: Integrated Power and Automation

Knowledge Management IssuesKnowledge Management Issues

More information for the operatorpMore information for MaintenanceHow to use this information effectively?Do you have an accurate picture of your plant’s energy usage? D h th i h tiDo you have the in house expertise necessary to provide you with a good baseline?Work practices must be changed to adapt

27© ARC Advisory Group

Page 28: Integrated Power and Automation

Future Trends & StrategiesFuture Trends & Strategies

More products and solutions will become availableavailableIntegrated MAC/MEC approach more common on large projectsPenetration of 61850Growth in power auditing and consultative/lifecycle services for powerconsultative/lifecycle services for power and automation integrationExpanded worker roles and new workExpanded worker roles and new work practicesA good opportunity for both end users and

li

28© ARC Advisory Group

suppliers

Page 29: Integrated Power and Automation

Thank YouThank YouFor more information, contact the author at

[email protected] or visit our web pages at www arcweb com

29© ARC Advisory Group

or visit our web pages at www.arcweb.com