jouko karjalainen, 31.01.2013 cpmplus energy manager · 2018-05-09 · abb group february 1, 2013 |...

© ABB GroupFebruary 1, 2013 | Slide 1

Jouko Karjalainen, 31.01.2013

cpmPlus Energy Manager


Why is Energy Management essential?

Focus in sustainablemanufacturing

Energy is a major productioncost item in many processindustries(1)

In pulp & paper industryapproximately 10% ofproduction cost

In mining industry 15%

In cement industry 30 %

In steel industry even 50%

Experience shows thatEnergy savings up from 10% to25% can be reached byvarious actions (2)

(1) Based on geographical area(2) Source: ARC Best Practices for Energy Management report, Jan. 2009

Derived from EIA, International EnergyStatistics database (as of November 2009),web site www.eia.gov/emeu/international.Projections: EIA, World Energy ProjectionSystem Plus (2010).

0

10

20

30

40

2007 2015 2020 2025 2030 2035

Nuclear

Renewables

Natural gas

Coal

Liquids

World electricity generation by fuel, 2007-2035trillion kilowatthours


Implementation of Energy Management Strategy

Strategy, Policy and Targets

Targeted Initiatives

Progress & Results

A successfulEnergy Management strategy

must be initiated and supportedfrom the top down

Market Analysis


What is cpmPlus Energy Manager ?

A software package for

Large energy consumers in allindustries

A software package that allows you to:

• Monitoring energy usage at Plant and Processlevel with real-time visual displays and dataMonitor

• Identify best performance of process areas andopportunities for improvementIdentify

• Report energy consumption patterns of processareas and production linesReport

• Analyze inefficiencies in Plant and process areasAnalyze• Alarm capabilities - enable corrective measures

to be taken immediatelyAlarm• Forecast energy consumption schedules for

process areas based on production plansForecast• Optimization environment to design and

implement complete energy optimization modelsOptimize

• Monitoring energy usage at Plant and Processlevel with real-time visual displays and dataMonitor

• Identify best performance of process areas andopportunities for improvementIdentify

• Report energy consumption patterns of processareas and production linesReport

• Analyze inefficiencies in Plant and process areasAnalyze• Alarm capabilities - enable corrective measures

to be taken immediatelyAlarm• Forecast energy consumption schedules for

process areas based on production plansForecast• Optimization environment to design and

implement complete energy optimization modelsOptimize


Module1 = Energy Monitoring and Targetingdecreasing energy consumption

Module 2 = Energy Demand Planningreducing energy purchase costs

Module 3 = Energy Optimizationoptimizing energy mix and time of use

cpmPlus Energy Manager is a Modular PackageEasy and seamless scalability from Modules 1-3

Energy Monitoring and Targeting

Start with monitoring and reportingagainst targets

Energy Demand Planning andWhat-if scenarios

Energy demand planning andsensitivity analysis

Energy Optimization

Comprehensive optimization ofenergy demand and supply

800xAIntegration

OPCIntegration

cpmPlus History

Database

cpmPlus Clients

User interface

1 2 3

Prod PlanIntegration


Monitoring & Targeting (Module 1)Functionality

• Understanding operation at Plant andProcess level

Monitor, Target andReport measured

energy consumption

• Identify best performance of processareas from past history to set targetsfor energy consumption

Monitoring energyefficiency and energy

costs

• Monitor peak load, powerconsumption and actual consumptionv targets

Power Monitoring

• Analyze and Report energyconsumption patterns of processareas and production lines

Analysis and Reporting

• Alarm capabilities with several alarmtypes, e.g., deviation from target,equipment running idle, high limit etc.

Alarms to alertoperators to take action


Monitoring & Targeting (Module 1)Benefits

1. Accurate Performance MonitoringPlant level and Process level

2. Highlight improvement areas allowing corrective action

3. Improve energy efficiency and energy consumption

4. Increase profitability by 10-15%


Main Dashboard - Plant OverviewActual current energy performance v target values

KPI includingtarget

Trend display forthe indicator

Baseline, Currentvalue and Targetfor the selectedtime level

Title of the display

D

Navigation matrix: Columns represent different type of displays to be activated. Rows representprocess areas. The selection is shown by highlighting. Color of the traffic light next to process areaindicates deviation from the target. Navigation within the process hierarchy is possible.


Monitoring & Targeting (Module 1)Sub-process analysis

The key is to be able toaccurately predict theelectricity consumptionbased on real time data

Accurate electricity plansreduce demand chargesand lower penalties

Improvement of 10% inelectricity plan accuracyresults in 1% savings inelectricity costs


Monitoring & Targeting (Module 1)Display template hierarchy

Main overview

Energy overviewEnergy efficiency trend Subprocess overview

Target setting AnalysisReport

Allows drill-down toProcess area forspecific details, e.g,

Energy efficiency

Targets, Settings

Analysis and Reports


Monitoring & Targeting (Module 1) - Energy Overview

You canselect whichenergy formyou want todisplay, or

Total

You can select whether you want to display Energies, Costs,CO2 or SEC

Trend selection: Periodic shows periodicalvalues. Cumulative shows sum from the

beginning of the time selection

The losses are shownhere divided into two

parts: operationallosses and partial load

losses.

This graph shows theselected year and previous

year values for Energy,Costs, CO2 or SEC

(depending on what isselected above)

Time level selection. You canselect the time level and

navigate. In this example oneWEEK is selected

Monitoring & Targeting (Module 1) - Analysis



Increase Profitability

Monitoring & Targeting (Module 1) - Summary

Accurately Monitor & Target the Plant’soverall operations in real-time

Identify the inefficient operational areaswithin the Plant

Empower Plant operators to take correctiveaction based on high-grade data

Maximize operational efficiency


cpmPlus Energy ManagerEnergy Load Planning (Module 2)

Calculation of predicted energyconsumption patterns for eachconsumer

Accumulation of consumer specificconsumption patterns into total facilityconsumption

Can predict up to 5 separate utilities perconsumer, e.g. consumption of electricpower, steam, gas, water, oil

Prediction methods include productiontype dependent profiles, productioncycle dependent profiles, timedependent profiles, self-adaptiveprofiles, and constant loads

Standard interface to ProductionPlanning systems

© AB B G rou pA pri l 2 7 , 2 0 10 | S l i de 1 2

E xa m p le: B en e fits o f A c c u r ate P la n n ing & M on ito r in g

4 0$ /M W h1 00 M WD a y-a hea d

P o w e r [M W ]

S u rpl u sp o w e r t ot h e g ri do p er at o r:3 0$ /M W h

M e as u re dc on s um pt io n :92 M W

C as e 1P o w e r [ M W ]

D ef ic it p ow erf r o m t h e g r i do p era to r:5 0$ / M W h

M eas u re dcon s um pt io n:10 8M W

C as e 2

A v era g e p r ice :40 .8 7 $/M W h

A v er a g e p r ice :4 0.74 $ /M W h

P o w e r [M W ]

M ea s ur edc o nsum p tion :9 9M W

A ve r ag e p ric e:40 .1 0$ / M W h

I d ea l S i tu a ti o n

S u rp lu sp o w er tot he g rido p era to r :30 $ /M W h


Load Forecasting (Module 2)Minimizing Electricity Purchase Costs

40$/MWh

100MW

Day-ahead

Power [MW]

Surpluspower tothe gridoperator:30$/MWh

Measuredconsumption:92MW

Case 1Power [MW]

Deficit powerfrom the gridoperator:50$/MWh


Case 2

Average price:40.87$/MWh


Power [MW]



Ideal Situation

Surpluspower tothe gridoperator:30$/MWhAnnual savings

~600.000$= 2% of total electricity costs

Annual savings~600.000$

= 2% of total electricity costs


Energy Supply Planning and Optimization (Module 3)

Optimize the schedule of availablesupply resources to meet plannedenergy consumption - at minimum totalcost - in real-time

Optimization of running schedules forselected consumers based on minimumenergy cost and given restrictions

Optimization utilizes a real-time LP/MIPoptimization environment and EconomicFlow Network

Energy process is divided into logicalsub-processes, which are connected toeach other through a flow network

Optimizes the complete energy flownetwork in real-time when any of theinput parameters change


Energy Supply Planning and Optimization (Module 3)Planning Electricity Use and Generation is Essential

Motivation

Scheduling and optimization of power generation capacity

Benefits for Power Companies:

More stable power grid

Less spinning and fast reserves

Regulating less expensive

Less CO2 emissions

Operating on optimal efficiency

Benefits for Consumers:

More stable power grid

Unit price of electricity is lower

Less penalties

Improved energy efficiency


cpmPlus Energy ManagerSummary

A software package that allows you to:

Establish targets for energy usage

Monitor and report energy usage and efficiency against targets

Predict energy demand based on production data

Balance energy usage against purchased energy commitment

Optimize energy usage, production and procurement

Benefits

Improve energy efficiency, reduce energy costs and carbonfootprint

Purchase or produce your energy at the lowest market price

Optimize the use of alternative energy sources

Improve energy cost consciousness

Support energy improvement projects

cpmPlus Energy Manager is winner of the 2010 Control Engineering “Engineers Choice” Award for bestsoftware package in the Energy Dashboard category


Return On Investment

Case - Steel MillPrice Consumption

MW price €MWh savings savings Annual use,h Total savings - year

1 40 1% 1% 8000 640010 40 1% 1% 8000 64000

100 40 1% 1% 8000 640000

Price and Consumption savings here are 1% each - can be up to 5 %.Many Steel Mills use more than 100 MWPrice Savings = accurate forecasting / avoiding peaks + penaltiesConsumption savings = accurate monitoring of where and how muchelectricity is consumed / load planning and optimization

cpmPlus Energy Manager reference systemsMill wide and corporate wide installations


Proven solution with references in

Pulp & paper mills, board mills

Steel mills

Mining sites

Power utilities

Oil refinery

Water processing site

Proven corporate wide installations

UPM-Kymmene

Mayr-Melnholf

Public Works and GovernmentServices Canada


UPM Corporate wide Energy ManagementCorporate-wide energy management network

20 TWh/y total electricenergy procurement

17 Mill systems and twocorporate centers

Energy procurement andproduction planning,real-time monitoring andreporting on mill andcorporate level

UPM-Kymmene is the third biggest forestindustry company in the world, and the leading

manufacturer of magazine papers.

Reductions in carbon dioxide and sulphur dioxideemissions

© ABB GroupFebruary 1, 2013 | Slide 23©

AB

BP

roce

ssIn

dust

ries

-23

PVO-Pool, Finland

Operating a 3.4GWpowerportfolio including

21 thermal powerplants

2 nuclear units

12 hydro stations

5 wind powerstations

Approximately 25%of total electricityproduction in Finland

Energy management for PVO Power Utility

Pohjolan Voima (PVO) is a privately owned group of companies in the energy sector, which produceselectricity and heat at cost for its shareholders in Finland. The Group also develops and maintains technologyand services in its sector. PVO-Pool Oy, a subsidiary of Pohjolan Voima Oy, is responsible for the optimalpower procurement and the related electricity trade for Pohjolan Voima Group.” (www.pvo.fi)

© ABB GroupFebruary 1, 2013 | Slide 24©

AB

BP

roce

ssIn

dust

ries

-24

PVO-Pool, Finland, continued

Transactions on the Nordic power market (Nord Pool)

Invoicing to power plants, shareholders, customers

Balance settlement and continuous power balance

Covers many of Finnish power grid and electricitymarket participants

Dynamic calculation and reporting for highperformance and availability (redundant systemconfiguration)

Energy management for PVO Power Utility


2008

Consumption forecasting for steel mills,Lux railways, etc.

Electric Arc Furnace Load management forpeak shaving

Power Monitoring to predict peaks inload demandEAF load control to avoid crossingcontract limitsCommunication links to 3 steel millsto control EAF “traffic lights”

2010

Additional functions to support planning andoperation of power procurement, including :

Managing of power interruptrequests

Mill level functions for consumptionand interrupt monitoring

2011

Extended to France

Sotel, Luxembourg/Belgium/France - Arcelor MittalLoad management to limit peak demand

LKAB Sweden



LKAB: Energy ManagementWorld’s largest underground iron-ore Mine

Consumes 2 % of totalelectricity in Sweden

1 x HQ, 3 x Mines and2 x Harbours

Energy monitoring, targetingand reporting

Energy load planning (future)

Increase energy and operational efficiency

Reduce energy consumption

Reduce carbon dioxide and sulphur dioxide emissions

Typical investment payback time ~ months

jouko karjalainen, 31.01.2013 cpmplus energy manager · 2018-05-09 · abb group february 1, 2013 |...

Documents