L19 - Combining the Latest Rockwell
Automation® Hardware and Software for
Improved Energy Management
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Rev 5058-CO900E
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Sustainable Production Inputs
Add this flow to next slide
Materials / parts
Materials / parts
Information
Energy
Materials
Information
Energy is a great place to start
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
2
Why Manage Industrial Energy?
The Industrial sector consumes more
energy than any other.
Total Energy Consumption
by Sector
Top Market Pressures
Source: US Energy Information Agency:
Aberdeen Group Report 2011
Rockwell Automation is an Industry Leader in helping customers
optimize their production operations to reduce cost
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
What is the difference?
For the sake of this discussion:
 Power/Energy Management:
 Providing solutions that enable a customer to optimize the
consumption and demand of energy in their plant or at a specific
process.
 Power Quality Management:
 Providing solutions that minimize the impact of both external and
internal power quality events/conditions that can impact the uptime or performance of a plant or a specific process.
 Both solutions have similar aspects or parts:
 Power Monitoring, Data organization or analysis through a tool or
software, *System optimization

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*Very different remediation solutions (Solving a different problem)
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
4
Power Management (Direct cost)
 Consumption
 Real, Reactive, and Apparent Energy
 Demand
 Real, Reactive, and Apparent Power
 Time interval determined by utility
 Time of day matters
 Ratchet Penalties
 Power Factor
 Lagging (penalty for reactive energy draw)
 Leading (giving away energy to utility)
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
5
Power Quality
Harmonics
Voltage
Sag/Swell
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Transient
Detection
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Energy Usage vs. Production
 Energy usage is traditionally metered to the Factory wall as part of facilities infrastructure
 Limitations:
Difficult to correlate energy consumption with real-time production information
 Difficult to compare energy used during different batches
 Difficult to compare energy costs for a particular product run

 What is happening within a manufacturing facility ‘with’ the energy resources being consumed is
typically a ‘black’ box
What am I actually making with all of these resources?
 How much electricity was used during this production run?
 How is the power quality?
 How much energy is consumed during peak?

‘Measured to the Building’
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
7
Energy Usage vs. Production
 Identify large or critical loads
 Install Powermonitors where needed
 Implement monitoring software
 Drive accountability
 Monitor results
Utility Feeds 138 kV
Powermonitor 3000 M6
West
East
Allen-Bradley
Powermonitor 3000
L1
25.04M
WATT
Utility meter
kWh
Switchgear 12,470 V
Powermonitor 1000
Typical for 5
RS-485
EtherNet/IP
RS-485
RX
ACT
LNK
+
-
TX
STATUS
Boiler house
Substation
Mod Net
SHLD
Shipping / Receiving
Substation
Production
Substation #1
Power house
Substation
4160 V
Powermonitor 1000
Production
Substation #2
480 V
RS-485
EtherNet/IP
RS-485
RX
ACT
LNK
+
-
TX
STATUS
Powermonitor 1000
RS-485
EtherNet/IP
Mod Net
RS-485
RX
480 V
SHLD
ACT
LNK
+
-
TX
STATUS
RS-485
RX
RS-485
STATUS
480 V
RX
ACT
MCC 4
RS-485
EtherNet/IP
RS-485
EtherNet/IP
LNK
+
-
TX
Powermonitor 1000
ACT
Mod Net
LNK
+
TX
STATUS
Powermonitor 1000
Mod Net
480 V
-
SHLD
SHLD
Powermonitor 1000
Mod Net
SHLD
MCC 5
MCC 6
MCC 3
MCC 1
‘Measured to the Production Line’
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MCC 7
MCC 9
Data
center
UPS
MCC 2
MCC 8
EtherNet/IP
R
S
-
4
8
RS-485
5
RX
ACT
LNK
+
-
TX
STATUS
Powermonitor 1000
Mod Net
SHLD
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
8
Understanding Energy
 Reduce Consumption



Power-down equipment when not in use
Install more energy-efficient equipment
Repair/Replace broken equipment
 Reduce Demand



Stagger startups
Perform startups during off-peak hours
Reduce frequency of startups
 Correct Power Factor


Install capacitor banks to balance load
Reduce operation of inductive loads
 Reduce Downtime


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Optimize preventative maintenance
Diagnose power quality issues impacting equipment health and grid stability
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
9
Thank you!!
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Rev 5058-CO900E
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.