ESL-IE-13-05-11a
The Role of Visualization Systems
in Managing the Energy of Production Systems
Prepared for…
Session 6
May 2013
Robb Dussault, P.E.M
Offer Manager, Industrial Energy Management Solutions
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
0
Agenda
1
Facility vs. Process Energy
2
Barriers and How to Overcome
3
The Five Process Demand Functions
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
ESL-IE-13-05-11a
1
ESL-IE-13-05-11a
Energy Management in “Process” vs.
“Facility” Systems
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
2
Energy Management Initiatives Employed in US
Manufacturing Facilities
ESL-IE-13-05-11a
Facility
Process
21% of plants have performed an Energy
Assessment…
…and only 12%, make any impact to the
process.
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
EIA, Manufacturing Energy Consumption Survey (194,733 respondents)
Schneider Electric - US Industry Business – May 2013
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MECS Table 8.1 Number of Establishments Participating in Energy Management Activities .xls
ESL-IE-13-05-11a
84% of Energy Consumed in Manufacturing is PROCESS Related
*US Manufacturing Energy Consumption Survey (MECS) table 5-4, End Uses of Fuel Consumption, All Manufacturing
Industries (Electricity,Fuel
Gas,NGL,Coke
and
Proceedings of the Oil,Diesel,Natural
Thrity-Fifth Industrial Energy
Technology Conference
NewBreeze)
Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
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How PROCESS Energy Management
influences Control System Integration
ESL-IE-13-05-11a
Energy Awareness
Control System Influence
Fixing the basics and
understanding the opportunity in
moving beyond the infrastructure
for greater energy impact.
Energy Optimization
Continuous Improvement
Automate active energy
management into the
process to remove energy
waste at the source.
Track energy data, quantify
energy waste in the process
and identify projects for
continuous improvement.
Advanced
Process-Centered
Rudimentary
Energy Management Program Maturity Level
Increased link between PROCESS
optimization and ENERGY optimization
More control system integration
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
OBJECTIVE: ELEVATE MATURITY LEVEL OF YOUR FACILITIES
5
ESL-IE-13-05-11a
The BARRIERS to Process Energy
Management
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
6
Active Energy
Management:
Jurassic
Energy
Management Techniques
ESL-IE-13-05-11a
The fastest way to save on energy, curb CO2 emissions
and reduce operation cost
1
Find out what the challenge is…
ActiveENERGY
Energy Management
ACTIVE
MANAGEMENT
Passive Energy Efficiency
2
3
Fix the basics
Low consumption devices,
insulation material, power
factor correction
Energy audit
& metering
Optimise through
automation &
regulation
4
Monitor,
maintain,
improve
Focus: PROCESS
Solutions in :
Metering, monitoring and
Industrial Automation,
consulting services, EM analysis
building management,
software
power management, lighting
Proceedings of the Thrity-Fifth Industrial Energy
Technology Conference New Orleans, LA. May 21-24, 2013
control
Schneider Electric - US Industry Business – May 2013
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Credit currency analogy: Christopher Russell, “Managing Energy from the Top Down”
ESL-IE-13-05-11a
Barrier
How to Overcome
● Organizational Structures:
“Facility” vs. “Process”
departments
● Top-Driven initiatives centered
around common Energy
Performance Indicators (EnPIs)
● Production Priorities:
“Production can’t be
impacted”
● Educate: Process Energy
Efficiency leads to Reduced
Downtime and Production
Optimization.
● ROI Expectations:
18-24 months
● Highlight “Energy Wasted” line
item, and factor in Operational
Efficiency
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
8
ESL-IE-13-05-11a
“Getting Lost” in the energy management
landscape…
Consider your PROCESS!
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
9
Watch Out for “Dashboard Label”
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
ESL-IE-13-05-11a
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ESL-IE-13-05-11a
Energy Software and Service Growth Trend
● 5x increase within this
decade
● Slower growth rate at end of
decade due to expansion of
skillsets
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Energy Management Systems for
Schneider Electric - US Industry Business – May 2013
4Q11, from table 5-2
Industrial Markets, Pike Research
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ESL-IE-13-05-11a
Adoption Rates
This gap is
driving services
growth trend
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
12
Watch out for the “Dashboard” label!
ESL-IE-13-05-11a
Professional Disciplines
Key questions:
Chief executive
Energy Procurement
Sustainability Officer
Facility Manager
Enterprise
Energy Manager
1. Which level?
2. What’s the scope of
information?
3. Frequency of Updates?
Env Health & Safety
ICEBREAKER questions:
Production Manager
Single or
Multi-Site
Operations
Plant Manager
IT Manager
Engineering Manager
Area Crew Supervisor
Maintenance Mgr
Control
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
13
ESL-IE-13-05-11a
The “Language” of Process Energy
Efficiency:
The Five Process Demand Functions
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
14
Getting at the 86% of Energy Used in Industrials
ESL-IE-13-05-11a
Energy Supply Functions
● Manage Procurement
● Manage Sustainability Metrics
● Manage Energy Projects
Infrastructure Demand Functions
● Power Factor Correction
● Speed Control in Fans/Pumps
● Boiler/HVAC Control
● Critical Power Systems
● Lighting, Meters, Etc
Process Demand Functions
HIGH Value,
Automation-Centric
● Energy Events
● Peak Demand
● Scheduled Demand
● Idle State
● Demand Response
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
15
Process Demand Management
ESL-IE-13-05-11a
The management of actions to control and reduce the usage/cost of energy within
the process on a continuous basis
Demand Management Functions
1.
2.
3.
4.
5.
Peak Demand Management
Minimizing peak demand which triggers higher rates
Scheduled Demand Management
Minimizing costs by shifting demand to low cost time periods
Idle State Management
Minimizing energy draw during idle process conditions
Demand/Response Management
Offering energy capacity back to grid per request in exchange for incentives
Energy Event Management
Detection and Analysis of process changes that cause consumption to exceed forecast
Technologies Used…a combination of:
MES, SCADA, EMIS, Modeling, Meters, Process Automation, etc
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
16
Peak Demand Management
ESL-IE-13-05-11a
Minimizing peak demand which triggers higher rates
Peak Demand:
● Occurs when process events or operator actions align to create a peak in
demand
● The higher the peak in a billing period, the higher the energy rate structure
● Typical at start-up of major equipment,
line changes, shift changes, etc
● Dependent on HVAC and other loads
What can be done?
● Monitor/document sources of peak
● Automate the start-up sequence of
equipment
● Augment with alternate supplies
(“peak shaving”)
● Establish near-peak alarms
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
17
Scheduled Demand Management
ESL-IE-13-05-11a
Minimizing costs by shifting demand to a low cost time periods
Due to energy generation limitations, it can be more cost-effective to run
processes at lower energy cost “tariff” periods
What can be done?
● Analyse amount of energy per product
● Optimize production rate according to energy cost
● Coordinate production schedule based on expected production output
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
18
Idle State Management
ESL-IE-13-05-11a
Minimizing energy draw during idle process conditions
During process idle time, placing your plant in one of several predefined
“wait” states enables the reduction of energy demand and unnecessary
wear on equipment
What can be done?
● Analyse and define ideal idle states for all production equipment
● Trigger idle states according to upstream, downstream process conditions
● Schedule idle states based maintenance and production demands
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
19
Demand/Response Management
ESL-IE-13-05-11a
Offering energy capacity back to grid per request in exchange
for incentives
Utilities and intermediaries often provide incentives for industrial
customers if they are allowed to trigger demand reductions on a
temporary basis
What can be done
● Define multiple levels of demand based on per-unit energy costs,
process speed or other process conditions
● Aggregate energy stored throughout the process (heaters,
oxygenators, mixers, tank levels, mechanical momentum, etc)
● Automate process response to requests when appropriate
● Negotiate beneficial contracts with energy supply chain
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
20
Sources of Energy Stored within
Industrial facilities and processes
ESL-IE-13-05-11a
Tolerances
converted to kW
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
21
Credit Graphics: Enbala”
Energy Event Management
ESL-IE-13-05-11a
Detection and Analysis of process changes that cause
consumption to exceed forecast
Managing instances where actual energy exceeds predicted energy
enables continuous improvements to energy and process optimization.
What can be done
● Build an energy model to predict demand based on process conditions
● Model is automatically and continuously refined for greater accuracy
● Generate analysis tools to readily identify the process conditions which
generate the most frequent or most significant energy events
● Provide alerts and alarms to operators, maintenance and energy
management personnel to guide responses to events
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
22
Agenda
ESL-IE-13-05-11a
Facility vs. Process Energy
Barriers and How to Overcome
The Five Process Demand Functions
Proceedings of the Thrity-Fifth Industrial Energy Technology Conference New Orleans, LA. May 21-24, 2013
Schneider Electric - US Industry Business – May 2013
23