PQ04
Understanding Power Monitoring
Understanding Power Monitoring
Randy Keranen
Drives, Motors, and Power Monitors Product Manager
April 9, 2015
Related Classes at the Expo
PQ05 – Energy Intelligence: EnergyMetrix
PQ06 – Energy Intelligence: VantagePoint
Energy
PQ02 – Power Quality and Monitoring..
PQ03 – Using Test Equipment to Detect and
Measure PQ Issues
PD02 – Power Quality and Monitoring
Agenda – Main Objectives
Why do we care about Energy?
Electricity Basics – PT, PF, PQ, Consumption & Demand
The Electricity Bill – 2 Examples
Power Monitors
Power Monitor Software
PowerMonitor 5000 Setup Demo
Sustainable Production Inputs
Add this flow to next slide
Materials / parts
Materials / parts
Information
Energy
Materials
Information
Energy is a great place to start
Online Article from 6/7/15
“New Minneapolis ordinance aims to reduce
energy, Save money
“We want people to understand where their
energy comes from, how they’re using it, and
how efficient buildings are in the city.”
- These commercial buildings account for more
than 40% of the energy used in the city.
http://kstp.com/news/stories/s3465838.shtml?cat=1
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
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 up-time 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
• *Very different remediation solutions (Solving a different problem)
The Power Triangle
Real Power (kW) produces
heat, mechanical and
chemical work
V&I are in phase
Reactive Power (kVAR)
is stored in magnetic and
electric fields.
V&I are 90O out of phase
Apparent Power (kVA)
dictates the capacity
requirements of the system
Reactive Power
(kVAR)
Real Power
(kW)
Power Factor
• Ratio of Real to Apparent Power
Real Power (P)
PF =
Apparent Power (S)
• Power factor can be Leading or Lagging
– Lagging - the load is more inductive (i.e. motors)
– Leading - the load is more capacitive
• Utilities may impose a Power Factor Penalty
Power quality
Bad power quality
Sag, transients
Ongoing harmonic
distortion
Good power quality
Nice, clean, balanced
voltage sine waves
Some current THD,
not enough to impact
the voltage
Power Quality
Transient
Detection
Voltage
Sag/Swell
Harmonics
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)
Energy
Power = Rate of Energy
Transfer
Energy like an
odometer
Energy = Power * Time
Interval (Integrated)
Units of measure:
Watt-hours (Wh)
kWh, MWh
A little “weird” since time
is part of the energy unit
Power like the
speedometer
Demand
Demand = energy usage
averaged over an interval
Plant A – low load factor
1300 kW
Momentary peaks do no
damage
Sustained overloads cause
Plant
heating and damage
Demand profiles
factor
Plant B uses more energy
1300 kW
but the same demand as A
They both need the same
supply capacity
Demand charges
compensate the utility for
investment
B – high load
Xcel Energy Demand Charge
Xcel Energy Demand Charge Definition:
Charge to commercial and industrial customers for the
fixed costs of the electric capacity required to meet the
peak electric loads on Xcel Energy’s System.
Applies to the highest 15 minute kW demand during the
billing period
Ratcheting Demand
Price Impact
Demand Charges are 46% of the billed amount
Another Electric Bill Example
Demand Ratcheting
Your Utility Bill Expained
The Utility Bill video -> http://www.youtube.com/watch?v=Yo2jOJb
VJHo
Understand your Xcel Energy Bill ->https://myaccount.xcelenergy.com/ebill/und
erstandingbill_mn.jsp
Energy Usage vs. Production
• Energy usage is traditionally metered at one point on
the outside of the building
• Limitations:
– Difficult to correlate energy consumption with real-time production
information
– Difficult to compare energy used during different batches or
production run
• What is happening within the factory with the energy
resources being used 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’
Energy Usage vs. Production
• Identify large or critical loads
– Install PowerMonitors where needed
– Implement monitoring software
FactoryTalk EnergyMetrix
– 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
+
-
SHLD
TX
STATUS
Mod Net
Powermonitor 1000
Boiler house
Substation
4160 V
Production
Substation #1
Power house
Substation
Production
Substation #2
480 V
RS-485
EtherNet/IP
RS-485
RX
‘Measured to the Production Line’
ACT
LNK
+
-
SHLD
TX
STATUS
Mod Net
Powermonitor 1000
RS-485
EtherNet/IP
RS-485
RX
480 V
ACT
LNK
+
-
TX
STATUS
RS-485
STATUS
480 V
RX
ACT
MCC 4
RS-485
EtherNet/IP
LNK
+
-
TX
Powermonitor 1000
Mod Net
SHLD
Powermonitor 1000
Mod Net
SHLD
MCC 5
MCC 3
Product Overview – How it Works
• The PowerMonitor is wired to PTs (Potential Transformers – if required)
and CTs (Current Transformers)
• The PowerMonitor will then measure current/voltage and calculate
energy related data
• This data can be read on the local LCD, be read into an AB PLC, be
viewed through RSPower or RSView, or logged to FactoryTalk
EnergyMetrix
Calculate energy
related data
CT
Measure
Current/Voltage
PT
How to Differentiate Power
Monitors
Measurement Capacity
• Consumption / Demand
• Power Factor
• Power Quality: Sag/Swell Detection, Harmonics, Transients
• Waveform Capture
Accuracy
• Accuracy as a percentage; “Revenue Grade Accuracy”
Networking / Communication
• EtherNet/IP, ControlNet, DeviceNet, Wireless, Serial
• Local Display?
Internal Data Logging Capacity
• Record activity without external data logging software
How to Differentiate Power
Monitors
Embedded Inputs / Outputs
• Status Inputs: Log data from external meters via
pulse inputs
• Relay Outputs: Direct control over connected devices
• KYZ Outputs: Standardized pulse output for
electrical metering
Setpoint Control
• Activate outputs based on internal metering setpoints
• Example: Turn off Relay 1 if power consumption
exceeds 3 kWh
CIP Energy Support
• CIP Energy: Common Industrial Protocol for Energy
Data
PowerMonitor™ W250
Metering
 Consumption (kWh)
 Demand (kW)
– Derived in EnergyMetrix
Communication
 Wireless to Serial
Receiver


802.15.4 Wireless
standard
Modbus RTU from
receiver
Key Features
 Wireless repeater for extended range
 Integrated current transformer coils
 Wireless diagnostic tools in EnergyMetrix
 Self-configuring wireless networking
Future Developments
 Ethernet receiver
 Wireless Pulse Meter
Wireless Sub-Meter
PowerMonitor™ 1000
Metering
 Consumption (kWh)
 Demand (kW)*
 Power Factor (%)*
Communication
 EtherNet/IP
 Serial
* Optional
Key Features
 Embedded web page for real-time data and
configuration
 DIN-rail mounted
 Diagnostic utility for incorrect wiring
 Two status inputs for external metering
(Water, Air, Gas, etc.)
 Integrated display for configuration
Sub-Process Meter
PowerMonitor™ 500
Metering
 Consumption (kWh)
 Demand (kW)
 Power Factor (%)
Communication
 EtherNet/IP
 Serial
Key Features
 Door mounted
 Large backlit display for real-time monitoring
 Fully configurable by touchkeys and display
 Configurable alarming
 Integration with FactoryTalk EnergyMetrix
 Integrated analog or digital outputs (optional)
At-Process Meter
Other Energy Monitors
Symcom
http://www.symcom.com
Model 777 - 777-KW/HP-P2
- Our unit has a DeviceNet
Card back to the PLC
egauge
http://www.egauge.net/
EG 3000 – BACnet/IP
to Ethenet/IP via a
Prosoft Gateway
Warehouse fans and Compressor - 4-20ma from CT’s to the PLC
PowerPad™ or Fluke
Metering
 Consumption (kWh)
 Demand (kW)
 Power Factor (%)
 THD, Crest Factor
 Sag/Swell
 Harmonics (n=50)
 Waveform Capture
Communication
 Serial
 USB
Key Features
 Display screen for data analysis
 Memory for up to a month of data collection
 Separate probes integrate with meter for flexible
configuration
 Waveform capture and review without a separate
software required
 Automatic current probe recognition and scaling
Sub-Process Meter
PowerMonitor™ 5000
Metering







Consumption (kWh)
Demand (kW)
Power Factor (%)
THD, Crest Factor
Sag/Swell, Flicker
Harmonics (n=127)
Waveform Capture
Key Features









Logix Add-On Profile (v22)
Virtual correction of wiring errors
Revenue Grade Accuracy (Class 0.2)
IEEE 1588 Time Synchronization
CIP Energy Support
Status Inputs / Relay Outputs
ControlFLASH Upgradable
Flicker
Sub-cycle Transient Detection
Communication
 EtherNet/IP
 EtherNet/IP DLR*
 ControlNet
 DeviceNet
* Future Releases
Feed Meter
PowerMonitor™ 5000 - Demo
Live demonstration of the
PowerMonitor 5000
PowerMonitor 5000 USB Driver Installation and Configuration
http://literature.rockwellautomation.com/idc/groups/literature/d
ocuments/in/1426-in001_-en-p.pdf
Feed Meter
Metering







Consumption (kWh)
Demand (kW)
Power Factor (%)
THD, Crest Factor
Sag/Swell, Flicker
Harmonics (n=127)
Waveform Capture
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
– Optimize preventative maintenance
– Diagnose power quality issues impacting equipment health and grid
stability
Plant level - CAPEX project estimating
Simple ROI
1. Do Nothing
Assume similar operation, Rate Increases on kWd, kWh….
2. Improve PF
Improve from 0.830 to 0.900
3. Demand Mangement Program
Attack
FY13
FY14
$1,272,272
$1,296,361
-$24,088
FY13
FY14
$1,272,272
$1,293,858
-$21,585
$1,272,272
the max kWd rates and decrease by 10%
$1,232,261
+40,011
$64,099 Benefit when compared to “Do Nothing”
4. Demand Response Program
Utility offers 24 hour look-ahead plan
~-$15,000 with a 50% reduction requirement, TBD by plant management
FY13
FY14
FY13
FY14
$1,272,272
UNK
+UNK
Questions to qualify Power Management
Opportunities
Who to talk to:
–
–
–
–
Top Management
Corporate Energy Manager
Plant Manager
Plant Energy Champion CEM (Certified Energy Manager
)
– Sustainability Manager
– Energy Teams
Questions to ask:
End User
– Do you have a Corporate energy
initiative?
– What is your monthly electric bill?
– What is your total energy cost as
a percentage of your operating
costs?
– Do you conduct any energy
monitoring inside your plant?
OEM
– Are your customers concerned
with energy consumption?
– Do they include energy
expectations in their
specifications?
Energy Management Application Cycle
Analyze
Negotiating Better Utility Rates
Managing Production Schedules
Determining Actual Manufacturing Costs
Driving Simple Behavioral Changes
Optimize
Efficient Energy Usage
Improving Equipment
Performance
Handling Power Outages
Understanding
What-When-Where
Energy is Consumed
Monitor
What is the next step?
36
Reduce Energy Cost , Waste, Emissions and Downtime
Related Classes at the Expo
PQ05 – Energy Intelligence: EnergyMetrix
PQ06 – Energy Intelligence: VantagePoint Energy
PQ02 – Power Quality and Monitoring..
PQ03 – Using Test Equipment to Detect and
Measure PQ Issues
PD02 – Power Quality and Monitoring
You can find this items in the Solution Area SA1
Understanding Power Monitoring
You can’t control what you don’t measure.
Thank You!
Randy Keranen
Drives, Motors, and PowerMonitor Product Manager
rkeranen@wernerelec.com