Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Energy University
Intro to Energy Intel...
What’s the idea?
Make more with less!
Energy cost
30% of
operational cost
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How much Energy do we spend
per machine, area, product, …?...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The classical approach
 External consultancy or experts i...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Energy Intelligence approach
 Energy monitoring as an...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
What is my equipment utilization?
What are the energy
inte...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:
- Right Sources
- Right Granularity
- R...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:
- Right Sources
- Right Granularity
- R...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
 What is already available?
 Data in different data sour...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
SQL Server
Control System
Energy
Physical
model
...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:
- Right Sources
- Right Granularity
- R...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
 Energy consumption
 Baseline per area, line, machine, p...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
 Data must be plotted on a graph in order to define the g...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:
- Right Sources
- Right Granularity
- R...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Moulding Area Packaging Area
Plant
Calculated energy infor...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
EquipmentEnergyEfficiency
BoilerFuel input 100% + Air
Stea...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:
- Right Sources
- Right Granularity
- R...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
 Provide energy managers with feedback on operating
pract...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 21
 Primarily a management technique that uses
energy inf...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 22
Monitoring&Targeting
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
AlignEnergyDatawithProductionData
Energy and
Production da...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Monitor + Measure:
- Right Sources
- Right Granularity
- R...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Visualize: Key Performance Indicators
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Visualize: Real-time Dashboards
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 27
Fast and cost effective resolution
 Unexpected overspe...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Plant Floor Operator
Equipment / Line
Production
Managemen...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy
Management
activities
Fix Air
Leaks
VFD’s on
Pumps,...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
Performance
Control System
Energy
Information Po...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
Maintenance
Control System
Energy
Information Po...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Historian
Maintenance
Control System
Energy
Information Po...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy Intelligence
33
Customized examples
Trend
Excel Rep...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
 One central Information Portal
 Rich template and repor...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 35
PM 1000
PowerFlex® Drives
Power Control Components
PM 5...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Global food manufacturer
 Building the department and lin...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Reports of the department PH
 KPI Energy
 Report Consump...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Weekly Report Steam Generation
Weekly Report
Purified Wate...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Total Energy Consumption
in department PH
in the last 7 da...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Summary
 Customer uses mainly existing energy data from t...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
 Accurate visibility of energy consumption of your assets...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
TechED Labs
Related RSTechED 2014 sessions
Energy Universi...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
www.rsteched.com
Follow RSTechED on Facebook & Twitter.
Co...
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Energy University: Intro to Energy Intelligence

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Energy costs are some of the fastest growing costs in operations. Learn how Energy Intelligence provides visibility into energy information correlated with operational data providing insight into hidden inefficiencies and opportunities for savings. FactoryTalk VantagePoint Energy and FactoryTalk Energy Metrix helps to collect, aggregate and correlate disparate data from energy monitoring, manufacturing and production processes and business systems to provide Energy Intelligence.

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Energy University: Intro to Energy Intelligence

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Energy University Intro to Energy Intelligence
  2. 2. What’s the idea? Make more with less!
  3. 3. Energy cost 30% of operational cost
  4. 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
  5. 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How much Energy do we spend per machine, area, product, …? Where to save Energy without impact on performance?
  6. 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The classical approach  External consultancy or experts implementing energy monitoring  Disconnected from other existing systems and data  Existing information can/will not be used  Local production is not involved in the whole approach  Non integrated approach has limited success
  7. 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Energy Intelligence approach  Energy monitoring as an integrated approach  Existing systems, data and information will be used  Experts support implementation and use of system  Local production is involved in the whole approach  System can be extended or combined with other performance management initiatives
  8. 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What is my equipment utilization? What are the energy intensive processes? How do we avoid costly energy demand charges? How do I create a more energy efficient machine?How much energy is consumed to make this product? How to ensure uptime and reduce energy cost? How do I increase throughput while reducing energy usage?
  9. 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitor + Measure: - Right Sources - Right Granularity - Right Measurements Predict: - Baseline - Production Output - Energy and Carbon cost Calculate: - Production vs. Non-Production WAGES and Emissions - Actual cost of WAGES and GHG Analyze + Report: - Baselines, Production, Output, Targets, and Regulatory limits - KPIs and Benchmarks Visualize : - Energy usage against production output - Compare performance across multiple facilities EnergyMonitoring
  10. 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitor + Measure: - Right Sources - Right Granularity - Right Measurements Predict: - Baseline - Production Output - Energy and Carbon cost Calculate: - Production vs. Non-Production WAGES and Emissions - Actual cost of WAGES and GHG Analyze + Report: - Baselines, Production, Output, Targets, and Regulatory limits - KPIs and Benchmarks Visualize : - Energy usage against production output - Compare performance across multiple facilities EnergyMonitoring
  11. 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  What is already available?  Data in different data sources  Historian  PLC  Energy solution  Intelligent Motor Control  Where to start?  Define and document areas, machines, products with highest energy demand  What’s needed to get a clear picture?  Can we get more data from PLC’s?  Where do we need new power monitors? Monitor+Measure
  12. 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Historian SQL Server Control System Energy Physical model Data points Organized Information
  13. 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitor + Measure: - Right Sources - Right Granularity - Right Measurements Predict: - Baseline - Production Output - Energy and Carbon cost Calculate: - Production vs. Non-Production WAGES and Emissions - Actual cost of WAGES and GHG Analyze + Report: - Baselines, Production, Output, Targets, and Regulatory limits - KPIs and Benchmarks Visualize : - Energy usage against production output - Compare performance across multiple facilities EnergyMonitoring
  14. 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  Energy consumption  Baseline per area, line, machine, product, …  Listing of energy efficiency of lines and machines  Production  Output per area, line, machine, product, …  Energy and Carbon cost  W.A.G.E.S – detailed cost prediction  Carbon cost Definethebase-line
  15. 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  Data must be plotted on a graph in order to define the general consumption base-line  Consumption rates are plotted in a scatter plot against production or any other variable previously identified, and the best fit line is identified.  This graph is the image of the business average energy performance Definethebase-line
  16. 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitor + Measure: - Right Sources - Right Granularity - Right Measurements Predict: - Baseline - Production Output - Energy and Carbon cost Calculate: - Production vs. Non-Production WAGES and Emissions - Actual cost of WAGES and GHG Analyze + Report: - Baselines, Production, Output, Targets, and Regulatory limits - KPIs and Benchmarks Visualize : - Energy usage against production output - Compare performance across multiple facilities EnergyMonitoring
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Moulding Area Packaging Area Plant Calculated energy information
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. EquipmentEnergyEfficiency BoilerFuel input 100% + Air Steamoutput FlueGas Water
  19. 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitor + Measure: - Right Sources - Right Granularity - Right Measurements Predict: - Baseline - Production Output - Energy and Carbon cost Calculate: - Production vs. Non-Production WAGES and Emissions - Actual cost of WAGES and GHG Analyze + Report: - Baselines, Production, Output, Targets, and Regulatory limits - KPIs and Benchmarks Visualize : - Energy usage against production output - Compare performance across multiple facilities EnergyMonitoring
  20. 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  Provide energy managers with feedback on operating practices, results of energy management projects  Guidance on the level of energy use that is expected in a certain period  Give early warning of unexpected excess consumption caused by malfunctions, operator error, unwanted user behaviors and maintenance errors “you cannot manage what you cannot measure” Monitoring&Targeting
  21. 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 21  Primarily a management technique that uses energy information as a basis to  Eliminate waste  Reduce current levels of energy use  Improve existing operating procedures  Combines the principles of energy use and statistics  Monitoring is aimed at establishing a pattern of consumption  Targeting is the identification of desirable energy levels  Allows users understand what drives energy consumption  Production?  Weather?  Hours of Operation? Monitoring&Targeting
  22. 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 22 Monitoring&Targeting
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. AlignEnergyDatawithProductionData Energy and Production data Production Context Informatio n Software IMPROVED Decision Making Decision People
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Monitor + Measure: - Right Sources - Right Granularity - Right Measurements Predict: - Baseline - Production Output - Energy and Carbon cost Calculate: - Production vs. Non-Production WAGES and Emissions - Actual cost of WAGES and GHG Analyze + Report: - Baselines, Production, Output, Targets, and Regulatory limits - KPIs and Benchmarks Visualize : - Energy usage against production output - Compare performance across multiple facilities EnergyMonitoring
  25. 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Visualize: Key Performance Indicators
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Visualize: Real-time Dashboards
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 27 Fast and cost effective resolution  Unexpected overspend  Quick notice through email notification  Remote adjustments  Cloud based solutions possible
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Plant Floor Operator Equipment / Line Production Management Plant Enterprise Executive Role-basedspecificInformation
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Energy Management activities Fix Air Leaks VFD’s on Pumps, Fans, Dampers Fix Steam Leaks Influence behaviors Energy Efficient Motors Energy Efficient Lighting Power Factor Correction Change production schedule Strategiesimplemented
  30. 30. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Historian Performance Control System Energy Information Portal Electrical power consumption was 15% above plan – solved!  Utilized compressor built in timer to shutoff during non production periods  Reduced operating distribution pressure from 7.4 bar to 6.8 bar. No impact on OEE!  Consumption reduced and stays within base line!
  31. 31. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Historian Maintenance Control System Energy Information Portal Spike in Energy Consumption over a number of days – solved!  Maintenance changed replacement procedure of parts - increasing time between part maintenance.  After alignment of Maintenance schedule with Energy usage consumption went down again
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Historian Maintenance Control System Energy Information Portal Current energy bill much higher than expected – solved!  The discrepancy was caused by the Utility provider billing the customer of an incorrect meter where EnergyMetrix was creating the "Shadow Bill" from the correct meter.  Customer received a substantial refund from Utility Supplier in the region of €300,000
  33. 33. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Energy Intelligence 33 Customized examples Trend Excel Reports Dashboard Demand charts Demand vs. consumption charts 48hr dashboard Tabular reports Real time access to Power Meters Demand and consumption reporting Advanced billing capabilities Power Quality reporting and analyses
  34. 34. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  One central Information Portal  Rich template and report library  RSEnergyMetrix® connector now core component of VantagePoint  All RSEnergyMetrix reports can be attached to the physical model of the plant EnergyIntelligence  Impact on performance can immediately be measured  Role based specific information  Mobile ready
  35. 35. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 35 PM 1000 PowerFlex® Drives Power Control Components PM 5000 IntelliCENTER Intelligent Motor Control EtherNet/IP Logix Controller DirectconnectionwithRockwelldevices
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Global food manufacturer  Building the department and line structure as model in FactoryTalk® Vantage Point®  Using Vantage Point to connect to data sources with the built-in connectors  Generating KPIs and reports to summarize the relevant data on a weekly or monthly basis with the built-in Excel Add-In  Publishing the reports in the FactoryTalk VantagePoint Portal to make them available to the relevant user groups  Set-up and generation by the local customer staff supported by Rockwell Automation – very low budget for the project with a direct return on investment!  Easy to extend - include additional data sources and context VantagePointforUtilitiesReporting
  37. 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Reports of the department PH  KPI Energy  Report Consumptions last week  Weekly Report accessible Departments (Consumers)  The types have an additional sub group plant/line Monthly Consumptions  Report is generated automatically at the end of the month and published in the portal
  38. 38. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Weekly Report Steam Generation Weekly Report Purified Water Generation Specific Energy Consumptions (e.g. Pressurized air in the department PH)
  39. 39. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Total Energy Consumption in department PH in the last 7 days Via a link in the report, trend based analysis can be conducted
  40. 40. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Summary  Customer uses mainly existing energy data from two 3rd party Historians  Data organization/structuring in VantagePoint model  Cryptic lists of data points turned into mean full and structured information  Data points with mean full names and comments  Data points attached to the physical plant model  Energy manager is able to create reports, trends and dashboards on his own  First improvements directly after implementation VantagePointforUtilitiesReporting
  41. 41. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  Accurate visibility of energy consumption of your assets  Compare energy efficiency across plants and assets with normalized data  Analyze energy usage trends compared to historical patterns and forecasts  Trigger alerts from unexpected deviations  Prioritize actions and investments based on financial and operational parameters  Make more with less! Increasing Energy Efficiency is Team Work! We deliver the information, which enable your team to be successful! OvercometheChallenge
  42. 42. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. TechED Labs Related RSTechED 2014 sessions Energy University: Energy Intelligence with FactoryTalk EnergyMetrix Hands on Lab Introduction to FactoryTalk VantagePoint and Enterprise Manufacturing Intelligence FactoryTalk VantagePoint EMI: 50 Minutes to Value FactoryTalk VantagePoint EMI Basic Lab: Building an Information System Mobility and Portability with Today's Rockwell Software Introduction to FactoryTalk Historian: Overview Strategies for Collecting and Analyzing Data FactoryTalk VantagePoint EMI: 50 Minutes to Value
  43. 43. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 44 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  44. 44. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you! 45

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