“Mine the Data”: New trends in energy management systems and benefits for mining applications
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Presented at the 2013 Society of Mining, Metallurgy and Exploration Annual Meeting (SME 2013). Stakeholders from management to plant level are able to be empowered by actionable energy intelligence to reveal opportunities, isolate problems and drive cost and risk reduction strategies. Learn new strategies in enterprise energy management software that goes beyond the traditional boundaries of energy strategies across your entire mine enterprise while performing wide-area analysis of events and conditions.
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“Mine the Data”: New trends in energy management systems and benefits for mining applications
- 1. “Mine the Data” New trends in energy management systems and benefits for mining applications Ram Kaushik, Offer Manager, Professional Services Schneider Electric SME Annual Meeting and Exhibition 2013
- 2. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 The Mining Context: Two Key Facts Massive Energy Footprint1 Identifiable Savings Opportunities2 Schneider Electric – New trends in energy management systems – SME 2013
- 3. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012Schneider Electric – New trends in energy management systems – SME 2013 Energy Saving Opportunities in U.S. Mining Source: Mining Energy Bandwidth Study (Draft 2007) 30%
- 4. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 But Where is the Bang for the Buck? Source: Mining Energy Bandwidth Study (Draft 2007) Schneider Electric – New trends in energy management systems – SME 2013
- 5. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Challenges of Energy Programs in Mining I can’t add headcount? So I have to be an energy manager too? How do I calculate ROI? Where’s the low hanging fruit? How do I justify the project to management? Schneider Electric – New trends in energy management systems – SME 2013
- 6. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Energy Management Systems can Help! Energy Efficiency1 Power Availability & Reliability2 Power Quality Monitoring3 Asset Management4 Sustainability5 Schneider Electric – New trends in energy management systems – SME 2013
- 7. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Energy Efficiency1 Independent bill generation and verification Schneider Electric – New trends in energy management systems – SME 2013
- 8. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Energy Efficiency1 Cost Allocation to departments, processes, cost centers Schneider Electric – New trends in energy management systems – SME 2013
- 9. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Energy Efficiency1 Benchmarking against other processes, plants, mines Schneider Electric – New trends in energy management systems – SME 2013
- 10. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Energy Efficiency1 Modeling and Forecasting to identify discrepancies and energy behavior for new process scenarios Schneider Electric – New trends in energy management systems – SME 2013
- 11. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Power Availability & Reliability2 Automated generator and controls testing for disaster planning Schneider Electric – New trends in energy management systems – SME 2013
- 12. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Power Availability & Reliability2 Root cause Analysis – Sequence of Events High resolution synchronized timestamp can identify power system problems Schneider Electric – New trends in energy management systems – SME 2013
- 13. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Power Quality Monitoring3 ●Power Quality – The hidden killer! ● Voltage sags/swells, Transients ● Poor power factor, Harmonics ●Can cause: ● Reduced transformer life ● Reduced system capacity ● Degraded motor performance ● Tripped sensitive loads ● Telecom interference Cost of momentary interruptions and sags in mining is enormous! Schneider Electric – New trends in energy management systems – SME 2013
- 14. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Power Quality Monitoring3 Software can help classify and analyze power quality disturbances Schneider Electric – New trends in energy management systems – SME 2013
- 15. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 ●Leverage infrastructure capacity fully and avoid over-building ● Analyzing historical and current load patterns can reveal hidden capacity ●Support proactive maintenance to prolong asset life ● Real-time and historical data reveals relationships between equipment and the conditions affecting system stability Asset Management4 Pattern and Signature Analysis reveals discrepancies Schneider Electric – New trends in energy management systems – SME 2013
- 16. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Sustainability5 Not just a fad, sustainability can be a competitive differentiator rewarded by investors Mining industry particularly vulnerable to supply chain sustainability pressures and mandates Schneider Electric – New trends in energy management systems – SME 2013
- 17. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Comprehensive Lifecycle Approach Needed Integrated approach to supply, demand and sustainability Schneider Electric – New trends in energy management systems – SME 2013
- 18. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 ● Formerly Excel based (data errors / time waste) ●Centralized enterprise energy management and reporting system ●Collect energy and mining operations data ●Advanced analysis, billing ●Verification and cost allocation tools “At least 40% of the time required to consolidate the information has been saved. Unexpected new savings opportunities have been identified.” Case: Gold Mine Schneider Electric – New trends in energy management systems – SME 2013
- 19. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Conclusion ●Definite opportunities for energy savings ●Use a comprehensive lifecycle strategy to integrate supply, demand and sustainability ●Don’t forget power reliability, availability and quality! ●Don’t depend on Excel – invest in power and energy management systems and let advanced analytics do the work for you! Schneider Electric – New trends in energy management systems – SME 2013
- 20. Schneider Electric - Industry Business – How to Manage Your Legacy Automation Equipment – 2012 Thank You! Schneider Electric – TRDS IN CONTROL AND POWER TECHNOLOGIES AND ITS IMPACT FOR MINERAL RECOVERY RATES – SME 2013Schneider Electric – New trends in energy management systems – SME 2013
Editor's Notes
- $3.2B US annual spend and Energy constitutes 21% of overall costs Globally, 4% of energy consumption is mineral processing.
- Mining Energy Bandwidth Study - There is good opportunity for savings. Even 20% ~ $600M.
- Which practices are the best bang for the buck? Needs Technology + Best Practices - Measure and Verify.
- the demand for mining engineers is expected to exceed supply by 30% by 2013. Limited staff Lack of accurate economic and investment analysis to justify energy savings projects Lack of knowledge to identify low or no-cost savings opportunities Internal competition for resources simply no time and resources to create tools and run analysis/track results
- Shadow Bill verification – rates, consumption, power factor, demand charges. Negotiate contracts
- Makes energy consumption transparent and accountable Visibility – energy kiosks – drives behavior Competitions always get action! Managers performance goals can be set, KPIs etc. “ Who set the demand peak and why?”
- Use energy intensity KPIs to normalize values Rank best and worst performers – praise and shame to gain!
- Modeling and regression analysis can identify correlated variables accurately. When compared to the forecasted consumption, discrepancies can be identified to find problems. Not just a theoretician’s delight – real practical benefits. Federal Facility example – misfiring valve GSA example – BMS incorrectly programmed for holiday schedule
- Disaster Power Planning is a critical component after natural and man-made disasters of recent years – hurricanes, floods, homeland security, Superbowl disruption etc. Ad-hoc generator testing is simply not sufficient. State and Federal Regulations around disaster planning now demand accurate documentation and compliance.
- Accurate Sequence of Events Reporting (1ms) to identify mis-coordinated relay trips, stuck breakers, etc.
- Wide variety of Solutions may include – improved grounding systems, surge suppression, capacitor banks, UPS, active filtering etc. But first, know what you are dealing with! Variable Speed Drives and advanced motors can contribute to degrading power quality while improving energy efficiency! One- to two-second outage $ 14,900, 15-cycle voltage sag $ 10 ,400
- Analyze impact of power quality on equipment life
- Technology to accurately track sustainability scorecards, project ROI, decision analysis on investment
- Comprehensive approach to sourcing, demand, reliability and sustainability. Continuous EM approach to maximize effectiveness Identifies all areas for direct and indirect improvements Examines total facility & systems performance, life cycle costs, compliance and safety