L19 - Combining the Latest Rockwell Automation Hardware and Software for Improved Energy Management

Transcription

1 L19 - Combining the Latest Rockwell Automation Hardware and Software for Improved Energy Management PUBLIC INFORMATION Rev 5058-CO900E

2 2 Sustainable Production Inputs Add this flow to next slide Materials / parts Information Materials / parts Energy Materials Information Energy is a great place to start

3 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

4 4 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 *Very different remediation solutions (Solving a different problem)

5 5 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)

6 Power Quality Voltage Sag/Swell Harmonics Transient Detection

7 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 PUBLIC INFORMATION 7

8 EtherNet/IP RS-485 RS-485 STATUS Powermonitor 1000 EtherNet/IP R S Powermonitor EtherNet/IP RS-485 RS-485 STATUS EtherNet/IP Powermonitor 1000 RS-485 RS-485 STATUS Powermonitor 1000 RS-485 STATUS 1000 Allen-Bradley Powermonitor 3000 L1 EtherNet/IP RS-485 RS-485 STATUS Powermonitor 1000 EtherNet/IP RS-485 RS-485 STATUS Powermonitor 1000 Energy Usage vs. Production Identify large or critical loads Install Powermonitors where needed Implement monitoring software Drive accountability Monitor results Utility Feeds 138 kv East West Powermonitor 3000 M6 Utility meter 25.04M WATT kwh Switchgear 12,470 V Powermonitor 1000 Typical for 5 Boiler house Substation 4160 V Power house Substation Production Substation #2 Production Substation #1 480 V Shipping / Receiving Substation 480 V MCC V 480 V MCC 5 MCC 3 MCC 6 MCC 1 MCC 7 MCC 9 Measured to the Production Line MCC 2 MCC 8 Data center UPS PUBLIC INFORMATION 8

9 9 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

10 Thank you!! PUBLIC INFORMATION Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900E