$1T. 80% More Steel. 50% More Energy. Increased Demand on Industrial Production. By $8T to consumer spending

Transcription

1 By billion new middle class consumers will add $8T to consumer spending Increased Demand on Industrial Production GLOBAL POPULATION TRENDS INCREASE DEMAND FOR Manufacturing Resources Infrastructure EMERGING MARKET CONSUMERISM 30% 100% More Water More Vehicles 80% More Steel 50% More Energy RESOURCE PRODUCTIVITY INVESTMENT $1T Annually Source: McKinsey Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 1

2 Connected Enterprise Delivers Optimized for Rapid Value Creation Supply Chain Integration Collaborative, Demand Driven Compliant and Sustainable $ Faster Time to Market COMPANY CONFIDENTIAL - Internal Use Only Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management Copyright 2012 Rockwell Automation, Inc. All rights reserved.

3 <14% PRODUCTION In the U.S. have tied their facilities to the enterprise network. SOURCE: Industry Week Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

4 Energy Information Architecture FT EnergyMetrix Server FT VantagePoint Server Other Business Servers Engineering Workstations Manager Workstations Wide Area Network Local Area Network 3 rd Party Power Monitors OPC Server 4-20ma Discrete A-B Power Monitors 3 rd Party PLCs A-B PLCs & Sensors Water, Air, Gas, Electricity Steam, Instrument Air, Process Air, Fuel, Nitrogen and Effluent Measurements PUBLIC INFORMATION 4 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

5 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 5 Not Just Electricity 4-20ma Discrete Logix controllers can also collect energy data from digital or analog outputs of a variety of energy meters or transmitters such as water, air, gas, steam, electric, steam and other fuels

6 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 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

7 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Energy Trends in the Industrial Space Past Operations pays the bill every month Energy as overhead Energy programs come secondary to production Metering for billing only Amortized across all BU s Present Internal team addresses pricing & low hanging fruit Use consultants for domain areas Expressed as $/Square Foot Metering and automated control of major equipment Broken down by dept/shifts Future Realtime models determine optimum production and purchasing Expressed as $/SKU or BTU/unit Metering and control plant-wide Energy as Cost of Goods Sold (BOM) to determine true margins of each product $0.03/GAL $7.23/sqft $0.05/mL 0.23 BTU/UNIT $0.0012/SKU

8 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. The IT Floor? Most Factory Automation is Left Unprotected And Can Represent as Much as 30% Of A Plant s Unplanned Downtime There is More Micro-processing Power on the Factory Floor Than in the Average IT Room

9 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 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 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Impact on Common Industrial Components Relays Drop Out Controllers Drop Out 00 Source: IEEE Std

11 Energy Management - is a Closed loop Process Adjust Control + Monitor Analyze Control PUBLIC INFORMATION Electrical Systems Distribution Monitoring Load Profiling Power Quality Mechanical Systems HVAC Pumps Motors Energy Costs Monthly Bills Price Forecasts Utility Tariffs Time of Use Demand Charges Rate Options Poor Power Factor Process Efficiencies Cost Allocation Energy Per Unit Solution Options Energy Strategy Energy Sources Solution ROI Demand Demand Management System Emergency Load Shedding Peak Shaving Consumption Boiler/Chiller Control/Optimization Efficient Motors & Gears Variable Frequency Drives Procurement On-Site Generation Real Time Purchasing Load Shaping Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

12 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 12 Rockwell Automation Power Quality Monitoring I-Sense PowerMonitor 5000 Information I-Grid FactoryTalk Energy Metrix Interruption UPS Portfolio Sag DySC Dynamic Sag Corrector Portfolio Surge / Noise Surge Filters Rockwell Automation has a portfolio of products to identify and mitigate power quality events

13 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 13 Intelligent Motor Control portfolio Energy information at the device level Scalable energy monitoring capabilities Monitor power consumption across the network Correlate energy consumption with operational data to track equipment performance LV E300 Overload Relay Full Voltage starters --Fixed speed - Intelligent overload relays Soft starters -Reduced voltage -Fixed speed Variable Frequency Drives - Variable speed Motor Control Centers -Single assembly for multiple starters

14 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 14 Can your overload relay reduce your electric bill? The energy consumed by electric motors in a manufacturing facility is one of the main contributors to the total electrical cost for manufacturers. However, many manufacturers do not realize that these same electronic overload relays provide some form of power based diagnostic information that can provide a manufacturing facility with insightful information about how to efficiently use electrical energy and lower their overall electric costs

15 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 15 Can your overload relay reduce your electric bill? If network based electronic overload relays already exist in a facility, they can also be used to monitor energy usage at the individual motor loads. Using a historical data collection system, users can monitor current usage (at a minimum) for the respective electric motor that the overload is protecting.

16 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 16 i-sense Voltage Monitoring Easy to use and install Connected to cloud-based power grid monitoring network Accessible from anywhere, on any device Near instant notifications via SMS or No software to install or configure Corroboration notifications: transmission event or local distribution Simple, permanent voltage sag detection and monitoring

17 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Energy Intelligence Aligning energy usage with production data Energy and production data Context Information Decision IMPROVED decision making Production Software People

18 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 18 DySC (Dynamic Sag Corrector) DySC (pronounced Disk ) Battery-free UPS Up to 5 seconds of ride through U.S. and International voltages available Scalable solution MiniDySC (single-phase; 2-50 Amp) ProDySC (3-phase; A) MegaDySC (3-phase; Amp)

19 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Effective Energy Management You Can t Manage What You Don t Measure Turbine Refrigerator Mixer Chiller Boiler 1. Know what you are using, (who s using it), and what that usage is over time. 2. Understand why you are using it. 3. Understand how energy consumption is contributing to your costs (e.g. peak demand).

20 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 20 Energy Intelligence Product Overview Trend Excel Reports Demand vs. consumption charts 48hr dashboard Dashboard Customized examples Tabular reports Demand charts Actionable Information Real time access to Power Meters Demand and consumption reporting Advanced billing capabilities Power Quality reporting and analyses

21 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 21 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, Serial Internal Data Logging Capacity Record activity without external data logging software

22 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 22 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

23 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 23 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

24 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 24 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

25 PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 25 PowerMonitor 5000 Metering Consumption (kwh) Demand (kw) Power Factor (%) Sag/Swell, Flicker Harmonics (n=127) Waveform Capture Communication EtherNet/IP 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 Feed Meter

26 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. What can we help you achieve? Gain 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 Rockwell Automation is an industry leader in helping customers optimize their production operations to reduce costs

27 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 27 What can Rockwell Automation services do for you? Site surveys and site power analyses The basic objectives of surveys and site power analyses are as follows: Determine the soundness of the premises wiring and grounding system supplying the equipment. Determine the quality of the ac voltage supplying the equipment. Determine the sources and impact of power system disturbances on equipment performance. Analyze the survey data to identify cost-effective improvements or corrections, both immediate and future. The key is to understand and define the problem before attempting to solve it. The following are some of the parameters that need to be defined: When did the problem start? What type of equipment is experiencing problems? What types of equipment malfunctions or failures are occurring (e.g., data loss, lock-ups, component damage)? When do the problems occur (e.g., time of day, day of week, particular system operation)? Are coincident problems occurring at the same time (e.g., lights flicker and motor slowdown)?

28 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 28 What can Rockwell Automation services do for you? Site surveys and site power analyses (cont.) What are the possible problem sources at site (e.g., arc welders, air conditioning, copy machines)? What is the proximity to the equipment? Is there any existing or recently installed protection for equipment [e.g., transient voltage surge suppressor (TVSS) or isolation transformer]? Has the addition of protection or power conditioning equipment alleviated the problem or made it worse? Are there any possible environmental concerns [e.g., lightning, electrostatic discharge (ESD), and radio-frequency interference/electromagnetic interference (RFI/EMI)]? Are there any recent changes to the premises wiring distribution system (e.g., ground scheme, additional electrical service entrances, and equipment relocation)? Are there any recent changes to the electric utility s distribution system?

29 POWER SYSTEM STUDY QUESTIONNAIRE PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 29 This form requests details needed for a proposal. Provide as much details as possible to help us with an accurate estimation. Date of walk-through: RA Project Contact/Phone: Company Name: Company Address: Plant Electrical Contact: Contact Phone: Distributor: Distributor Phone: Distributor Name: Distributor Please provide at least one of the following two (2) options 1. Are one-line drawings available? YES NO (Circle one) What is the estimated percent accuracy of the drawings? (If one-lines are less than 70% accurate or not available this questionnaire will also be required.) (While on site, obtain electronic files if available. If paper copies only get photocopy or photograp.) (i.e % accurate) 2. If ACCURATE one lines are not available the following data is required: A Data Collection Transformer Nameplate Data Main/Utility Transformer Transformer 1 Transformer 2 Transformer 3 Transformer 4 Secondary Voltage kva Rating ( Continue on another sheet if required. ) Indicate operation characteristics: (i.e. 24hrs./7day, 8 hr/5 day, etc.) Indicate # of weeks of extended shutdown for the past 12 months: B Utility /Building Service Information i)is there a substation on-site? YES NO (If YES please list specifics on a separate sheet.) ii) Utility Entry Switch(es) (Specify which XFMR each switch is fed from) Amperage of Switch(es) iii)are there capacitor banks on-site? YES NO How many? iv) Alternate modes of operation (type/qty.): Co-gen: Bus-tie: Other: C Remainder of Facility i) Switchgear (SWGR) # of switches/gear SWGR (cont'd) # of switches/gear

30 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 30 Utility Information Request Maximum Minimum Maximum Minimum Primary Utility Source 3P 3P SLG SLG Side Transformer Source Voltage Fault Fault 3P Fault Fault SLG Protective Size & Utility Company Name Description (KV) Current Current X/R Current Current X/R Device %Z (SAMPLE) ABC Energy Sample Road Meter # kA 10.7kA kA 7.2kA A cut-out S&C, SMC-4, E-rated 300kVA Delta-Wye 1.6%Z Utility Company Contact Information Name Address Phone

31 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 31 Industrial Plant Services Our Goal is to partner with industrial facilities and consultants to provide a full range of electrical consulting services with uptime and maintainability in mind. Our Staff is comprised of registered engineers, designers, drafters, and technicians. Our experience allows us to better understand our customer s needs and provide a structured approach to project engineering and electrical services. Power Studies Power System Coordination Arc Flash solutions Power Quality monitoring and reports Load flow analysis Power factor correction Ground System testing Transient motor starting (TMS) Device evaluation Power one line development

32 Questions? PUBLIC INFORMATION Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. 32