Energy monitoring and load management with PCS 7 Industry Library

Application example 03/2016 Energy monitoring and load management with PCS 7 Industry Library SIATIC PCS 7 / SIATIC PCS 7 Industry Library V8.1 SP1 https://support.industry.siemens.com/cs/ww/en/view/109483048

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Table of contents Table of contents Warranty and liability... 2 1 Task and solution... 4 1.1 The task... 4 1.2 The solution... 4 1.2.1 Pumping station and sludge drying with local load management... 4 1.2.2 Overview of the complete solution... 5 1.3 Hardware and software components... 6 1.3.1 Validity... 6 1.3.2 Components used... 6 2 Basics... 7 2.1 Load management... 7 2.2 "Peakon" basics... 8 2.3 "Ldgmt8" basics... 9 3 Structure and principle of operation... 10 3.1 Project structure... 10 3.2 Technical functions... 11 3.2.1 Simulation parameters and motor control SWSBP1-SWSBP6... 11 3.2.2 Simulation parameters and control of the motors SDP1-SDP6 and generators... 12 3.2.3 Coordination of motors and generators... 14 4 Starting the application... 16 4.1 Preparation... 16 4.2 Commissioning... 17 5 Controlling the application... 18 5.1 Overview... 18 5.2 Example scenario... 18 6 References... 20 7 History... 20 Entry ID: 109483048, V1.0, 03/2016 3

1 Task and solution 1.1 The task 1 Task and solution 1.1 The task Certain sectors of the industry have a requirement to adhere to agreed performance limits provided by power supply companies in a defined time window. The operation of a plant without consumption monitoring may even lead to penalties. For this reason (and others) the plant operator should have an efficient load management system that monitors fuel consumption and that engages in the process if necessary. The following figure shows the RI process picture for an external pumping station. JQIRA P-34 Energy use Waste Water Treatment Plant Coarse Screen NS P-02 N3 NS P-29 N1 NS P-33 N3 NS P-30 N1 TIRSA P-28 N1 NS FQIRSA NS P-32 P-21 N1 P-31 YS P-06 Y4 Pump hall YS YS YS P-10 P-14 P-18 Y4 Y4 Y2 PIRSA P-07 PIRSA P-11 PIRSA P-15 PIRSA P-19 NS P-01 N3 YS P-22 Y1 UC P-24 Aggr08 UC P-25 NIC NIC NIC NIC P-04 P-08 P-12 P-16 N4 N4 N4 N4 LIRSA P-26 LIRSA P-27 LIRSA P-23 N1 NS P-22 LIRSA P-20 YS P-05 Y2 YS YS P-09 P-13 YS P-17 Y2 Y2 Y2 Sewage Inlet Sewage collection chamber 1.2 The solution 1.2.1 Pumping station and sludge drying with local load management PCS 7 Industry Library allows the delivery of comprehensive functions for the peak-load monitoring of a plant. In the example project, a local load management system is used in a pumping station together with a sludge drying plant to meet a limit agreed with a power supply company. If the projection of the power consumption exceeds the agreed limit value, the consumers are switched off or run on generators. This intelligent monitoring and coordination uses the blocks "Peakon" and "Ldgmt8". Benefits Time and cost savings in project planning and service Increased transparency in power consumption Delimitation The following topics are not described in this application example: How to create the PCS 7 project How to install the PCS 7 Industry Library Required knowledge It is required to have basic knowledge of SIATIC PCS 7 Entry ID: 109483048, V1.0, 03/2016 4

1 Task and solution 1.2 The solution 1.2.2 Overview of the complete solution The following figure shows the process screen of this application example. 1 5 6 7 8 4 9 2 10 11 3 1 2 3 4 5 6 7 8 9 10 11 Water basin Inflow, outflow and total flow Pumps (pump station) Aggregate control (pump station) Load management Consumption monitoring Parameter set (flow und power) Integration time and basic load (power) Aggregate control (sludge drying plant) Pumps (sludge drying plant) Generators Entry ID: 109483048, V1.0, 03/2016 5

1 Task and solution 1.3 Hardware and software components 1.3 Hardware and software components 1.3.1 Validity This application example is valid from SIATIC PCS 7 V8.1 SP1 with PCS 7 Industry Library V8.1 SP1. 1.3.2 Components used The Application Example was created with the following components: Hardware components Table 1-1 Component Note SIATIC PCS 7 ES/OS For the PCS 7 V8.1 SP1 demo project Software components Table 1-2 Component Note S7 PLCSI The license does not form part of the SIATIC PCS 7 ES/OS PCS 7 Industry Library V8.1 SP1 The license does not form part of the SIATIC PCS 7 ES/OS Entry ID: 109483048, V1.0, 03/2016 6

2 Basics 2.1 Load management 2 Basics 2.1 Load management The load management of PCS 7 Industry Library addresses the connection and shut down of consumers according to load management principles based on the limits agreed with the power supply company. A cyclic calculation leads to warning/alarm messages if the agreed limits are exceeded. If necessary, consumers are switched off according to the engineering. To avoid unnecessary switching activities, there are parameters which allow the load management to be adapted to the process situation. Standard PCS 7 hardware and software components are used. Note For further information on the load management topic, refer to chapter 4 "Energy management blocks" in the manual "PCS 7 Industry Library for PCS 7", which can be downloaded from https://support.industry.siemens.com/cs/ww/en/view/81179761 Entry ID: 109483048, V1.0, 03/2016 7

2 Basics 2.2 "Peakon" basics 2.2 "Peakon" basics Tasks The "Peakon" (peak monitoring) block has the following tasks: Setpoint value specification for the available power onitoring the power range Projection of the expected power consumption in the interval Calculation of the difference in power and performance reserve based on existing power consumption Trend display of the current and last 5 intervals via the Histogram View Entry ID: 109483048, V1.0, 03/2016 8

2 Basics 2.3 "Ldgmt8" basics 2.3 "Ldgmt8" basics Tasks The "Ldgmt8" (Load anagement) block has the following tasks: Coordination of up to 8 consumers and/or generators Fast or late switching of loads Setting options: The following settings are possible at the block: Definable ON and OFF times per load Selectable switching sequences: Priority oriented Power oriented In the configured sequence Reserve hours can be set for the beginning and end of the interval 1 2 3 4 5 1 2 3 4 5 Button linked to the consumer/generator Priority Current nominal power aximum nominal power Remaining waiting time Consumer Generator Note about the next switching action Entry ID: 109483048, V1.0, 03/2016 9

3 Structure and principle of operation 3.1 Project structure 3 Structure and principle of operation 3.1 Project structure The "APL_IL81_P" project is designed as a multiproject. The process display can be found in the plant hierarchy of the AS project. APL_IL81_P AS project AS - Projekt UseCaseWater Engines (Wastewater) TimeSwitch Aggregate SWSBP1 SWSBP4 SWSBP2 SWSBP5 SWSBP3 SWSBP6 Tank Level LI811 Engines (Sewage sludge) SD_Agg SDP1 SDP2 SDP3 SDP4 SDP5 SDP6 Generators Loadan Gen1 Gen2 Simulation Simu_SDP_Pow Simu_SWSBP_Pow Simu_SWSB_Flow PDL WaterBasin Entry ID: 109483048, V1.0, 03/2016 10

3 Structure and principle of operation 3.2 Technical functions 3.2 Technical functions The application example consists of several functionalities. The following components are included: Parameter assignment and control of motors Coordination of motors and generators 3.2.1 Simulation parameters and motor control SWSBP1-SWSBP6 Control With increasing level in the water basin, up to 8 upper limit violations are triggered. A converter module enables the number of upper limit violations to be transmitted to the aggregates block. The aggregates block switches an additional pump with each upper limit violation. Simulation parameters The following figure shows the simulated power values of the pumps for the sludge drying plant in the example project via the block "Paraem". Inputs 1 to 6 show the parameters for the pumps "SWSBP1" to "SWSBP6". 1 2 3 4 5 6 In the example project, the block "SWSBP_POW_PV" is configured in the "Simu_SWSBP_Pow". In the WinCC runtime, you can change and edit the parameter sets. Entry ID: 109483048, V1.0, 03/2016 11

3 Structure and principle of operation 3.2 Technical functions 3.2.2 Simulation parameters and control of the motors SDP1-SDP6 and generators Control The motors "SDP1" to "SDP6" are controlled by the aggregates block in the "SD_Agg". Four aggregates are controlled i.e. the motors "SDP1" to "SDP4" run during normal operation. If there is too much inflow into the water basin, the block "Ld" can deactivate one or multiple motors of the sludge drying plant. This is to ensure that the limits agreed with the power supply companies are not exceeded. The following figure shows the control of the motors "SDP1" to "SDP6" by the block "Aggr", as well as deactivation by the block "Ld". The input "UnitReqOp" allows the number of requested motors to be modified during normal operation. SD_Agg Aggr UnitReqOp SDPX Aggr Start01 Start02 Start03 Start04 Start05 Start06 P StartAut StopAut Intlock Loadan Ld Load1Lock Load2Lock Load3Lock Load4Lock Load5Lock Load6Lock Load7Start Load8Start Gen1 G1 StartAut StopAut Gen2 G2 StartAut StopAut Entry ID: 109483048, V1.0, 03/2016 12

3 Structure and principle of operation 3.2 Technical functions Simulation parameters The following figure shows the simulated power values for pumps and generators via the "Paraem" block. Inputs 1 to 6 show the parameters of pumps "SDP1" to "SDP6", while inputs 7 and 8 show the parameters of the generators. 1 2 3 4 5 6 7 8 In the sample project, the block "SDP_POW_PV" is configured in the "Simu_SDP_Pow". In the WinCC runtime, you can change and edit the parameter sets. Entry ID: 109483048, V1.0, 03/2016 13

3 Structure and principle of operation 3.2 Technical functions 3.2.3 Coordination of motors and generators The coordination of motors and generators allows the power consumption of the plant to be regulated. In this case, the coordination of motors is limited to the deactivation of motors. For information on the control of motors, please refer to chapter 3.2.2. The blocks "Peak" and "Ld" are connected by a structure. The following figure shows the layout and contents of this structure. Through this connection, the block "Ld" receives the power values calculated by the block "Peak". Based on the transmitted power values, the block "Ld" controls whether it is necessary to intervene in the process or not. An intervention may consist of the connection of generators or the reduction of consumption by shutting down the motors. The manner of intervention depends on the parameters used to adapt the load management to different requirements. Below you will find further information about the parameters selected in the example project. Entry ID: 109483048, V1.0, 03/2016 14

3 Structure and principle of operation 3.2 Technical functions Assigning parameters to the "Ld" block The following table lists the selected values for the connections and their meaning: Table 3-1 Connection Value Description Load1Device Load6Device Load1IdleTime Load6IdleTime Load1Prio Load6Prio Load7Device / Load8Device Load7IdleTime / Load8IdleTime Load7Prio / Load8Prio 0 Device type: 0 = consumer / 1 = generator (otor 1 to 6) 60.0 Wait time (in seconds) after deactivating the motor until the next restart (otor 1 to 6) 1 6 Priority of the consumers (otor 1 to 6) 1 Device type: 0 = consumer / 1 = generator (Generator 1 and 2) 60.0 Wait time (in seconds) until restart (Generator 1 and 2) after deactivating the generator 7 8 Priority of the generators (Generator 1 and 2) Loadode 2 Switching operation: 0 = normal / 1 = consumer first / 2 = generator first PrefLoadode 0 0 = performance oriented / 1 = priority oriented Timeode 1 Consumer shut down: 0 = early / 1 = late Load 1 to 6 are consumers, load 7 and 8 are generators. "Idle time" allows the wait times to be added to prevent frequent switching cycles. The priorities were added as an example and therefore numbered from 1 to 8. In the example project, the "Ld" block is performance oriented. The consumers are switched off as late as possible in the time interval. If more switching operations are pending, the generators are switched first followed by consumers. Entry ID: 109483048, V1.0, 03/2016 15

4 Starting the application 4.1 Preparation 4 Starting the application 4.1 Preparation The following instructions describe how to launch the example project by simulating the controller with the "S7 PLCSI" program. If there is a real controller, you have to configure existing hardware components in the HW Config. 1. Copy the file "IL_Loadanagement_PCS7" into any folder on the configuration PC and open the SIATIC anager. 2. Click on "File > Retrieve" in the menu bar and select the file "IL_Loadanagement_PCS7". Click the "Open" button. 3. Select the folder in which the project should be saved and confirm by pressing "OK". The project is retrieved. 4. Confirm the "Retrieve" dialog with the "OK" button and click on "Yes" in the following dialog to open the project. 5. Right click on "APL_IL81_Prj > ESV81" and select the "Object properties..." command in the shortcut menu. Enter the name of your computer in the "Name" field. You can find the computer name in "Start > Control Panel > System > Computer name". 6. Right click on "APL_IL81_Prj > ESV81 > WinCC Appl. > OS" and select the "Open Object" command in the shortcut menu. 7. In the WinCC Explorer, open the properties of your PC and, in the opened Properties dialog, click on the "Use Local Computer Name" button. 8. Confirm the "Change computer name" message with "OK". 9. In the WinCC Explorer, click on "File > Exit" and in the subsequent dialog select the command "Terminate WinCC Explorer and close project". 10. Confirm with "OK". 11. Reopen the WinCC Explorer as described in step 5. 12. Double-click on "tag management" to open it. 13. In the "WinCC Configuration Studio", open "Tag anagement > SIATIC S7 Protocol Suite > TCP/IP" and select the entry "System parameters" in the shortcut menu. 14. In the "Unit" tab, check the "Logical device names" setting. If the "S7 PLCSI" program is used, the device name "PLCSI.TCPIP.1" is selected. A restart is required after a device name change. Entry ID: 109483048, V1.0, 03/2016 16

4 Starting the application 4.2 Commissioning 4.2 Commissioning The following instructions describe how to commission the project. The visualization contains a process screen, which allows you to simulate different scenarios. For commissioning, it is required that SIATIC anager is already open and that the project has been selected in the component view. Starting the simulation (S7 PLCSI) To start the simulation, proceed as follows: 1. Select the command "Options> Simulate odules". The "S7 PLCSI" dialog window opens. 2. In the "Open project" dialog, select the "Open project from file" option. 3. Select the file "PCS7_IL81.plc" from the path <Project path\apl_il81\aplil_prj\ PCS7_IL81.plc>. Activate OS (WinCC runtime) To activate the OS, proceed as follows: 1. Right click on the OS and select the "Open object" command in the shortcut menu. 2. To activate the OS (WinCC Runtime), select the command "File > Activate" in WinCC Explorer. 3. In the "System Login" dialog, enter the user name "user1102" as "Login" and the password "aaaaaa" as the password, then confirm with "OK". 4. Select "UseCaseWater" in the icon area. Entry ID: 109483048, V1.0, 03/2016 17

5 Controlling the application 5.1 Overview 5 Controlling the application 5.1 Overview All components of the external pump station can be controlled and monitored from the process screen. In addition, the plant operator receives information for the current process. The following scenario illustrates the behavior of load management at a constant inflow. Priority is given to the compliance with the limit value. The overflow of the water basin is taken into account. 5.2 Example scenario This scenario simulates a medium inflow. Proceed as follows: 1. If the fields "TI Waterbasin / Energy Basic Load" and "Sewage Inlet / Sewage Outlet / Total Flow" are not visible, click on "Show/Hide Tag" (1). 2. Click "Switch all to Automatic" to switch motors and generators to automatic mode. (2) 3. Select the following settings for the "Ldgmt8" (3) block: a. Command = Active b. ode = Automatic 4. Check whether "Ti Waterbasin" (4) has the value "20" and "Energy Basic Load" the value "50". 5. Check whether "Sewage Inflow" (5) has the value "20". 6. Click on "Reset Sewage Basin" (6) and "External Trigger Peakon" (6). 7. Check whether the "SD_Agg" block (7) is switched on. 8. Check whether the "Aggregate" block (8) is switched on. 3 6 4 1 6 8 5 7 2 3 Entry ID: 109483048, V1.0, 03/2016 18

5 Controlling the application 5.2 Example scenario Evaluation All pumps in the pumping station remain deactivated until the first limit value in the water basin is reached. If the first limit value is exceeded, the aggregates block controls the first pump. In the example scenario, the activation of just one pump is not sufficient. Therefore, more pumps are activated until the fill level in the reservoirs remains constant. If the limit values agreed with the power supply companies are exceeded, the load management block switches off the generators or deactivates the pumps in the sludge drying plant. Entry ID: 109483048, V1.0, 03/2016 19

6 References 6 References Table 6-1 Topic \1\ Siemens Industry Online Support Title http://support.industry.siemens.com/ \2\ Download page for this entry https://support.industry.siemens.com/cs/ww/en/view/109483048 \3\ SIATIC PCS 7 Industry Library manual \4\ Service Pack 1 for SIATIC PCS 7 Industry Library V8.1 \5\ What are the system requirements for using SIATIC PCS 7 Industry Library? https://support.industry.siemens.com/cs/ww/en/view/81179761 https://support.industry.siemens.com/cs/ww/en/view/109477851 https://support.industry.siemens.com/cs/ww/en/view/73133562 7 History Table 7-1 Version Date Change V1.0 02/2016 First edition Entry ID: 109483048, V1.0, 03/2016 20